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Generac Power Systems 005324-0 User's Manual

1. 14 DD EIC DECEM CM MIC MEN CIE MN 4 WIRING DIAGRAM REVISION 1 6L 2 POLE DATE 03 03 06 DRAWING 0G0925 GROUP G CONTROL PANEL LEGEND AVR AUTOMATIC VOLTAGE REGULATOR BCH BATTERY CHARGER BR1 BRIDGE RECTIFIER CIRCUIT BREAKER EXCITATION NOT USED F1 FUSE BAT POWER 15A NOT USED J2 CONNECTOR 2 PCB BLACK W1 33 CONNECTOR RED We R4 FIELD BOOST RESISTOR WHITE W3 RL1 RELAY 1 START RELAY GREEN W4 RL2 RELAY 2 ENGINE RUND SW1 AUTO OFF MANUAL SWITCH SW SET EXERCISER SWITCH TR1 TRANSFORMER 1 6 240 16 VAC e 2 158 START RELAY 2 56 15 FUELCRUN RELAY 3 144 SW2 SW1 1 2 WIRE STARTCD 4 183 9 15 _ MOMENT DPEN 5 15E IET SIS 2 WIRE STARTC 7 6 178 og a MAN AUTO INPUT 17 158 1 1 s 16 SENSEG2T8 224 m m ALARM RELAY 9 XFER RELAY 710 23 ____ MAN INPUT 111 239 1 16VAC SENSE 2 412 225 IEMISSIDNS ENABLE 13 o 680 8114 0 1 iid amm CONNECT FOR OPTIONAL EMISSIONS ONLY 144 E 15 e ICT 2 UTILITY FROM T
2. Naturally Aspirated Valve Seals uoces ani cnim celeres Replaceable Litter RD Hydraulic Engine Parameters Rated Synchronous 60 Hz 3600 ed 45 Hz Exhaust System Exhaust Flow at Rated Output 60 7 249 Exhaust Temperature at Rated Output 1015 F Combustion Air Requirements Natural Gas Flow at rated power 60 90 cfm Governor De Electronic Frequency Regulation ses Isochronous Steady State Regulation sss 2596 Adjustments Selectable Standby Generator Sets aa INFORMATION Specifications INFORMATION Engine Lubrication System Type of Oil Pump Gear Oil Flan Full Flow Cartridge Crankcase Oil 4 U S gts COOLING SYSTEM Closed VIOE F UD e Belt Driven FAN 2550 Diamo 15 inches Fan Pusher Air Flow inlet air including alternator and combustion air sees 1528 ft3 min Coolant Capacity cac ordei tres 2 0 U S gal Heat Rejection to Coolant 117 000 Btu h Maximum Operating Air Temp on Radiator 60 C 150 F M
3. FUEL HOSE FUEL HOSE E BRASS HOSE BRASS H puis E FITTING FITTING To reconfigure the fuel system from NG to LP 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 No provision for dual fuel has been made 6 Install pipe plug into Port 1 7 Connect carburetor gas hose to brass fitting ___ A IDANGER A 8 Tighten all clamps and plugs 9 Make sure fuel supply is of the proper pressure Serious injury or damage may occur if not con and type for configuration figured properly Please consult an Authorized Dealer with any questions 90 70 0 220090599 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 unit s 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 diagram
4. L GS dowd EXPLODED VIEW GOVERNOR ASSEMBLY DRAWING 061231 APPLICABLE TO BREE BRE DATE 3 24 06 PART QTY DESCRIPTION ASMMOTOR STEPPER HOUSING GOVERNOR CONNECTOR CONNECTOR INTERFACE ASSEMBLY COVER CONNECTOR HOUSING SCREW FHM 2 X 5 8 SELF TAP SCREWHHC 1 0 10G88 WASHER LOCK 1 4 SCREWPHMNBO5X 12 LEVER STEPPER MOTOR NUT LOCK HEX 40 32 NYL INS ASSY CARBURETOR LINKAGE ROD BRACKET STEPPER MOTOR OIL DIP STICK BRACKET 1 64 TIE WRAP 7 4 X 19 BLK UL SCREWHHC 1 4 20 1 2 5 SPRING LASH SCREW TAP HAH 46 25 X 38 ZINC GROUP D PAGE 2 OF 2 69 090 ONIA VIG HOVd 90 0 ALVA 1421279 Ad VON WALSAS 1 NOISH3ANOO HOdVA M Ino E NOLLVINHOJNI da 61 N D HO LVINDSY 2 ASSV 214 Sines m8 2 ALON 336 i 2 NOLLVYLSNTI1 NI NMOHS NI ONLLNIOd MOHHV Q3TIVILSNI 38 LSNW CIONTIOS LINVLYOdWI SS3NHVH ANIONS OL LOANNOO OL OL 3SVOXNVHO WOHS 81 e JSOH DNILSIXE dodo EXPLODED VIEW FUEL SYSTEM 1 6L C1 CPL DRAWING 060769 APPLICABLE TO ITEM PART DATE 3 22 06 QTY DESCRIPTION ELBOW90D 3
5. NOILOSNNOD lt dWV 672 170A 021 3398VHO9 1198 NDUIIO3NNDO JVALNIN NOILOSNNOD LINGNOD 4931 907 4 vadv dN ANLS ACISNI Cp SASNMO NIHLIM 133HS 199131 345 33 NOTLYWAOSNI a3 Vv3s8 LINDAIO CE SNUILVOIdddV 3D001NO 414 862640 N d 301 9 11 15 33N3433319 SDOLVS N39 3911N3 3H1 UNNDAIV 432 45 N3d0 30 43134 WOWINIW 1003 S V MOTY 11 Y NDA 1333 S 30 3 1510 WAWINIW Y 0319901 38 LSAW YOLVIINID SaNI34105 1430 ANY LN3W3OSDJNI3S Vd 31343 3 03 8628430 N d 30109 NOILVVIVLSNI 329N3 334d 8 9 1 0 562 X JAIM 0 66 3Z1S 094 1383 3 CSACNSWWO93YS WNWINIW CT SALON 4 441 11 3SV33ONI SUCIAS DNIddIHS 917647 593962 MAGZ 1971 917147 93682 MADOC 1971 D 0049 9190 IHDI3N 770150 4 1 JO HDVd 90 C e ALYA MAGZ 8 0c 19 NOLLVTITV LSNI ra LINGAN 100 303 l 4 123 2 3NI 13014 SNOISNAWIG ALIAYAD 30 1 32 eee MITA VA S MISIT UNVHLHDIS 0 21 959 dAL 335 1109419 1 49 6 906 3LON 33S dAL N3ADO 1ND3y 88 821 9 335 G EEZ NIHLIA 2350793 S33 1430 LSAVHX3 131 3IV NIHLIM 3 075 3 SI 1
6. 8 1 Prior to Initial 8 1 Engine Coolant bent 8 1 ee 8 1 Elecmical SM soeieg 8 1 Initial Inspection for QT Genset Start up 8 1 Startup Checklist 8 2 Preparation for SEO 8 2 Start up Inspection oe 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 10 1 Maintenance Performed by Authorized Service Facilities reete needed 10 1 Every Three Months ertet 10 1 Once Every Six Months enesis nnr 10 1 Once Antal ys der doo cada tub 10 1 First 100 Operating 10 1 Every 500 Operating HQUES 10 1 Every 800 Operating Hours 10 1 Exhaust Manifold Procedure 10 1 Intake Manifold Procedure eornm 10 1 Cyl
7. NOTE For temperatures below 32 F 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 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 listed 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 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 cap 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
8. 0 6839 GROUP G OPTION 4 THREE PHASE R SERIES CONTROL PANEL 12 WIRE 120 208 LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER B NEUTRAL BLOCK TB1 ES DIRECT DRIVE AS GENERATOR OUTPUT CUSTOMER CONNECTION El TO Ee Ee 208 E1 El E2 NB 120 THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 208VAC 4 4 WIRING DIAGRAM REVISION G 7501 B R SERIES CPL ALTERNATOR DATE 02 22 06 DRAWING 0 6839 GROUP G f CONTROL PANEL LEGEND i O AVR AUTOMATIC VOLTAGE REGULATOR BCH BATTERY CHARGER CUSTOMER CONNECTION BRI DIODE lt FIELD BOUST gt x CIRCUIT BREAKER EXCITATION amp ALTERNATOR LEGEND BRUSH ASSEMBLY GENERATOR BAT PLNER ISA ICT INTERCONNECT TERMINAL BLOCK Je CONNECTOR 2 ON MCB MAINLINE CIRCUIT BREAKER CONNECTOR 3 ON PCB NEUTRAL BLOCK FIELD BOOST RESISTOR 25 OHM UCT UTILITY CONNECT TERMINAL BLOCK RL1 RELAY 1 START RELAY RL2 RELAY 2 ENGINE RUN SW1 AUTD DFF MANUAL SWITCH NOTE ALL VIRES ARE IR Tee BER o OTHERWISE NOTED A
9. 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 50 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 667090 ONIMVUG HOVd ALVA SLUVd 195 NOILOANNOO MHIA 71 65 11 2 9 2 1 TW 2 dni e let 1 11 1 4 ul 1 1 1 1 E 1 T i i 1 1 E oq D 1 1 1 1 i 27 e 1 wt 1 1 2 1 1 2 2 lt dnodd EXPLODED VIEW CONNECTION BOX SPL PARTS DRAWING 060433 APPLICABLE TO GROUP A ITEM PART QTY DESCRIPTION BREAKER TRAY BACK BOTTOM SUPPORT CONTROL PANEL SIDE RH SUPPORT CONTROL PANEL SIDE LH COVER CIRCUIT BREAKER 2P COVER CIRCUIT BREAKER 3P PLATE WIRE SNGL GALV DECAL CUST CONN 120V UTILITY BLOCK TERM 20A 6X 3X 1100 DECAL UTIL SENSE CUST CONN BLOCK TERM 20A 8X 6X 1100V HANG TAG 2 START NOT SHOWN
10. 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 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 not crank the 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 W
11. 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 zoodmby 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 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 automat
12. 2 022131 17 WASHER FLAT 38 ZINC 23 045772 9 NUT HEXMIO 15G8 YEL CHR 2 060161 1 GASKET INTAKE MANIFOLD LEL 5 0G0465 1 GASKET EXHAUST MANIFOLD 18 26 052858 14 NUT TOP LOCK FL 125 27 061652 1 SCREWHHC 15 85688 28 057624 4 SCREWHHC 1 5 100G88 29 019541 4 SCREWHHC 15 35688 30 0894114 1 SCREWHHC 1 25 35688 31 022129 4 WASHER LOCK 5 16 2 022145 4 WASHER FLAT 5 164 ZINC 3 0203334 1 TIE WRAP UL 7 4 X 19 BLK 34 057821 3 SCREWHHC 1 25 40G88 35 045771 3 NUT HEX MB L25 G8 CLEAR ZINC 36 022507 2 SCREWHHC 1 4 20 1 2G5 37 022097 2 WASHER LOCK 1 4 38 022173 5 WASHER FLAT 14M6 ZINC 39 057223 1 HOSE 40 56 106 40 077996 1 CAP ANTIFREEZE RUBBER 41 046751 1 SWITCHH TEMP 245 DX 3 8 NPT 2 085579 1 BSHG RDCR HEX 1 4TO 1 8 B 028581 1 SWITCH OIL PRESSURE 10PSI 2POL 44 0 1852 1 ADAPTER DRAIN OIL 45 070828 1 HOSE OIL DRAIN 46 069860C 1 HOSE OIL DRAIN ASSY 21 4 069811 1 CAP HEX 1 4NPT BRASS 48 051241 1 THERMOSTAT HOUSNG MACHIND LEL 49 1 BY PASS COOLANT 50 040173 1 HOSE 55 62 62 51 E3257 3 SCREWHMHIF 1 0 16 52 048830 28 WASHER FLAT 4 1DX 750D 53 050905 1 HARN LEL R 200CPL NOT SHOWN DATE 3 22 06 GROUP D PAGE 2 OF 2 162190 ONIM VNA HOVd ALVA 19N3SSV 1 1971 38 9 WHY 1 G IO3INVIN 4
13. 4 NPT FLANGE FUEL INLET FUEL REGULATOR 1 8 REWORK SCREWHHC 1 25 20688 WASHER FLAT 5 16 ZINC WASHER LOCK 5 16 NUT HEXIVE L25 G8 YEL CHR BODY CARBURETOR ASSEMBLY BARBEDEL 90 1 8 X 38 HOSE 3 3 IDLOWPRES OIL MATER 816 NIPPLE PIPE 3 4 NPT HOSE 3 3 IDLOWPRES OILMATER 13 LG COVER AIR CLEANER HOSE COOL 5810250 316 DECAL INLET PRESSURE ITEM PART 42 11 059402 087561 D 059401 091526 E0527 L 3081P 01808 085579 MURNHHIHHHHHHBHHNNHHHIHIHHBHBHHHNHHBHHBHNAPRBHHHIH EBEBH GROUP E DESCRIPTION ADAPTER CARB TOAIR CLNR FILTER ELEIVENT NUT WING 1 4 20NYLK ASSY CARBURETOR 1 6 CARBURETOR GASKET SCREW PPHMIVB 0 8 X 12 ZNC WASHER LOCK NIPPLE CLOSE 34 1375 STUDTH 1 4 20X3 G2 ZNC FULL NUT HEX 1 4 20STEEL PINSPRING 3 16 X58 DECAL FUEL INLET NG DECAL FUEL INLET LPG SCREWHHC 5 16 18 X 1G5 HARNESS FUEL J UMPER SINGLE REG GASKET AIR CLEANER ADAPTER ORING 2 028 138X L50X 06 VENTURI 20MM BARBEDEL 9038 NPT X58 HOSE 5 3 IDLPG amp NG 16 LG HOSE 10 56 106 HOSE BAND 41 BARBEDEL 903 16 1 8 HOSE 3 16 ID FUEL LINE 22416 HOSE 3 4 ID SAE 30R2 31 HOSE BARB TEE 3 4 NYLON PCV VALVE 25L FORD HOSE BARB REDUCER 58 3810 SHAFT THROTTLE 19 THROTTLE VALVE PLATE 271M SCREWRHMS 6 32 X 1 4 ZINC SEAL SHAFT COVER HOSE 88 CLAMP HOSE BAND 63 HOSE BAND 1 0 BSHG RDCR 1 4 TO 1 8 1 I
14. ASSY WIRE AVG 138 GRN YEL 9 0012970000 2 ASSY WIRE 14AWG 33 5 GRNYEL 10 E5968 1 GASKET EXTRUDED TRIM 356 LG E3257 6 SCREWHMHIF 1 0 16 1298 077992 18 HEXLOCK M6 LOSS INS B OF5049 3 TAB PULL 14 050482 3 VISE 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 2 SCREWTHF 1 16 ZJ 5 19 078115 2 WASHER SELF LOCKING DOME 2 38008 2 RETAINER INSULATION 820 21 qr3800 4 RETAINER INSULATION 450 2 OF 7365 2 INSULATION SIDE DOOR C1 23 0F7365B 1 INSULATION REAR DOOR C1 CPL 2 0F7365A 1 INSULATION ROOF C1 CPL 5 OF8869D 1 KEY VISE ACTIONLATCH SLOT GR REVISION G 7989 C DATE 4 25 06 OPTIONAL COMPARTMENT 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 ANDITEM 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 F EXPLODED VIEW EXHAUST SYSTEM 1 6L C1 DRAWING 060435 PAGE 1 OF 2 3 21 06 DATE EXPLODED VIEW EXHAUST SY
15. 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 building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no 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 units fuel system frequently and correct any leaks immediately Fuel supply lines must be 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 produc
16. LEVEL SWITCH COIL A 15 25A DISTRIBUTOR 16 DISTR INPUT 17 DEG PWM 18 DEG ENABLE 19 LOW DIL PRESS 120 86 CRANK SHIELD 21 SHLD COIL C gt gt 22 COIL lt B 23 25B MP1 asa 8 105 18258 i 86 529 0 JEMISSION 85 0 gt 805 OPTIONAL HCT CONTROL T FRON 573 gt 0 DC VR 18345 e 54 09 LFP 601 1 0 4 LE 4 SCHEMATIC DIAGRAM REVISION 1 6L 2 POLE DATE 03 13 06 DRAWING 0G1042 770190 4 ONIM VNG dO 1 HDVd 90 2 ALVA MASC 8 02 197 NOLLWTIVLSNI AJIA 51 JAVSIDVIG ONISILAA 1 LON 33S dvd ONILNNOW 3134 Q3Q0N3WWD238 517108 YOHONY AYNOSVW VIC G2 D 21 5332 gt 3710H ONILNNOW VIC ES gt 52015 INV 1 043 SAJANDI J AVH SIA 419 ANY LSNVHXS 1343nN 15 553999 330 1417 3AUW3S 9 SDONINAVM 11 11 414 IWANVYW SS3NMD 22 4444484 S 5 NV NO 01 93139 30 ONILNNOW 3403 04410944 SI 410 LND 01314 Vv 53999 303 33A09 1NOY3 538418 1 41 HILIMS 3 1 01 55342339
17. SW ICT 3 TRANSFER COIL RELAY 94 4 COIL RELAY 1 56 83 5 START y Tas 78 6 START HT eee Lisa 56A TOM NNECTION RNATOR BA BRUSH ASSEMBLY GENERATOR CB1 MAINLINE CIRCUIT BREAKER 240V OUTPUT TO TRANSFER SWITCH ICT INTERCONNECT TERMINAL BLOCK NEUTRAL BLOCK UCT UTILITY CONNECT TERMINAL BLOCK INOTE 1 WIRING SHOWN FOR NB AND STATOR IS TYPICAL FOR SINGLE PHASE FOR 3 PHASE SEE DWG OF6839 Es ls o eee ee ER UU ee eis 4 SCHEMATIC DIAGRAM REVISION 1 6L 2 POLE DATE 03 13 06 DRAWING 0G1042 GROUP G E THE EGE 1 ENGINE WIRING LEGEND AFS AIR FUEL SOLENOID CB J ALT D C CHARGE ALTERNATOR BAT 12VDC BATTERY DEG 12V T 1 CP COIL PACK OX INP RET72 805 DCVR DC VOLTAGE REGULATOR DEG GND 3 FS FUEL SOLENOID COOLANT TEMP 4 85 FS2 AUX FUEL SOLENOID 0 5 HCT HIGH COOLANT TEMP SWITCH cov sv 6 Ji CONNECTOR 1 CON PCB DISTRIBUTOR 12 7 LFP LOW FUEL PRESSURE SWITCH COOLANT LEVEL 8 573 LOS LOW OIL PRESSURE SWITCH CRANK SENSOR 9 79 MP1 MAGNETIC PICKUP CRANK SENSE RET T10 0 DXYGEN SENSOR LFP INP 11 601 SC STARTER CONTACTOR GOV FDBK 12 SM STARTER MOTOR OX 113 804 STM STEPPER MOTOR 14 15R WLS COOLANT
18. 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 blown 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 generato
19. by an Authorized 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 an Authorized 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 an Authorized Service Dealer 11 1 50 01 200 95 45 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 be done Comp be done Comp Required Comp to be done Date 3 months Date Semi Date to be done Date monthly Initials Break in Initials annually Initials Annually Initials 10 Hrs 30 Hrs Disable the unit from operating per the first page warning Check the engine oil level Adjust as necessary
20. 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 col 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 t
21. 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 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 40 01 d ed 200025415 TROUBLESHOOTING Standby 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 amp fuse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery 5 fuse blown Out of fuel Fuel solenoid FS is defective Open Wi
22. quarts 3 8 liters caution amp 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 25 59 5 5 TENE 705676 e lt 5 o 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 groun
23. 0 3600 RPM 1 6L DRAWING 061291D APPLICABLE TO ITEM PART QTY DESCRIPTION mmogoo REVISION G 8000 B DATE 4 28 06 COMPONENTS INCLUCEDINOGIZSIE PRPRPPANINJONANNPRRWPNPAPPPPPAPPPNPPPPAPJIDBDOPPP ENCL HSB CONTROL PANEL COVER CONTROL PANEL HINGE CONTINUOUS HIPANEL 125 27555 SCREWPHMINVB 0 5 X 10MM WASHER FLAT MB ASSY PCB CPL2CTRLR 3600 RPM HOLDER FUSE WICKIVANN 178 6150 ADPTRRHSIDE VWICKIVAN 178 6191 ADPTRLHSIDE WICKIVAN 178610 ASSY PCB 2 IM UL BATT CHGR ASSY VOLTAGE REGULATOR RELAY BLOCK TERM20A 12X6X 1100 DECAL CPL CONTROL PANEL FUSES DECAL CPL 39L 1 SPACER 95H32ID DIOBRIDGE 25A 600 CRCTBRK4X1ETA46500P PLATE HARNESS CLAMP SWTCHRKREPST D3 SPD SWITCHRKR DPDT ON OFF ON DECAL CONTROL HSB SEAL COVER 318 12 7 382 SEAL COVER 318X127X 283 SCREWHHPMIMB 08 X12 WASHER FLAT MB WASHER LOCKIV5 RES WIVIBR 2 SCREWPHIT VB506X10 SCREWPHIT VB506X16 SCREWPHIT M4 0 7X 12 ZYC RELAY SOLENOID TA 0C PNL SCREWHHC 1420X34G5 WASHER FLAT 14HV5 ZINC WNSHERLOCKIVe 1A NUT HEX 1 4 20STEEL SEAL WEATHER 45 GROUP B PAGE 2 OF 2 IO I HDVd 90 07 667090 DNIMVY4U 2719 WALSAS 1 ONILNNOW ualdvav LVLSOWYSHL eg NO
24. 125 25 75 SCREW HHTT 12 BP WASHER LOCK WASHER FLAT SCREWPHIT 0 7 X 16 ZYC WASHER LOCK 38300 FMR DUAL 104V 16V PHASE FMR DUAL 1201 16 1 PHASE NUT HEX 3 8 16 STEEL WASHER LOCK 38 LUG SLDLSS 350 6 X 1332 AL CU JUNCTION BLOCK 38 16 BUSHING SNAP 5 2000 26 SCREWHMWHIF M6 L0 X16 0E7890 REF BRKT CB MIG BACK 2P 0E6002 REF MIG TRACK BQ SIEMENS CB 3P 042077 REF CB 0125A 2P 240 5 BQ2 LL 2 POLE REF CB 0100A 240 5 LL 3POLE 023897 n m REF SCREWHHC 20G8 8 SHOWN REF WASHER FLAT 10 ZINC NOT SHOWN 049226 REF WASHER LOCK NOT SHOWN 051716 REF NUT HEX M50 8 G8 CLEAR ZINC NOT SHOWN 025433 1 LUG SLDLSS 46 14 X 13 64 CU OA1354A 1 REGULATOR DC ALT 0E3257 REF SCREWHWHIF 1 0 16 002473 REF WASHER FLAT 14M5 ZINC 02209 REF WASHER LOCK 5 1 4 067210A 1 DECAL GROUND LUG 0F7194 REF BRACKET PANEL SUPPORT 1 5 057503 1 CABLE TIE MOUNT BLACK 0F1733 1 DECAL CUSTOMER CONNECT INSIDE 023762 1 WASHER SHAKEPROOF EXT 4051 84 ORBNNEBE 5 45050 5 DATE 3 24 06 PAGE 2 OF 2 697090 ONIMVUd 1 4DVd 90 S1 ALVA SLYVd NOWAOO Liv 1059 0 NOISIATY 14 5 3NION3 OL ONISNOH OL E o dnodd EXPLODED VIEW ALT COMMON PARTS
25. 198 0028 3NVd D31NDO M 86 89 962 VG 9E 826 1 86 04 08T JDLVIINID 30 ACIS and XODA 330 1311 3004 434 2191 1499 3SIA 34933 ONTLNNOW AJIA dDI 301953439 40 WOLLO NO 2 1319201 533914 310H LIFES 5091 26 2 ONILNMOW VIC GES SET DNDINUMS 1092 629 LOA cT 1198 28 9 SONIISI 1494 IN3W3OV 1938 31401534 303 TYNNYW SIINMO 394353335 seest __ 1 914 19 2000 1H9I3 NAHL 11384 1 918 SON1d 5 G 88 agoa 1HDIN IN3N3713 9312 419 48 L2 802 NAHL 4 NIVeG 40191094 33S 3004 3SOH NIVAd 110 93 9 dn gnls 914 3317113 MODI 1H9I3 MIILS did IU 1337 1113 110 06 553329 3OIAS3S LYVHD 55392 351 4358 D dNOND L Z7 8 Corl 493 71114 anividva 01 554339 4 3ADW3S3S ALIAVAD 30 331N32 Ge vE 048 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 r
26. 38n L I3INI H31VM JO 38V4 OL EXPLODED VIEW COOLING SYSTEM 1 6L C1 DRAWING 060429 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 027211 1 SUPPORT RADIATOR LH SIDE 2 05070 1 VENTURI 167 DIA FAN 3 0F7210 1 SUPPORT RADIATOR RH SIDE 4 CE9837B 1 RADIATOR 1 4 5 0202308 1 FANCOOL 16 DIA 8 BLADE 6 046526 5 WASHER LOCK MIO 7 0G0910 1 LOWER RADIATOR HOSE LaL 8 099502 4 CLAMP HOSE 24 1 06 2 00 9 069860C 1 HOSE OIL DRAINASSY 21 10 055596 1 BARBEDSTR 38NPT X 38 050908 1 UPPER RADIATOR HOSE LEL 046627 1 CAP RADIATOR B 052250 2 TAPE 1 1 24 LG 022473 10 WASHER FLAT 14M6 ZINC 15 022097 12 WASHER LOCK 1 4 16 0 8566 8 SCREWHHFC 10 20688 17 049813 4 NUT HEX M5 X LOG8 YEL 18 0C2454 28 SCREWTHF 1 16 2 5 19 042568 4 SCREWHHC 10 20688 20 060982 1 GUARD FANLHC1 2 050933 1 GUARDFANRHCI 22 0C7649 1 CLAMP HOSE 38 87 B 0F7320 1 BLOCK OFF UPPER 24 OF 1433 1 BRACKET 2 5L FORD WATER BOTTLE 25 076749 1 TANK COOLANT RECOVERY 26 O48081C 2 CLAMP HOSE BAND 1 4 27 029082 1 HOSE 932 ID 43 LG 28 050275 3 DECAL WARNING FAN 29 022131 1 WASHER FLAT 3 8 M10 ZINC 30 029107 1 GROMMET 78 3 16 58 31 060568 1 ASSY FAN BEARING SUPPORT 2 0G0405 1 BRACKET FAN ALT ADAPTER 1 3 059980 1 SCREWHHC 15 25 109 Y 051756 4 SCREWHHC MI0 1L5 X 20688 35 1 TIE WRAP UL 7 4 X 19 BLK 36 042907 4 SCREWHHC 1 25 16 G88 37 026850 4 WASH
27. ANSFER RELAY COIL REMOTE START REMOTE START A A ea A A A lr N J WIRING DIAGRAM REVISION 1 6L 2 POLE DATE 03 03 06 DRAWING 0G0925 GROUP G rl a 1 5 AIR FUEL SOLENOID ALT D C CHARGE ALTERNATOR BAT 12VDC BATTERY COIL PACK DCVR DC VOLTAGE REGULATOR FUEL SOLENOID AUX FUEL SOLENOID GND GROUND CB J DEG 12V 1 HCT HIGH COOLANT TEMP SWITCH OX INP RET 1 2 805 Ji CONNECTOR 1 DEG GND 3 LFP LOW FUEL PRESSURE SWITCH COOLANT TEMP 4 85 LOS LOW DIL PRESSURE SWITCH GOV 0 5 MP1 MAGNETIC PICKUP cov svte _ OXYGEN SENSOR DISTRIBUTOR 12 7 SC STARTER CONTACTOR COOLANT LEVEL 8 573 SM STARTER MOTOR CRANK SENSOR 9 79 STM STEPPER MOTOR CRANK SENSE RET T10 0 WLS COOLANT LEVEL SWITCH LFP IN 11 601 WIRE SPLICE GOV FDBK 12 Ox INP 113 804 COIL 41415155 COIL A 15 8254 DISTRIBUTOR RET 16 DISTR INPUT 17 A 79 DEG ig MP1 DEG ENABLE 19 SHLDY 9 LOW OIL PRESS 20 86 CRANK SHIELD 21 SHLD CDIL C 22 COIL 42318258B 808 AFS 808 A DC VR 12345 02 48 0 491314 ALT E is OPTIONAL EMISSION CONTROL
28. 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 as necessary gt a 50 21 gy 20049546 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 be done Comp Comp Required Comp to 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
29. DRAWING 060463 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 098986 1 ASSY RTR 5KW2PH 2 0G0820 1 HOUSING BLOWER MACHINED 14 3 051019 1 GUARD BLOWER HOUSING 14 4 020746 4 SCREWPPHMIVB 08 X 8 ZINC 5 4 WASHER LOCK 6 051713 4 WASHER FLAT M 7 022129 4 WASHER LOCK VB 5 16 8 061317 1 ASSY STATOR 2ZKWIPHD 0G1316 1 ASSY STATOR 25KW3PHD 9 045382 1 BEARING CARRIER REAR 10 075591 1 ASSY HOLDER BRUSH 051787 4 SCREWHHC 07 16G88 12 OA5601A 1 COVER REAR BEARING 13 075554B 4 BOLT STATOR X 16 LG 039875 4 SCREWRHM7IO21X2 15 022152 4 WASHER LOCK 40 16 0504350 1 FLYWHEEL amp RING GEAR 55 18 17 012558 1 KEY SQ38X1STEEL 18 051 52 1 PLATE SPACER 1G 19 050965 1 PLATE FLEX 1G 2 053557 1 SCREWHHC 2 1 75 40 88 21 051769 1 WASHER LOCK MD 2 4 SCREWHHC 1 5 35 G88 23 016525 4 WASHER LOCK MIO 05772 4 NUT HEXMIO L5GBYEL CHR 26 048830 4 WASHER FLAT A4IDX 7500 27 mE 1 FLEX CONDUIT BLACK NOT SHOMN 28 22131 10 WASHER FLAT 38MIOZINC 2 072578 1 SPACER ROTOR SHAFT 30 0F3353 6 SCREWHHC MIO LOX20G109 3l 023365 4 WASHER SHAKEPROOF INT 8 REVISION G 6501 A DATE 3 16 06 APPLY LOCTITE 242 TO 30 BEFORE THREADING INTO CRANKSHAFT GROUP A PAGE 2 OF 2 0162190 ONIM VNG HOVd 90 80 9 ALVA 191 009 002 4 9 0008 0 3 315 1 N3d0 TW 3405 LON 4 EXPLODED VIEW R 20
30. E3257 17 18 022473 DATE 3 22 06 QTY Uum m5mHBm BHNHBHABAEHERHNONNMNMH DESCRIPTION MOUNTING BASE 1G WASHER SHAKEPROOF EXT 5 16STL DAMPENER VIBRATION MB ISO 70 75 DURO SCREWHHC 1 25 2088 WASHER FLAT 5 16 ZINC WASHER LOCK 516 NUT HEXMB 125 GB YEL CHR WASHER FLAT VB SCREWHHC 1 25 X 60G88 EARTH STRAP BRACKET PANEL SUPPORT WASHER SHAKEPROOF EXT 1 4STL NUT HEXM6 X LOGS YEL CHR LUG SLDLSS 2 4 8X 17 64 CU SCREWHMHIF M6 L0X 16 WASHER LOCK 6 1 4 WASHER FLAT 1 446 ZINC GROUP C PAGE 2 OF 2 GROUP D EXPLODED VIEW ENGINE COMMON PARTS 47 DRAWING 060487 PAGE 1 OF 2 DATE 3 22 06 EXPLODED VIEW ENGINE COMMON PARTS DRAWING 060487 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0207 REF ENGINE GENERAC 1 4 NG 2 0G0834 1 ENGINE PLATE 14 3 050820 REF HOUSING BLOWER MACHINED 18 4 0E9747 1 STARTER 12VOLT 5 0G0839 2 ENGINE MOUNTING FOOT STAMPING 6 0G0781 1 EXHAUST MANIFOLD 1G MACHINED 7 050722 1 INTAKE MANIFOLD MACHINED 1 8 050758 1 HEAT SHELDLOMER 1 64 9 0G0431 1 HEAT SHELD UPPER 14 10 0G0663 1 PULLEY CRANKSHAFT MACHINED 050786 1 WASHER PULLEY R 050186 1 BRACKET TENSIONER B OFS617A 1 SPACER ALTERNATOR 14 041358 1 DC ALTERNATR HAN KOK 15 050823 1 VBELT 38X 306 16 0G1467 1 HEAT SHELDFRONT 1 17 1 ASSY MAGPICKUP 3824 MALE 18 086710 2 PINSPRING 1 4X3 4 19 0C5479 1 SCREWHHC MI2 15X 40G109 059980 7 SCREWHHC MIO 15X 25G109 21 04656 16 WASHER LOCK MIO
31. ER SHAKEPROOF EXT 1 4 STL 38 042628 1 PULLEY FAN 95 DIA 39 E2507 1 PROBE COOLANT LEVEL 3 8 NPTF 4 558K 2 CLAMP VINYL 1G X 3432 41 E3257 2 SCREWHWHTF 1 0 16 APPLY LOCTITE 242 TO 36 BEFORE THREADING INTO 1 DATE 3 20 06 GROUP C PAGE 2 OF 2 267090 ONIMVUG HOVd 90 17 ALVA 191 143 19 AY3LILVA SS3NHVH HOJIOVINOO d3luvls OL EXPLODED VIEW BATTERY C1 CPL 1 6L DRAWING 060432 APPLICABLE TO 2 DATE 3 21 06 PART DESCRIPTION BATTERY TRAY STRAP BATTERY RETAINVENT WASHER SHAKEPROOF EXT 7 16STL SCREWHHC 15 25 109 WASHER LOCK 5 16 BATTERY 75 AH 26 BATT POST COVER RED BATT POST COVER BLK CABLE BATTERY BLK 4 3000 CABLE BATT RED 74 1500 NUT HEXMBE 125 G8 YEL CHR WASHER LOCK 5 16 WASHER SHAKEPROOF EXT 5 16STL BOOT BATTERY CABLE SCREWTHF 1 16 NWA 2 S WASHER FLAT 5 1644 ZINC GROUP C PAGE 2 OF 2 76 090 ONIA VIG HOVd 90 77 ALVA 3SV8 ONILNNOW A E 224 27 ef OL EXPLODED VIEW MOUNTING BASE DRAWING 060754 APPLICABLE TO ITEM PART 1 060759 2 027482 3 070986 4 070086 5 6 7 122129 8 015771 9 071956 10 051730 n 021991 2 7194 13 026850 14 019813 15 055414 16
32. EW 10 4 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer 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 Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not 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 WARNING amp Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the 120VAC power supply to the battery is turned OFF or sparking may occur at t
33. LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER NB NEUTRAL BLOCK eS DIRECT DRIVE AS 1 Ee GENERATOR OUTPUT CUSTOMER CONNECTION E1 Ee TO 1 1 NB 120VAC XNOTE THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 208VAC PAGE 2 OF 4 WIRING DIAGRAM REVISION G 7501 B R SERIES CPL ALTERNATOR DATE 02 22 06 DRAWING 0F6839 GROUP G eae Mm ea See eg C TO 71 OPTION 3 THREE PHASE R SERIES CONTROL PANEL 6 WIRE 277 480 LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER NB NEUTRAL BLOCK TB1 DIRECT DRIVE GENERATOR OUTPUT CUSTOMER CONNECTION 1 Ee Ee TU E1 El E2 TO NB 277VAC NOTE THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES VOLTAGE 227 480 PAGE 3 OF 4 5 41 WIRING DIAGRAM REVISION G 7501 B R SERIES CPL ALTERNATOR DATE 02 22 06 DRAWING
34. NCLUDED IN TEM 19 CARBURETOR ASSY NOTES 1 REGULATOR N 3 AS SHOANINILLUSTRATIONIS SET UP FOR NATURAL GAS APPLICATION 2 TO CONFIGURE REGULATOR FOR LP VAPOR SWITCH HOSE BARB HOSE CLAMP 41 AND HOSE I N 40 FROM OUT I TO OUT 2 REPLACE PIPE PLUG FROM OUT 2 TO OUT 1 USE PIPE SEALANT ON HOSE BARB AND PIPE PLUG MAKE SURE TO KEEP PORTS FREE FROMDEBRIS DURING RECONFIGURATION PROCESS APPLY LOCTITE TO N 51 BEFORE THREADING INTO IJN49 4 FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL INLET DECAL P N 050280 FOR NG FUEL INLET DECAL P N 050279 ITEM 27 5 WHEN SWITCHING FUEL TYPES THE PROPER DIP SWITCHSETTINGS MUST BE MADE TO THE CONTROL PANEL SEE OWNERS MANUAL FUEL SECTIONFOR MORE DETAILS PAGE 2 OF 2 GROUP F INSULATION AND RETAINERS LOCATED ON THE NEAR SIDE O 7 S INSULATION AND RETAINERS LOCATED ON THE FAR SIDE TYPICAL MOUNTING OF ACOUSTIC INSULATION EXPLODED VIEW ENCLOSURE C1 CPL DRAWING OQ a oo 58 Xe Ex a 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 C1CPL 3 OF 7008 1 DOOR REAR C1 CPL 4 OF 7005 1 CORNER POST RH SIDE C1CPL 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
35. RMATION Figure 1 Interconnections 000000 Utility In Transfer Switch CONTROL PANEL ar ae NEUTRAL TO ALTERNATOR NEUTRAL GENERATOR 194 CONNECTION or 4 14GA BREAKER WIRES TO 1 GENERATOR CONNECTION GROUND BOX a To Generator Control Panel TO GENERATOR CONNECTION BOX 120 Vot Neutral loo ADO FRAME RAIL CIRCUIT BREAKER SIZE KW VOLTS AMPS SIZE 25 24010 125 4 to 1 0 Ground Level 25 20830 100 4to1 0 Concrete Slab STUB UP AREA ite 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 OF6148 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 All models are configured for natural gas LP or vapor from the factory PORTS
36. S SHOWN TR1 TRANSFORMER 1 MO 4 We WITE 5 GE 6 V4 Eu BBI CB J AFS DUT 12 808 1 565 START RELAY 2 56A FUELCRUN RELAY 3 14 EC 2 WIRE STARTCD 4 183 5 MOMENT DPEN 5 15 808 PUR 2 WIRE START 7 6 28 11 cds eret esca A A 16 SENSEQD y 8 224 ALARM RELAY 9 N2 XFER RELAY T10 23 14 INPUT 11 239 A TB1 16VAC SENSEC2 gt 412 225 is EMISSIONS ENABLE 13 0 AES Le e 0 iS 0 TO 419 4 248462 959 6 a E a z 4453 48785 44 2 N 3 dS we I m 14 9 E14 2 gt 154 2 15 GESA A 15791245 0 1 601 601 SINGLE PHASE STATOR SHOWN FOR 3 PHASE SEE DWG OF 6839 MAN AUTO INPUT CENTER TERMINAL NOT USED UTILITY FROM T SW UTILITY FROM T SW TRANSFER RELAY COIL TR
37. STEM 1 6L C1 DRAWING 060435 APPLICABLE TO ITEM PART 1 027366 2 07647 3 0F8005 4 F738 5 257 6 7 0 6119 8 086434 9 0B6449 10 12 088750 B 051043 14 O34 15 16 049813 17 022473 DATE 3 21 06 QTY DPRRRPROOWWARNARAAEA DESCRIPTION MUFFLER C1 MUFFLER SADDLE PIPE EXHAUST OUTLET PIPE EXHINLET MUFLR SIDE L5L SCREWHMWHIF M6 LOX 16 MUFFLER STRAP BOLT 95 16 18 2 1 4 BOLT U Y16 18X 2 09 SADDLE 2 INCH WASHER LOCK 516 NUT HEX 16 18 STEEL SCREWHHC 5 10 30 88 EXHAUST PIPE 18 EXHAUST BLANKET 600MMLONG WASHER LOCK 6 1 4 NUT HEXM6 X LOGS YEL CHR WASHER FLAT 1 446 ZINC GROUP F PAGE 2 OF 2 GROUP G mee i pe pee a ree grat eh ee cepe MT eg ey 71 OPTION 1 SINGLE PHASE R SERIES CONTROL PANEL 240V LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER B NEUTRAL BLOCK MLCB ofo a N DIRECT DRIVE 5 GENERATOR CUSTOMER CONNECTION E ES El NB 240VAC 120 120 PAGE 1 OF 4 WIRING DIAGRAM REVISION G 7501 B R SERIES CPL ALTERNATOR DATE 02 22 06 DRAWING 0 6839 GROUP G OPTION THREE PHASE R SERIES CONTROL PANEL 6 WIRE 120 208V
38. Serial Number 1 6L 25kW Models 005324 0 005325 0 STANDBY GENERATOR OWNER S MANUAL A new standard of reliability UAR D IAN by Generac Power Systems Inc UIETSOURCE Not intended for use in critical life support applications CAUTION A ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY This manual should remain with the unit 092190 ON Hed 90 90 V ed 6901902 OF SECTION PAGE SAFETY RULES 1 1 INTRODUCTION 1 3 Read this Manual 1 3 Operation and Maintenance 1 3 How to Obtain 1 3 IDENTIFICATION 2 1 Data Lapel diia 2 1 EQUIPMENT DESCRIPTION 3 1 Equipment Description 3 1 Engine Oil Recommendations 3 1 Coolant 3 1 ENGINE PROTECTIVE DEVICES 4 1 High Coolant Temperature Switch 4 1 Low Coolant Level 4 1 Low Oil Pressure
39. Switch reete eere edens rebate ren 4 1 Overcrank Shutdown eee reete 4 1 Overspeed Shutdown eet mea tr nein dae 4 1 RPM Sensor Loss Shutdown eese 4 1 FUSE Em 4 1 FUEL SYSTEMS 5 1 Fuel Requirements 5 1 Natural Gas Fuel System 5 1 Propane Vapor Withdrawal Fuel Systemna 5 1 LP Fuel SySsteI 5 1 SPECIFICATIONS 6 1 GENET ORE 6 1 catan 6 1 Cooling cie 6 1 Fuel SYS 6 1 Electrical System e conte tee 6 1 Cold Weather Kit tope estate 6 2 Reconfiguring the Fuel 6 2 GENERAL 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 8 1 1 06 16 1 AOU 8 1 Preparation Before Start up 8 1 Transter 8 1 Fuel System curan id 8 1 Generator Set Lubrication
40. TO 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 AND 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
41. al number and its rated voltage amps wattage capacity phase frequency rpm power factor etc rator Sets E General Information INFORMATION 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 Data Label GENERATOR SET DATA MADE IN USA MODEL SERIAL RATED KW RATED KVA PHASE RATED VOLTAGE RATED AMPS POWER FACTOR HERTZ 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 90 21 V 200 GENERAL INFORMATION EQUIPMENT DESCRIPTION This equipment is a revolving field alternating cur rent generator set It is powered by a gaseous fueled engine operating at 1800 rpm for 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 c
42. attery Maintenance eret rettet eret hee 10 4 Battery ete iret tenete 10 5 SERVICE SCHEDULE 11 1 TROUBLESHOOTING 12 1 Troubleshooting Guide sees 12 1 NOTES EXPLODED VIEWS amp PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS WARRANTY 90 60 0 700902 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 poss
43. aximum Ambient Temperature 50 C 140 F FUEL SYSTEM Type s tontos Natural Gas Propane Vapor A Down Draft Secondary Fuel Regulator Standard Fuel Shut off Solenoid sss Standard Operating Fuel Pressure 5 in 14 in Water Column Fuel Consumption ft3 hr Natural Gas LPV Exercise 2596 5096 7596 100 Cycle Load Load Load Load 60 24 161 64 253 101 345 138 437 175 ELECTRICAL SYSTEM Battery Charge Alternator 12V 15 Amp Static Battery Chargef 2 Amp Recommended Battery Group 26 525CCA System Voltage cnt re eren cess 12 Volts Voltage Regulator Dc Electronic SIME E Single phase Regula 1 A emi V F Adjustable Adjustable Voltage and Gain LED Indicators Power Adjustment for Ambient Conditions Temperature Deration 3 for every 10 C above C 25 1 65 for every 10 above 77 Altitude Deration 1 for every 100 m above 182 3 for every 1000 ft above 600 Controller R 200 90 70 2200905090 Standby Generator Sets E INFORMATION Specifications INFO
44. condition tightness rosion or damage Clean tighten or replace as necessary 90 70 0 LOWEN 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 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 Excessi
45. conjunction with the genset If a Non Generac Power 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 po
46. d 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 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 e
47. d 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 70 0 LOWEN 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 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 accompa
48. ec 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 the fuel supply system to the 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 proper 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 amp Prior to initially starting the generator it must be
49. eplace any part s which upon examination inspection 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
50. es light bulbs engine fluids and overnight freight 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
51. he 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 REPAIR PARTS The latter portion of this manual consists of exploded views parts lists and electrical data pertaining to this generator set The parts lists consist of a an item number b a part number c the quantity required and d a description of the part The item number corresponds to an identical number on the exploded view drawing 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 unit is used in an average service application They will need to be decreased performed more frequently if the unit is used in a severe 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 proble
52. heck engine compression 4 Check valve clearance COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See the installation diagram WARNING 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 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 caution 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 shou
53. hen 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 Set 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 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 Connect
54. ible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If 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 Also make sure the procedure work method or operating tech nique utilized does not render the generator unsafe 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 appl
55. ic 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 OIL 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 should 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 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
56. icable 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 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 provis
57. inder Head Procedure 5 nort rot een 10 1 Cooling 10 2 Overload Protection for Engine DC 1 10 2 Checking Fluid Levels 10 2 Check Engine Oll 10 2 Battery Fluid oie eee esos 10 2 Engine Coolant 10 2 Maintenance Owner Operator Can Perform 10 3 Check Engine Oil 1 20 11 1 10 3 Check Battery 432444 454 10 3 Exercise 10 3 Inspect Cooling 10 3 Check Engine Coolant 10 3 Perform Visual 10 3 Inspect Exhaust 2 2 10 3 Check Fan 10 3 Inspect Engine Governor 10 3 Changing Engine Oil 10 3 Changing the Engine Air Cleaner 10 3 Spark Phigs idad 10 4 Coolant Changes 10 4 Miscellaneous Maintenance 10 4 Cleaning the Generator 10 4 Battery de MD 10 4 B
58. ions In addition please note the dangers under Engine Start up and Transfer 90 80 0 1004990 Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES WARNING amp Before working on the generator ensure the 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 Devices 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 30 OPERATING HOURS 1 Change engine break in oil and filter FIRST 100 OPERATING HOURS 1 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 1 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 C
59. ions 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 Inspect 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 on the gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc Z 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 insulate
60. ld 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 70 0 LOWEN Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance Figure 10 1 Oil Dipstick and Oil Fill Cap Ir on Bo OIL FILL CAP OIL DIPSTICK 26 dt 5 P BATTERY FLUID Check battery electrolyte fluid based 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 TAP 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
61. lectric 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 Asles Standby Generator Sets Important Safety Instructions SAFETY RULES 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 on 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
62. m areas Performed monthly this requires approximately 5 man hours unit to complete This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the control panel AUTO OFF MANUAL switch to the OFF position e 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 standby 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
63. nce 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 mation 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 u
64. ny the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury 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 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 90 70 0 LOIW
65. o provide the necessary heat for conversion of the fuel from a liquid to a gaseous state 90 80 0 100545114 SPECIFICATIONS GENERATOR Synchronous Rotor Insulation rite eren Class F Stator 55 Total Harmonic 5 Alternator Output Leads 3 phase 4 wire DO MS Sealed Ball Flexible Disc Load Capacity Standby Rating 25kW NOTE Generator rating and performance in accordance with 1508528 5 BS5514 SAE J1349 1503046 and DIN 6271 Standards KW rating is based on LPG fuel and may derate with natural gas Excitation System seen Direct Generator Output Voltage kW 60 Hz kW Amp CBSize 120 240V 1 phase 1 0 pf 25 104 125 120 208V 3 phase 0 8 pf 25 87 100 Generator Locked Rotor KVA Available Voltage Dip of 35 Single phase or 208 3 34 KVA ENGINE Generac In Line Cylinders and Arrangement cancer 4 DISPIACOMONL 1 6 Liter BO 3 15 in coin att aire Mena 3 13 in Compression 9 75 to 1 Air Intake System
66. oint 00 is either 277V 120V depending on the model Figure 7 2 Stator Power Winding Connections 3 phase 277 480V 6 Lead 1 El 1 INTERNAL CONNECTIONS a Ll 56 lt 54 NEUTRAL Y E3 S3 S2 Tw Figure 7 3 Stator Power Winding Connections 3 phase 120 208V 6 Lead E1 S4 84 00 NEUTRAL 3 53 52 40 80 0 ed LOQUUOJOY 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 ser 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 and or service intervals please refer to the Maintenance section and the Service Schedule TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents el
67. omes 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 Rotor and Stator insulation is Class rated as defined by NEMA 1 32 6 NEMA MG1 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 SF Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Temperature Above 80 F 27 C SAE 30W or 15W 40 SAE 20W 20 or 15W 40 32 to 80 F 0 to 27 C Below 32 F 0 C See Note caution amp 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
68. ons 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 10 9 ed 10088 INSTALLATION Standby Generator Sets Installation INSTALLATION START UP CHECKLIST A WARNING amp 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 fuse 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 it
69. 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 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 QT50 0770 QT100 QT150 Adequate air flow clearances and ventilation per installation drawings and applicable codes Correct AC and DC wire size connecti
70. r 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 FUEL 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
71. re 14A 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 necessary 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
72. s 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 10115 33 l 10 240 33 NOLES 120 l i 10115 1 1 11 L I El 2111 Lio 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 1 2 1 E2 E3 is either 480V or 208V depending on the model The rated voltage between each circuit breaker termi nal and the neutral p
73. s 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 10 100185 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 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 AU
74. sage 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 manual 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 aT i Standby Gene 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 seri
75. t 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 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 WARNING amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution A 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 a
76. vely 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 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
77. wer in place of existing utility power where utility 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 fus

Generac Power Systems 005324-0 User's Manual

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