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Generac QT 1.5L User's Manual

1. 4 SCHEMATIC DIAGRAM REVISION 1 5L COMM PROD LINE DATE 08 04 05 DRAWING 0 7419 999 40 4 ONIAAV C dO MASZ 197 9 19 N ILSNI TRES naa T 3LON 33S D 313 9 0 9 03 511048 VIC G2 D S39V1d C GES NIN 1 9 53415 ANY 584001 353VHO9SI ANY 150 437133 LSAVHXS 553009 3 4 5070 3 1320 1411 3AUW3S 9 11311 404 WANVW 39N3233339 NV 401943 30 30 11 404 1310934 A IND SI 31DH 119 1313 553009 403 S3AUO 3ADUW3S 1081 09 H31IMS 01 553009 lt dWv 672 021 ABSIIVS 12 WALAAN NOILIANNOD LINGNOD 0931 4901 403 9349 dn gnls 3TISNI Cr LASHS 199131 345 33 NDIIVWSDJNI 2329398 1119819 534112141438 ASHLO W Sd S39NVISIG WAWINIW 403 53400 19001 NV 31915 1943034 SV 113M SV SOSVINVIS OZ Vd4N ANY ZE VddN 3 8V2I lddV 1 HLIM 30 440009 G3TIVISNI LSAW LINN
2. J REVISION DATE 08 04 05 SCHEMATIC DIAGRAM 1 5L COMM PROD LINE DRAWING 0F7419 PAGE 1 OF 2 GROUP ENGINE WIRING LEGEND 2 AFS AIR FUEL SOLENOID ALT D C CHARGE ALTERNATOR BAT 12VDC BATTERY DEG 12V DCVR DC VOLTAGE REGULATOR OX INP RET 42 805 DIST DISTRIBUTOR DEG GND 3 FS FUEL SOLENOID COOLANT SENSORS 4 85 FSe AUX FUEL SOLENOID DEG 0 5 HIGH COOLANT TEMP SWITCH DEG 56 CONNECTOR 1 ON PCB DISTRIBUTOR 12V 7 LOW FUEL PRESSURE SWITCH AFS 8 808 LOS LOW DIL PRESSURE SWITCH CRANK SENSOR 9 79 1 MAGNETIC PICKUP CRANK SENSE 10 0 OXYGEN SENSOR INP 11 601 SC STARTER CONTACTOR DEG FDBK 12 SM STARTER MOTOR INP 113 804 STM STEPPER MOTOR eo 14 WLS COOLANT LEVEL SWITCH DISTRIBUTOR 116 DISTR INPUT 17 DEG 418 DEG ENABLE 19 LOW DIL PRESS l20 86 CRANK SHIELD Le1 sHLD COIL C 22 COIL B 23 8 5 79 N C MP1 ee DIST 14 LOS 86 A CONTROL 2 WLS 85 5 gt DC VR
3. 5 NV 39NVN3INIVNW 404 401945 30 30 53015 119 ND WOO 1 31314405 11 S3NI 13105 313339ND9 403 LINN HLIM 144101530109 NOILVYVIVISNI 39N32334329 0 X 3 IM C O Tv 3ZIS 094 31340 0 I3N3NWNWDO932 WNWINIW I SALON 44141 LHDI3M 11 94 jSV38ONI 54185 ONIddIHS N3 DDM d1EvOT 93686 1G 1 53682 MAOZ 1671 VIVI LIHOI3A 90 1 9 168 0 909 40 C JO 90 1 9 ILVA MASZ 18728 MAOZ 21 8 0 Vv 3LON 335 ANNO NOILOSNNOO M3IA 3015 1441 31VWN34 14 v E LINGNOD 3015100 102 01314 4011594405 INIT TANI SNDISN3WIG 30 331N32 Cr cis W3IA NV S 1 918 70 521 959 335 3yy3yg 1109515 NIN 9 661 ___ 906 162 ACIS QNVHL 3312 S6 2 268 33S dAL 1 44 wood 1 88 8421 2 310 335 NIHLIM 3SO19N3 say 1jJnN 15 l3 NI IV NIHLIM SI 29 2 443119 00 3NVd 1031 00 L 86 82 9EL vG 9 826 86 07 6081 YOLVASNSD 30 3015 aad 4004 440 1417 3NO 9009 X3d 2191 ASIA 3WV34 9NILNnON W3IA 1943 39 30 WDLIUS
4. 5 1 Puel Requirements aaa 5 1 Natural Gas Fuel System 5 1 Propane Vapor Withdrawal Fuel 5 1 LP Fuel SySUSIY 5 1 SPECIFICATIONS 6 1 6 1 6 1 Cooling 6 1 SYS 6 1 Electrical System 6 1 Cold Weather uu saksa naaaqa shaspaqa minaqp aqa qaha ays 6 2 Reconfiguring the Fuel 6 2 GENERAL INFORMATION 7 1 Generator AC Lead Connections 7 1 Four lead Single phase Stator 7 1 Alternator Power Winding Connections 7 1 S phase Alternators ea 7 1 INSTALLATION 8 1 Installation aww sa 8 1 Preparation Before Start up usa 8 1 Transter 8 1 8 1 Generator Set Lubrication 8 1 Prior to Initial StarEuD u 8 1 Engine Coolant bent 8 1 Belt Tensi n haqa 8 1 Electrical 22 sa Qusa 8 1 Initial Inspection for QT Genset Start up 8 1 Startup CHE
5. BERGEB PART 022473 REVISION G 8323 A DATE 6 9 06 QTY DESCRIPTION MOUNTING BASE 15L C1 WASHER SHAKEPROOF EXT 5 1651 DAMPENER VIBRATION MB ISO 70 75 DURO SCREWHHC 1 25 20088 WASHER FLAT 5 16 ZINC WASHER LOCK VB 5 16 HEX MB L25G8 YEL CHR WASHER FLAT SCREWHHC 1 55 60088 WASHER SHAKEPROOF EXT 1 4 NUT HEX LOGBYEL CHR LUG SLDLSS 72 28 X 17 64 CU SCREWHHC M5 LOX 16G88 WASHER LOCK 1 4 WASHER FLAT 1 446 ZINC GROUP C PAGE 2 OF 2 GROUP C EXPLODED VIEW COOLING SYSTEM 1 5L C1 TO BASE OF WATER INLET TUBE ON BLOCK TO THERMOSTAT ADAPTER zu Lu Lo REVISION G 6885 B DATE 12 9 05 DRAWING 0F7466 PAGE 1 OF 2 EXPLODED VIEW COOLING SYSTEM 1 5L C1 DRAWING 0F7466 APPLICABLE PART QTY DESCRIPTION 1 7211 1 SUPPORT RADIATOR LH SIDE 2 OF7209 1 VENTURI 15 DIA FAN 3 0F7210 1 SUPPORT RADIATOR RH SIDE 4 0 9837 1 RADIATOR 2 5L CPL 5 E1936 1 FAN COOLING 15 6 1 WASHER LOCK 516 7 027166 1 RADIATOR HOSE 1 5 8 099502 4 CLAMP HOSE 724 1 06 2 00 9 069860C 1 HOSE OIL DRAIN ASSY 21 10 085461 1 BARBEDSTR 1 4 NPT X38 1 HOSE UPPER RADIATOR 12 1 RADIATOR 13 2 1 17 LG 4 WASHER FLAT 1 4HV5ZINC 15 8 WASHER LOCK
6. 70 cfm Power Adjustment for Ambient Conditions Temperature Deration Governor 3 for every 10 C above 25 Electronic 165 f 10 above F 5 Frequency Regulation Isochronous d D Steady State Regulation sss 2590 M Adjustments for every 100 m above 182 Speed as usnu Selectable 3 for every 1000 ft above R 600 Controller aas R 100 6 1 d ed erooedgueo Standby Sets E INFORMATION Specifications INFORMATION Figure 1 Interconnections 000000 Utility In Transfer Switch CONTROL PANEL PR NEUTRAL E TO Glo ALTERNATOR M NEUTRAL ii GENERATOR 81 23 23 CONNECTION ae H GENERATOR CONNECTION BOX _ m GENERATOR Pp CONNECTION BOX To Generator Control Panel FRAME RAIL CIRCUIT BREAKER SIZE KW VOLTS AMPS LUGSIZE 20 24010 100 4 to 1 0 Ground Level 20 208 3 0 80 4 to 1 0 Concr
7. my EI a 1 1 n E Pd 2 27 om 7 dnodd EXPLODED VIEW CONNECTION BOX SPL PARTS DRAWING 0F7352 APPLICABLE GROUP A DESCRIPTION 1 027135 1 BREAKER TRAY 2 FXD2 1 SUPPORT CONTROL PANEL SIDE RH 3 F721 1 SUPPORT CONTROL PANEL SIDE LH 4 027250 1 COVER CIRCUIT BREAKER 2P 7136 1 COVER CIRCUIT BREAKER 5 026156 1 PLATE WRE SNGL GALV 6 0 4464 1 DECAL CUST CONN 120 UTILITY 7 0D4698 REF BLOCK TERM20A 6X 3X 1100 8 OF3824 1 DECAL UTIL SENSE CUST CONN 9 057701 REF BLOCK TERM20A 8X 6X 11007 10 6146 1 HANG TAG 2WRE START NOT SHOWN 12 081008 1 GROMMET 125X 25 75 13 0C2267 2 SCREWHHITN5O08X 12 2 WASHER LOCK 15 051713 2 WASHER FLAT 16 0 2212 SCREWPHITM407X 16ZYC 17 WASHER LOCK 8 18 OF6366A 1 DUAL 104 16V 3 PHASE OF6366B 1 DUAL 120 16 1 PHASE 19 022211 1 NUT HEX 78 16STEEL 20 1 WASHER LOCK 3 8 21 057329 1 LUGSLDLSS 350 6 X 13 32 AL CU 2 057073 1 JUNCTIONBLOCK 38 16 23 023483 1 BUSHING SNAP SB 2000 26 24 E3257 15 SCREWHMWHIF 6 10 16 5 27990 REF BRKTCB 2 6002 REF MIG TRACK BQSIEMENS 26 REF CB 20 5 BQ2 LL 15 2POLE 0D5544 062812 0080 210 5 LL 15 042077 0125A 2P 210 5 BQ2 LL 2 5L 2 POLE REF CB 0100A 240 5
8. 10115 33 1 00 240 900 1 120 i 10115 1 1 11 I H Y Y CIRCUIT BREAKER Standby Generator Sets General Information GENERAL INFORMATION ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS The generator is designed to supply 3 phase electri cal loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit breaker with a Y configuration as shown in Figures 7 2 and 7 3 The rated voltage between circuit breaker terminals E1 E2 1 and E2 E3 is either 480V or 208V depending on the model The rated voltage between each circuit breaker termi nal and the neutral point is either 277V or 120V depending on the model Figure 7 2 Stator Power Winding Connections 3 phase 277 480V 6 Lead S1 E1 1 INTERNAL CONNECTIONS L L 56 lt gt 84 NEUTRAL 21 53 S2 Tw Figure 7 3 Stator Power Winding Connections 3 phase 120 208V 6 Lead E1 S4 54 00 NEUTRAL 53 53 52 40 80 0 INSTALLATION Standby Generator Sets C y Installation i INSTALLATION INSTALLATION Refer to the separate Installation Guide QT Product Line supplied with the unit PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed se
9. ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground 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 INITIAL INSPECTION FOR QT GENSET STARTUP Inspect for the following Freight Damage Manuals present Fluid Levels Oil coolant battery Gear Drive Correct fuel piping Correct muffler installation for external applica tion Adequate air flow clearances and ventilation per installation drawings and applicable codes Correct AC and DC wire size connections and grounding Control and communication wiring to from the transfer switch must be run in a separate conduit from the AC power leads Battery charger connection to 120 VAC Communication wires connected between transfer switch and generator HTS only Unit secured to pad 90 40 2 10018154 INSTALLATION Standby Generator Sets Installation INSTALLATION START UP CHECKLIST A Before working on the generator ensure the fol lowing The AUTO OFF MANUAL switch is in the OFF position The 120VAC supply to the battery charger is switched OFF PREPARATION FOR START UP Ensure that the 120VAC circuit breaker to the bat tery charger is open Remove the fus
10. Manually move the transfer switch handle to its UTILITY NORMAL position i e load circuits connected to the utility Turn ON the utility power supply to the transfer switch using the means provided such as the util ity power source main line circuit breaker Let the generator run at no load for a few minutes to stabilize internal temperatures Shut down the generator OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If the generator has been installed with an automatic transfer switch such as an RTS HTS or GTS type transfer switch the engine may be started and stopped automatically or manually NOTE Refer to the applicable manual for your trans fer switch and to Transfer Switch Start Signal Connections In addition please note the dangers under Engine Start up and Transfer 90 80 0 1001990 Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES warninc Before working generator ensure fol lowing The AUTO OFF MANUAL switch is in the OFF position The 15A fuse has been removed from the con trol box The 120VAC supply to the battery charger is switched OFF EVERY THREE MONTHS Check battery condition Inspect and test fuel system Check transfer switch Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTHS 1 Test Engine Safety Dev
11. dAl 0319907 530914 L ITE9 9NILINnON GES ONDINVN2O 1109 629 dte LWA 1198 59 11517 91 39N3213432 MODI 1331 000 1 913 198 ouis 1738 LESD m is E 802 1331 1H9IS N3W313 43 9310 419 1331 1431 ISOH NIvad anoa 1H9IS 3SOH NIVad MODO 1431 331113 HD ien neu OTIS ID 777 2 1 30 831439 111181553299 3214395 ALON 335 15 90 71114 191094 01 553299 MASZ LS21 76 4 404 3AUWJS S E 0 8 D Standby Generator Sets Warranty 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 Generac Power Systems Dealer or branch thereof Generac Power Systems Inc will at its option repair or replace any part s which upon examination inspec
12. 25 lt CD pom ee 5 tke Le o 2 CN 15 STARTER SOLENOID EXPLODED VIEW BATTERY C1 CPL REVISION G 6517 D 0F7422 DRAWING PAGE 1 OF2 9 23 05 DATE EXPLODED VIEW BATTERY 1 CPL DRAWING 0F7422 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0 34088 1 BATTERY TRAY 1 2 OF34 11 1 STRAP BATTERY RETAINVENT 3 025507 REF WASHER SHAKEPROOF EXT 7 16 STL 4 052647 REF SCREWSHC 1015 25 129 5 046526 REF WASHERLOCK 6 022131 REF WASHER FLAT 3 8 MIO ZINC 7 1 REF BATTPOST COVER 8 060831 BATT POST COVER BLK 9 088805 1 CABLE BATTERY 30 00 10 088804U 1 CABLE BATTERY RED 28 00 n 015771 REF HEX MB L25G8 YEL CHR 12 WASHER LOCK 516 B 027482 REF WASHER SHAKEPROOF EXT 5 16 STL 023976 3 CONTACTOR CABLES 15 0C2454 4 SCREWTHF 51 16 ZJ S 16 WASHER FLAT 516 MBZINC 17 077483 BATTERY 12 0 75 AH 26 18 0742600131 1 ASSY WRE 16 RED 16 REVISION G 6517 D DATE 9 23 05 GROUP C PAGE 2 OF 2 957 30 DNIA VIG 2 3SV8 ONILNNOW vi N 349018 FONTVN T dO N N N I HDVd 90 6 9 68 0 17 d N CN o zi 4 EXPLODED VIEW MOUNTING BASE DRAWING 0F7456 APPLICABLE
13. LL 2 5L 3 POLE REF SCREWHHC 08 20688 NOT SHOWN 023897 REF WASHER FLAT 40 ZINC NOT SHOWN WASHER LOCK NOT SHOWN 051716 REF HEXIVB 0 8G8 CLEAR ZINC NOT SHOWN 025433 1 LUGSLDLSS 6 1364CU ABSA REF REGULATOR DC ALT 33 0E3257 REF SCREWHWHIF M6 LOX 16 022473 02209 027194 057593 EB BBN REF WASHER FLAT 14 6 ZINC REF WASHER LOCK 1 4 37 2 BRACKET PANEL SUPPORT L5L 38 1 CABLE TIE MDUNT BLACK 39 90 1733 1 DECAL CUSTOMER INSIDE 40 1 WASHER SHAKEPROOF EXT 4051 USEDON 15L ONLY REVISION G 8323 H DATE 6 8 06 PAGE2 OF 2 22850 ONIMVUC YOLVYANSS IO I HDVd 90 81 6 18 0 14 5 3NION3 OL DuisnoH JeNolg O L 2 gt s a OKRA d Ny uy gt dnodd EXPLODED VIEW GENERATOR DRAWING 0F8222 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 098675 1 ASSY ROTOR 20KW 2 OA5336A 1 HOUSING BLOVER 3 1659 1 SCREENAIR OUTLET 4 020746 4 SCREWPPHMM608X8ZNC 5 4 WASHER LOCK 6 051713 4 WASHERFLAT 7 022129 4 WASHER 5 16 8 OF8218 1 ASSY STATOR XKWIPHA 0 8220 1 ASSY STATOR 20 9 045382 1 BEARING CARRIER REAR 10 075591 1 ASSY HOLDER BRUSH 075476 4 SCREWPPHMM tO7X 16 2 QA560IA 1 COVER REAR BEARING 13 075554B 4 BOLT STATOR X 16 LG 14 049875 4 SCREW RHM 410 24 X 2 15 0
14. LVUL BATT 12 067680 1 ASSY VOLTAGE REGULATOR 60 7 0 6875 2 RELAY 12 0 C FORMWDIODE 055011 1 BLOCK TERM2DA D 6 1100 7 16 1 DECAL CPL CONTROL PANEL FUSES 17 1 DECAL CPL 391 1 18 045064 4 SPACER 9 5H321D 19 29673 1 DIO BRIDGE 25A 600 20 019850 1 CB4X1ETA46500P a 0F1958 1 PLATE HARNESS CLAMP 22 082573 1 SWITCHRKR DPST 125 SPD 23 A 1 SWITCH RKR DPDT 023215 1 DECAL CONTROL HSB 5 025886 3 SCREWHHPMN508X12 26 051713 14 WASHERFLAT 27 14 WASHERLOCK 28 F572B 1 RES WW25R 5 25 CONN 29 0F5884 2 SCREWPHIT 5 06 10 30 025896 2 SCREWPHIT 5 06 16 A 0C2265 4 SCREWPHIT M 07X 12 ZYC 32 0 3990 2 SCREWPHIT M 07X 10ZYC 091526 8 8 12 ZNC x 051716 7 8 G8 CLEAR ZINC 36 043182 7 WASHERLOCK 37 061714 7 NUTHEXMBQ5G8YEL CHR 38 F312 1 SUPPORT ANGLE PCB 3 COE740BC 1 15 BLUE 4 024416 1 HARN 1800RPMR 100 CONTROL PNL NOT SHOAN 41 OF6305 2 SEAL COVER 318 12 7 382 42 6 1 SEAL COVER 318 1227 X 283 43 0 2627 1 PLATE COVERHPANEL COMPONENTS INSTALLED PER OF7380D A 056739 1 RELAY SOLENOID 12 0 B 2 SCREWHHC 1 4 20X3 4G5 C 022173 4 WASHER FLAT Y 4HV6 ZINC D 2 WASHER LOCK M5 1 4 E 022127 2 NUT HEX Y4 20STEEL F F61 5 AR SEAL WEATHER 45 REVISION G 6795 C DATE 11 12 05 GROUP B PAGE 1 OF2 STARTER QO 24 O
15. READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest Authorized Service Dealer for start ing 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 incorrectly or carelessly Observe them carefully Their definitions are as follows A After this heading read instructions that if not strictly complied with will result in personal injury or property damage amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution 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 infor ma
16. Generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to person nel 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 the transfer switch In case of accident caused by electric shock imme diately 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 imple ment such as a dry rope or board to free the vic tim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents 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 extin guisher 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 b
17. BCH BATTERY CHARGER BR1 BRIDGE RECTIFIER CIRCUIT BREAKER EXCITATION F1 FUSE BAT POWER 154 TYPED Je CONNECTOR UN PCB J3 3 UN PCB R4 FIELD BOOST RESISTOR RL1 RELAY 1 5 RELAY RELAY 2 RUN 5 1 AUTO OFF MANUAL SWITCH 5 2 SET EXERCISER SWITCH TR1 TRANSFORMER 1 6 240 16 VAC e N 15 15 502 15E Lo 15 SW1 9 154 e39 9 194 n ALARM RELAY 9 XFER RELAY 10 23 y MAN INPUT 111 239 16 SENSECO 112 225 ANALDG INP 13 GND B 14 0 UCT 1 L1 NOTE 1 UCT 3 GND e s 15 1 ICT 1 UTILITY FROM T SW 66222 2 ICT 2 UTILITY FROM T SW ee 56A ICT 3 TRANSFER COIL RELAY 33 94 ICT 4 TRANSFER RELAY NB S6 83 5 START Y T 15 78 6 START Ez cc sun CUSTOMER CONNECTION amp ALTERNATOR LEGEND BA BRUSH ASSEMBLY GENERATOR CB1 MAINLINE CIRCUIT BREAKER 240V DUTPUT TO TRANSFER SWITCH ICT INTERCONNECT TERMINAL BLOCK NEUTRAL BLOCK UCT UTILITY CONNECT TERMINAL BLOCK t WIRING SHOWN FOR 1 BA AND IS TYPICAL FOR SINGLE PHASE 3 PHASE SEE DWG OF6839 a
18. HEAT SHELDEXH 1 5 76 WASHER LOCK 6 1 4 77 SCREWHHC 1 4 20 1 2G5 79 SCREWHHC MI0 L25X25G88 80 WASHERH OCK MIO WASHER FLAT 8 ZINC STAMPING ENG FOOT SPACER 41 75 X I2 STL ZNC NUT HEXMIO L5 G8 YEL CHR SCREWSHC 5 16 18 2688 NZ STARTER 12V SPACER 56X 1 37 ST ZNC SCREWHHC 1 5 60G88 ENGINE PLATE SLEEVE DOVEL BLHSG SCREWHHC 1 5 70G88 SCREWHHC 1 5 90G88 WASHER FLAT 5 16 ZINC WASHER LOCK 5 16 NUT HEX 5 16 18 STEEL SCREWHHC 1 25 X20G88 SCREWHHC M6LOX16G88 SCREWHHC 1 25 45 08 8 SCREWTBHNBE 125X 30 NUTHEXMB125G8YEL CHR SCREWSHC 1 25 25 12 9 SCREWHHC 5 16 18 165 ADAPTER THERIVDSTAT GASKET INLET MANFOLD MANIFOLD INTAKE MACHINED PROBE COOLANT LEVEL 38NPTF 245 DEG 38 PLUG STD PIPE 38STEEL SQ HD PLUG STDPIPE 8SCKT HD SCREWHHC MB L25X20G88 PIPE ORING 11 16 15 16X 18 WASHER SHAKEPROOF EXT 7 16 STL SPACER 1 75 25512 SWITCHOIL PRESSURE ELBOWSCDSTREET 1 8 ADAPTOR 18 28 PLUGSTDPIPE 1 4STEEL SQ HD SCREWHHC MIO 15X 110688 SCREWHHC 1 25 35 688 WASHER LOCK PULLEY CRANKSHAFT 3600 RPM BRACKET ALT SUPPRT DC ALTERNATOR 12V ARMAD UST ALTERNATOR HOSE ASM OIL DRAIN GUARD CRANKSHAFT 1 5 SCREWCRIMPTITE 1 420 58 PULLEY FAN95DIA V BELT 38X 289D SPACER PULLEY FILTER OIL ADAPTER DRAINOIL GROUND WRE STARTER CLANP HOSE OIL DRAIN HOSE OIL DRAINASSY 21 GROUP
19. 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 dealer 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 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
20. oil and exhaust leaks Close the generators main line circuit breaker Turn the generator set off Connect the UTILITY supply to the transfer switch Set the AUTO OFF MANUAL switch to AUTO Disconnect utility power before the transfer switch Engine should start transfer to load Run at least 15 minutes on generator power Make certain all 3 phase loads are functioning correctly correct phase rotation Reconnect Utility power Transfer switch will transfer back to Utility and engine will shut down within the given time parameters set up for the specific transfer switch and controller Install all covers access plates and door panels Put the Owners Manual in a safe and accessible place Make certain the AUTO OFF MANUAL switch is in the AUTO position START UP INSPECTION When a startup is performed by an Authorized Service Dealer a standard three part form titled Start up Inspection for Standby Power Systems part no 067377 should be completed by the instal lation technician or engineer See page 1 3 for infor mation on locating the nearest Authorized Service Dealer The installer should complete the form and disseminate copies as follows White copy Mail to Generac Warranty Department PO Box 340 211 Murphy Dr Eagle WI 53119 2062 Pink Copy For service file of installing dealer Yellow Copy For the customer s records Standby Generator Sets OD GENERATOR CONTROL A
21. 1 4 16 0 8566 8 SCREWHHFC 41 0 20088 17 049813 4 NUT HEX M6X LOGBYEL CHR 18 0C2454 24 SCREWTHF 1 16 ZJ S 19 4 SCREWHHC 1 0 70G88 20 OF7594 4 GUARDFANLHC1CPL 21 027595 4 GUARD FAN 1 22 0769 1 CLAMP HOSE 38 87 23 OF7320 1 BLOCK OFF UPPER 24 OF1433 1 BRACKET 2 5L FORDWATER BOTTLE 5 076749 1 26 0480B C 2 CLAMP HOSE BAND 1 4 27 029082 1 HOSE 932 ID 40 LG 28 040976 1 SCREWSHC 1 25 200129 2 1 WASHER FLAT 5 16 MB ZINC 30 029107 1 7 8X 316X 58 31 026850 4 WASHER SHAKEPROOF EXT 1 4STL REVISION G 6885 B 12 9 05 GROUP PAGE2 OF 2 910140 DNIM YAA 7 dO I HDVd ATENISSY 9 dado TdXA 338 15 9 19 7 NAOHS SV ILL SS3NdYH SUNOS SS3NHVH vL 1 WILI 6 ALVA 8 26 4 EXPLODED VIEW GOVERNOR ASSEMBLY 0 721 DRAWING 0 7216 GROUP D APPLICABLE TO ITEM PART QTY DESCRIPTION 1 098290 1 ASM MOTOR STEPPER 2 098941A 1 HOUSING GOVERNOR CONNECTOR 3 098958A 1 CONNECTOR INTERFACE ASSEMBLY 4 098942A 1 COVER CONNECTOR HOUSING 5 098225 2 SCREW FHM 2 X 5 8 SELF TAP 6 043146 3 SCREW HHC 6 1 0 X 10 G8 8 7 022097 5 WASHER LOCK 6 1 4 8 064526 2 SCREW TAP HWH 6 25 X 3 8 ZINC 9 098
22. 8 PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS WARRANTY 90 60 0 t001u9luoo Standby Generator Sets SAFETY RULES Important Safety Instructions 7 N 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 WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before 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 reli ably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings this manual and on tags and decals affixed to the unit are therefore not all inclusive If a pro cedure work method or operating technique is used that the manufacturer does not specifically recom mend ensure that it is safe for others Al
23. D DESCRIPTION CLAMP HOSE 2 50 125 CAP ANTIFREEZE RUBBER CAP 1 4 NPT BRASS REGULATOR DC ALT SCREWHWHTF 1 0 16 WASHER FLAT 1 4 M6 ZINC WASHER LOCK 6 1 4 ASSY MAGPICKUP 3 8 24 MALE ASSY PCB WATERLEVEL SNSR INTFC QTY CLAMP FOR WRING HARNESS SHOWN NOT SHOWN PAGE2 OF 2 GROUP IMPORTANT SOLENOID MUST BE L P VAPOR CONVERSION INSTALLED WITH FLOW ARROW POINTING IN DIRECTION SHOWN IN ILLUSTRATION ABOVE 19 ENGINE HARNESS ASSY CONNECT TO CARBURETOR 1 2 amp 3 REGULATOR INFORMATION 7 FUEL SYSTEM NG LPV 1 5L C1 CPL EXPLODED VIEW DRAWING 0F7494 REVISION G 7534 B DATE 3 3 06 PAGE 1 OF 2 EXPLODED VIEW FUEL SYSTEM NG LPV 1 5L C1 CPL DRAWING 0F7494 APPLICABLE TO 1 5L ITEM PART QTY DESCRIPTION 1 026812 2 ELBOW9O0D 34 2 075580 1 FLANGE FUEL INLET 3 OF6364A 1 FUEL RGLTR L5L REWORK 4 4 SCREWHHC 1 25 20G88 5 022145 2 WASHER FLAT 5 16 ZINC 6 022129 6 WASHER LOCK 5 16 7 045771 2 NUT HEXIVE L25 G8 YEL 8 0F1570 1 BODY CARBURETOR ASSEIVBLY 9 1 BARBEDEL 905 16X 1 8 10 029082 1 9320 005424 1 NIPPLE PIPE 34NPTX6 12 7 1 HOSE CRANKCASE BREATHER 13 035547 1 COVER AIR CLEANER 048031 4 CLAMP HOSE BAND 1 4 15 001509 1 DECAL INLET PRESSURE 16 E0591 1 ADAPTER CARB AIR CLNR 17 0594002 1 FILTER ELEMENT 18 087561 1 NUT WING 1 4 20 19
24. 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 AN Do not use any jumper cables or booster battery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging warninc 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 A Be sure the 120VAC power supply to the battery is turned OFF or sparking may occur at the bat tery posts as the cables are attached and cause an explosion BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 26 525 0 deg F NOTE The BCI number should be located directly on the battery PERIOD DEDI N DAR Oil Filter 4531 244 046627 059402 Spark Plug 0A45310275 Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule SERVICE SCHEDULE The following is a recommended maintenance schedule for small standby and residential generator sets The established intervals in the schedule are the maximum recommended when the un
25. 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 10 2 counterclockwise and remove Properly dispose of old filter Figure 10 2 Oil Filter OIL FILTER 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 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 7 Start engine and check for oil leaks CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 059402 simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 10 3 See the Service Schedule for air cleaner mainte nance Figure 10 3 Engine Air Cleaner Air Cleaner 59 5
26. manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon monox ide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate 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 stan dards 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 venti lating air is critical in any room or building hous ing the generator 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 seri ously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspe
27. system 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 A If a circuit breaker opens fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse CHECKING FLUID LEVELS CHECK ENGINE OIL Check engine crankcase oil level Figure 10 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 Engine Oil Recommen dations for recommended oils 90 0 Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance Figure 10 1 Oil Dipstick and Oil Fill Cap on Bo OIL FILL CAP OIL DIPSTICK 26 A P BATTERY FLUID Check battery electrolyte fluid based on the Maintenance Schedule Fluid should cover separa tors in all battery cells If fluid level is low add dis tilled water to cover tops of separators DO NOT USE TA
28. tempera ture oil pressure or rpm For that reason the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low the coolant temperature is too high the coolant level is too low or the engine is running too fast NOTE Engine protective switches and sensors are men tioned here for the reader s convenience Also refer to the applicable control panel manual for additional automatic engine shutdown informa tion HIGH COOLANT TEMPERATURE SWITCH This switches contacts close if the temperature should exceed approximately 140 C 284 F initiating an engine shutdown The generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level LOW COOLANT LEVEL SENSOR Should the engine coolant level drop below the level of the high coolant temperature switch it is possible for the engine to overheat without automatic shut down To prevent such overheating the engine has a low coolant level sensor If the level of engine coolant drops below the level of the low coolant level sensor the engine automatically shuts down LOW PRESSURE SWITCH This switch has normally closed contacts that are held open by engine oil pressure during cranking and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit sh
29. transfer switch In order to transfer load from the utility source to the generator follow these directions Turn OFF or disconnect the utility power circuit to the transfer switch using the means provided such as the utility source main line circuit break er Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the standby generator s main line circuit break er to its OFF or OPEN position Start the generator Operation caution Do crank engine continuously for longer than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge read ings When certain that all readings are correct move the transfer switch manual handle to its STANDBY GENERATOR position i e load cir cuits supplied by the generator the standby generator s main line circuit break er to its ON or CLOSED position Load circuits are now powered by the standby generator RETRANSFER AND SHUTDOWN For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch To transfer the load back to the utility power source and shut down the generator follow these direc tions Set the standby generator s main line circuit break er to its OFF or OPEN position
30. 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 BATTERY MAINTENANCE The battery should be inspected per Section 4 7 Scheduled Maintenance The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 90 21 10 4 2 Check battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer DIG A A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charg ing The slightest spark can ignite the gas and cause an explosion Such an explosion can shat ter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smok ing open flame sparks or any spark producing tools or equipment near the battery AN Battery electrolyte fluid is an extremely corro sive sulfuric
31. 0 1028 1 ASSY CARBURETOR 1 5 1 2 050401 1 CARBURETOR GASKET 21 091526 4 SCREWPPHMM608X12ZNC 22 019226 4 WASHER LOCK 23 026915 2 NIPPLE CLOSE 34 1 375 24 1 STUDTH 1 4 20X3 G2 ZNC FULL 25 022127 1 HEX 1 4 20STEEL 26 2 HEX 516 18 STEEL 27 1 DECAL FUEL INLET NG 1 DECAL FUEL INLET LPG 28 036125 2 STUD y16 18X L25 F THR 29 6155 1 HARNESS FUEL J UVPER SINGLE REG 30 0 1104 1 GASKET AIR CLEANER ADAPTER 31 0 0668 1 ORING 2 028 138 150 06 32 0 0590 1 VENTURI 18 33 0C5133 1 ORING 2222 X 262 0 0665 1 SCREWTHROTILE PIN STOP 35 1108 1 THROTTLE ARMREWORK 36 083138 1 SCREWHHM 410 32 X 5 8 37 022152 1 WASHER LOCK 0 38 0 0645 1 LEVER THROTTLE STOP 084339 1 BARBEDEL 9038 X58 40 0591982 1 HOSE 5 8IDX 20 5 LG 41 057823 2 CAMP HOSE 240 56 106 42 010173 2 CLAMP HOSE 35 5 62 62 43 089617 1 BARBEDSTR 14 X 1 4 44 080840 1 HOSE 1 4 IDSAE 3087 45 QA7040 1 BRACKET RAD HOSE INCLUDEDINITEM 19 CARBURETOR ASSY NOTES 1 REGULATOR AS SHOWNINILLUSTRATIONIS SET UP FOR NATURAL GAS APPLICATION 2 TOCONHGURE REGULATOR FOR LP VAPOR SWITCH HOSE BARB HOSE CLAMP N41 AND HOSE VN 40 TO OUT 2 REPLACE PIPE PLUG FROM OUT 2 TO OUT 1 USE PIPE SEALANT ON HOSE BARB AND PIPE PLUG SURE TO KEEP PORTS FREE FROM DEBRIS DURING RECONFIGURATION PROCESS 3 FOR LP VAPOR APPLICATIONSUBSTITUE LPG FUEL INLET DECAL P N 05
32. 0280 FOR NG FUEL INLET DECAL P N 050279 27 4 WHENSWITCHING FUEL TYPES THE PROPER DIP SWITCH SITTINGS MUST BE MADE TO THE CONTROL PANEL SEE OV NERS MANUAL FUEL SECTION FOR MORE DETAILS REVISION G 7534 B DATE 3 3 06 GROUP E PAGE 2 OF 2 GROUP INSULATION AND RETAINERS LOCATED ON THE NEAR SIDE 7 S INSULATION AND RETAINERS LOCATED ON THE FAR SIDE TYPICAL MOUNTING OF ACOUSTIC INSULATION EXPLODED VIEW ENCLOSURE C1 CPL DRAWING 58 Xe 0F7356 PAGE 1 OF2 EXPLODED VIEW ENCLOSURE C1 CPL DRAWING 0F7356 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 1 ROOF C1CPL 2 OF 7004 1 CORNER POST LHSIDE 3 OF 7008 1 DOOR REAR CPL 4 OF 7005 1 CORNER POST RH SIDE 5 OF 7007 2 DOOR LH amp RHSIDE C1 CPL 6 OF 7006 1 DUCT FRONT DISCHARGE C1CPL 7 0C2634A 1 ASSEMBLY COVER ACCESS 8 0912970001 1 ASSY AVG 13 8 GRN YEL 9 0012970000 2 ASSY WRE 14AWG 33 5 GRN YEL 10 E5968 1 GASKET EXTRUDED TRIM 356 LG E257 6 SCREWHMHIF 1 0 16 12 077992 18 HEXLOCK 6 1 055 NY INS 13 OF5049 3 TAB PULL 050482 3 VSE ACTION LATCH SLOTTED CIR 15 022473 1 WASHER FLAT 14M6 ZINC 16 02209 1 WASHER LOCK 1 4 17 022127 1 HEX 1 4 20STEEL 18 0C2454 24 SCREWTHF 1 16 ZJ 5 19 078115 2 WASHER SELF LOCKING DOIVE 20 2 RETA
33. 16 178 gt MAN AUTO INPUT 7 153 h _ 31 16 SENSED 8 224 mu ALARM RELAY 9 N XFER RELAY 710 23 14 MAN INPUT 11 239 16 SENSECO 12 225 o o ARE NS m deest 4 16 36 4 6 5 6 1 51 E 1336 13 Nw I 14 14 15 148 9 G14 154 2 emm c 15 OF 15 m DET 15 51 FROM T SW UTILITY FROM T SW TRANSFER RELAY COIL TRANSFER RELAY COIL REMOTE START REMDTE START REVISION GROUP G WIRING DIAGRAM 1 5L COMMERCIAL PROD LINE PAGE 1 OF2 DATE 05 24 05 DRAWING 0F7132 GROUP G es ENGINE WIRING LEGEND AFS AIR FUEL SOLENOID ALT D C CHARGE ALTERNATOR BAT 12VDC BATTERY DCVR DC VOLTAGE REGULATOR DIST DISTRIBUTOR CB J FS FUEL SOLENOID 5 AUX FUEL SOLENOID DEG 12V 1 GND GROUND OX INP RET 2 805 HIGH COOLANT TEMP SWITCH DEG GND 3 6 CONNECTOR 1 ON PCB COOLANT SENSORS 4 85 LFP LOW FUEL PRESSURE SWITCH DEG 0 5 LOS LOW DIL PRESSURE SWITCH DEG 5 6 MP1 MAGNETIC PICKUP DISTRIBUTOR 12V 7 OXYGEN SENSOR AFS 8 STARTER CONTACTOR CRANK SENSOR IN 9 79 STARTER MOTOR CRANK SENSE 10 0 STM STEPPER LFP IN 11 601 WLS COOLANT L
34. 22152 4 WASHER LOCK 0 16 097146 1 FAN amp RING GEAR ASSEM 17 012558 1 KEY SQ38X1STEEL 18 QA506L 1 SPACER FLEX PLATE 19 044989 1 PLATE FLEX 20 05360 1 SCREWHHC MI 175X35G88 21 051769 6 WASHER LOCK MI2 2 049541 4 SCREWHHC 1 5 35688 23 046526 4 WASHER LOCK MIO 24 045772 4 NUT HEXMIO 15 G8 YEL 26 087509 2 PLUG PLASTIC 38NPT 27 077013E 1 FLEXCONDUIT 1 BLACK NOT SHOWN 28 022131 4 WASHER FLAT 3 8 M10 ZINC 29 072578 1 SPACER ROTOR SHAFT 30 073 5 SCREWHHC 2 1 25 25 8 8 31 049808 5 WASHER FLAT MI2 32 058589 1 DECAL WARN ENG START 33 023365 4 WASHER SHAKEPROCF INT 8 35 048830 4 WASHER FLAT 34 75 OD 36 072080 1 DECAL DANGER STANBY UNITS REVISION G 8142 B DATE 5 18 06 GROUP A PAGE2 OF 2 0086740 1 JO ALVA 18 Wd 009 001 4 27 6L9 D QHGO Id XJ 19134 SATOH 33N31SV3 N3d0 2305 310 4 EXPLODED VIEW 100 3600 RPM 1 5L 240V DRAWING 0F7380D APPLICABLE IIEM PART DESCRIPTION 1 OF 1823A 1 ENCL HSB CONTROL PANEL 2 0 3078 1 COVER CONTROL PANEL 3 02206 1 HINGE CONTINUOUS HPN 4 08626 6 125 27555 5 013181 4 SCREWPHMIVBO5X 6 02777 7 WASHERFLAT NB 7 OF4245F 1 ASSY CPL 3600RPM 8 021262 4 HOLDER FUSE WCKMANN 1786150 9 FRG 1 ADPTR RHSIDE WCKMAN 1786191 10 021264 1 ADPTRLHSIDE 1786192 n 1 ASSY PCB 2
35. 5 TENE 3229 e 3 Doors Removed for Clarity SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary Figure 10 4 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 commercial 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 0 5 0 6 mm 0 020 0 025 inch by carefully bending the ground electrode Figure 10 4 Figure 10 4 Setting the Spark Plug Gap SET PLUG GAP AT 0 5 0 6 mm 0 020 0 025 inch COOLANT CHANGE Every year have an Authorized Service Facility drain flush and refill the cooling system See Specifications for cooling system recommendations 90 0 MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance MISCELLANEOUS MAINTENANCE 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
36. 6 18 STEEL SCREWHHC 10 30 88 PIPE EXINLET MANIFLDSIDE 15 EXHAUST BLANKET 800MM NIPPLE 1 5 5 5 BLK IRON HEXM6 X LOGS YEL CHR WASHER FLAT 1 446 ZINC WASHER LOCK 6 1 4 GROUP F PAGE 2 OF 2 CONTROL PANEL LEGEND AVR AUTOMATIC VOLTAGE REGULATOR BATTERY CHARGER DIODE lt FIELD BOOST CIRCUIT BREAKER EXCITATION FUSE BAT POWER 154 ATO TYPE CONNECTOR PCB CONNECTOR 3 PCB FIELD BOOST RESISTOR 25 OHM RELAY 1 START RELAY RELAY ENGINE RUN AUTO OFF MANUAL SWITCH SWe SET EXERCISER SWITCH SUC TR1 TRANSFORMER 1 SINGLE PHASE STATOR SHOWN FOR 3 PHASE SEE DWG OF 6839 CUSTOMER CONNECTION amp ALTERNATOR LEGEND BRUSH ASSEMBLY GENERATOR ICT INTERCONNECT TERMINAL BLOCK MCB MAINLINE CIRCUIT BREAKER NB NEUTRAL BLOCK UCT UTILITY CONNECT TERMINAL BLOCK NOTE ALL WIRES ARE 18 TB OTHERWISE NOTED AS SHOWN SIZ CAWG UL LISTED UNLESS 5 s wa 4 ec SW2 L1 120 VAC mrua 1 NOT USED 2 W1 4 We pone R4 wen 5 W3 CUSTOMER 5 6 W4 13 BRI 22 ANALOG INP RET J LL START RELAY 2 56A FUELCRUND RELAY 3 14A E WIRE STARTCD 4 183 MOMENT 5 18 15 2 WIRE START D
37. 783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX 10 32 NYL INS 11 0A7041 1 ASSEMBLY CARBURATOR LINKAGE 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 LIQUID NEOPRENE 14 029333A 1 TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZINC REVISION F 5248 B DATE 12 4 01 PAGE 2 OF 2 WATERPUMP HARDWARE GROUP D INCLUDED WITH ENGINE CP L CA ENGINE COMMON PARTS 1 5L CPL EXPLODED VIEW DRAWING 0F7444 REVISION G 7283 E DATE 2 20 06 PAGE 1 OF2 EXPLODED VIEW ENGINE COMMON PARTS 1 5L CPL DRAWING 0F7444 APPLICABLE ITEM 04531 REF 022473 2 1 044355 0 2632 048584 086277 042574 0461 0B9414 051769 OQM800A 045839 0413548 044839 069860C 0F3856 058443 042628 045586 OM5310244 0 1852 0912970066 070828 069860C 5 0 60 0 8 8 amp REVISION G 7283 E DATE 2 20 06 PART 085473 077996 060611 OA1354A 257 02273 022097 02244M F8 DESCRIPTION ITEM ENGINE L5L 7 WASHER FLAT 1 4ZINC 72 CLAMP VINYL 5 4062 GASKET EXHAUST MANFOLD 74 MANFOLDEXHAUST 75
38. ALT RPM ENGINE RPM PRODUCTION DATE ALTERNATOR SUBTRANSIENT REACTANCE ALTERNATOR TRANSIENT REACTANCE CLASS ROTOR STATOR WINDING INSULATION AT 25 C AMBIENT GENERAC POWER SYSTEMS INC WAUKESHA WI NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Generator Model and Serial Number This number is the key to numerous engineering and manufacturing details pertaining to your unit Always supply this number when requesting service order ing parts or seeking information PUT Standby Generator Sets E EX GENERAL GENERAL INFORMATION General Information Identification Code Use this code to obtain important information about the generator For example if the code is M Q T 1 0 0 5 4 M Designates generators capable of paralleling NOTE Only 100kW and 150kW 6 8L units are currently available for this configura tion QT Quiet Test Generator Series 100 kw Rating 5 4 Engine Size in Liters A Voltage Code A 120 240 Single phase G 120 208 Three phase K 277 480 Three phase J 120 240 Three phase L 346 600 Three phase N Fuel Natural Gas Vapor Propane S Enclosure Material A Aluminum S Steel Corrosion Resistant Aluminum Enclo
39. CKUSt u y u 8 2 Preparation for SEO 8 2 Start up Inspection oe erp 8 2 TABLE Standby Generator Sets TABLE CONTENTS Table of Contents CONTENTS OF OPERATION 9 1 Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch 9 1 Engine Start up and Transfer 9 1 Retransfer and Shutdown 9 1 Operating Unit with Automatic Transfer Switch 9 1 MAINTENANCKE u eene nennen nennen nnn 10 1 Maintenance Performed by Authorized Service Facilities 10 1 Every Three Months ertet 10 1 Once Every Six Months enesis nnr 10 1 Once Antal ys 10 1 First 100 Operating 10 1 Every 500 Operating 5 10 1 Every 800 Operating Hours 10 1 Exhaust Manifold Procedure 10 1 Intake Manifold Procedure aus eornm 10 1 Cylinder Head Procedure assqa sasa rot een 10 1 Cooling 10 2 Overload Protection for Engine 1 10 2 Checking Fluid Levels 10 2 Check
40. EL SYSTEM Natural gas is supplied in its vapor state In most cases the gas distribution company provides piping from the main gas distribution line to the standby generator site The following information applies to natural gas fuel systems Gas pressure in a building is usually regulated by national state and local codes To reduce gas pressure to a safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff sole noid should not exceed approximately 14 inches water column 0 5 psi Optimum pressure at the fuel shutoff solenoid is 11 inches water column 0 4 psi Standby Generator Sets Fuel Systems GENERAL INFORMATION PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid fuel in the supply tank Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state The vapor withdrawal system is generally best suited for smaller engines that require less fuel The installer should be aware of the following The natural gas and LP gas systems are similar However the natural gas system delivers gas at a pressure of approximately five inches water co
41. EVEL SWITCH DEG FDBK 12 WIRE SPLICE OX 113 804 14 COIL 4 2 15 DISTRIBUTOR RET 16 DISTR INPUT 17 DEG PWM 18 DEG ENABLE 19 LOW OIL PRESS T20 86 CRANK SHIELD 21 SHLD C 22 lt B 23 DIST AFS 808 DC VR i 2 3 45 48 0 4913 14 ALT amp 6 05 85 85 o 02 70 5 DPTIDNAL EMISSION CONTROL EX 0 0 14 4 WIRING DIAGRAM REVISION 1 51 COMMERCIAL PROD LINE DATE 05 24 05 DRAWING 0 7132 GROUP DIE aaa C DX quar RS if USED USED BLACK W1 RED We WHITE W3 GREEN W4 PCB 92 ANALOG INP RET 1 START RELAY 2 56A FUEL RUN RELAY 3 14A 2 WIRE STARTCD 4 183 J es gt MOMENT OPEN 5 15E WIRE START T 6 178 j INPUT 7 15A 16 SENSECD 8 224 NTRUL AVR AUTOMATIC VOLTAGE REGULATOR
42. Engine Oll 10 2 Battery Fluid oie eee ua esos SEES yasa 10 2 Engine Coolant 10 2 Maintenance Owner Operator Can Perform 10 3 Check Engine Oil Level esee 10 3 CHECK Battery 10 3 Exercise 10 3 Inspect Cooling 10 3 Check Engine Coolant 10 3 Perform Visual 10 3 Inspect Exhaust 10 3 Check Fan R 10 3 Inspect Engine Governor 10 3 Changing Engine Oil 10 3 Changing the Engine Cleaner 10 3 Spark 225545 455 455554 3455 5 8545433558458 580143 10 4 Coolant Changes eens 10 4 Miscellaneous Maintenance 10 4 Cleaning the Generator 10 4 Battery de MD 10 4 Battery Maintenance eret eret hee 10 4 Battery ete iret tenete 10 5 SERVICE SCHEDULE 11 1 TROUBLESHOOTING 12 1 Troubleshooting Guide 12 1 NOTES EXPLODED VIEWS
43. INER INSULATION 820 21 qr3800 4 RETAINER INSULATION 450 2 0 7365 2 INSULATIONSIDE DOOR C1 23 73658 1 INSULATION REAR DOOR C1 2 F7365A 1 INSULATION ROOF C1 25 OF8869D 1 KEY MSE ACTIONLATCH SLOT CIR REVISION G 7989 C DATE 4 25 06 OPTIONAL MATERIALS ALL P NS WTHAN 00 SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER GooooSN STEEL TAN ALUMNUM STEEL ALUMNUM ALUMINUMENCLOSURE NOTE ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 18 amp 11 THREAD FORMING FASTENER AND ITEM 12 LOCK NUT LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS ALL ROOF PANELS ARE TO BE SECURED IN THE SAIVE MANNER GROUP F PAGE 2 OF 2 GROUP EXPLODED VIEW 1 5L C1 0F7492 DRAWING PAGE 1 OF2 10 14 05 REVISION G 6609 B DATE EXPLODED VIEW EXHAUST SYSTEM DRAWING 0F7492 APPLICABLE TO ITEM PART REVISION G 6609 B DATE 10 14 05 ES IS OY O0 UJ UJ I IN I EPP EE DESCRIPTION MUFFLER C1 MUFFLER SADDLE PIPE EXHAUST OUTLET PIPE EXHINLET MUFLR SIDE 15 SCREW HMHIF M6 L0X 16 MUFFLER STRAP 51618 214 BOLT U 31618X 2 09 SADDLE 2INCH WASHER LOCK 516 NUT HEX 5 1
44. INTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp be done Comp to be done Comp Required to be Date 3 months Semi to be Date monthly Initials Break in Initials annually Initials Annually Initials 10 Hrs 30 Hrs Disable the unit from operating per the first page warning Check the engine oil level Adjust as necessary Check the engine coolant level Adjust as necessary Check the engine coolant thermal protection level Correct as necessary Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 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 a
45. ND OPERATION Refer to the appropriate control panel operator s manual for this unit OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the generator was installed in conjunction with a transfer switch capable of manual operation only the following procedure applies A manually operated transfer switch is one that will not provide automatic start up and does not include an intelligence circuit ENGINE START UP AND TRANSFER For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch DIG A The Maintenance Disconnect Switch and the AUTO OFF MANUAL switches if so equipped must be set properly or the generator will crank and start as soon as the utility power to the transfer switch is turned off Refer to applicable control panel and transfer switch manuals for more information Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to UTILITY Do not attempt manual operation until all power supplies to the transfer switch have been posi tively turned off or extremely dangerous pos sibly lethal electrical shock will result Transfer switch enclosure doors should be kept closed and locked Only authorized personnel should be allowed access to the transfer switch interior Extremely high and dangerous voltages are present in the
46. P WATER IN BATTERY ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications Add recommended coolant mixture as necessary Periodically remove radiator pressure cap only when engine has cooled down 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 Service Dealer Inspect cooling system and coolant recov ery system for leaks MAINTENANCE OWNER OPERATOR CAN PERFORM CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels CHECK BATTERY See Checking Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary 40 01 EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 20 minutes See Weekly Exercise Cycle INSPECT COOLING SYSTEM Inspect engine cooling system See Maintenance Schedule Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose
47. Rotor Class F COOLING SYSTEM Stator Class F Total Harmonic Distortion ette lt 5 U Closed Telephone Interference Factor 50 Water Pump Belt Driven Alternator Output Leads 3 4 wire 8 2550 P Sanga us D E E Sealed Ball 15 inches Flexible Disc Fan Pusher Load Capacity Standby Rating 20kW Air Flow inlet air including alternator and NOTE Generator rating and performance in accordance with 1508528 5 BS5514 SAE J1349 combustion air 1528 ft3 min 1503046 and DIN 6271 Standards KW rating is based on LPG fuel and may derate with natural Coolant Capacity se 2 0 U S gal Bs Das Heat Rejection to 107 000 Btu h iii dna d d ERE HEEL irec ina Ai i Garrat i Amp 120 240V 1 phase 1 0 pf 20 83 100 120 208V 3 phase 0 8 pf 20 69 80 Generator Locked Rotor KVA Available Voltage Dip of 35 FUEL SYSTEM Single phase or 208 3 34 KVA Type of Fuel Natural Gas Propane Vapor Sco mE Down D
48. Serial Number 1 5L Models STANDBY GENERATOR OWNER S MANUAL 4 a GENERAC SNSRAS new standard of reliability GENERAC POWER SYSTEMS INC This manual should remain with the unit 267740 ON Hed 90 80 V ed OF SECTION PAGE SAFETY RULES 1 1 INTRODUCTION 1 3 Read this Manual 1 3 Operation and Maintenance 1 8 How to Obtain Service uo reinan 1 3 IDENTIFICATION RECORD 2 1 2 1 EQUIPMENT DESCRIPTION 3 1 Equipment Description 3 1 Engine Oil Recommendations 3 1 Coolant Recommendations 3 1 ENGINE PROTECTIVE 4 1 High Coolant Temperature Switch 4 1 Low Coolant Level Sensor 4 1 Low Oil Pressure Switch reete eere edens 4 1 Overcrank Si Own 4 1 Overspeed Shutdown eite eet nein dae 4 1 RPM Sensor Loss Shutdown 4 1 DSS 4 1 FUEL SYSTEMS
49. al assume that the standby electric system has been installed by an 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 simply contact an Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting an Authorized Service Dealer or the factory 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 LABEL affixed to the unit AUTHORIZED SERVICE DEALER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 or locate us on the web at www generac com 90 80 0 ed 100 jejes INFORMATION IDENTIFICATION RECORD DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator The data label which can be found attached to the gen erator s lower connection box lists the unit s serial number and its rated voltage amps wattage capacity phase frequency rpm power factor etc GENERATOR SET DATA MADE IN USA MODEL SERIAL RATED KW RATED KVA PHASE RATED VOLTAGE RATED AMPS POWER FACTOR HERTZ
50. brass fitting ___ IDANGER A 8 Tighten all clamps and plugs 9 Make sure fuel supply is of the proper pressure Serious injury damage may occur if not con and type for configuration figured properly Please consult an Authorized Dealer with any questions S0 LL 8 6109905099 6 2 GENERAL INFORMATION GENERATOR AC LEAD CONNECTIONS See Voltage Codes This generator may be rated at any one of three voltages either single phase or three phase The electrical wires in the units AC con nection lower panel should be installed according to the number of leads and the voltage phase required for the application If there are any questions regard ing lead connection refer to the wiring diagrams at the back of this manual Voltage codes apply to the type of stator assembly installed on a particular generator FOUR LEAD SINGLE PHASE STATOR Four lead generators see Figure 7 1 are designed to supply electrical loads with voltage code 240V 1 60 Hz Electrical power is produced in the stator power windings These windings were con nected at the factory to the main circuit breaker as shown in Figure 7 1 The rated voltage between each circuit breaker ter minal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator m tm oen E M p E3 120
51. cessary Replace contactor Replace starter motor Remove change or replace battery Replace fuse Replenish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Close door on tank Clean or replace as needed Unclog fuel line Clean regap or replace plugs Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch 1 Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Auto reset Wait 5 min and attempt restart Contact the nearest Authorized Dealer for assistance 12 1 90 80 0 100149191 NOTES Standby Generator Sets Notes NOTES NOTES Standby Generator Sets Notes NOTES NOTES Standby Generator Sets Notes NOTES NOTES Standby Generator Sets Notes NOTES 638140 ONIM V YA C JO 1 HDVd 90 8 9 31VG 81 4 145 NOLLO3NNOO 8 0 NOISIATH 65 at 274 2 1 gt 01 N z Nus 7 1 2 1 co 1 lt M 1 wy a 1 1 1 s
52. ct the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts 90 80 0 ed 100 jejes Before performing any maintenance gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE 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 con ditions from leaking exhaust gases fuel leakage oil leakage etc A 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 well as the standby generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appropriate covers guards and barriers are in place before operating the gen erator 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 personnel must stand on metal or concrete while installing operating servicing adjusting or repair
53. d in the specifications Use only deion ized 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 mixture caution 4 AN Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chro mium hydroxide green slime forms and will cause overheating Engines that have been oper ated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment DIG A Do not remove the radiator pressure while the engine is hot or serious burns from boiling liquid or steam could result Ethylene glycol base antifreeze is poisonous Do not use mouth to siphon coolant from the radiator recovery bottle or any container Wash hands thoroughly after handling Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them 90 80 0 GENERAL INFORMATION ENGINE PROTECTIVE DEVICES The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant
54. e from the the control panel For the H 100 and R series Open the front door of the control box and remove the 15 Amp ATO fuse in the lower left hand corner of the control box Connect the battery cables to the battery Attach negative battery cable last Close the 120VAC circuit breaker to the battery charger Measure the voltage at the battery before and after the charger is turned on Verify all AC electrical connections are tight at the circuit breaker and transfer switch Visually inspect entire area looking for loose paper plastic wrappings leaves etc Check all hoses clamps fittings for leaks or dam age Check all electrical plugs throughout the genera tor Ensure each plug is seated correctly and fully inserted into its receptacle Verify the AUTO OFF MANUAL switch is in OFF position Open the valve to the engine fuel line Bleed the fuel system of air necessary for long fuel lines Open the generator main line circuit breaker Connect a manometer to the gas line and record the static pressure It must be as listed in the Specifications Insert the fuse into the control panel Move the AUTO OFF MANUAL switch to the MAN UAL position The engine should now crank and start 90 50 9 10019541 Check voltage at the generator terminals For 3 phase units check phase rotation at the transfer switch terminals The generator phase rotation must match the utility phase rotation Check for coolant fuel
55. ete Slab SIDE AREA See Install Dwg for Dimensions COLD WEATHER KIT 10 Reverse the procedure to convert back to natural gas 11 The Dip switch inside the control panel must be in the LP or NG position when switching to differ For cold climates optional cold weather kit part number 0 6148 is recommended The kit includes Battery Warmer ent fuels 4 Junction Box with hardware 6 qt pack 5W 30 synthetic oil engine Figure 6 2 Reconfigure the Fuel System RECONFIGURING THE FUEL SYSTEM in epee All models are configured for natural gas or LP Pore vapor from the factory FUEL HOSE BRASS HOSE BRASS H puis m E FITTING FITTING To reconfigure fuel system from NG to 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 6 2 NG FUEL SYSTEM LP FUEL SYSTEM 3 Remove the brass hose fitting from the outlet port Port 1 of the demand regulator NOTE 4 Remove pipe plug from Port 2 5 Install brass hose fitting into Port 2 Port 1 is for NG only and Port 2 is for LP vapor only provision dual fuel has been made 6 Install pipe plug into Port 1 7 Connect carburetor gas hose to
56. ght cost for replacement part s THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC POWER SYSTEMS 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 purchaser owner GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS INC NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitations may not apply to purchaser owner Purchaser owner agrees to make no claims against Generac Power Systems Inc based on negligence This warranty gives purchaser owner specific legal rights Purchaser owner also may have other rights that vary from state to state Generac Power Systems Inc Box 8 Waukesha WI 53187 Ph 262 544 4811 Fax 262 544 4851 Bulletin 0171360SVE Printed in U S A 7 05 Printed in U S A
57. ices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY 1 Test engine governor adjust or repair if needed 2 Clean inspect generator 3 Flush cooling system FIRST 50 OPERATING HOURS 1 Change engine break in oil and filter FIRST 100 OPERATING HOURS l Change engine oil and oil filter After initial change service engine oil and filter at 100 operat ing hours or six months whichever comes first 2 Retorque cylinder head 3 Retorque intake and exhaust manifold EVERY 500 OPERATING HOURS l Service air cleaner 2 Check starter 3 Check engine DC alternator EVERY 800 OPERATING HOURS 1 Retorque cylinder head 2 Retorque intake and exhaust manifold 3 Check engine compression 4 Check valve clearance COOLING 5 5 intake outlet openings generator 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 the installation diagram warninc amp The exhaust system parts from this product get extremely hot and remains 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
58. ing 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 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 maxi mum electrical current ampacity to which they will be subjected Before installing or servicing this and related equipment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in hazardous and pos sibly fatal electrical shock Connecting this unit to an electrical system nor mally 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 operat ing 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 90 80 0 100 5 Standby Generator Sets Important Safety Instructions SAFETY RULES
59. it is used in an average service application They will need to be decreased performed more frequently if the unit is used in a severe applica tion Use calendar time or accumulated run time from the previous maintenance interval to determine the next required maintenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten tial problem areas Performed monthlu this requires approximatelu 5 man hours per unit to complete This inspection mau 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 5 amp and 15 amp control panel fuses Turn off the battery charger turn OFF utility supply to ATS Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to s
60. l umn to the carburetor When ambient temperatures are low and engine fuel consumption is high the vapor withdrawal system may not function efficiently Ambient temperatures around the supply tank must be high enough to sustain adequate vaporiza tion or the system will not deliver the needed fuel volume In addition to the cooling effects of ambient air the vaporization process itself provides an additional cooling effect LP FUEL SYSTEM LP is supplied as a liquid in pressure tanks It is usually made up of propane butane or a mixture of the two gases Propane tends to vaporize readily even at temperatures as low as 20 F 29 C However butane reverts to its liquid state when temperatures drop below 32 F 0 C LP in a liquid withdrawal system must be converted to its gaseous state before it is introduced into the engine carburetor A vaporizer converter is generally used to accomplish this In such a converter heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state 90 80 100545114 INFORMATION Standby Generator Sets Fena INFORMATION Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump Gear GENERATOR FILE Full Flow Cartridge WO E um Synchronous ON RAPACI
61. missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks 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 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 of an inch Adjust belt tension as required INSPECT ENGINE GOVERNOR Visually inspect electronic governor DIG A 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 incor rect frequency and or voltage Only qualified service technicians should adjust the governed speed Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance CHANGING ENGINE OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies Drain the oil while the engine
62. ould not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO Standby Generator Sets Engine Protective Devices GENERAL INFORMATION OVERCRANK SHUTDOWN After a prespecified duration of cranking this func tion ends the cranking if the engine has failed to start The overcrank LED will turn ON Turn OFF the AUTO OFF MANUAL switch then turn switch back to AUTO to reset the generator control board NOTE If the fault is not corrected the overcrank feature will continue to activate Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total OVERSPEED SHUTDOWN A speed circuit controls engine cranking start up operation and shutdown Engine speed signals are delivered to the circuit board whenever the unit is running Should the engine overspeed above a safe preset value the circuit board initiates an automatic engine shutdown Contact the nearest Authorized Dealer if this failure occurs RPM SENSOR LOSS SHUTDOWN If the speed signal to the control panel is lost engine shutdown will occur DC FUSE This fuse is located inside of the control panel It protects the panel wiring and components from damaging overload Always remove this fuse before commencing work on the generator The unit will not start or crank if the fuse is blo
63. r viced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules as well as all other safety information in this manual before attempting to operate this and related equipment Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information service intervals please refer to the Maintenance section and the Service Schedule TRANSFER SWITCH If this generator is used to supply power to 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 FUEL SYSTEM Make sure fuel supply system to genera tor a delivers the correct fuel at the correct pres sure and b is properly purged and leak tested according to code No fuel leakage is permitted See Specifications for more information GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the prope
64. r and Stator insulation is Class F rated as defined by NEMA MG1 32 6 NEMA 1 1 66 The generator is self ventilated and drip proof con structed The voltage waveform deviation total harmonic content of the AC waveform and telephone influ ence factor have been evaluated and are acceptable according to NEMA MG1 32 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE SE 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 Temperature Above 80 F 27 C SAE 30W or 15W 40 SAE 20W 20 or 15W 40 32 to 80 0 to 27 C Below 32 F 0 C See Note caution Ak 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 NOTE For temperatures below 32 it is strongly recom mended to use the optional Cold Weather Start Kit part number listed in the Specification Section The oil grade for temperatures below 32 F is 5W 30 synthetic oil Standby Generator Sets Equipment Description GENERAL INFORMATION COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is liste
65. r level the dipstick FULT mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications and Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with break in oil This oil should be changed after 30 hours of operation Check the oil level in the generator gearbox if so equipped prior to initial use and at the intervals indicated by the Service Schedule The recom mended oil is SAE 90 gear lubricant Also if the engine is equipped with a mechanical gov ernor make sure the governor is properly lubricated with clean engine oil PRIOR TO INITIAL START UP caution 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 ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications and Coolant sections 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
66. raft ENGINE Secondary Fuel Regulator Standard Make Generat Fuel Shut off Solenoid I Standard T SSS Pael Consumption Natural Gas LPV OO 2 97 in 2 do 208 Strok 3231 Cycle Load Load Load Load 9 1 a 60 24 124 49 188 75 250 99 31 5 1 25 Air Intake asas Naturally Aspirated ELECTRICAL SYSTEM 0 Charge Ate ator 124 15 MM Static Battery 2 Engine Parameters Recommended Group 26 525CCA Rated Synchronous 60 Hz 3600 System sss 12 Volls HP rated KW 60 Hz 32 Voltage Regulator Exhaust System Type Rm Electronic Exhaust Flow at Rated Output 60 177 cfm 4 Exhaust Temperature at Rated Output 910 F Adjustable Adjustable Combustion Air Requirements Natural Gas Voltage and Gain LED Indicators Flow at rated power 60 Hz
67. s necessary gt a 90 90 00 98 11 2 Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp done Comp Required Comp to be done Date 3 months Date i Date be done Date monthly Initials Break in Initials Initials Annually Initials 10 Hrs 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 the engine oil filter s 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 100 Hrs 11 3 90 50 2 00 TROUBLESHOOTING Standb
68. so make sure the procedure work method or operating tech nique utilized does not render the generator unsafe DIE A AN Despite the safe design of this generator operating this equipment imprudently neglect ing 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 generators GENERAL HAZARDS For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by an Authorized Service Dealer or other competent qualified electrician or installation tech nician who is familiar with applicable codes stan dards and regulations The operator also must comply with all such codes standards and regula tions 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 electri cal and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operated and serviced in accordance with the
69. sure Material Steel is Standard N Emission Equipment N No Equipment Y Catalytic Converter and Air Fuel Ratio Controller A Industrial Dealer Product Voltage Codes The identification code letter following the unit s engine size is the generator s voltage code Groups and Assembly Numbers The manual drawing listing lists the groups and cor responding assembly numbers for each unit The assembly numbers refer to exploded view drawing numbers that are applicable to the specific generator model These drawings are located in the back half of this manual 90 70 O 100Auepl GENERAL INFORMATION EQUIPMENT DESCRIPTION This equipment is revolving field alternating rent generator set It is powered by a gaseous fueled engine operating at 1800 rpm 4 pole direct drive units 3600 rpm for 2 pole direct drive units and 2300 3000 rpm for quiet drive gear units See the Specifications section for exact numbers The unit comes complete with a sound attenuated enclosure internally mounted muffler control console main line circuit breaker battery charger and protective alarms as explained in the following paragraph All AC connections including the power leads from the alternator 120 volt battery charger input and control connections to the transfer switch are avail able in the main connection box The generator incorporates the following generator features Roto
70. tandby setup for normal operation when required 2 A break in service inspection of the generator set to insure 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 30 run time 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 a Service Dealer 3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed semi annually this 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 a Service Dealer 4 A mid level inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed annually this 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 a Service Dealer 11 1 90 50 9 00 5 Standby Generator Sets MAINTENANCE MA
71. tion and testing by Generac Power Systems or an Authorized Certified Generac Power Systems Dealer or branch thereof is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be examined by the nearest Authorized Certified Generac Power Systems Dealer or branch thereof This warranty applies only to Generac Power Systems Generators used in Standby applications as Generac Power Systems Inc has defined Standby provided said generator has been properly installed and inspected on site by appropriate personnel Scheduled maintenance as outlined by the generator owner s manual is highly recommended This should be performed by an Authorized Certified Generac Power Systems Dealer or branch thereof This will verify service has been performed on the unit throughout the warranty period WARRANTY SCHEDULE YEARS ONE and TWO Limited comprehensive coverage on mileage labor and parts listed e ALL COMPONENTS Start up and or On line Registration or Registration Card along with Proof of Purchase must be performed and or sent in Guidelines Any and all warranty repairs and or concerns must be performed and or addressed by an Authorized Certified Generac Power Systems Dealer or branch thereof A Generac Power Systems Inc Transfer Switch is highly recommended to be used in conjunction with the genset If a Non Generac Po
72. tion that if not followed could endanger personal safety and or property of others A This symbol points out potential explosion hazard Important Safety Instructions 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 The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly 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 an Authorized Service Dealer Normal maintenance service 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 ensure a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and accessories Operating instructions presented in this manu
73. ty is present or in place of utility power where utility power service does not normally exist Failures caused by any external cause or act of God such as but not limited to collision fire theft freezing vandalism riot or wars lightning earthquake windstorm hail volcanic eruption water or flood tornado hurricane terrorist acts or nuclear holocaust Products that are modified or altered in a manner not authorized by Generac Power Systems in writing Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation or sizing 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 10 Failure due to misapplication misrepresentation or bi fuel conversion 11 Telephone facsimile cell phone satellite internet or any other communication expenses 12 Rental equipment used while warranty repairs are being performed i e rental generators cranes etc 13 Overtime holiday or emergency labor 14 Planes ferries railroad busses helicopters snowmobiles snow cats off road vehicle or any other mode of transportation deemed abnormal 15 Any and all expenses incurred investigating performance complaints unless defective Generac materials and or workmanship were the direct cause of the problem 16 Starting batteries fuses light bulbs engine fluids and overnight frei
74. uilding 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 com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris These generator sets may operate using one of several types of fuels All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulat ing the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks immediately Fuel supply lines must be prop erly installed purged and leak tested according to applicable fuel gas codes before placing this equip ment 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 Standby Generator Sets INTRODUCTION Thank you for purchasing this model of the standby generator set product line Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice
75. wer Systems Inc Transfer Switch is substituted for use and directly causes damage to the genset no warranty coverage shall apply All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty Policies and Procedures Flat Rate Manual Units that have been resold are not covered under the Generac Power Systems Warranty as this Warranty is not transferable Unit enclosure is only covered against rust or corrosion the first year of the warranty provision Use of Non Generac replacement part s will void the warranty in its entirety Engine coolant heaters block heaters heater controls and circulating pumps are only covered during the first year of the warranty provision If applicable THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Any unit built manufactured prior to January 1 2005 Costs of normal maintenance i e tune ups associated part s adjustments loose leaking clamps installation and start up Any failure caused by contaminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted or Rental Unit definition and warranty Units used for prime power in place of existing utility power where utili
76. wn Replace the fuse with one of the same size type and rating See the exploded views and parts lists at the end of this manual for replacement part number 90 80 0 ed 100lold6u3 GENERAL INFORMATION FUEL SYSTEM FUEL REQUIREMENTS The standby generator may be equipped with one of the following fuel systems Natural gas fuel system Propane vapor PV fuel system The Manual Drawing Listing that is affixed to the unit includes the Identification Code which may be used to identify the type of fuel system installed on the unit Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is 5 inches to 14 inches water column 0 18 to 0 5 psi and for liquid propane 5 inches to 14 inches of water column 0 18 to 0 5 psi NOTE Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below five inches water column for natural gas or 5 inches water column for propane vapor for all load ranges NOTE It is the responsibility of the installer to make sure that only the correct recommended fuel is sup plied to the generator fuel system Thereafter the owner operator must make certain that only the proper fuel is supplied NATURAL GAS FU
77. y Generator Sets Troubleshooting TROUBLESHOOTING GUIDE CAUSE PROBLEM Engine won t crank Engine cranks but won t start Engine starts hard runs rough Engine starts then shuts down AUTO OFF MANUAL Switch at OFF engine continues to run No AC output from generator 1 2 15 fuse blown Loose corroded defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery 5 amp fuse blown Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Door on tank not closed Flame arrestor air cleaner plugged or damaged Plugged fuel line Defective spark plugs Fuel pressure incorrect Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch Defective AUTO OFF MANUAL switch Open disconnected wire 415A between AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open ww CORRECTION 1 2 Replace fuse Tighten clean or replace battery cables as ne

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