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Land Pride 4400NT Utility Vehicle User Manual

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1. 10 4 Battery Maintenance eret rettet eret hee 10 4 Battery ete iret tenete 10 5 SERVICE SCHEDULE 11 1 TROUBLESHOOTING 12 1 Troubleshooting Guide 12 1 NOTES EXPLODED VIEWS amp PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS WARRANTY 90 60 0 t001u9luoo Standby Generator Sets SAFETY RULES Important Safety Instructions 7 N SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas Safety should be stressed to all operators potential operators and service and repair technicians for this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before install ing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reli ably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions
2. 8 1 Engine Coolant iiec eter pd 8 1 Belt Tensi n 8 1 Elecmical SM 8 1 Initial Inspection for QT Genset Start up 8 1 Startup Checklist u y u ina teri 8 2 Preparation for Start up 8 2 Start up Inspection oe 8 2 TABLE Standby Generator Sets TABLE CONTENTS Table of Contents CONTENTS 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 10 1 Every Three Months ertet 10 1 Once Every Six Months enesis nnr 10 1 Once Antal ys 10 1 First 100 Operating 10 1 Every 500 Operating Hours 10 1 Every 800 Operating Hours 10 1 Exhaust Manifold Procedure 1
3. 40 1 65 for every 10 above 104 Altitude Deration 1 for every 100 m above 915 3 for every 1000 ft above 3000 Controller cero er Io rer e ey sess R 200 6 1 90 20 6109edgueo GENERAL INFORMATION Standby Generator Sets Specifications GENERAL INFORMATION Figure 1 Interconnections CONTROL PANEL TO ALTERNATOR NEUTRAL GENERATOR CONNECTION BOX CIRCUIT BREAKER o o o GROUND 120 Nowra Edo FRAME RAIL Ground Level Concrete Slab STUB UP AREA See Install Dwg for Dimensions COLD WEATHER KIT For cold climates optional cold weather kit part number OF6148 is recommended The kit includes Battery Warmer 4 Junction Box with hardware 6 qt pack 5W 30 synthetic oil engine RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for natural gas or LP vapor from the factory 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 3 Remove the brass hose fitting from t
4. Puller Air Flow inlet air including alternator and combustion air sees 3200 ft min Coolant Capacitan 2 5 U S gal Heat Rejection to 134 000 Btu h Maximum Operating Air Temp on Radiator 60 C 150 F Maximum Ambient Temperature 50 C 140 F FUEL SYSTEM Type of Fuel 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 87345 150596 291 115 7 405 160 8 560 222 3 ELECTRICAL SYSTEM Battery Charge Alternator 12V 30 Amp Static Battery 2 Amp Recommended Battery Group 26 525CCA System 12 Volts Voltage Regulator Electronic SENSO area Single phase tet tach 1 Pal V F Adjustable Adjustable Voltage and Gain LED Indicators Power Adjustment for Ambient Conditions Temperature Deration 3 for every 10 C above
5. eet mea tr nein dae 4 1 RPM Sensor Loss Shutdown 4 1 FUSE Em 4 1 FUEL SYSTEMS 5 1 Fuel Requirements 5 1 Natural Gas Fuel System 5 1 Propane Vapor Withdrawal Fuel System 5 1 LP Fuel SySUSIY RDuE 2S 5 1 SPECIFICATIONS 6 1 RON ta RE ORE 6 1 catan 6 1 Cooling SY Stems 6 1 Fidel System od 6 1 Electrical System uu 6 1 Cold Weather Riti uu saksa naaaqa shaspaqa estate 6 2 Reconfiguring the Fuel 6 2 GENERAL INFORMATION 7 1 Generator AC Lead Connections 7 1 Four lead Single phase Stator 7 1 Alternator Power Winding Connections 7 1 S phase Alternators 7 1 INSTALLATION 8 1 1 06 16 aww sa 8 1 Preparation Before Startup on usa 8 1 Transter Switch misas 8 1 Fuel System curan 8 1 Generator Set Lubrication 8 1 Prior to Initial
6. 040 EXPLODED VIEW MUFFLER EXHAUST 2 4L 45KW C2 DRAWING 0F9812 GROUP F APPLICABLE TO ITEM PART QTY DESCRIPTION 1 029794 1 MUFFLER 7 X9 X 18 1 2 2 INOUT 2 050113 1 EXHAUST ELBOW2 1 40D 21 20D 3 0F9937 1 BRACKET MUFFLER 4 0F2830 1 MUFFLER BRACKET STIFFENER 5 OF 2062 1 MUFFLER STRAP 6 2 BOLT U 38 16 2 62 7 OEOT 0A 1 EXHAUST BLANKET 988 2 8 0C2454 4 SCREWTHF 1 16 ZJ S 9 0F9736 1 PIPE EXHAUST 24 G1 10 050007 1 DIFFUSER EXHAUST MELDIVENT 11 044149 1 GASKET EXHAUST RING 2 085917 2 WASHER LOCK 38SS B 002611 2 SCREWHHC 3 3 16X 13455 0 8816 1 EXHAUST FLANGE 2 PIPE 1 019721 2 SCREWHHC M6 10X 35G88 BLK 16 022097 2 WASHER LOCK 1 4 17 22473 2 WASHER FLAT 14M6 ANC 18 086797 1 BOLT U5 16 18X2 25 19 022259 2 NUT HEX 5 16 18 5 20 070006 2 WASHER LOCK MBSS 21 088775 2 WASHER FLAT 3855 2 022241 4 398 165 23 085917 4 WASHER LOCK 38 SS REVISION G 7647 A DATE 3 14 06 PAGE 2 OF 2 GROUP G mee i eh O 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 a N l D
7. 9 335 000 c 13 228 200 1431 MDDG 1 918 3SOH NIVSG 110 1HOI3 391113 110 323115 414 S87 34944 aasia 7713 110 30 N31N32 SOLVIINID JO WOLLO ND 0319907 533914 31DH Te WALT 321 435 1114 191098 OL ONILNNOW Vid GES LAVHD ALITIIS8ISS329OV W311 5 55322 X04 3ADN32 GROUP H C2 UNITS C5 UNITS C4 CB CONNECTION BOX SHIELDING C2 C4 EXPLODED VIEW DRAWING E z 5 C3 UNITS 0G0258D PAGE 1 OF 2 1 18 06 DATE EXPLODED VIEW C4 CB CONNECTION BOX SHIELDING C2 C4 DRAWING 0G0258D APPLICABLE TO ITEM 1 A DATE 1 18 06 PART C2UNTS 0 9832 OF9832GGSOR 0 2454 5 0F98328B OF9832KGSOR 0 2454 C4UNTS 2 0 2454 C5UNTS FRC 0298322 OFOSSEGSOR OF9632HGSOR 9822 GSOR OF9832FGSOR OC2464 QTY WEEP EEE DESCRIPTION SHIELD CONN BOXC2 SHIELD CONTROL STAND C2 SCREWTHF 1 16N WA 2 S SHIELD CONTROL STANDC3 SHIELD CONTROL STANDC3 SCREWTHF 1 16 2 S SHIELD CONTROL 5 SCREWTHF 1 16 2 S SHIELD CONTROL STANDC5 SHIELD CONTROL STANDC5 SHIELD CONTROL STANDC5 SHIELD CONTROL STANDC5 SHIELD CONTROL STANDC5 SHIELD CONTROL STAND C5
8. 12VDC BATTERY DEG 12V 7 1 14 STARTER CONTACTOR OX INP RET T 2 805 DEG DRIVER ELEC GOVERNOR DEG GND 3 0 COOLANT TEMP 4 85 GOV 5 767 GOV 45v 6 765 DISTRIBUTOR 12V 7 194 COOLANT LEVEL 8 573 CRANK SENSOR IN 9 79 CRANK SENSE RET 10 0 DIST DISTRIBUTOR FS FUEL SOLENOID FS2 AUX FUEL SOLENOID GOV ELEC GOVERNOR ACTUATOR HIGH COOLANT TEMP SWITCH IC IGNITION COIL CONNECTOR 1 PCB LFP LOW FUEL PRESSURE SWITCH LFP INP 11 601 LOS LOW OIL PRESSURE SWITCH GOV FDBK 112 766 1 MAGNETIC PICKUP OX INP 113 804 02 OXYGEN SENSOR SM STARTER MOTOR COIL 14 94 WLS COOLANT LEVEL SWITCH COIL A 15 25 DISTRIBUTOR RET 16 0 DISTR INPUT 17 402 DEG PWM 18 769 DEG ENABLE 19 768 LOW OIL PRESS 20 86 CRANK SHIELD 21 SHLD RR ES II O 0 79 1 808 B 584 OPTIONAL EMISSION 6 5 ICONTROL 1 A a a an E m m re _ 4 SCHEMATIC DIAGRAM REVISION 2 4L 2 POLE DATE 01 09 06 DRAWING 0G0118 96509
9. 2 5 029289 1 ELEC 1 2 FOAM AS REQD L 01733 1 DECAL CUSTOMER CONNECT INSIDE 2 UL CIRCUIT BREAKER FD A 03138 1 B 065469 1 DECAL DANGER HIGH VOLTAGE 005572 1 B 050 P 600 5 FD6LL 005573 01754 600 5 FD6LL 005574 02004 600 5 FD6LL 005575 0225A 600 5 FD6LL 015576 02504 600 5 FD6LL 1 INSULATOR CB FD FRAME 30ML E 081320 4 SCREWSHC 1 4 20X4 5G88 NZ F 022473 4 WASHER FLAT 4 52 G 022097 4 14 H 022127 4 NUT HEX 1 4 20STEEL J 0C2454 7 SCREWTHF 1 16 ZJ S K 029289 1 ELEC 1 2 FOAM AS REQD L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE REVISION G 7783 J DATE 5 1 06 rA rommgouou pu PART 08626 002454 029289 0F1733 QTY PPAAPBARAN PPP GROUP DESCRIPTION UL CIRCUIT BREAKER J D LD COVER J DLDCB SHRT STAND DECAL DANGER HIGH VOLTAGE 600 5 J D6 LL INSULATOR CIRCUIT BR J DLD SCREWRHM1 420X3 WASHER FLAT 14M5 ZINC WASHER LOCK 6 1 4 NUT HEX 1 4 20STEEL SCREWTHF 1 16 ZJ 5 TAPE ELEC 1 2 FOAM AS REQD DECAL CUSTOMER CONNECT INSIDE UL CIRCUIT BREAKER QN COVER QNFRMCB DECAL DANGER HGH VOLTAGE 0150A 2P 240 5 QN2 LL 0175A PS QN2LL 2XV BASE QN CIRCUIT BREAKER SCREWHHIT 10 BP COVERQNCB DISH POP 125 X 275 SS SCREWTHF 1 16
10. ALTERNATOR POWER WINDING CONNECTIONS 3 5 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 El E2 El E3 and 2 is either 480V or 208V depending on the model The rated voltage between each circuit breaker termi nal and the neutral point 00 is either 277V or 120V depending on the model Figure 7 2 Stator Power Winding Connections 3 phase 277 480V 6 Lead S1 El 1 INTERNAL CONNECTIONS a Ll 56 lt gt 84 NEUTRAL Y E3 S3 S2 Tw Figure 7 3 Stator Power Winding Connections 3 phase 120 208V 6 Lead E1 S4 54 00 NEUTRAL 53 53 52 40 80 0 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
11. 6 78 0971 3ZIS 31389NDO CACNSAWWODSS WNWINIW CT SALON 41 862 LHOI3M 11 3SV38JNI 50135 SNIddIHS N3 DDM 81 gt 53299 MAGY Y Tp 9194 9 4 90 61 1 922090 ONIMVUG C HOVd 90 61 1 ALVA 9 MASE 172 143 NOLLVTIVISNI 335 AINO M3IA 3015 1441 LINGNOD 30151010 103 011314 SNDISN3WIG 9 30 331N329 G 335 S32V d P NOISIAQYd S 82 4 4 115 022 Hb 3015 SIHL NO 0319201 ONIIdNOD 319833 LAN P E NOTLOGNNO9 SANIT SVD IVINLYN L 2 21 33S 11024129 133 NI 08 33s 88 AJADI INU233 788 S SrII 9 ALON NIHLIM 8314304 1SAVHXI G 3SD42N3 SI ANBLIVE T3N d IDYLNDO NDIVN3N39 40 3015 vad SODA 440 1417 SODA aad 3ND 2191 NDILOV ASIA dAl Lv8vy 6EII 44 941 0561 SdWV ONDINVAD 102 629 LIA 421 4931194 M3IA dul Lr 6 89 0541 001 ee 31DN 335 1511 1999 LIN3N3OV 2304 WANVYW SAINMO 39N3213332 2009 1431 19 L SZ 1 PIN 435 1138
12. Generac Power Systems Inc P O 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
13. VOLTAGE 227 480 PAGE 3 DF 4 5 41 WIRING DIAGRAM REVISION G 7501 B R SERIES CPL ALTERNATOR DATE 02 22 06 DRAWING 0F6839 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 08 El TO ES El E2 OR NB 120VAC XNOTE 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 CONTROL PANEL LEGEND NOTE ALL WRES ARE 1 HE 18 AWG UL LISTED UNLESS AR REGULATOR OTHERWISE NOTED AS SHOWN BR1 DIODE FIELD BOOST 7 CB2 CIRCUIT BREAKER 7A EXCITATION AWG EC EMISSIONS CONNECTOR FUSE BAT POWER de ATO TYPE CONNECTOR 2 ON PCB 120 VAC R4 FIE
14. 19 770 4 DEG ENABLE 19 768 N C 5 LOW OIL PRESS 20 86 LH 766 6 CRANK SHIELD 21 SHLD COIL 22 MP1 COIL B 23 RU gm 49 VUSHLD sasa B 808 AFS 0 808 402 OPTIONAL EMISSION CONTROL 549 alah T DIST p L Q EH Eb N IC A 2725 A te NEM ee ee E EE 4 WIRING DIAGRAM REVISION 2 4L 2 POLE DATE 12 01 05 DRAWING 0F9705 F1 m PCB 2 AFS OUT 1 808 START RELAY T 2 564 FUEL RUN RELAY 3 144 2 WIRE START 1 T 4 183 _ MOMENT OPEN 5 15E 2 WIRE START 2 T 6 178 MAN AUTO INPUT 7 15A 16VAC SENSE 1 8 224 ALARM RELAY 9 XFER RELAY 710 23 MAN INPUT 11 239 16VAC SENSE 2 12 225 J lEMISSIONS ENABLE 13 0 GND B 114 0 CONNECT FOR OPTIONAL EMISSIONS ONLY 14A 14 15 RL2 15 56 56 T
15. 2 S ELEC 1 2 FOAM AS REQD DECAL CUSTOMER CONNECT INSIDE 1 ITEMINCLUDED WITH HARNESS 2 ITEMINCLUDED WITH 0054648 3 DOUBLES FOR 277 480V 4 MEMUSED WTH 277 480V UNITS ONLY 5 ITEMUSED WITH 208V UNITS ONLY PAGE 2 OF 4 9165640 p 40 aDVa uices dSH X314 tO 20 140 8LL D NOISIATY MATA V 0049 EXPLODED VIEW CPL C2 amp C4 FLEX HSB DRA 0F3391D ING GROUP A APPLICABLE TO ITEM PART QTY DESCRIPTION ITEM PART QTY DESCRIPTION 5 UL CIRCUIT BREAKER QJ 2P 8 NEUTRAL BLOCK 390 200 400 A 028137 1 COVER 2P FRMCB A 005466 2 BUS BAR NEUTRAL BLOCK 390 B 065469 1 DECAL DANGER HIGH VOLTAGE B 089287 1 SCREWHHC 1 25 45 G88FT 225A 240V P S Q 22 022145 1 WASHER FLAT 5 16 MB ZINC D 08136 1 COVER 2 CB DISH D 022129 1 WASHER LOCK 5 16 E 086261 4 125 X 275 SS E 045771 1 NUT HEX MB 1 25G8 YEL CHR F 022473 2 WASHER FLAT 1 44 ZINC F 2 SCREWHHC 1 4 28X 34G5 G 022097 2 WASHER LOCK 1 4 G 083806 2 WASHER LOCK 1 45 55 H 022127 2 NUT HEX 1 4 20STEEL H 047822 1 LUG SLDLSS 600 250 1 0 1 4 28 J 0F8139 1 INSUL CB 2P QJ K 0C2454 7 SCREWTHF 1 16 ZJ S L 2 WASHER LOCK 3 3 1 HARDWARE FOR MIG CB TERMINAL COVERS IS M 018527 2 SCREWSHC 3 8 16 3 4 088 NZ SUPPLIEDWTHCIRCUIT BREAKERS N 1 TAPE ELEC 1 2 FOAM AS REQD P 022770 2 SCREWRHM 1 4 20 2 23QTY 2POLE amp 3POLE Q
16. Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten tial problem areas This inspection may be performed bu the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the control panel Auto Off Manual switch to the OFF position Remove the 15 amp control panel fuse Turn off the battery charger Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current 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 wear 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 the first 30 hours of operation after purchase of the unit This inspection contains some maintenance tasks which require special too
17. The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If 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
18. e ALL COMPONENTS Start up and or On line Registration or Registration Card along with Proof of Purchase must be performed and or sent in Guidelines Any and all warranty repairs and or concerns must be performed and or addressed by an Authorized Certified Generac Power Systems Dealer or branch thereof A Generac Power Systems Inc Transfer Switch is highly recommended to be used in conjunction with the genset If a Non Generac 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
19. REF REF REF 1 1 REF REF 1 4 REF REF DESCRIPTION BATTERY TRAY STRAP BATTERY RETAINVENT WASHER SHAKEPROOF EXT 7 16 STL SCREWHHC MIO 125 X25G88 WASHER LOCK MIO WASHER FLAT 3 amp MIO ZINC BATTERY POST COVER RED BATTERY POST COVER BLACK CABLE BATTERY BLACK X 1800 CABLE BATT RED 1X 1800 125 GBYEL CHR WASHER LOCK 516 BOOT CONTACTOR CABLES SCREWTHF 1 16 2 S WASHER FLAT 516 ZINC BATTERY 12V0C 75 25 GROUP C PAGE 2 OF 2 E 8 5 zo 8 c O 5 N Qs Z a PAGE 1 OF 2 REVISION G 7647 C DATE 3 13 06 EXPLODED VIEW ENGINE COMMON PARTS DRAWING 0F9805 APPLICABLE TO ITEM 1 000158 1 2 022131 3 3 029585 1 4 046525 3 5 05212 1 REF 6 9 1 7 0F3216B 1 REF 8 060115 9 0486220296 REF 10 0084880 1 11 OFOBOL 1 REVISION G 7647 C DATE 3 13 06 DESCRIPTION ENGINE 24 G1 WASHER FLAT 3 amp MIO ZINC EXHAUST ADAPTER 2 4L MACH NUT HEXMIO L25 GB YEL CHR SCREWHHC MIO 125 X25 G88 ALTERNATOR DC WOUT PULLEY PULLEY 117 ODDC ALTERNATOR BRACKET TENSIONER CARTRIDGE OIL FILTER BELT SERPENTINE 44 13 ADAPTER 2 4L CRANKSHAFT MACH 8980820 8 6 5802 08 888 RUN HB PART QTY 1 REF 1 REF 1 REF 1
20. SCREWTHF 1 16 2 S GROUP H PAGE 2 OF 2 Standby Generator Sets Warranty GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR HOME STANDBY LIGHT COMMERCIAL PRODUCT 45kW AND BELOW For a period of two 2 years from the date of sale or start up by Authorized Certified Generac Power Systems Dealer or branch thereof Generac Power Systems Inc will at its option repair or replace any part s which upon examination 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
21. See the Specifications section for exact numbers The unit comes complete with a sound attenuated enclosure internally mounted muffler control console main line circuit breaker battery charger and protective alarms as explained in the following paragraph All AC connections including the power leads from the alternator 120 volt battery charger input and control connections to the transfer switch are avail able in the main connection box The generator incorporates the following generator features Rotor and Stator insulation is Class H rated as defined by NEMA MG1 32 6 NEMA 1 1 66 The generator is self ventilated and drip proof con structed The voltage waveform deviation total harmonic content of the AC waveform and telephone influ ence factor have been evaluated and are acceptable according to NEMA MG1 32 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE 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 serv
22. column 0 18 to 0 5 psi NOTE Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below five inches water column for natural gas or 5 inches water column for propane vapor for all load ranges NOTE It is the responsibility of the installer to make sure that only the correct recommended fuel is sup plied to the generator fuel system Thereafter the owner operator must make certain that only the proper fuel is supplied NATURAL GAS 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
23. x SWICH PRESSURE GAS 5 RISE INCLUDED WITHIN 3 13 057823 4 CAMP HOSE 0 56 1 06 059057 1 HOSE 3 4 ID SAE 30R2 30 0 LG 1 0418 1 BARBED STR Y2NPT X 5 3 16 0D1509 1 DECAL INLET PRESSURE 175 1 DECAL FUEL INLET NG NATURAL GAS 050280 1 DECAL FUEL INLET LPG LP VAPOR APPLICATION 18 23 1 REF INTAKE ADAPTER MACHINED 19 0 6586 1 GASKET BOSCH 2 20 E4391 1 ACTUATOR BOSCH40GOVERNOR 45KW E4395 1 ACTUATOR BOSCH 32 GOVERNOR 21 040105 1 HOSE COOL ANID 2084 45KW 0577538 1 HOSE 15IDX2LG 2084 35KW 22 0 63828 1 VENTURI HOLDER W40MMACTUATOR KW 0 6382 1 VENTURI HOLDER W32MMACTUATOR 35KVJ 23 0 7790 1 VENTURI THROTTLE 26 24 E7121 1 ORING 47 625 IDX 2 38 25 040976 4 REF 5 5 125 20 129 26 02209 4 WASHER LOCK 1 4 27 051751 4 SCREWHHC 1 0 50688 28 085685 2 CLAMP HOSE 28 132 2 25 29 026155 1 HARNESS CPL FUEL J UVPER 30 017290 1 HOSE 38IDSINGLE 10016 31 080840 1 HOSE 1 4 IDSAE 3087 221 gt 02574 1 REF ADAPTOR 1 8 1 8 5 028414 1 REF BARBED STR Y1 8NPT X 1 4 34 040173 2 CAMP HOSE 55 62 62 35 or2119 1 ORING 45 63 IDX 2 62 WDTH REVISION G 7590 B DATE 3 7 06 NOTES 1 2 REGULATOR AS SHOANINILLUSTRATIONIS SET UP FOR NATURAL GAS APPLICATION TO CONFIGURE REGULATOR FOR LP VAPOR SWITCH HOSE BARB HOSE CLAMP 13 AND HOSE 14 FROM OUI 1 OUT 2 REP
24. 0G0588 1 GUARD REAR BEARING CARRIER ROTOR REPLACEMENT PARTS REVISION G 7799 C DATE 4 19 06 PAGE 2 OF 2 1969630 ONIM VAGA S0 6 71 ALVA 0096 002 4 MATA 3 YANALSV4 N3dD 4 EXPLODED VIEW R 200 3600 RPM DRAWING 0F9696D APPLICABLE TO ITEM PART QTY DESCRIPTION COMPONENTS INCLUDED IN OF9696E 1 OF 1823A 1 ENCL HSB CONTROL PANEL 2 0F3078 1 COVER CONTROL PANEL 3 0F2606 1 HINGE CONTINUOUS H PANEL 4 08626 6 RIVET POP 125X 27555 5 043181 4 5 05 10 6 052777 7 WASHER FLAT 7 0 87108 1 ASSY PCB CPL2 CTRLR 3600 8 021262 4 HOLDER FUSE WCKMANN 178 6150 9 0F1263 1 ADPTR RH SIDE WCKIVAN 178 6191 10 0F1264 1 ADPTR LH SIDE 178 6192 11 0 1725 1 ASSY 2 127 UL BATT CHGR 22 067680 1 ASSY VOLTAGE REGULATOR 60HZ B 0 6875 2 RELAY 12VDC FORMWDIODE 14 055911 1 BLOCK TERM20A 12 X 6X 1100V 5 OF5459 1 DECAL CPL CONTROL PANEL FUSES 16 0E3161 1 ASSY PCB BOSCHGOV DRIVER 17 0F5090 1 ASSY PCB SCR BRIDGE 18 025462 1 DECAL CPL 39 1 19 035062 4 SPACER 9 5 3 20 20 029673 1 DIO BRIDGE 25A 600 21 048467 1 CIRCT BRK 7X LETA 46 500 P 2 OF 1958 1 PLATE HARNESS CLAMP 2 082573 1 SWTCHRKR DPST 125V SPD 24 0E4494 1 SWITCH RKR DPDT 25 0F3215 1 DECAL CONTROL HSB 26 0F6305 3 SEAL COVER 3 18 12 7 382 27 0F6305A 1 SEAL COVER 3 18 12 7 283 28 OF5886 3
25. 1 REF 1 1 1 REF 1 1 6 1 REF 1 1 REF 1 REF 1 1 2 3 1 REF 1 6 3 1 REF 1 REF 1 1 REF 1 REF 1 REF 1 REF 1 REF GROUP D DESCRIPTION PLUG STDPIPE 3 8STEEL 50 HD SWITCHH TEMP 245D 38 NPT SPACER ALTERNATOR 24 G1 STARTER 12 VOLT ADAPTER ENGINE 2 4L MACHINE FLEX PLATE 2 POLE 2461 ADAPTOR 1 8 1 8 BSPT PRESSURE 10 PS 2 POL CLAMP HOSE 38 87 HOSE DRAIN ASSY 28 SPACER ALTERNATOR 24 G1 SCREWHHC 3816X 365 WASHER FLAT 531 IDX 106200 CAP HOSE CLAMP HOSE 40 56 106 ADAPTER FLEX PLATE PILOT 2 4L NUT HEX MIO L5G8 YEL CHR NUT HEX 38 16 STEEL BARBEDEL 90 38 NPT X 38 ADAPTER MIA L50X 3 8 NPT SCREWHHC MI0 L25X45G88 WASHER LOCK 5 16 WASHER FLAT 5168 ZINC WASHER NYLON 565 SCREWHHC MI2 125X 15 6109 WASHER LOCK MIO SPACER DC ALTERNATOR PULLEY SCREWHHC 15 80 88 HARNENG 24L R 200G1 NOT SHOWN SCREWHHC 1 25 60688 CAP VACUUM Y32 CAP ANTIFREEZE RUBBER CLAMP HOSE 38 87 ORING 5 8 IDX7 8 OD BUNAN PLUG WATER SCREWHHC 0 1 25 3068 8 WASHER FLAT 38 MI0ZINC PLUG EXPANSION 16 SCREWHHC 2 1 25 X20G88 SCREWHHC 10 125 16G109 HEAT SHELD24L G1 WASHER LOCK MIO WASHER FLAT MD SCREWSHC 1 25 30G129 WASHER FLAT 5 16 MB ZINC WASHER LOCK 5 16 SCREWHHC 1 25 X 16 G88 GASKET INTAKE COVER G1 COVER INTAKE G1
26. 15 15 INOTE 1 WIRING SHOWN FOR 1 AND STATOR IS TYPICAL FOR SINGLE PHASE FOR 3 PHASE SEE DWG 0 6839 REVISION DATE 01 09 06 A 224 N2A N1B LJ elis 15 2 SW1 15 09 15 9 194 239 194 R4 GROUP G CONTROL PANEL N AVR AUTOMATIC VOLTAGE REGULATOR BCH BATTERY CHARGER BR1 BRIDGE RECTIFIER 2 CIRCUIT BREAKER EXCITATION F1 FUSE BAT POWER 15A ATO 42 CONNECTOR 2 MOV VARISTOR 680V 1 2 820 5 5 470 5 4 FIELD BOOST RESISTOR RELAY 1 START RELAY RL2 RELAY 2 ENGINE RUN SCR SCR BRIDGE SW AUTO OFF MANUAL SWITCH SW2 SET EXERCISER SWITCH TR TRANSFORMER 6VA UTIL 16 VAC FOR 480V SYSTEMS NOT CONNECTED L1 UCT 2 N 0 3 GND NIA 1 FROM T SW N2B ICT 2 UTILITY FROM T SW ICT 3 TRANSFER COIL RELAY 53 ICT 4 TRANSFER COIL RELAY NB ICT 5 REMOTE START ICT 6 REMOTE START T N TION ALTERNATOR BRUSH ASSEMBLY GENERATOR CB1 MAINLINE CIRCUIT BREAKER 240V OUTPUT TO TRANSFER SWITCH ICT INTERCONNECT TERMINAL BLOCK NEUTRAL BLOCK UCT UTILITY CONNECT TERMINAL BLOCK SCR SCHEMATIC DIAGRAM 2 4L 2 POLE DRAWING 0G0118 GROUP G ENGINE WIRIN N 1 AFS AIR FUEL SOLENOID CB J ALT D C CHARGE ALTERNATOR
27. GASKET THROTTLE BODY INTAKE ADAPTER MACHINED SCREWSHC 1 25 20G129 SCREWSHC MI4 15X 35G109 SCREWHHC 1 25 35 GB8 WASHERLOCK 38 ASSY MAGPICKUP 3 3 24 MALE WASHER SHAKEPROOF EXT 7 16 STL PAGE 2 OF 2 A ED 2 O gt ti 92 as o AS 28 gt 777777 770777077 lt o9 EZ e LL LLI co OF 9806 DRAWING PAGE 1 OF 2 DATE 1 10 06 EXPLODED VIEW C2 COOLING SYTEM amp FAN DRIVE DRAWING 0F9806 APPLICABLE TO GROUP D ITEM PART QTY DESCRIPTION DESCRIPTION 1 029529 1 WELDIVENT RADIATOR SUPPORT 2 4L 11 1 ARMTENSIONER 2 0F2608 1 RADIATOR 598 568 49 CPL RH 2 1 SCREWSHC SHLDR LKG 3 025263 1 V BELT 31 64 X57 38 13 1 SPRING TENSIONCPL 4 01526 5 WASHER LOCK 1 PULLEY V BELT 4 FLANGED 5 059981 4 SCREWHHC 15 306109 15 7 WASHER FLAT 3 8 MIO ZINC 6 2 SCREWHHC 5 16 24 X 1 1 2 G5 16 1 PROBE COOLANT LEVEL 3 8NPTF 7 1 SHIELD RADIATOR C5 7 4 CLAMP HOSE 28 1 32 2 25 8 012568 8 SCREWHHC 1 0 20688 18 OF2561 1 HUB FLEX PLATE 9 0F2573 1 PULLEY FAN GROOVE 9 19 0 8 5 8 WASHER FLEX THIN 10 0 4011 1 FANCOOL 22 DIA 10 BLADE LH 20 052250 2 FOAM1X 1 26 75 LG 21 0 7043 2 DISK FLEX 2 013790 1 BARBEDEL 903 8 NPT X38 23 022173 16 WASHER FLAT 1 4HV6 ZINC OC8146 2 SCREWHHC 5
28. PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid fuel in the supply tank Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state The vapor withdrawal system is generally best suited for smaller engines that require less fuel The installer should be aware of the following The natural gas and LP gas systems are similar However the natural gas system delivers gas at a pressure of approximately five inches water 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 thi
29. SCREWHHPMNb5O08X 12 29 051713 22 WASHER FLAT 30 22 WASHER LOCK 31 0F5752F 1 RES WW I5R 5 25WQK CONN 2 0F5884 2 SCREWPHIT 506 10 3 OF5896 2 SCREWPHIT 506 16 3A 0C2265 4 SCREWPHIT M 07 X 12 ZYC 35 0 3990 2 SCREWPHIT 0 7 X 10 ZYC 36 091526 4 SCREWPPHMM508X 12 ZNC 37 051716 9 NUT HEX 8 G8 CLEAR ZINC 38 079224 2 SCREWPPHMIV50 8X 3055 39 075476 2 SCREW PPHMM4 0 7 X 16 40 043180 2 WASHER FLAT 41 022264 2 WASHER LOCK 3 8 42 051715 2 NUT HEX M4 07 G8 YEL CHR 4 043182 7 WASHER LOCK 4 051714 7 NUT HEX 05 G8 YEL CHR 4 0F3192 1 SUPPORT ANGLE PCB 46 0 7403 1 FUSE ATOTYPE 15 ANP BLUE 47 029785 1 HARN 3600RPM R200 CONTROL PNL COMPONENTS INSTALLED PER THIS DRAVUNG A 056739 1 RELAY SOLENOID 12VDC B 022287 2 SCREW HHC 1 4 20X 34 5 022473 4 WASHER FLAT 1 4 ZINC D 022097 2 WASHER LOCK M6 1 4 E 022127 2 NUT HEX 1 4 20 STEEL F 0 6145 AR SEAL WEATHER 45 DIA G 0F2627A 1 COVER CONTROL PANEL SIDE H 091526 4 5 12 ZNC J 4 WASHER LOCK K 051713 4 WASHER FLAT REVISION DATE 12 9 05 GROUP B PAGE 2 OF 2 GROUP C TO ENGINE SUPPORT 5 477 8 6 7 P 25 EXPLODED VIEW 9 MOUNTING BASE 2 4L C2 REVISION G 7801 B DATE 3 31 06 DRAWING 0F9807 PAGE 1 OF 2 EXPLODED VIEW MOUNTING BASE 2 4L C2 DRAWING 0F9807 APPLICABLE TO ITEM PART QTY DESCRIPTION 1
30. Task Required mended Comp to be done Comp to be done Comp Required Comp to be done to be done Date 3 months Date Semi Date to be done Bi monthly Initials annually Initials Annually Initials annually 10 hrs 30 hrs 50 hrs 100 hrs 250 hrs Start and 18 19 20 21 22 23 24 25 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 Perform an engine oil analysis send a sample to a lab for results Change the engine oil and filters if the analysis results indicate this is required engine oil engine oil filter s Replace engine spark plugs Clean and re gap or replace as necessary Replace the engine air filter s Perform a 5 minute no load operational run of the unit looking for any post service problems Return the unit to standby setup for operation when required 90 60 V 100 11 4 MAINTENANCE Task Comp Date Initials 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
31. WCB 23 WASHERLOCK MIO REVISION G 7783 J DATE 5 1 06 PAGE 4 OF 4 08640 DNIMV NOILV LIOXS 194410 HOLVNSALTV 149 QHGO IdXH V dodo JO HDVd 90 61 p O 66LL D 1 201 EXPLODED VIEW CPL ALTERNATOR DIRECT EXCITATION DRAWING 0F9803 APPLICABLE TO GROUP A ITEM PART QTY DESCRIPTION 1 050056 1 RTR 2390 35KDLCPL 0G1155 1 RTR 2390 35KD1 CPL G2 029677 1 RTR 2390 45KD1 060959 1 RTR 2390 45KD1 CPL G2 2 1 STR 2390 35AD1 029664 1 STR 39045K 2P IPH DIRECT 060058 1 STR 2390 35KD1 CPL 0050181 1 STR 390 45KW2P 3PH 480V 060059 1 STR 2390 35GD1 CPL 1 STR 390 45KW 2P 3PH 208V 3 0 9708 REF INSTRHYPOT TEST NOT SHOWN 4 SEE ENGINE EV REF ENGINE ADAPTER 5 SEE ENGINE EV REF FLEXPLATE 6 0F57678 1 ASSY FLYWHEEL CPL W40VMFANB 7 E5706 1 REAR BEARING CARRIER 390DRCT 8 OF 7874 1 ASSY BRUSH HOLDER 3909HSB 9 1 GUARD REAR BEARING CARRIER 10 088150 4 WASHER FLAT 78 ZINC 11 23454 1 KEY WOODRUFF E 12 077043F 1 CONDUIT FLEX 1 1 4 30 LG B 04576100BU 4 STUD MI4 2 0570G5 ZINC 052646 4 WASHER FLAT 1 013123 4 WASHER LOCK 16 051779 4 NUT HEX MI4 20 G8 YEL CHR 7 042601 1 SCREWHHC 16 20 45688 18 04260 1 WASHER FLAT 688IDX 325 OD 19 0F8408 4 SCREWHHC MIO L50X 16 G109 20 046526 4 WASHER LOCK 21 0C3998 4 SCREWHHIT M1 0 7 X25 BP 22 02264 4 WASHER LOCK 644 23 017248 1 BALL BEARING 45 MM 24 070892 1 SLIP RING MACHINED 25
32. con figured properly Please consult an Authorized Service Dealer with any questions 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 nection lower panel should be installed according to the number of leads and the voltage phase required for the application If there are any questions regard ing lead connection refer to the wiring diagrams at the back of this manual Voltage codes apply to the type of stator assembly installed on a particular generator FOUR LEAD SINGLE PHASE STATOR Four lead generators see Figure 7 1 are designed to supply electrical loads with voltage code A 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 I 10115 33 1 00 240 33 NOLES 1 120 i 10115 1 11 Ld gt 1 H Y Y Lio CIRCUIT BREAKER Standby Generator Sets General Information GENERAL INFORMATION
33. for purchasing this model of the standby generator set product line Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice 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 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
34. gen erator s lower connection box lists the unit s serial number and its rated voltage amps wattage capacity phase frequency rpm power factor etc 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 21 200 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
35. hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety infor 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 with
36. must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT If personnel must stand on metal or concrete while installing operating servicing adjusting or repair 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 whe
37. oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted or Rental Unit definition and warranty Units used for prime power in place of existing utility power where 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 genera
38. 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 connections and grounding Control and communication wiring to from the transfer switch must be run in a separate conduit from the AC power leads Battery charger connection to 120 VAC Communication wires connected between transfer switch and generator HTS only Unit secured to pad 90 10 10088 INSTALLATION Standby Generator Sets Installation INSTALLATION START UP CHECKLIST A WARNING 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 15 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 cab
39. to the transfer switch using the means provided such as the util ity power source main line circuit breaker Let the generator run at no load for a few minutes to stabilize internal temperatures Shut down the generator OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If the generator has been installed with an automatic transfer switch such as an RTS HTS or GTS type transfer switch the engine may be started and stopped automatically or manually NOTE Refer to the applicable manual for your trans fer switch and to Transfer Switch Start Signal Connections In addition please note the dangers under Engine Start up and Transfer 90 80 1001990 Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES WARNING 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 in
40. 0 DNIA V zd MASY 9 MASE 1 199 NOILVTIVLSNI MATA IO HDVd M3IA LINOJ aq 3352 ONILNNOW 31332ND2 517108 AANDSYW VIG 1281 3997 3 DH ONILNNOW VIC GES NIA 5244 SOE SOE 53015 1 JIDIVHISIA Iv ANY 150 1738 ANY 3314308 15 553339 73 3015 NVH 1331 3H1I3 9 5 ONILJIT 03 IWANVYW SS3NAD 39N333433 9 15 NV NO 3DIV33N39 ONILNNOW 304 341N034 AINO SI 1 103 1313 Vv 553229 304 AJADI 1 WALNOD HOLIMS 333SNV31 55352 12 lt dWV 672 170A 081 33539H3 3119 4 123 WAaLNAN NOILOSNNOD LINGNOD 4931 9907 29 an 9349 dn g8nis 3015 1 Cp TWANVYW SIINMO NIHLIM 133HS 1119314133 5 33 232398 1119819 SNIILVOI ddV 3004 4000110 3404 862640 N d 301119 NOILVVIVLSNI 39N3233439_ 9019494359 UNNDAV 33945 N3dD 30 1 ANNINIW 1003 S MDTIV JONAA v 1334 S 30 1510 WAWINIW V 81319901 38 LSAW 1 39 D S3NI 13105 1430 Vd ANY IN3WN32303NI33 Vd 341389 05 03 862840 30109 NOILVVIVISNI 39N32333329 OND lt 8 0012 0962 X
41. 0 1 Intake Manifold Procedure aus eornm 10 1 Cylinder Head Procedure assqa sasa rot een 10 1 Cooling 10 2 Overload Protection for Engine DC Electrical Sy Stemi usaron 10 2 Checking Fluid Levels 10 2 Check Engine Oil 10 2 Battery Fluid 10 2 Engine Coolant 10 2 Maintenance Owner Operator Can Perform 10 3 Check Engine Oil 1 20 11 1 10 3 Check 432444 454 10 3 Exercise 10 3 Inspect Cooling 10 3 Check Engine Coolant 10 3 Perform Visual Inspection 10 3 Inspect Exhaust 10 3 Check Belt R 10 3 Inspect Engine Governor 10 3 Changing Engine Oil 10 3 Changing the Engine Air Cleaner 10 3 Spark Phigs idad teni 580143 10 4 Coolant Changer y k uu asha teer ep 10 4 Miscellaneous Maintenance 10 4 Cleaning the Generator 10 4 Battery de MD
42. 021733 1 DECAL CUSTOMER CONNECT INSIDE 6 UL CIRCUIT BREAKER 225 A 0F4185 1 COVER CB C2 C4 225AF B 065469 1 DECAL DANGER HIGH VOLTAGE 0741656 REF CIRCUIT BREAKERS 200A FRAME D 074136 1 COVER DISH 225AF E 4 RIVET POP 125 X 275 SS F 053640 4 SCREWRHM 8 32 3 1 4 G 088150 4 WASHER FLAT 8ZINC H p2264 4 WASHER LOCK 814 J 022471 4 NUT HEX 8 32 STEEL K 029289 2 ELEC 12 FOAM L 021733 1 DECAL CUSTOMER CONNECT INSIDE M 022129 9 WASHER LOCK 5 16 N 0 8432 1 INSULATOR 225 P 0C2454 7 SCREWTHF 1 16 ZJ S R 0 8451 3 LUG SLDLSS 300 MCM6 AL CU s 049897 9 SCREWSHC 125 2068 T 022145 6 WASHER FLAT 5 16 MB ZINC U 045771 3 NUT HEX ME L25 G8 CLEAR ZINC v 0F8843 3 BUS BAR 2004 LUG ADAPTOR w WCB 2 TERMNAL COVER CB 7 UL CIRCUIT BREAKER 4004F A 04187 1 COVER CB C2 C4 400AF B 065469 1 DECAL DANGER HGHVOLTAGE 0741665 REF CIRCUIT BREAKERS 400 D 0F1733 1 DECAL CUSTOMER CONNECT INSIDE E 012419 4 SCREWRHM 10 32 X 4 F 023897 4 WASHER FLAT 10 ZINC G 4 WASHER LOCK 10 H 4 NUT HEX 40 32 STEEL J 0C2454 7 SCREWTHF 1 16 ZJ S K 020289 1 ELEC 1 2 FOAM QL 052647 23 SCREWSHC MI0 L5X25G129 2M 046526 23 WASHER LOCK N WCB 3 BUS BAR ADAPTER 225 400 A P 047822 3 LUG SLDLSS 600 250 1 0 X 1 4 28 95 WCB 2 TERMCOVER CB T 023334 6 SCREWHHC 1 4 28 1265 U 022097 6 WASHER LOCK 1 4 v 022473 6 WASHER FLAT 1 44 ZINC 2 W WCB 23 SCREWSHC 1 5 25 129 23x
43. 16 24 1124 25 022097 16 WASHER LOCK M6 1 4 26 076749 1 TANK COOLANT RECOVERY 7 0 1 CLAMP HOSE BAND 1 4 28 081971 1 BEARING 6205 2NSE SRI2S 29 024496 1 PULLEY 4 5 DIA MACHINED 30 042911 1 SCREWHHC 1 5 30688 31 0F2872 1 SCREWHHC 1 2 13 2 G8 2 2 WASHER FLAT 1 2 ZINC 022195 1 WASHER LOCK 1 2 A 022196 1 NUT HEX 1 2 13 STEEL 8651 9 SCREWHHFC 1 25 X 20 WIV6 36 01772 1 NUT HEXMIO L5G8 YEL CHR 3 029867 1 SHAFT FAN DRIVE 3 OF246L 1 RETAINER BEARING 39 022145 1 WASHER FLAT 5 16 B ZINC 4 022129 10 WASHER LOCK 5 16 41 0389114 1 SCREWHHC 1 25 35 G88 42 082774 1 KEY WOODRUFF 4X 19D B 0F9982 1 HOSE LOWER RADIATOR M 0F978L 1 HOSE UPPER RADIATOR 2 4L HYUND 45 049813 8 NUT LOGBYEL CHR 46 052644 1 SPACER 5 15 551 21 47 0 8566 8 SCREWHHFC 1 0 2050588 48 0 2454 2 SCREWTHF 16 ZJ 49 1 CAP RADIATOR 13 PSI 50 080713 1 BRACKET COOLANT TANK 51 045764 1 SCREWHHTT IM4 0 7 52 065852 1 SPRING CLIP HOLDER 37 62 53 069811 REF 1 4NPT BRASS 54 069860 1 HOSE OIL DRAINASSY 21 007649 1 CLAMP HOSE 38 87 ITEM53IS INCLUDED WTHITEM64 BEARING PRESS NOTE APPLY LOCTITE 620 BEARING RETAINVENT COMPOUND TO BEARING SURFACE ONITEM37 PRIOR TO PRESSING ITEM28 ONTO ITEM 37 ALSO APPLY LOCTITE 620 BEARING RETAINVENT COMPOUND TO THE OUTSIDE OF 28 PRIOR TO INSTALLING ITEM28 INTO ITEM3 amp DATE 1 10 06 PAGE 2 OF 2 608640 DNIA V ZH
44. 17 1 WELDIVENT FRAME 241 C2 2 052860 4 NUT FLANGED HEX 12 1 75 3 052251 5 DAMPENER MBRATION 40 BLUE 4 062257 5 SPACER 49 X 62 X 187 PADR ZNC 5 052252 5 DAMPENER VIBRATION 6 052259 5 WASHER FLAT MI2 7 062891 5 SCREWHHC 12 175 80688 8 0536210410 1 ASSY WRE 14 00 9 012909 1 SCREWHHC 1 25 30G88 10 017411 1 SCREWHHC 1 0 16G88 11 055414 1 LUG SLDLSS 2 48X 17 64 CU R 022447 1 WASHER SHAKEPROOF INT 1 4 13 022097 1 WASHER LOCK 1 4 022173 2 WASHER FLAT M6 I4 ZINC 15 049813 1 NUT 10 8 CHR 16 1 WASHER SHAKEPROOF INT 38 7 OF9597A 1 SUPPORT LH ENGINE 24 18 015764 1 SCREWHHIT M 07X8BP 19 062963 4 SCREWHHC 1 25 3088 20 022302 4 WASHER LOCK 7 16 a 022131 4 WASHER 38 MILO ZINC 22 065852 1 SPRING CLIP HOLDER 37 62 23 0F9597 1 SUPPORT RHENGINE 2 4L 24 022129 1 WASHER LOCK 5 16 25 02620 1 WASHER SHAKEPROOF INT 5 16 26 022145 1 WASHER FLAT 5 164 ZINC 27 045771 1 NUT HEXIVE L25 G8 CLEAR ZINC 29 9596 1 SPACER ENGINE MOUNT 2 4L G1 OF9506A 1 SPACERLH ENGINE IVDUNT 24 G2 REVISION G 7801 B DATE 3 31 06 GROUP C PAGE 2 OF 2 618640 ONIM VAA C JO HDVd 90 r ALVA 7149 17 AH3LLV8 lt 08 0 QHGO Id XA dIONTIOS YALYVLS OL 2 EXPLODED VIEW BATTERY 2 4L CPL DRAWING 0F9813 APPLICABLE TO PART HRGEREBeCaNouaWNeH lt REVISION G 7805 B DATE 4 3 06 QTY 1 1 REF REF REF
45. AO 1 HDVd 90 6 1 ALYA CO YINVITO HHGO IXH NR FS UD gt gt gt lt dowd EXPLODED VIEW AIR CLEANER C2 DRAWING 0F9809 APPLICABLE TO DATE 1 9 06 PART 0 6586 0 0519 0 8127 022127 062974 0501 087561 DESCRIPTION GASKET BOSCH 32 amp 40 ADAPTER CARBURETOR WPVC CONN ELEMENT AIR CLEANER SCREWHHC 20688 NUT HEX1 420STEEL STUDTH 1 4 20X 4 1 2 G2 ZNC PLATE AIR CLEANER TOP 2 4L NUT WING 1 4 20 WASHER LOCK 1 4 GROUP D PAGE 2 OF 2 35 GROUP E 2 13 3 it lt A S9 ETO N 2 2 am 217 T A Hin a pS U SEE NOTE 1 2 amp FOR REGULATOR INFORMATION CONNECT TO WIRE HARNESS REVISION G 7590 B DATE 3 7 06 0F9810 DRAWING PAGE 1 OF 2 EXPLODED VIEW FUEL SYSTEM 2 4L C2 CPL DRAWING 0F9810 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 026915 2 NPPLE CLOSE 34X 1375 2 075580 1 FLANGE FUEL INLET 3 0263908 1 REGULATOR ASSY 24 4 089253 2 SCREW HHC IVB 1 25 X 20688 5 022145 2 WASHER FLAT 5 16 MB ZINC 6 022129 2 WASHER LOCK MB 5 16 7 05771 2 NUT HEX MB 125 GB CLEAR ZINC 8 050180 1 REF GASKET THROTTLE BODY 9 1 STREET EL 45D 1 2 NPT BRASS 10 026812 2 34 11 028379 1 NIPPLE PIPE 341 7 12 023869 1 REF
46. ERM2DA8X6X 1100 10 022155 4 WNs HERLOCK 6 11 0 2128 4 SCREWPHIT 632 1 22 2 02382 1 DECAL UTIL SENSE CUST CONN B 049457 1 DECAL NEUTRAL 057073 2 JUNCTIONBLOCK 3816 215 005466 REF BUS BAR NEUTRAL BLOCK 390 2 16 047822 REF LUGSLDLSS 600 250 1 0X 14 28 17 022237 2 WASHERLOCK38 18 022241 2 HEX 38 16 STEEL 19 049226 4 WASHERLOCKIV5 20 4 SCREWPHITM508X16ZYC 21 0C2454 8 SCREWTHFM51X16NVAZJS 23 022473 8 lt 4 1 4 2 022097 4 14 126 001608 REF BLOCKTERM20A 6X3X 100 7 27 0F4464 1 DECAL CUST CONN 120V UTILITY 28 025433 1 LUG SLDLSS 6 14X 13 64 29 024469 1 SCREWHHIT 0332 38CZ 30 0672104 1 DECAL GROUNDLUG 31 026029 4 SCREWHHIT 1 0 16ZYC 32 081008 1 125 5 5 077033 1 CONDUTFLEX2O 10 36 LG x 051713 2 WASHER FLAT 026156 1 PLATE WRE SNGL GALV 36 1 TAPE ELEC 1 2 FOAM AS REQD 37 077411 4 5 10 16 88 4 38 064153B 2 WIRE J UVPER TRANSFORMER NOT SHOWN 5 39 060770 1 HARNESS TRANSFORMER ADAPTER UL CIRCUIT BREAKER ED A 03328 1 COVEREDCBSHORTSTND B 065460 1 DECAL DANGER HIGH VOLTAGE 005552 1 CBOOOA P 480 5 ED4LL 005554 00704 3P 490 5 ED4LL 005556 00904 490 5 ED4LL 00063 0125 490 5 ED4LL 1 INSULATOR S ED 3P 018027 4 SCREWRHM d0 2X4 Y2 F 23897 4 WASHER FLAT 0 2 G 022152 4 0 H 4 NUT HEX 40 32 STEEL J 0C2454 7 SCREWTHF 1 16
47. FER RELAY COIL 4 REMOTE START REMOTE START E 2 CUCONNECTIONS 2 u y i e 4 WIRING DIAGRAM REVISION 2 4L 2 POLE DATE 12 01 05 DRAWING 0F9705 GROUP G CUSTOMER CONNECTION amp ALTERNATOR LEGEND ENGINE N BRUSH ASSEMBLY GENERATOR AFS AIR FUEL SOLENOID ICT INTERCONNECT TERMINAL BLOCK ALT D C CHARGE ALTERNATOR MCB MAINLINE CIRCUIT BREAKER BAT 12VDC BATTERY NB_ NEUTRAL BLOCK STARTER CONTACTOR UCT UTILITY CONNECT TERMINAL BLOCK DEG DRIVER ELEC GOVERNOR CB J DIST DISTRIBUTOR DEG 12V 11M 14 DEG FS FUEL SOLENOID 0 1 FS2 AUX FUEL SOLENOID DEG 314 0 5 GOV ELEC GOVERNOR ACTUATOR COOLANT TEMP 4 85 HEl 14 2 HCT HIGH COOLANT TEMP SWITCH GOV ov 5 767 H 5 IGNITION COIL GOV 5V 6 765 5 J1 CONNECTOR 1 ON PCB DISTRIBUTOR 12V 7 194 LOW FUEL PRESSURE SWITCH __ LEVEL 8 573 H ugs LOW OIL PRESSURE SWITCH CRANK SENSOR IN 9 79 H 771 8 CRANK SENSE 10 0 02 GEN SENSOR EINE a 11 COOLANT LEVEL SWITCH FDBK 12 766 769 12 OX INP 113 804 8 1418 9 COIL 1518 25 M DISTRIBUTOR RET 16 0 mm umm 5 DISTR INPUT 17 402 Hee pw lis 765 7653
48. HEX LOCK M6 LOSS NY INS ROOF C2 SLITTER CA SPLITTER LOWER C4 SPLITTER STINGER C2 SUPPORT SPLITTER LHC2 TAB PULL ASSEMBLY COVER ACCESS WASHER FLAT 14M6 ZINC WASHER LOCK 1 4 NUT HEX 1 4 20STEEL INSULATION RETAINVENT HANGER WASHER SELF LOCKING DOME INSULATION DOOR C2 INSULATION ROOF TOP MSE ACTIONLATCHSLOTTED CIR GASKET EXTRUDEDTRIM 440 64 LG INSULATION SPLITTER INSULATION SPLITTER INSULATION DUCT RETAINER INSULATION 820 INSULATION DUCT SIDES RETAINER INSULATION 450 RETAINER INSULATION 740 INSULATION LOWER SPLITTER SCREWHHC 1 0 20688 ASSY WIRE 14 AWG 34 8 GRN YEL WASHER SHAKEPROOF INT 1 4 INSULATION W REFL HT SHELD KEYMSE ACTION LATCH SLOT CIR PEP NNNPWANDOENNENENBRPRPWENNERPNENNENNANNGE OPTIONAL COMPARTIVENT MATERIALS ALL P NS WTHAN 009 SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION USE THE FOLLOWING LEGENDTO IDENTIFY THE CORRECT PART NUMBER ALUMNUMENCLOSURE NOTE ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM2 amp 5 THREAD FORMING FASTENER ANDITEM39LOCK NUT LOCK NUT IS TO BE INSTALLEDAFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER GROUP F PAGE 2 OF 2 218640 ONIM VYA C dO 1 4 90 PL E HLIVA 29 MASY Tr 5 S3 1H30N V LV9L D NOISIATH MATA 15 341 H H OL LNAWLYVdNOS OL
49. IRECT DRIVE 5 GENERATOR CUSTOMER CONNECTION El ES El NB 240VAC 120 120 PAGE 1 4 WIRING DIAGRAM REVISION G 7501 B R SERIES CPL ALTERNATOR DATE 02 22 06 DRAWING 0F6839 GROUP G OPTION THREE PHASE R SERIES CONTROL PANEL 6 WIRE 120 208V 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 Fl NB 120VAC XNOTE THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 208VAC PAGE 2 4 WIRING DIAGRAM REVISION G 7501 B R SERIES CPL ALTERNATOR DATE 02 22 06 DRAWING 0F6839 GROUP G eae Mm ea eg eS eS LO 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 TO Ee Ee 1 Fl OR TO 277VAC NOTE THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES
50. LACE PIPE PLUG FROM OUT 2 TO OUT 1 USE PIPE SEALANT BARB AND PIPE PLUG MAKE SURE TO KEEP PORTS FREE FROMDEBRIS DURING RECONFIGURATION PROCESS FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL INLET DECAL P N 050280 FOR NG FUEL INLET DECAL P N 050279 ITEML7 WHEN SWITCHING FUEL TYPES THE PROPER DIP SWITCH SITTINGS MUST BE MADE TO THE CONTROL PANEL SEE OWNERS MANUAL FUEL SECTIONFOR MORE DETAILS GROUP E PAGE 2 OF 2 GROUP F INSULATION AND RETAINERS RETAINER 30 62 63 LOCATED ON THE NEAR SIDE gt INSULATION AND RETAINERS LOCATED ON THE FAR SIDE TYPICAL MOUNTING OF ACOUSTIC INSULATION SEE DETAIL A AND B FOR SPLITTER VARIATIONS EXPLODED VIEW ENCLOSURE C2 DRAWING 0F9811 O lt m FRAME PAGE 1 OF 2 WU 58 LMM LMM UMMM ZZ REVISION G 7460 B DATE 3 10 06 EXPLODED VIEW ENCLOSURE C2 DRAWING 0F9811 APPLICABLE TO ITEM PART QTY DESCRIPTION 0 0045 0 2454 0F5849 000 087233 0E3257 OF5852 0F9833 OF5851 049813 077992 9835 REVISION G 7460 B DATE 3 10 06 REAR WRAP C2 CPL SCREWTHF 5 1 16 ZJ S DOOR C2 RIVET POP 1875 X 45055 SCREWTH FRMM6 WCAP SHKPRF W DISCHARGE DUCT LH amp RH SIDE C2 FRONT CORNERS C2 DISCHARGE CENTER DUCT C2 HEX LOGS YEL CHR NUT
51. LD BOOST RESISTOR 15 OHM UTILITY RL1 RELAY 1 START ERUN SUPPLY CUSTOMER CONNECTIONS RELAY 2 ENGINE RUN R SCR BRIDGE MODULE AUTO OFF MANUAL SWITCH SET EXERCISER SWITCH TERMINAL BLOCK TRANSFORMER 6 UTIL 16 Sim WK a o fo CB J q A SET AFS OUT f 1 808 808 FOR 208V amp 240V SYSTEMS FOR 480V SYSTEMS 808 808 START RELAY 2 56 1 225 lt FUEL RUN RELAY 3 14A 224 lt lt TR1 0 4 lt lt 0 2 WIRE START 1 T 4 183 1 1 1 MOMENT OPEN 5 15 TR 2 WIRE START 2 6 pg 178T MAN AUTO INPUT 7 1815A 16 SENSE 1 y 8 224 ALARM RELAY 9 2 XFER RELAY 110 23 2 2 INPUT 11 239 0 162 _ EMISSIONS ENABLE 713 0 m GND B 1418 0 16 SENSE 2 12 225 2 CONNECT FOR N OPTIONAL EMISSIONS I ONLY 2 5 2 56 601 56 TERMINAL ICT 8 SINGLE PHASE STATOR SHOWN I USED WITH FOR 3 5 SEE DWG 0 6839 277 480V UNITS I ONLY CENTER TERMINAL NOT USED royo UTILITY FROM T SW UTILITY FROM T SW TRANSFER RELAY COIL TRANS
52. Serial Number 2 AL Model 005259 0 STANDBY GENERATOR OWNER S MANUAL A new standard of reliability GUARDIAN by Generac Power Systems Inc CAUTION ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit 862090 ON Hed 90 00 0 SECTION PAGE SAFETY RULES 1 1 INTRODUCTION 1 3 Read this Manual Thoroughly 1 3 Operation and Maintenance 1 3 How to Obtain Service nat dp e 1 3 IDENTIFICATION RECORD 2 1 Data papas diia 2 1 EQUIPMENT DESCRIPTION 3 1 Equipment Description 3 1 Engine Oil Recommendations 3 1 Coolant Recommendations 3 1 ENGINE PROTECTIVE DEVICES 4 1 High Coolant Temperature Switch 4 1 Low Coolant Level Sensor 4 1 Low Oil Pressure Switch reete eere edens rebate ren 4 1 Overcrank Shutdown eee reete 4 1 Overspeed Shutdown
53. ast once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks security damage CHECK FAN BELT Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 of an inch Adjust belt tension as required INSPECT ENGINE GOVERNOR Visually inspect electronic governor DIG A Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incor rect frequency and or voltage Only qualified service technicians should adjust the governed speed Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance CHANGING ENGINE OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies Drain the oil while the engine 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 retaini
54. 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 elec trical backfeed between two different electrical sys tems For additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with applicable codes standards and regulations FUEL SYSTEM Make sure 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 shippe
55. ch it is possible for the engine to overheat without automatic shut down To prevent such overheating the engine has a low coolant level sensor If the level of engine coolant drops below the level of the low coolant level sensor the engine automatically shuts down LOW 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 ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total OVERSPEED SHUTDOWN A speed circuit controls engine cranking start up operation and shutdown Engine speed signals are delivered to the circuit board whenever the unit is running Should the engi
56. continues to run No AC output from generator 1 2 15 amp luse 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 Wire 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 Clea
57. d 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 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
58. ermit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts 90 80 0 100 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 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
59. he 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 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 the bat tery posts as the cables are attached and cause an explosion BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 26 525 0 deg F NOTE The BCI number should be located directly on the battery Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule SERVICE SCHEDULE 30 KW 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to 150 kW in size The established intervals in the schedule the maximum recommended when the unit is used in an average service application They will need to be decreased performed more frequently if the unit is used in a severe application Use calendar time from the previous maintenance interval to determine the next required maintenance interval
60. he outlet port Port 1 of the demand regulator 4 Remove the brass hose fitting with solenoid from Port 2 5 Install brass hose fitting into Port 2 6 Install the brass hose fitting with solenoid into Port 1 7 Connect carburetor gas hose to brass fitting Tighten all clamps and plugs 9 Make sure fuel supply is of the proper pressure and type for configuration 90 20 61059dsu o Utility In Transfer Switch NEUTRAL 4 14 GA WIRES we GENERATOR CONNECTION 2s TO GENERATOR CONNECTION BOX To Generator Control Panel CIRCUIT BREAKER SIZE KW VOLTS AMPS 512 35 24010 175 6 to 300 mcm 35 20830 150 6 to 300 mcm 35 48030 60 6 to 300 mcm 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 ent fuels Figure 6 2 Reconfigure the Fuel System A A FUEL HOSE FUEL HOSE REGULATOR REGULATOR FUEL HOSE FUEL HOSE BRASS BRASS HOSE FITTING REDUCER REDUCER HOSE FITTING JET 2 JET 2 PORT 1 a Q PORT 2 PORT 1 PORT 2 NG FUEL SYSTEM LP FUEL SYSTEM NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made DIG A Serious injury or damage may occur if not
61. iced with the recom mended oil may result in an engine failure 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 F is 5W 30 synthetic oil Standby Generator Sets Equipment Description GENERAL INFORMATION COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is 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 AN Ethylene glycol base antifreeze is poi
62. in the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and accessories Operating instructions presented in this 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 0188 100 ejes 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
63. junction with a transfer switch capable of manual operation only the following procedure applies A manually operated transfer switch is one that will not provide automatic start up and does not include an intelligence circuit ENGINE START UP AND TRANSFER For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch DIG A The Maintenance Disconnect Switch and the AUTO OFF MANUAL switches if so equipped must be set properly or the generator will crank and start as soon as the utility power to the transfer switch is turned off Refer to applicable control panel and transfer switch manuals for more information Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to UTILITY Do not attempt manual operation until all power supplies to the transfer switch have been posi tively turned off or extremely dangerous pos sibly lethal electrical shock will result Transfer switch enclosure doors should be kept closed and locked Only authorized personnel should be allowed access to the transfer switch interior Extremely high and dangerous voltages are present in the 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 t
64. les to the battery Attach negative battery cable last Close the 120VAC circuit breaker to the battery charger Measure the voltage at the battery before and after the charger is turned on Verify all AC electrical connections are tight at the circuit breaker and transfer switch Visually inspect entire area looking for loose paper plastic wrappings leaves etc Check all hoses clamps fittings for leaks or dam age Check all electrical plugs throughout the genera tor Ensure each plug is seated correctly and fully inserted into its receptacle Verify the AUTO OFF MANUAL switch is in OFF position Open the valve to the engine fuel line Bleed the fuel system of air necessary for long fuel lines Open the generator main line circuit breaker Connect a manometer to the gas line and record the static pressure It must be as listed in the Specifications Insert the fuse into the control panel Move the AUTO OFF MANUAL switch to the MAN UAL position The engine should now crank and start 90 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 s
65. ls equipment and or knowledge to accomplish and should be performed only 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 or following each 50 hours of operation of the unit 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 or following each 100 hours of operation of the unit 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 5 comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required and to identify any potential problem areas Performed annually or following each 250 hours of operation of the unit 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 90 60 LOOPUSSMS MAINTENANCE MAINTENANCE Standby Generator Set
66. mes Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extin guisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or 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 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
67. mp cloth or sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer That dealer will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying BATTERY All lead acid storage batteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always 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 chargi
68. n or replace as needed Unclog fuel line Clean regap or replace plugs Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch 1 Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Auto reset Wait 5 min and attempt restart Contact the nearest Authorized Dealer for assistance 12 1 S0 80 0 100149191 NOTES Standby Generator Sets Notes NOTES NOTES Standby Generator Sets Notes NOTES NOTES Standby Generator Sets Notes NOTES 166640 ONIM VAGA v JO 1 4 90 1 S ALVA SH X313 95 9 69 149 8LL D NOISIAHA MATA 4 dnodd EXPLODED VIEW CPL C2 8 C4 FLEX HSB DRAWING 0F3391D APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F3137 1 PAN CB CONN BOX 2 0F3188 1 STANDRHCONTROL 3 0F3189 1 STANDLHCONTROL 4 AAN 1 BUSHING SNAP SB 2 5 31 3 5 0F6366B 1 2 XFMR DUAL 120 10 FOR 120 240V 8 277 48 UNITS 0F6366A 1 XHVRDUAL 104 16 FOR 120 208 UNITS 36 043180 2 4 MASHERFLATM1 3 7 022264 2 4 WASHERLOCK 8 1 3 8 0 3990 2 4 SCREWPHITMIO7X10ZYC 09 057701 REF BLOCKT
69. n the generator is operat ing Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy 90 80 100 Aiejes 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 ti
70. ne overspeed above a safe preset value the circuit board initiates an automatic engine shutdown Contact the nearest Authorized Dealer if this failure occurs RPM SENSOR LOSS SHUTDOWN If the speed signal to the control panel is lost engine shutdown will occur DC FUSE This fuse is located inside of the control panel It protects the panel wiring and components from damaging overload Always remove this fuse before commencing work on the generator The unit will not start or crank if the fuse is 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 O 0 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
71. ng Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury 90 20 0 OLOUIEN 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 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer DANI 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 t
72. ng 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 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters caution AN 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 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 NON ec 292 e 3 o Doors Removed for Clarity SPARK PLUGS Reset the spark plug gap or replace the spark plug
73. oro noi dedo dn 2 4 Liter i 3 41 in O 3 94 in Compression 8 5 to 1 Air Intake Naturally Aspirated Hardened ce ere dl Hydraulic Engine Parameters Rated Synchronous 60 Hz 3600 HP atrated KW vin sa saq minae nana 60 Hz 55 Exhaust System Exhaust Flow at Rated Output 60 7 360 cfm Exhaust Temperature at Rated Output 1050 F Combustion Air Requirements Natural Gas Flow at rated power 60 Hz 129 cfm Governor Electronic Frequency Regulation Isochronous Steady State Regulation sss 0 2596 Engine Lubrication System Type Of OIL PUMP termo ntt Gear AAA eee Full Flow Spin on Cartridge Crankcase Oil Capacily ses 4 0 5 qts Standby Generator Sets aa INFORMATION Specifications INFORMATION COOLING SYSTEM TYDE Pressurized Closed Recovery Water Pump u cis id adn Belt Driven Fan 2150 rpm A 22 inches Mola
74. ransfer 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 When certain that all readings are correct move the transfer switch manual handle to its STANDBY GENERATOR position i e load cir cuits supplied by the generator the standby generator s main line circuit break er to its ON or CLOSED position Load circuits are now powered by the standby generator RETRANSFER AND SHUTDOWN For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch To transfer the load back to the utility power source and shut down the generator follow these direc tions Set the standby generator s main line circuit break er to its OFF or OPEN position 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
75. related equipment must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electri cal and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operated and serviced in accordance with the 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 p
76. ry 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 or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse CHECKING FLUID LEVELS CHECK ENGINE OIL Check engine crankcase oil level Figure 10 1 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Engine Oil Recommen dations for recommended oils 90 00 0 0101 Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance Figure 10 1 Oil Dipstick and Oil Fill Cap Oil Fill Cap gt lt ER 4 Oi s COSE Dipstick E A BATTERY FLUID Check battery electrolyte fluid based on 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 neces
77. s In such a converter heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state 90 80 100545114 SPECIFICATIONS GENERATOR WO vice s m Su E aswa Synchronous Rotor Class H Stator Insulation soa ttr nes Class H Total Harmonic DISIrtI0g LLL u uu Lu L uu Q lt 3 5 Telephone Interference Factor 50 Alternator Output Leads 3 phase 4 wire P Sanga s Sealed Ball Flexible Disc Load Capacity Standby 35kW 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 Systetri ada ina Direct Generator Output Voltage kW 60 Hz kW Amp CBSize 120 240V 1 phase 1 0 pf 35 146 175 120 208V 3 phase 0 8 pf 35 121 150 277 480V 3 phase 0 8 pf 35 53 60 Generator Locked Rotor KVA Available Voltage Dip of 35 Single phase or 208 69 KVA DS BSEC 76 KVA ENGINE 1 Generac s en ss UH In Line Cylinders and 4 cn oio hire a
78. s Service Schedule Maintenance Tasks 1 Disable the unit from operating per the first page warning 2 Check the engine oil level Adjust as necessary 3 Check the engine coolant level Adjust as necessary 4 Check the engine coolant thermal protection level Correct as necessary 5 Check the natural gas delivery system for leaks and correct pressure on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level and specific gravity 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 90 60 V ed LOOPUISAIS Level 1 Level 2 Level 3 Level 4 Level5 Recom Task Required Task Required Task Task Required Task mended be done Comp be done Comp Required Comp lto be done Comp to be done Date 3 months Date Semi Date to be done Date Bi Date monthly Initials Break in Initials annually Initials Annually Initials annually Initials 50 hrs 100 hrs 250 hrs 10 hrs 30 hrs 11 2 Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Task
79. s 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 1 07 1 17 mm 0 042 0 046 inch by carefully bending the ground elec trode Figure 10 4 Figure 10 4 Setting the Spark Plug Gap SET PLUG GAP AT 1 07 1 17 mm 0 042 0 046 inch COOLANT CHANGE Every year have an Authorized Service Facility drain flush and refill the cooling system See Specifications for cooling system recommendations 90 00 0 0101 Standby Generator Sets MAINTENANCE 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 da
80. s Recom Task Required Task Required Task Task Required Task mended Comp to be done Comp to be done Comp Required Comp to be done Comp to be done Date 3 months Date Semi Date to be done Date Bi Date monthly Initials Break in Initials annually Initials Annually Initials annually Initials 10 hrs 30 hrs 50 hrs 100 hrs 250 hrs 10 Check the engine accessory drive belts and fan coupling device if equipped for correct tension wear weather cracking and damage Replace as necessary 11 Check the engine valve clearance Adjust as necessary 12 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 13 Test the engine and transfer switch safety devices Correct and or adjust as necessary 14 Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 Replace the engine accessory drive belts 16 Check gearbox oil level if equipped L TL TIT TT oil if equipped 11 3 90 60 V ed LOOPU9SAIS Standby Generator Sets MAINTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom Task Required Task Required Task
81. sary Periodically remove radiator pressure cap only when engine has cooled down to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radiator filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact an Authorized Service Dealer Inspect cooling system and coolant recov ery system for leaks MAINTENANCE OWNER OPERATOR CAN PERFORM CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels CHECK BATTERY See Checking Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary 90 20 0 OLOUIEN 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 le
82. sonous Do not use mouth to siphon coolant from the radiator recovery bottle or any container Wash hands thoroughly after handling Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them 90 80 004 034 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 swit
83. spect 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 Check 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 Batte
84. tors cranes etc 13 Overtime holiday or emergency labor 14 Planes ferries railroad busses helicopters snowmobiles snow cats off road vehicle or any other mode of transportation deemed abnormal 15 Any and all expenses incurred investigating performance complaints unless defective Generac materials and or workmanship were the direct cause of the problem 16 Starting batteries fuses light bulbs engine fluids and overnight 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
85. witch to AUTO Disconnect utility power before the transfer switch Engine should start transfer to load Run at least 15 minutes on generator power Make certain all 3 phase loads are functioning correctly correct phase rotation Reconnect Utility power Transfer switch will transfer back to Utility and engine will shut down within the given time parameters set up for the specific transfer switch and controller Install all covers access plates and door panels Put the Owners Manual in a safe and accessible place Make certain the AUTO OFF MANUAL switch is in the AUTO position START UP INSPECTION When a start up 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 con

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