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Generac QT 5.4L Portable Generator User Manual

1. PANEL Utility In O O O Transfer Switch NEUTRAL AG CERE 5 618 3 Q DOO D Gen m RS485 SSP RS485 8 Sh 2 WIRE zm B4 Xfer Sig B4 Xfer To SHIELDED ALTERNATOR CABLE AN gf o 6 W GROUND EE TO 6 SD NEUTRAL GENERATOR GENERATOR oo Es CONNECTION BOX CONNECTION CIRCUIT BOX BREAKER CIRCUIT BREAKER WIRE AND CONDUIT SIZE KW VOLTS CBAMPS LUG SIZE et 100 240 1 0 500 2 3 0 to 500 mcm 45 AMP 120 100 20830 400 2 3 0 to 500 mcm VOLT 251 9 100 480 3 200 6 to 350 mcm CHARGER CIRCUIT EN LZ 2 WIRE SHIELDED x gt CABLE W GROUND Us TO TRANSFER SW JJ GROUND ONLY AT GENERATOR BOX Ground Level STUB UP AREA Concrete Slab See Install Dwg for Dimensions COLD WEATHER KIT For cold climates optional cold weather kit part num ber OF6148A is recommended The kit includes Battery Warmer 4 Junction Box with hardware Thermostat 20 deg ON 40 deg OFF 6 qt pack 5W 30 synthetic oil engine S0 LL 9 ed 002905 9 6 2 5 4L amp 6 8L IGNITION DESCRIPTION This single fire Ignition is intended to operate with a 10 cylinder 6 8L engine and an 8 cylinder 5 4L engine The 6 8L engine uses a 40 1 crank sensor a mag pickup CAM sensor and individua
2. 029226 0C2266 EEN REVISION G 7604 A DATE 3 7 06 DESCRIPTION PANEL CB CONNBOX STAND RHCONTROL CPL C5 STAND RH CONTROL CPL C52 HOLE STAND LH CONTROL CPL C5 BUSHING SNAP 5 2 5 31 ASSY PCB INTERFACE 1PH 240V INTERFACE 3 5 416 480 INTERFACE 3PHS 208 240 WASHER FLAT M4 WASHER LOCK 48M SCREWPHIT M407 X 10ZYC BLOCK TERM2DA 8X 6X 1100V WASHER LOCK 26 SCREWPHIT 26 22 X Y2ZYC DECAL CPL CUST CONN CTRL DECAL NEUTRAL JUNCTION BLOCK 32816 BUS BAR NEUTRAL BLOCK 390 LUG SLDLSS 600250 1 0X 1428 WASHER LOCK 38 NUT HEX 38 16 STEEL WASHER LOCK MB SCREWPHIT N508X 16ZYC SCREWTHF M amp 1X I6NVA 2 S SCREWHHC 10 20 88 WASHER FLAT 14 5 ZINC WASHER LOCK M54 NUT HEXM5X LOGBYEL CHR BLOCK TERM2DA 6X 3X 1100 DECAL CUST CONN 120 UTILITY LUG SLDLSS 6 14X 1361CU SCREWHHIT 34032 38 2 DECAL GROUNDLUG SCREWHHIT M5 L0X 16ZYC WASHER FLAT N5 GROMVET 125X 25X 75 CONDUIT FLEX2 0 ID PLATE WIRE SNGL GALV gt gt Bhauwgu E PART 989 GROUP A QTY DESCRIPTION ELEC 1 2 FOAM AS REQD F HSB CTRL IGN MODULE SCREWHHC M amp LOX 16G88 SCREWPPHM7ZIQ2X2 WASHER FLAT 10 ZINC WASHER LOCK 40 NUT HEX 40 32 STEEL UL CIRCUIT BREAKER 800 F COVER 98 5 DECAL DANGER VOLTAGE CIRCUIT BREAKERS 800A FRAME INSUL CB 800AF SCREWRHM1 4 20X 1
3. 10 2 Inspect Exhaust Systetn trente 10 2 Check Fan Belt e tune 10 2 Inspect Engine 10 2 Changing Engine Oll rusas 10 2 Changing the Engine Air Cleaner 10 3 Spark PIGS m 10 3 10 3 Miscellaneous Maintenance 10 3 Cleaning the 10 3 Battery dM t 10 4 Battery Maintenance u s iocans 10 4 Battery sees inv eee bes 10 4 SERVICE SCHEDULE 11 1 30 kW 150 kW Standby Gas Engine Driver Generator Sets neo tunes 11 1 TROUBLESHOOTING 12 1 Troubleshooting Guide er inorse keinend 12 1 NOTES EXPLODED VIEWS amp PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS WARRANTY 90 80 0 00 u U09 Standby Generator Sets SAFETY RULES Important Safety Instructions 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 Califo
4. 16 156 F3 NOTE 7 17 GND NOTE 18 150 CYLI CYLIO IGNITION COL PWR 19 806 27 IGNITION ALARM 22 CAMSHAFT SENSOR ENGINE CONTROL MODULE CONNECTIONS PIN WRE FUNCTION 3 810 MOD 2 EXTERNAL MODEM GROUND 4 805 02 OXYGEN SENSOR OPTION 5 804 _ OXYGEN SENSOR OPTION 10 R15B RBTA S ESI OVERSPEED WATCHDOG FUEL RELAY 12 0 NOE 9 14 811 5 DCD A 16 805 BAT CHARGER CURRENT 18 766 GA 1 THROTTLE POS 19 69R OPS 3 OIL PRESS RIN j 21 808 AFS AIR FUEL SOLENOID OPTION 24 0 MPUI 2 SIGNAL 25 79 MPUI 3 SIGNAL 32 809 842 REVISION G 8444 C DATE 6 28 06 PAGE 1 OF4 J2 FUNCION C 1 391 CUST CON RS485 XFER SW COM 3 RS232 TX GENLINF CUST CON LINE POWER SIGNAL 6 224 V SENSE GEN APH L8 403 AVR 6 GATE TRIGGER B L9 399C CT GEN C PH CURRENT 15 390 CUST CON RS485 XFER SW 114 387 COM 2 RS232 RX GENLINK 16 RIS X ES EMERGENCY STOP 19 405 AVR 11 AVR GROUND 24 SHLD CUST CON RS485 DRAIN XFER SW 25 389 5 RS232 COM GENLINK CONNECTIONS NOT USED IN 19 UNITS SCHEMATIC DIAGRAM 4 6L 5 4L amp 6 8L H PANEL
5. 1 4NPT BRASS 49 080713 1 BRACKET COOLANT TANK 50 002473 16 WASHER 14M6 ZINC 51 02209 16 WASHER LOCK 5 1 4 52 2568 8 SCREWHHC M6 L0X 20 88 5 152022 1 SHIELD RADIATOR C5 54 089253 1 SCREW HHC VE L25X 20 G88 55 051769 1 WASHER LOCK MI2 56 0 8145 8 WASHER FLEX THIN 57 0E2507 1 PROBE COOLANT LEVEL 38 NPTF 58 1 CAP RADIATOR 13 PSI 59 0 8566 8 SCREWHHFC 10 20 88 0 F2776 1 BRACKET SIGNAL CONDITIONER 6L 0644 1 SPACER 5X 15 X 25 STUZINC REVISION G 6633 J DATE 10 12 05 48 5 INCLUDEDWTH 47 GROUP C PAGE 2 OF 2 684640 ONIM VAA JO I HDVd SO LI S ALVA 3SV8 ONILNNOW 1665 0 AHIA HHGO IXH L d3lHuvo SNIHV38 OL d 1O ID EXPLODED VIEW MOUNTING BASE DRAWING 0F3589 APPLICABLE 5 4L SP 100KW ITEM PART QTY DESCRIPTION 1 1 MIG BASE CP 54 100KWDD 2 D65852 1 SPRING CLIP HOLDER 37 G2 3 052252 5 DAVPENER VIBRATION 4 052257 5 SPACER 49 X 62 1 87 PADR ZINC 5 052250 5 WASHER FLAT MI2 6 055507 5 SCREWHHC 12 175 85 88 7 052251A 5 DAMPENER VIBRATION 8 052860 4 NUT LOCKING MI2 175 9 022805 2 SUPPORT ENG 54 LHRH 68L RH 10 045764 1 SCREWHHIT M 07X8BP 002447 1 WASHER SHAKEPROCF INT 1 4 2 061383 1 LUG SOLDERLESS 30 74 X 13 32 CU 13 013107 1 SCREWHHC 1 25 25 88 14 002473 1 WASHER FLAT 14M6 ZINC 15 049813 1 NUT HEX M5 X LOGS YEL CHR
6. 3 0F3685 4 AN AN 8 3 NNNNA Bee mm BBBUH REVISION G 8253 H DATE 5 30 06 DESCRIPTION STAND RH CONTROL TWO HOLE FOR 54L 100KW amp 48 SOKW IPHASE STANDLH CONTROL C5 GRBX BUSHING SNAP 5 2 5 31 BUSHING SNAP SB 25 31 FOR 54L 100KW amp 4 SOKWIPHASE INTERFACE 1PH240V INTERFACE 3 5 416 480 INTERFACE 3PHS 206 240 WASHER FLAT M4 WASHER LOCK 84 SCREWPHIT M407 X 10ZYC BLOCK TERM2DA 8X 6X 1100V WASHER LOCK 26 SCREWPHIT 46 32 X 127 DECAL CPL CUST CONNHCTRL DECAL NEUTRAL JUNCTION BLOCK 3816 BUS BAR NEUTRAL BLOCK 390 LUG SLDLSS 600250 1 0X 1428 WASHER LOCK 38 NUT HEX 38 16 STEEL WASHER LOCK MB SCREWPHIT N508X 16ZYC SCREWTHF M amp 1X J6NVA 2 S SCREWHHC M5 L0X 20G88 WASHER FLAT 14 5 ZINC WASHER LOCK M5 1 4 NUT HEXM5X LOGBYEL CHR BLOCK TERM2DA 6X 3X 100V DECAL CUST CONN 120V UTILITY LUG SLDLSS 6 14X 1361CU SCREWHHIT 00 32X 38 CZ DECAL GROUNDLUG SCREWHHIT M5 L0X 16ZYC WASHER FLAT N5 125X 25X 75 CONDUIT FLEX2 0 ID CONDUIT FLEX 20 ID FOR 54L 100KW amp 4 4L 30KW PHASE PLATE WRE SNGL GALV TAPE ELEC 1 2 FOAM AS REQD ASSY PCB 4 6L IGNITION MODULE ASSY PCB HSB CTRL IGNIMDDULE ALL OTHER APPLICATIONS EXCEPT 48 G3 SCREWHHC M5 L0X 16G88 SCREWPPHM 022 X 2 WASHER FLAT 440 ZI
7. 3 1 x x x GROUP G iB 3 3 OPTIONAL EMISSION CONTROL _ 5 I I I 5 3 GI m 2 Ir E lez 5 lez lt gt d o I L lt gt 9 q1Hs z o 8 gt D a CENE s nse x l 9 lt Y WAV IM M69 be o 9 2 8 Jg S 2 85 Aces 5 l oe ee lt 1 a o uec 5 D 3 I I I p x E x 2 I o 2 9 52 x oe e Z Sz z o gt 3 I I 5 PAGE 3 OF 4 4 6L 5 4L amp 6 8L H PANEL SCHEMATIC DIAGRAM REVISION G 8444 C DATE 6 28 06 DRAWING 0F3901 PAGE 3 OF 4 L1 L2 36 ONLY 00 NOTES D WIRE 0 IS CHASSIS GROUND UNLESS NOTED OTHERWISE 9 WIRES 13 IS UNFUSED 12VDC BATTERY 3 WIRES 14 IS FUSED 1e VDC WHEN GENERATDR IS CRANKING DR RUNNING 4 WIRES 15 IS FUSED 12VDC WHEN E STOP IS NOT ACTIVATED 5 WIRE 15A IS FUSED 12VDC FOR GENER
8. LEGEND AS ALTERNATOR STATOR dHEH gt CT CURRENT TRANSFORMER P an EF EXCITER FIELD a MLCB MAIN CIRCUIT BREAKER NB NEUTRAL BLOCK BRUSHLESS GENERATOR OUTPUT CUSTOMER CONNECTION TD E2 Ee 208 OR 480 E1 TD E 2 UR TO NB x 120 OR 277VAC THE 8th DIGIT THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE 120 208 K 277 480VAC 3 OF 4 mem WIRING DIAGRAM REVISION A 3PH CPL ALTERNATOR DATE 04 12 06 PAGE 3 OF 4 DRAWING 0F6587 GROUP G pe S o Pel 491 v 27784 qu a Sicya pe E cR UE EUR 71 OPTION 4 THREE PHASE DELTA 100 CONTROL PANEL DIRECT DRIVE 7 LEAD LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATOR TS Pb aor OFFER HH lt P DIRECT MLCB MAIN CIRCUIT BREAKER AGED NB NEUTRAL BLOCK BRUSHLESS GENERATDR DUTPUT CUSTOMER CONNECTION Ee TU 240VAC E1 TD E OR E3 N 120VAC THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE J 120 240VAC PAGE 4 OF 4 ee i u WIRING DIAGRAM REVISION A 3PH CPL ALTERNATOR DATE 04 12 06 PAGE 4 OF 4 DRAWING 0F6587 Standby
9. P J BARE SCREEN NOT USED AT THIS END CAMSHAFT SENSOR NOT USED WITH 5 4L CRANKSHAF T SENSUR BARE SCREEN NOT USED AT THIS END ENGINE BLOCK ENGINE BLOCK VIEW TOP VIEW PAGE 8 OF 8 WIRING DIAGRAM REVISION G 6035 C 5 4 amp 6 8L H PANEL DATE 07 27 05 DRAWING 4 0F2576 GD CONNECTOR IN WIRE FUNCTION ra DA YK 1 O GND NOTE 1 RB1 7 NOTE 3 8 771 GAt 1 THROTTLE DRIVE 9 770 4 THROTTLE DRIVE Hi 10 GND AVR CONNECTOR PIN WRE FE 21194 J2 31 e12VC S PME PME OUTPUT 4 4 RI FED j S 4 FIELD f FIELD 403 2 8 GATE TRIGGER BO 7 404 J2 20 GATE TRIGGER A 10 406 J2 30 ZERO 5 111 405 J2 19 GROUND SO 13 162 CB PME OUTPUT AFTER CB GROUP S ICM IGNITION MODULE CONNECTOR P WRE FUNCION 3 Li 459 9 IGNITION COL DRIVE 9 L6 452 CYL2 IGNITION COIL DRIVE 2 L8 454 4 IGNITION COIL DRIVE 4 L9 455 5 IGNITION COIL DRIVE 5 10 SHLD CUT SENSOR DRAN 13 O
10. SLINN 78 3 M 001 3 310NX ANOET SS dAl 092781 L8 D IHOIN NAHL 9 0 9 1113 XU83V3D9x Gzzz ose L 6S GT 4934 AS311V8 493 71114 1914 4 OL 553229 303 3 34 96 9 31DN 335 1138 NV4 9 335 SN3144nW LIES S000 IND233 Sond S000 4 X3HLI3 IN34313 N3NV312 NIV NUDO IND33 1431 NAHL 3SDH NIvad aoLviava 4 IHDIS NAHL 3SDH NIvad 08 1 NUDO IND33 1431 NAHL 331113 S96 5 2811 548 wood IND33 1431 NAHL XJIIS did 110 e 1NUBJ 1HDIS NAHL 492 3113 ID OINIK dn g8nis mos moet woot os wall 55322 139 9 1111 155322 WILI 391IA33S 18 9 8 IS GIET SNDINVAD 0109 555 8 9 MNOET 8v OEel dave 1 LAVHI 335 41 331N32 18 9 M001 2 OS SZel 53 1 8 S MOOT C E SS XOLYJINI9 4 17 S MAOS C IS OTET 1 NO 1319211 533 14 C ALIAVMO 40 331N32 30H GES GEI dnowd d GROUP G CL DI c CI CE OPTION 1 SINGLE PHASE 100 CONTROL PANEL LEGEND AR ALTERNATOR ROTOR 1 BLACK gt AS ALTERNATOR STATOR ARED HH lt P DIRECT
11. BCC 1 TA 2 BCC co 6 3 TA ono 505 42 27 0 TB3 3Y 5 s CENTER TERMINAL 2 NUT USED 141 o E J1 16 6 803 CHARGE CURRENT LOCATED IN CONTROL PANEL 13 TB3 12Y LOCATED BACK OF CONTROL PANEL 14 TB3 7Y 14 0 56 1 10 FSP 0 0 Lo 49 DB STARTER MOTOR WIRE LOCATIONS MAY CHANGE 2 9 9 9 9 0 ON GROUND BAR E ESC3 3 0 12V CONNECTION FOR ICM 13 0 46 amp 5 4L ONLY PAGE 2 OF 4 WIRING DIAGRAM REVISION G 8444 E 4 6L 5 4L amp 6 8L H PANEL DATE 6 27 06 PAGE 2 OF 4 DRAWING 0F2576 GROUP G A c LEG MEI DI OE PTT MU q COMPONENTS LOCATED IN ALTERNATOR CONNECTION BOX 398A J2 12 399A J2 11 398B J2 355 399B J2 34 398C J2 10 399C J2 9 L1 EXCITER CB nat 70 10 2 AVR 1 e gt 6 TB1 4X 259 K K K 9 lt Z CT1 CT2 CTS 59 L SIDE OF CT TO STATOR 2 TO GENERATOR BO C 51 52 J2 13 390 S3 zc 224 J2 6 J2 1 391 25 2 225 J2 29 os 65 226 42 17 J2 24 SHLD 5 227 J2 7 z 5X TB2 5X 0 lt 0 J2 4 183 Bo J2 3 DI3 518 F lt 15 J2 26 014 9
12. Overtime holiday or emergency labor Planes ferries railroad busses helicopters snowmobiles snow cats off road vehicle or any other mode of transportation deemed abnormal 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 Generac Power System
13. AN3LLV8 TANVd H 41786 87D NOISIA8I MHIA QHGO IdX4 G WALT 40 4934 NO IOVINUO OL S3HOVIIV 62 WALT 1 31UN S3 DH 33N31SV3 9 N3dU TV 31DN EXPLODED VIEW H PANEL 2A BATTERY CHARGER DRAWING 0F1826D APPLICABLE TO ITEM PART QTY DESCRIPTION mooo 056739 0F2627A AB 043182 01714 052777 0C2323 5459 0r5461 002127 025400 0 7403 074088 06145 091526 051713 deagggsesodgpBseuSdSUEOUHNHZ REVISION G 8398 F DATE 6 20 06 COMPONENTS INCLUDED IN OF 1826E PREP EP RB BWWUWORORP EP HEE HERP OPE ENCL HCONTROL PANEL COVER CONTROL PANEL HINGE CONTINUOUS HPN RIVET POP 125 275 SS ASSY PROGRAMVEDPMH 100 DECAL FUSES LOCATED INSIDE RAIL SNAPTRACK PCB HOLDER BULK 12 LG ASSY PCB 2ANP IX UL BATT CHGR PLATE HARNESS CLAIVP ASSY PCB PAR AVR WAIVP HEADER ASSY PCB BOSCH GOV DRIVER DIO BRIDGE 25A 600V WASHER LOCK SCREWPPHMIVMB 0 8 X 30 SS WASHER FLAT M5 SCREWHHPMIV5 0 8 X 12 NUT HEXIV6 0 8 GB CLEAR ZINC SCREWPHITM407 X 10ZYC WASHER FLAT M4 SCREWPPHMIM4 0 7 X 8 BLK OX WASHER LOCK M4 DECAL WARNING BATT CHRG 12 24 SCREWPHIT IVB 5 0 6 X 10 SCREWPHIT M 07X 12 ZYC CONN DUST CAP WCHAIN DBS WASHER FLAT VB5 SEAL COVER 3 18 X 12 7 X 382 SEAL COVER 318X 1227 X 283 ASSY HARNESS SW NOT SHOWN COMPONENTS INCLUDED IN WRE HARNE
14. DRAWING 0F3901 GROUP G DIE C CC ME s DU Nd EE EO 1 CYL1 CYL6 ICM SP6 CYL2 CYL7 SP7 CYLS CYL8 5 8 IGNITION CONTROL MODULE F L E NOT CONNECTED FOR 6 8L 1 1 1 Th NOT CONNECTED FOR q q 4 6L WITH LP FUEL 211 2 CAM CRK NOTES 15 15 1_0 SW1 J 175 i DX ji AUTO Li 11 388 J2 Ml 11 387 1 229 STOP RISB 14 RB1 15E 4 s229 NDTE4 15 ALT 49 DB Je R15 1 229 A2 445 J1 0 250 OR 500 1 0 5 15A 5 ES1 15E 1 FIELD VOLTAGE NOTES 15A 5158 J1 ES1 REGULATOR m 14 A 5 256 J1 4 15 hs 415 NOTE4 ICM SC 56 NOTE4 15 12 6 56A J1 C EE sO s s PAGE 2 OF_4 J SCHEMATIC DIAGRAM REVISION G 8444 C 4 6L 5 4L amp 6 8L H PANEL DATE 6 28 06 PAGE 2 OF 4 DRAWING 0F3901 11
15. Standby Generator Sets MAINTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom Task Required Task Required Task 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 Date Bi monthly Initials 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 LOOPYISAIS 11 4 MAINTENANCE Task Comp Date Initials TROUBLESHOOTING Standby Generator Sets Troubleshooting TROUBLESHOOTING GUIDE CAUSE PROBLEM
16. gt 010173 2 CLAMP HOSE 55 62 62 33 089130 1 NPPLE CLOSE 125 NPTX 1625 REVISION G 6298 C DATE 9 13 05 GROUP E PAGE 2 OF 2 GROUP F INSULATION AND RETAINERS LOCATED ON THE NEAR SIDE RETAINER 6869 60 7 S INSULATION AND RETAINERS LOCATED ON THE FAR SIDE TYPICAL MOUNTING OF ACOUSTIC INSULATION SEE DETAIL A AND B FOR SPLITTER VARIATIONS O P N U Z 53 88 Ne M ANS 4 FM TS VA 14K 7 M EXPLODED VIEW ENCLOSURE C5 DRAWING 0F3596 PAGE 1 OF2 REVISION G 8522 E DATE 7 13 06 EXPLODED VIEW ENCLOSURE C5 DRAWING 0F3596 APPLICABLE TO ITEM PART QTY DESCRIPTION 21 0F5873 1 REAR WRAP C5 Q2 F5868 4 DOOR C5 2 3 OF5872 2 CENTER SUPPORT C5 24 F5871 2 DISCHARGE DUCT LH amp RHSIDE C5 Q5 5559 2 FRONT CORNERS C5 26 0F5870 1 DISCHARGE CENTER DUCT C5 2 7 F5867 1 ROOF C5ALUM n 254 78 SCREWTHF 1 16NWAZ S 12 0F2766 2 SPLITTER 13 OF3181 4 SPLITTER SHORT 14 03185 2 STRINGER SPLITTERC3 15 5416 2 SUPPORT SPLITTER C5 130KW 16 0F3949 2 INSULATION CORNER POST 17 0C2634A 1 ASSEMBLY COVER ACCESS 18 022473 5 WASHER FLAT 14M5 ZINC 19 02209 1 WASHER LOCK M6 1 4 20 022127 1 NUT HEX 1 4 20STEEL a 0r3072 20 INSULATION RETAINVENT HANGER 2 078115 70 WASHER SELF LOCKING DOIVE 23 F3949B 3 INSULATION SPLITTER 24 F3949A 4 INSULATION SHORT LOUVER 5 4 VISE ACTION LATCH SLOTTEDOIR 26
17. ASSY ROTOR 2390 80KB3 CPL ASSY ROTOR 390 2P 100K BRSHLS ASSY ROTOR 390 2P 150K BRSHLS ASSY STATOR S0KW IPH 2P BRSHLS ASSY STATOR 390 2P 100K BRSHLS ASSY STATOR 390 2P 150K BRSHLS UL STATOR 2390 80 GB3 CPL STATOR 239080 KB3 CPL ASSY STR 390 100KW2P 208V ASSY STR 100KW1PH 2P BRSHLS ASSY STR 390 150KW2P 3PH 208V ASSY STR 150KW1PH 2P BRSHLS EXITER FIELD 2 LG SPD CONN ASSY EXCITER 20 STACK 2P KEY SQ3 8X3 1 4STEEL HYPOT TEST PROCEDURE NOT SHOWN ASSY FLYWHEEL CPL RING PRESSURE 390STATOR CAN KEY WOODRUFF SCREWHHC MIO L50X 16G109 WASHER LOCK MIO SCREWHHC MI6 2 0X 45 G88 WASHER FLAT 683IDX3250D WASHER FLAT 14M6 ZINC WASHER LOCK M6 1 4 GROUP A ITEM PART QTY DESCRIPTION 16 0C2454 11 SCREWTHF 1 16 2 5 17 092050 1 COLLAR SLIP FIT 320MM 18 04576100CF 4 STUD MI4 2 0X 760G5 ZINC 19 062646 4 WASHER FLAT MIA 20 013123 4 WASHER LOCK 21 051779 4 NUT HEX MI14 20G8 YEL CHR 2 022392 2 PINDOMEL 1 2X 1 1 4 B 52250 2 WASHER FLAT MI2 051765 3 WASHER LOCK 2 25 0E7230 3 SCREWHHC MI2 175X80G109 26 1 SHIELD ALT EXCITER 390 FAR 1 SHIELD ALT EXCITER 54 68 1 PHASE 27 0F272 1 COVER EXCITER SHELD 28 077043 1 CONDUIT FLEX 125 ID 29 000151 1 CLANPMNYL 312X XBZ 30 03365 3 WASHER SHAKEPROOF INT 8 31 083133 1 SCREWHHM 8 32 X 38 gt 083143 2 SCREWHHM 8 32 X 7 8 38 086082 2 LUG RT ANG 01012 x 1 BRIDGE SUPPORT DIODE 15 000064 1 CAP END ROTOR 390MM 36 090152 1 ASSY BRIDGE RECTIHER 3 0226
18. NAM NAM NAM FUEL NAT GAS FORD 5 4L 80KW 5 4L 6 8L 100 DRAWING 0F3593 REVISION G 6298 C DATE 9 13 05 PAGE 1 OF 2 EXPLODED VIEW FUEL NATURAL GAS FORD 5 4L 80KW 5 4L amp 6 8L 100KW DRAWING 0F3593 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 019721 4 SCREWHHC IM amp LOX 35G88 BLK 2 065908 1 SUPPORT NAT GAS SOLENOID 3 OF6261G 1 REGULATOR ASSM5AL 80KWNG OF6261C 1 REGULATOR ASSM5AL 100KWNG 0 6261 1 REGULATOR ASSMG 8L 100KWNG 4 062617 2 SCREWHHC 12 175 X20G88 5 022304 2 WASHER FLAT 1 2 ZINC 6 22129 4 WASHERLOCK 5 16 7 045773 2 2 175 G8 YEL CHR 8 2 WASHERLOCK 1 2 9 040173 2 CAMP HOSE 55 62 62 5 4L 0C7649 2 CLAMP HOSE 38 87 6 81 100K 10 080131 1 ELBOW SOD 1 YANPT n 081015 1 NPPLE PIPE 1 14 NPT 2 089130 1 NIPPLE CLOSE 125 NPTX 1 625 13 057222 9 CLAMP HOSE 8 53 100 14 059057 2 HOSE 3 4 IDSAE 30R2 2 LG 15 048064 2 BSHG RDCR 1 1 4 3 4 16 001509 1 DECAL INLET PRESSURE 17 1 DECAL FUEL INLET NG 18 0F2756A 1 MACHINING INTAKE ADAPTOR 60MM 5 4 FORD 006068 1 ADAPTOR THROTTLE BODY BOSCH 6 8L FORD GEARBOX 19 E4390 1 GASKET GOVERNOR ACTUATOR 20 2 1 ACTUATOR BOSCH 60GOVERNOR 21 080060 1 REDUCER 30 TO2 75 TURBO 2 OF3885 1 MIXER 40 60 M ACTUATOR ASSY 23 F364 2 ORING 2 7 8X3 1 16 X 332 2 OF3691C 1 VENTURI THROTTLE 38MM 5 4L 3150 0F369ID 1 VENTURI THROTTLE 40MM 54 FORD 2 POLE 10K OF3 01E 1 VENTURI THROTTLE 42MM 6 8L FORD GEARB
19. nal and the neutral point OO is either 277V or 120V depending on the model Figure 7 2 Stator Power Winding Connections 3 phase 277 480V 6 Lead S1 E1 1 INTERNAL CONNECTIONS a L L S6 lt 54 NEUTRAL 2 1 53 S2 E Tw Figure 7 3 Stator Power Winding Connections 3 phase 120 208V 6 Lead E1 S4 54 00 NEUTRAL S3 53 52 40 80 0 ed 100uu0D9V INSTALLATION Standby Generator Sets C y Installation i INSTALLATION INSTALLATION Refer to the separate Installation Guide QT Product Line supplied with the unit PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed ser viced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules as well as all other safety information in this manual before attempting to operate this and related equipment Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information and or service intervals please refer to the Maintenance section and the Service Schedule TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer s
20. REVISION G 8522 E DATE 7 13 06 GROUP F PAGE 2 OF 2 GROUP d m am 2 am m ERU 5 ERU w 56 RBI 10 AAS 2 asa 2 ssc 2 AAS 2 224 2 14 JMP 1 CYL10 CYL9 8 7 CYL6 GND ENGINE BLOCK TOP VIEW I 15C TB3 NOT USED 0 TB3 2X MERE B 5 1 27 54 CONNECTION FOR CSS ONLY CYL5 CYL4 CYL3 CYL2 CYL1 4 6L AND 5 4L I CONNECTION 8 ES 455 454 453 452 451 2 e 0 53 523 9 538 523 8 NOTE ALL WIRES 18 AWG I IIIN 300V UL LISTED UNLESS 6 68 5 SHOWN OTHERWISE p SS 8 J1 31 AWG SIZE DD 9 Ex 573V 31 30 55 71 573R 1 29 51 52 amp S3 ARE 600V UL OPTION NOT i LISTED AVAILABLE OTS1 ON CPL UNITS 69V J1 20 ate 69R J1 19 0 24 TB3 2Y 0 79 91 25 ECM CHASSIS RB1 7 14 TB3 2Y 0 J1 33 769 LOCATED IN JEN AGB CONTROL PANEL J1 18 766V 51 p nt Lal gt a J WIRING DIAGRAM REVISION G 8444 E 4 6L 5 4L amp 6 8L H PANEL DATE 6 27 06 PAGE 1 OF 4 DRAWING 0F2576 GROUP G
21. 0 Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance 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 charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury BATTERY MAINTENANCE The b
22. 16 057192 8 SCREWSHC 1 5 30 6129 17 022131 8 WASHER FLAT 3 8 M10 ZINC 18 046526 8 WASHER LOCK MIO 19 0536210360 1 20 072909 1 SCREWHHC ME amp L25X 30G88 21 022261 2 WASHER SHAKEPROCF INT 38 22 022129 1 WASHER LOCK MB 5 16 23 02145 2 WASHER FLAT 5 16 NBZINC 2 025771 2 HEXIVBE L25 G8 YEL CHR 25 088750 1 SCREWHHC M6 L0X 30G88 26 02209 1 WASHER LOCK 14 REVISION G 5391 A DATE 5 17 05 GROUP C PAGE 2 OF 2 GROUP C TO STARTER CONTACTOR 8 RED P a ec Pd P 11 12 HARNESS WIRE TO STARTER SOLENOID REF TO STARTER MOUNTING HOLE ON ENGINE BLOCK 7 BLACK EXPLODED VIEW BATTERY 5 4L CPL REVISION G 5390 A 0F3675 DRAWING PAGE 1 OF2 5 11 05 DATE EXPLODED VIEW BATTERY 54L CPL DRAWING 0F3675 APPLICABLE TO ITEM PART 1 0F3408 2 OF3411 3 4 002131 5 060831 6 050831 7 0888906 8 0888010 9 045771 10 022129 027482 2 075763 13 54 14 OF3409 REVISION G 5390 A DATE 5 11 05 QTY M 00 HH REE DESCRIPTION TRAY BATTERY STRAP BATTERY RETAINVENT BATT I2VDC 24F WASHER FLAT 3 amp MIOZINC BATT POST COVER RED BATT POST COVER BLK CABLE BATT BLK 74 X 1800 CABLE BATT RED 4 X2800 NUT HEX MB L25G8 YEL CHR SCREWTHF 1 16 2 5 SUPPORT BATTERY TRAY GROUP C PAGE 2 OF 2 0928130 ONIMVUd C dO 1 HDVd 90 02 9 ALVA
23. AUTO OFF MANUAL switch is in the AUTO position START UP INSPECTION When a startup is performed by an Authorized Service Dealer a standard three part form titled Start up Inspection for Standby Power Systems part no 067377 should be completed by the instal lation technician or engineer See page 1 3 for infor mation on locating the nearest Authorized Service Dealer The installer should complete the form and disseminate copies as follows White copy Mail to Generac Warranty Department PO Box 340 211 Murphy Dr Eagle WI 53119 2062 Pink Copy For service file of installing dealer Yellow Copy For the customer s records Standby Generator Sets OD GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator s manual for this unit OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the generator was installed in conjunction with a transfer switch capable of manual operation only the following procedure applies A manually operated transfer switch is one that will not provide automatic start up and does not include an intelligence circuit ENGINE START UP AND TRANSFER For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch A DIG A The Maintenance Disconnect Switch and the AUTO OFF MANUAL switches if so equipped must be set properly or the generator will cran
24. Cl CURRENT TRANSFORMER EF EXCITER FIELD ao MAIN CIRCUIT BREAKER BRUSHLESS NB NEUTRAL BLOCK e 6 TB 398B TD Je 2298 5 WIRE CDPTIDNAL USED BYPASS DN d 7 STATOR THERMAL PROTECTOR H PANEL 399A al S 55 MM 6 2 5x DIRECT DRIVE TU IFT 00 VOLTAGE N2 SENSING MODULE NI AS GEAR BUX DRIVE 1 E3 GENERATOR DUTPUT CUSTOMER CONNECTION 1 240VAC E1 N HR E3 N 120VAC PAGE 1 OF 4 WIRING DIAGRAM REVISION G 7905 A 3PH CPL ALTERNATOR DATE 04 12 06 PAGE 1 OF 4 DRAWING 0F6587 GROUP G OPTION 8 THREE PHASE 100 CONTROL PANEL DIRECT DRIVE 6 LEAD LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATOR mo 1 BLACK peer MLCB MAIN CIRCUIT BREAKER ARED NB NEUTRAL BLOCK BRUSHLESS 6 TE 3980 3990 TD Je p GENERATUR DUTPUT CUSTOMER CONNECTION Ee E3 208 DR 480VAC T E1 E1 2 TD NB 120 DR 277VAC THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE 0 120 208VAC 277 480VAC PAGE 2 DF 4 L WIRING DIAGRAM REVISION G 7905 A 3PH CPL ALTERNATOR DATE 04 12 06 PAGE 2 OF 4 DRAWING 0F6587 GROUP G OPTION 3 THREE PHASE 100 CONTROL PANEL GEAR BOX REVERSE ROTATION
25. Generator Sets Warranty GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR COMMERCIAL PRODUCT 50kW AND ABOVE 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 war ranty period WARRANTY SCHEDULE YEAR ONE Limited comprehensive coverage on mileage labor and parts listed ALL COMPONENTS YEAR TWO Limited comprehensive coverage on parts listed ALL COMP
26. LED IGNITION SHUTDOWN ON LOSS OF CRANK OR CAM SIGNALS The ignition will stop firing the coils immediately fol lowing the loss of the crank signal The ignition will stop firing the coils after approx 3 seconds following the loss of the cam signal DIAGNOSTIC BLINK PATTERNS RED LED LOCATED ON THE IGNITION CONTROL BOARD During normal ignition operation the RED LED flashes at a 0 5 sec ON and a 0 5 sec OFF rate This is considered one 1 blink LED Fault Code with Priority as shown 1 No Crank Signal LED blinks 2 times is OFF for 3 0 seconds and then repeats 2 No CAM Signal LED blinks 3 times is OFF for 3 0 seconds and then repeats Only one fault is displayed at a time If multiple faults exist then the highest priority fault must be resolved prior to a lower priority fault being displayed In the event that an ignition fault has occurred the ignition will wait 60 seconds before powering down NOTE The ignition cover does not need to be removed to see the LED S0 LL ed 200 GENERAL INFORMATION GENERATOR AC LEAD CONNECTIONS See Voltage Codes This generator may be rated at any one of three voltages either single phase or three phase The electrical wires in the units AC con nection lower panel should be installed according to the number of leads and the voltage phase required for the application If there are any questions regard ing lead connection re
27. THERMOSTAT ASSY FORD PULLEY FAN BELT FORD GASKET INTAKE MANIFOLD LEFT ITEM 13 6 8 REBBE X X x ggusugugggHEB 8 PART QTY PRPEPNNNONEPNERPRPEWNRENEWNNNOOONOPEP PEPE EBEEPNUEP EP OWWWORPREPERE GROUP D DESCRIPTION GASKET INTAKE MANIFOLD RIGHT INTAKE MANIFOLD 5 4L PLASTIC BUSHING REDUCER 3 8 TO 1 8GAL CONNECTION VATER OUTLET FORD INDICATOR ASSY OIL LEVEL FORD SCREWHHC V508X25G88 WASHER LOCK M5 A WASHER FLAT 1 4ZINC SCREWHHC M amp LOX20G88 WASHER LOCK 5 16 SENDER OIL PRESSURE 1 8 NPT ALTERNATOR DC WOUT PULLEY WASHER FLAT 5 16 ZINC GROMVET PULLEY 80OD DC ALTERNATOR 1800RPM PULLEY 117 OD DC ALTERNATOR 2650 RP PULLEY 1600D DC ALTERNATOR 3600 RPM SPACER DC ALTERNATOR PULLEY BRKT DC ALTERNATOR UPPER BRKT DC ALTERNATOR LOVER HARNENG 5 4L H 100 NOT SHOWN WASHER FLAT SCREWHHC MB 125X 90G88 SCREWHHC 125 50 88 WASHER LOCK 5 16 WASHER FLAT 5 16 MB ZINC SCREWHHC MI0 L5 X 20 88 WASHER LOCK MIO WASHER FLAT 3 SCREWHHC IMB 1 25 X 20G88 SCREWHHC MI0 L5 X 45 G88 FT WASHER FLAT 3 8 M10ZINC WASHER LOCK MIO SCREWWP PULLEY 1 25 19 BOLT HEX FL HDIVB L25 X28 BOLT HEX FL 1 25 31 TENSIONER ENG AUTOMATIC BELT PULLEY WATER PUMP FORD 1800RPM PULLEY ENGINE WATER PUMP 2650 amp 3600RPM PULLEY GROOVED ENGINE IDLER BRACKET SIGNAL CONDITIONER NUT HEXMIO L5 G8 YEL CHR NUT H
28. air the vaporization process itself provides an additional cooling effect LP FUEL SYSTEM LP is supplied as a liquid in pressure tanks It is usually made up of propane butane or a mixture of the two gases Propane tends to vaporize readily even at temperatures as low as 20 F 29 C However butane reverts to its liquid state when temperatures drop below 32 F 0 C LP in a liquid withdrawal system must be converted to its gaseous state before it is introduced into the engine carburetor A vaporizer converter is generally used to accomplish this In such a converter heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state 90 60 V ed 005451914 GENERAL INFORMATION SPECIFICATIONS GENERATOR WO vice Synchronous Rotor aii pite ete Class H Stator Insulation uocant erret nes Class H Total Harmonic Distortion 3 5 Telephone Interference Factor 50 Alternator Output Leads 3 856 6 wire P Sanga dictated Sealed Ball M Flexible Disc Load Capacity Standby 100kW NOTE Generator rating and performance in accordance with 1508528 5 BS5514 SAE J1349 1503046 and DIN 6271
29. discharged remove it from the generator for recharging warninc amp Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected A Be sure the 120VAC power supply to the battery is turned OFF or sparking may occur at the bat tery posts as the cables are attached and cause an explosion BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 24F 6 525 0 deg F NOTE The BCI number should be located directly on the battery REPAIR PARTS The latter portion of this manual consists of exploded views parts lists and electrical data pertaining to this generator set The parts lists consist of a an item number b a part number c the quantity required and d a description of the part The item number corresponds to an identical number on the exploded view drawing Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule SERVICE SCHEDULE 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 are the maximum recommended when the unit is used in an average service application They will need to be
30. fuel system Liquid propane LP 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 Btu s per cubic foot for natural gas or at least 2 520 Btu s per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is 11 inches to 14 inches water column 0 4 to 0 5 psi and for liquid propane 11 inches to 14 inches of water column 0 4 to O 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 11 inches water column for natural gas or 11 inches water column for liquid propane 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
31. regulat ing the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks immediately Fuel supply lines must be prop erly installed purged and leak tested according to applicable fuel gas codes before placing this equip ment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detectors accordingly Standby Generator Sets INTRODUCTION Thank you for purchasing this model of the standby generator set product line Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice 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 A Aft
32. starting sequence The start sequence consists of the number of crank attempts the length of each crank attempt and the rest time between each crank attempt If the engine has not started by the end of the final crank attempt an Overcrank alarm is generated the control panel will sound the alarm and display the message Failed to start OVERSPEED SHUTDOWN A speed circuit controls engine cranking start up operation and shutdown Engine speed signals are delivered to the circuit board whenever the unit is running Should the engine over speed 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 50 0 8 ed 600 3 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
33. to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators GENERAL HAZARDS For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by an Authorized Service Dealer or other competent qualified electrician or installation tech nician who is familiar with applicable codes stan dards and regulations The operator also must comply with all such codes standards and regula tions Installation operation servicing and repair of this and related equipment must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electri cal and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operated and serviced in accordance with the 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 gen
34. to a safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff sole noid should not exceed approximately 14 inches water column 0 5 psi Optimum pressure at the fuel shutoff solenoid is 11 inches water column 0 4 psi Standby Generator Sets Fuel Systems GENERAL INFORMATION PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid fuel in the supply tank Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state The vapor withdrawal system is generally best suited for smaller engines that require less fuel The installer should be aware of the following The natural gas and LP gas systems are similar However the natural gas system delivers gas at a pressure of approximately five inches water 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
35. 0 1374 553 Engine is not field convertible between natural gas and propane Jet size and ignition timing are factory set for the specific fuel ELECTRICAL SYSTEM Battery Charge 12V 30 Amp Static Battery Charger 12V 2 Amp Recommended 24F 525CCA System Vollgge scie 12 Volts Voltage Regulator jo Full Digital CRDI NUES 3 phase 2 na aa Danaus 1 496 POGUES X Built into H 100 Control Panel V F Adjustable Adjustable Voltage and Gain Power Adjustment for Ambient Conditions Temperature Deration 3 for every 10 C above 25 1 65 for every 10 above PF aa 77 Altitude Deration 1 for every 100 m above 183 3 for every 1000 ft above 600 Controller H panel S0 LL ed 002906 9 BEL Standby Generator Sets INFORMATION Specifications INFORMATION Figure 1 Interconnections H100 CONTROL
36. 00 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 Tasks 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 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 E TIT TT Ti oil if equipped 11 3 90 60 V ed LOOPYISMS
37. 1 2 WASHER FLAT 14M5 ZINC WASHER LOCK 6 1 4 NUT HEX 1 4 20STEEL DECAL CUSTOMER CONNECT INSIDE ELEC 1 2 FOAM SCREWSHC 10 1 50 40G12 9 WASHER FLAT 3 amp MIO ZINC WASHER LOCK 38 NUT HEX MIO L5G8 YEL CHR LUG SLDLSS 5007500 MCMAL CU SCREWSHC MIO L5X 70G109 TERM COVER VITZROTECH 400AF CB m NEUTRAL BLOCK 390 200 400A BUS BAR NEUTRAL BLOCK 390 SCREWHHC 1 25 45 G88FT WASHER FLAT 16 MBZINC WASHER LOCK 5 16 NUT HEXMB L25 G8 YEL CHR SCREWHHC 1428X 3A G5 WASHER LOCK 14 655 LUG SLDLSS 600 250 1 0X 1 4 28 MNNHHHHH ITEMINCLUDEDWTHHARNESS TEMINCLUDED WTH 0D5464B TEMIS PART OF 9R 7 HARDAMRE FOR MIG CB TERMINAL COVERS IS SUPPLIED WTH CIRCUIT BREAKERS PAGE 2 OF 2 01240 ONIM VYA C dO 1 HDVd S0 CLOI ALYA 3 NV 9 WALAS SNITOOO 99 D AHIA LIVHSYNVHO 5 IVLSOWYAHL OL d 1O ID EXPLODED VIEW COOLING SYTEM amp FAN DRIVE DRAWING 0F2703 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 OF 2687 1 WELDIVENT RADIATOR SUPPORT150 2 OF2611 1 RADIATOR 680 X 680 X 70 CPL 3 0F54 1 V BELT 31 6F X 6 38 0 5253 1 V BELT 3161 X 61 38 54 100KWONLY 0F7077 1 V BELT 1 2 38 644 100 130K 4 016526 1 WASHER LOCK MIO 5 051756 8 SCREWHHC MIO 15X 20G88 6 254 2 SCREWTHF 1 16 2 5 7 052250 2 FOAM1X 1 26 75 LG 8 07674
38. 22 83 CO 2 15A 2 L Be co CUSTOMER CONNECTIONS MOD J1 32 809 812 01 3 810 el J1 14 811 J1 26 812 GOVERNOR DRIVER AIR FUEL SOLENOID GROUND BAR CONNECTION ALARM HORN IGNITION CONTROL MODULE DC CHARGE ALTERNATOR INTERFACE TRANSFORMER AUTOMATIC VOLTAGE REGULATOR ELECTRONIC CONTROL MODULE CONNECTIONS BATTERY CHARGER CONNECTOR JUMPER CONNECTION FOR NATURAL GAS BATTERY CHARGER LOW FUEL PRESSURE SWITCH CAMSHAFT SENSOR MAIN LINE CIRCUIT BREAKER CIRCUIT BREAKER DPE MODEM CONNECTOR CROSSOVER CONNECTOR MAG PICK UP COMMUNICATIONS PORT 9 PIN D SUB OXYGEN SENSOR CRANKSHAFT SENSOR OIL PRESSURE SENDER CURRENT TRANSFORMER OIL TEMP SENDER CYLINDER IGNITION COIL RESISTOR DIODE BRIDGE RELAY BOARD ELECTRONIC CONTROL MODULE 100 RELAY BOARD CONNECTOR EMERGENCY STOP SWITCH START CONTACTOR ELECTRONIC SIGNAL CONDITIONER STARTER MOTOR CONNECTIONS FUSE AUTO MANUAL SELECT SWITCH FUEL SOLENOID OPERATOR SWITCH CONNECTOR FUEL SOLENOID PLUG TERMINAL BLOCKS FUEL SOLENOID RECEPTACLE COOLANT LEVEL SENDER GOVERNOR ACTUATOR COOLANT TEMP SENDER Pall J REVISION G 8444 E DATE 6 27 06 WIRING DIAGRAM 4 6L 5 4L amp 6 8L H PANEL PAGE 3 OF 4 DRAWING 0F2576
39. 261L 1 REGULATOR ASSMG amp L 130KWLPV 68L 1310 6261 1 REGULATOR ASSMG amp L 150KWLPV 681 150K 4 052617 2 SCREWHHC 12 175 X20G88 5 2 WASHER FLAT 1 2 ZINC 6 022129 4 WASHER LOCK MB 5 16 7 06773 2 NUT HEX 12 1 75 GB YEL CHR 8 064346 1 PIPE TEE 1 1 4NPT 9 048064 2 BSHG RDCR HEX 1 1 4 34 10 080131 1 ELBOW 90D 1 1 4 NPT 11 081015 1 NIPPLE PIPE 1 1 4 NPT 088963 1 NIPPLE PIPE 125 NPT X55 BL IRN G8L 150KWONLY R 0026015 2 NIPPLE CLOSE 34X 1375 13 057223 4 CLAMP HOSE 10 56 106 14 059057 2 HOSE 3 4 IDSAE 30R2 45 LG 15 000608 1 GASKET ADAPTER THROT BODY 16 001509 1 DECAL INLET PRESSURE 17 050280 1 DECAL FUEL INLET LPG LP VAPOR APPLICATION 18 0026068 1 ADAPTOR THROTTLE BODY BOSCH 68 0F2756A 1 MACHINING INTAKE ADAPTOR 60MM 5 4 19 0 4300 1 GASKET GOVERNOR ACTUATOR 20 2 1 ACTUATOR BOSCH 60GOVERNOR 21 1 REDUCER 3 0 TO2 75 TURBO 2 OF3885 1 MXER 40 60 MACTUATOR ASSY 23 35541 2 ORING 27 8 3 1 16 3 32 2 OF3691B 1 VENTURI THROTTLE 34VM 5 4L KW 0 3601 1 VENTURI THROTTLE 40MM 5 41 100KVJ 1 VENTURI THROTTLE 42MM 6 8L 100KVJ 1 VENTURI THROTTLE 44MM 6 8L 130KVJ F3 1 VENTURI THROTTLE 50MM 6 8L 15140 25 2 WASHER LOCK 1 2 26 0F6279 1 HARNESS FUEL J UVPER DUAL REG 27 081017 1 BARBEDSTR 14 12 28 046580 4 SCREWSHC 10 45 6129 29 080204 2 CLAMP HOSE 244 231 325 30 02209 4 WASHER LOCK 6 1 4 31 047290 1 HOSE 3 8 IDSINGLE BRAID 42 LG
40. 5 PAGE 6 DF 8 AIR FUEL SOLENOID ALARM HORN DC_CHARGE ALTERNATOR AUTOMATIC VOLTAGE REGULATOR BATTERY CHARGER CIRCUIT BREAKER DPE COMMUNICATIONS PORT 9 PIN D SUB CT CT B CT C9 BRIDGE EMERGENCY STOP SWITCH ELECTRONIC SIGNAL CONDITIONER FUSE FUEL SOLENOID AUX FUEL SOLENOID GAS ACTUATOR GAS DRIVER 14 PIN GROUND STUD CONNECTION IGNITION CONTROL MODULE J_ ELECTRONIC CONTROL MODULE CONNECTIONS PAGE 6 OF 8 LOW FUEL PRESSURE SWITCH CIRCUIT BREAKER CONNECTIONS MAG PICK UP OXYGEN SENSOR DIL PRESSURE SENDER DIL TEMP SENDER RESISTOR RELAY BOARD RELAY BOARD CONNECTOR START CONTACTOR STARTER MOTOR CONNECTIONS AUTO MANUAL SELECT SWITCH TERMINAL BLOCKS COOLANT LEVEL SENDER COOLANT TEMP SENDER GROUP G SSS SS SE SS eS eS at Se 5 WIRING DIAGRAM 5 4 amp 6 8L H PANEL DRAWING 0F2576 GROUP G PAGE 7 8 HE ER 15D 61 150815 jj S Bn TERR 0 ET x tg m 9C GGr 6 8 ESy 26 9 9 x HH 09r c WOI NOT CONNECTED FOR 6 8L TB3 7 1 10 CEDE WIRING DIAGRAM 5 4 amp 6 8L H PANEL DRAWING 0F2576 REVISION G 6035 C DATE 07 27 05 PAGE 7 OF 8 GROUP G o M
41. 61 1 SLEEMNG UL 0 33010 3 LG 38 D8730A 2 TIE WRAP UL 39 X 10 BLK 556525 1 TIE WRAP UL 17 7 X 35 BLK HT 40 068113 1 CARRIER REAR 15 BRUSHLESS 41 068406 1 SCREWHHC MI2 175X 60G109 2 0F7272 6 SCREW1 4 20X 58 TAPTITE SS 0398 1 BUSHING SNAP SB 25 31 ABAN 2 BUSHING SNAP SB 25 31 FOR 54 68 1 PHASE 4 CF6819 1 MOUNT CTS 54L 100KW 45 23 TRANSFORMER 46 208 2 SCREWPHIT 6 32 12ZYC 47 2 WASHER LOCK 6 48 072568 46 SCREWHHC 5 10 20G88 49 049813 46 NUT LOGBYEL CHR 50 02624 1 BEARING BALL 6212 SEALED 51 07080 1 SHROUD UPPER ALTERNATOR EXCITR 52 F77 1 SHROUD CENTER ALTERNATR EXCITR 53 1 SHROUD LOWER ALTERNATOR EXCITR 6 5554 1 ASSY SCROLL 390X 60MMCPL KIT PARTS INS GLTHRUGO 6L 38468 2 SHROUD ALT SHEET METAL CPL 2P 62 552 2 SCREEN 390 SAE ALT G0MMWIDE 2 BRACKET SAE SCROLL TENSIONER 61 56326 84FT VINYLTRIM1 8 GAP 6 02209 6 WASHER SPLIT 1 445 66 AB 6 WASHER FLAT 1 4ZINC 6 015757 2 SCREWHHC M5 L0x 25 LONG 68 07411 4 SCREWHHC IM6 L0X 16G88 e 042110 2 SCREWSWAGE 1 4 20 1 2 ZYC ROTOR REPLACEMENT PARTS 1PHASE UNITS REQUIRE SEPERATION OF LEADS QTY REQ 1 PHASE 3 PHASE PAGE 2 OF 2 GROUP A CPL C3 H CONTROL CB CONNECTION EXPLODED VIEW DRAWING 0F3393D PAGE 1 OF4 REVISION G 8253 H DATE 5 30 06 EXPLODED VIEW CPL C3 H CONTROL CB CONNECTION DRAWING 0F3393D APPLICABLE TO ITEM PART 1 OF 2885 2 OF 2883 09637 4
42. 807D 1 PIPE EXHIMANL H54L GB amp 2P 5 4L C5 OF9208 1 PIPE EXHMANFOLD AG LH 3 4505 REF GLASS PACK 235 LG 2 5 INOUT 4 046765 2 RINGGASKET 25 DIA 5 0F4710 6 WASHER LOCK MIOSS 6 07200 6 SCREWHHC 0 15 5055 FTH 7 080762 8 3 8 16 2 62 8 OF2809 1 PIPE EXHAUST CROSSOVER 9 QF2981A 2 MFLR7 X9 X25 2 25 IN25 OUT 10 OF2062 2 MUFFLER STRAP n 0C2454 4 SCREWTHF 5 1 16 NWA ZJ S 2 8 WASHER LOCK M6 1 4 13 OF2830 2 MUFFLER BRACKET STIFFENER 14 F462 REF RAIN CAP ALUMFCR 2 1 2 PIPE 15 2454 SCREWTHF 5 1 16 NVA ZJ S 16 4367 REF HEAT SHELD EXHAUST STACK 17 6 CAP HEAT SHELDEXHAUST STACK 18 0r2773c 2 EXHAUST BLANKET 900MMLONG 68L C5 0F2773D 2 EXHAUST BLANKET SSOMMLONG 5 4L C5 19 05159 2 FLANGE EXHAUST 20 088775 6 WASHER FLAT 3855 a OF 2808 2 EXHUAST OUTLET PIPE CPL 2 547 1 BRKTMUFFLER 23 22473 12 WASHER FLAT 1 4HV5ZINC 24 2 PIPE ELBOWEXHAUST MUFFLER 5 BOLT U3 8 16X 262 26 4 MUFFLER STRAP UPPER LOVER 27 049813 4 NUT HEX M6X LOGB8 YEL CHR 28 049721 8 SCREWHHC M5 LOX 35 G8 8 BLK 29 D88510 6 NUT HEXMIO L5SS PARTS INCLUDED IN OF6322 KIT GLASS PACK SHIP LOOSE REVISION G 8080 E DATE 5 25 06 PAGE 2 OF 2 GROUP D EXPLODED VIEW REVISION G 8018 C AIR CLEANER 5 4L 6 8L FORD DATE 4 26 06 PAGE 1 OF2 DRAWING 0F3569 EXPLODED VIEW AIR CLEANER 54L 6 8L FORD DRAWING 0F3569 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0005130 1 AIR CLNR BTMP
43. 9 1 TANK COOLANT RECOVERY 9 0F2573 1 PULLEY FAN V GROOVE 9 10 1 FAN26 LHROTATION 1 F2572 1 ARMTENSIONER 2 OF5689 1 SCREWSHC SHLDR LKG MBX 16 LG B CF 2882 1 SPRING TENSION CPL 14 0F2560 1 PULLEY V BELT 4 FLANGED 15 022131 14 WASHER FLAT 3 8MIO ZINC 16 080114 1 SCREWHHC 1 25 35 88 17 3 SCREWSHC 0 15 35G129 18 2561 1 HUBFLEXPLATE 19 5 NUT HEX LOCK 5 1624 NY INS 20 06795 1 SCREWHHC 2 15 60G88 21 12 DISK FLEX 2 8 1 COUPLING HUB FLEX MACH 23 048031C 1 CLAMP HOSE BAND 14 2 5 46 4 SCREWHHC 5 16 24 X 1 124 25 082774 2 KEY WOODRUFF 4 X 19D 26 F2656 1 HOSE RADIATOR UPPER CPL 27 5469 1 HOSE LOVER RADCPL 568 28 1 ASSY BRG SHAFT CPL FANDRIVE 29 4 2 1 PULLEY 65 DIA MACHINED 68 100KV OF4080 1 PULLEY 6 DIA MACHINED 68 130KVJ 4552 1 PULLEY 55 DIA MACHINED 54 80KW amp G8L 150 0F4496 1 PULLEY 45 DIA MACHINED 54L 100KW 30 OD911 1 SCREWHHC 1 55 30G88 31 F2872 1 SCREWHHC 1 2 13 2 G8 32 2 WASHER FLAT 1 2 ZINC 33 1 WASHER LOCK 1 2 34 1 NUT HEX 1 2 13 STEEL 35 049813 8 NUT HEX M5 X LOG8 YEL CHR 36 01920 1 NUT HEXLOCK ME 125 NY INS 30 02145 1 WASHER FLAT 5 16 NBZINC 40 022129 1 WASHER LOCK MB 5 16 2 085685 4 CLAMP HOSE 28 132 225 43 045764 1 SCREWHHIT M 07X8BP 4 065852 1 SPRING CLIP HOLDER 37 G2 45 0C7649 1 CLAMP HOSE 38 87 46 055506 1 BARBEDSTR 38 NPTX 38 47 OG9860E 1 HOSE DRAINASSY 28 48 060811
44. AL USE WIRE 15B IS FUSED 12VDC FOR THE ENGINE CONTROL MODULE 7 WIRE 15C IS FUSED 12VDC FOR THE IGNITION CUSTOMER CONNECTION BOX GENERATOR SET 601 J2 14 13 NOTE2 CT CURRENT TRANSFORMER LEGEND CUST CON CUSTOMER CONNECTION CYL CYLINDER IGNITION COIL DPE EXCITER ES1 E STOP SWITCH F FUSE BATTERY 12VDC FS FUEL SOLENOID BATTERY CHARGER GA GOVERNOR ACTUATOR CAMSHAFT SENSOR GD GOVERNOR DRIVER CIRCUIT BREAKER ICM IGNITION CONTROL MODULE COMMUNICATION CONNECTOR IFT INTERFACE TRANSFORMER CRANKSHAFT SENSOR ISO ISOLATED ELECTRICALLY REVISION G 8444 C DATE 6 28 06 PAGE 4 OF 4 GROUP G Z ans P s gt J El O E2 36 gt 2 z x gt 00 GROUNDED NEUTRAL IF SO EQUIPPED GND 5 z ul gt 8 183 o 183 15 a n e 390 RS485 v 391 Rs485 2 SHLD SHLD J2 3 0 O_LINE x 013 o POWER Ex oo D4 o w gt 0 0 POWER 2 o gt gt 452 ENGINE CONTROLLER CONNECTIONS MAIN LINE CIRCUIT BREAKER WLS_ WATER LEVEL SENSOR MAGNETIC PICK UP WTS_ WATER TEMPERATURE SENDER DIL PRESSURE SENDER RESISTDR RELAY BDARD STARTE
45. E5068 1 GASKET EXTRUDEDTRIM 566 LG 27 5080 4 TAB PULL 28 5951 2 INSULATION SPLITTER SML 29 F3949E 1 INSULATION ROOF TOP REAR 30 F3890A 8 RETAINER INSULATION 740 31 2 RMET POP 1875 X 450SS 32 OF3949C 1 INSULATION ROOF TOP 3 4 INSULATION DOOR 3 F394G 1 INSULATION DISCHARGE DUCT 58 2 INSULATION CENTER SUPPORT 36 OF3949K 1 INSULATION DISCHARGE DUCT TOP 37 Qr3949F 2 INSULATION INNER DUCT SIDE 38 5898 4 RETAINER INSULATION 820 39 OF3890 14 RETAINER INSULATION 450 40 042568 4 SCREWHHC M5 LOX20G88 41 0912970068 2 ASSY WIRE 14AWG 209 GRN YEL 42 022447 4 WASHER SHAKEPROOF INT 1 4 B 049813 4 NUT HEXM6X LOG8 YEL CHR 144 077992 28 HEXLOCK IV5 LO SS NY INS 45 0912970004 2 ASSY WIRE 14 AWG 348 GRNYEL 46 F2766A 1 SPLITTER C5 4 F3949M 1 INSULATION SPLITTER SHRT IVPS 48 1522222 1 KEY MSE ACTIONLATCHSLOT GR 49 E3257 6 SCREWTH FRMIVBWCAP SHKPRF W 1 ALUMINUMENCLOSURE NOTE ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM11 amp 49 THREAD FORMING FASTENER ANDITEMA4LOCK NUT LOCK NUT IS INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER 2 VNS 1 THRU 7 REFER TO CHART BELOWFOR ENCLOSURE COLOR amp MATERIAL TYPE SUFFIX 1 MATL SUFFIX 2 COLOR 01 TAN 03 BLACK AL ALUMINUM 05 WHITE 07 G FORCE ST STEEL RIC EXAMPLE SUFFIX OF19870AL 01
46. EXIVE L25 G8 YEL CHR PLUG EXPANSION 140D CLAMP HOSE 10 56 1 06 TIE WRAP UL 7 4 19 BLK NOT SHOWN CAP RUBBER TEMPERATURE SENDER DELPHI BRACKET DC ALT STABILIZER ELBOWS0D STREET 18 NOTE PART OF ENGINE MAKE P NOF3902 NOTE I N5IS PART OF 2 NOTE 5515 FOR HOLDING SENSOR TO I N 50 PAGE 2 OF 2 058630 ONIM VAA C JO 1 HDVd 90 LC v ALVA 142 175 ACIS SLYVd NOWWOO ANION 21 5781087D MAIA QHGO IdX4 91 SL SS3NHVH H3NV31O OL MOldVav TS di G 103INVIN SC OL S HOLdVav 3DIV LNI ONILNNOW j ISN EXPLODED VIEW ENGINE COMMON PARTS R H SIDE 5 4L CPL DRAWING 0F3850 GROUP D APPLICABLE TO ITEM PART QTY DESCRIPTION 1 000013 16 SCREWSHC 8125 X 3555 2 E9747 1 STARTER I2VOLT 3 OF3514 1 SPACER FLEXPLATE 54L 68L 1800 RPMONLY 4 OF3908C 1 FLEX PLATE 2 POLE 5 amp 68L 1800 RPMUNITS ONLY QF3908C 2 FLEX PLATE 2 POLE 54 amp 68L 3800 RPMUNITS ONLY 5 0F2776 1 BRACKET SIGNAL CONDITIONER 6 005417 8 SCREWHHC MI0 L0X25G109 7 8 WASHER FLAT 43X 100 8 2 1 TIE WRAP UL 7 4 19 BLK NOT SHOVIN 9 022131 1 WASHER FLAT 38MI0ZINC 10 065596 1 BARBEDSTR 38NPT X38 057772 1 WASHER NYLON 565 2 0572233 2 CLAMP HOSE 10 56 106 B 057765 1 ADAPTER MI4 L50X 38 NPT 14 0 3534 2 HEAT SHLDEXHAUST MANIFOLD 15 O69860E 1 HOSE DRA
47. Engine won t crank Engine cranks but won t start Engine starts hard runs rough Engine starts then shuts down AUTO OFF MANUAL Switch at OFF engine continues to run No AC output from generator 1 2 15 amp fuse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery 5 amp fuse blown Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Door on tank not closed Flame arrestor air cleaner plugged or damaged Plugged fuel line Defective spark plugs Fuel pressure incorrect Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch Defective AUTO OFF MANUAL switch Open disconnected wire 415A between AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open ww CORRECTION 1 2 Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or rep
48. Frequency Regulation 2 0 0 Isochronous Steady State Regulation sss 1 296 Adjustments SPCC Selectable Standby Generator Sets Specifications GENERAL INFORMATION Engine Lubrication System Type of Oil Pump Gear Full Flow Cartridge Crankcase Oil Capacity sss 5 US qts COOLING SYSTEM V o dee ceo E Closed Mater PUMP uu na Belt Driven Fan SPCC Osa 1700 Fan D mao ua chet endet coti cacti 26 inches Fan M00 iiss Puller Air Flow inlet air including alternator and combustion air senes 4800 ftS min Coolant Capacily acini 4 0 U S gal Heat Rejection to 8 376 000 Btu h Maximum Operating Air Temp on Radiator 60 C 1505 F Maximum Ambient Temperature 50 C 140 F FUEL SYSTEM Gl ll uu ua Natural Gas m Down Draft Secondary Fuel Standard Fuel Shut off Solenoid sss Standard Operating Fuel Pressure 11 in 14 in Water Column Fuel Consumption ft3 hr Natural Gas LPV Exercise 2596 5096 7596 100 Cycle Load Load Load Load 140 56 371 149 713 287 994 40
49. GROUP G E lg LSU WI I SC E E E lC Cd OE 1 COMPONENTS LOCATED CONTROL PANEL MOD a J1 32 809 812 M EE 4153 810 811 tae sea jo cag 01 26 812 WV ALT 49 oa DB MEM EE R1 AND CB VALUE BASED ON E PET ENGINE AND KW RATING R1g 29 M RATING R1 VALUE CB VALUE 1 1 TB2 4X 194 194 J2 31 55 KW 7 6 6 TB2 1X 80 KW 4 5A 4 100 KW 4 4 TB2 3X 70 KW 403 403 42 8 100 Kw 25 0 45A 20 JE Henne 130 KW 150 KW 406 406 J2 30 nYOII r 405 42 19 2 TB2 2X 56A 6 256 5 15 RB1A RI5BB 3prp 445 2 15A 1 15 15 56 56 15 15 14 14 15A 15A 15E BO T82 5x sm sss 0 60 1 60 10 BCC 7 16 0 R15B mb 256 CHASSIS J1 10 J1 11 AFS 15 ICM 12 14 FSP 4 14 14 DB 15A N C 15A TB1 15X NOT CONNECTED FOR 4 6L W LP FUEL L PAGE 40F 4 WIRING DIAGRAM REVISION G 8444 E 4 6L 5 4L amp 6 8L H PANEL DATE 6 27 06 PAGE 4 OF 4 DRAWING 0F2576 PAGE 5 DF 8 GROUP G T 7 m o o COM PC EE WIRING DIAGRAM 5 4 amp 6 8L H PANEL DRAWING 0F2576 REVISION G 6035 C DATE 07 27 05 PAGE 5 OF 8 REVISION G 6035 C DATE 07 27 0
50. INASSY 28 16 049821 2 SCREWSHC MB L25 X 30G129 7 022129 4 WASHERLOCK 5 16 18 089253 1 SCREWHHC MB L25 X20G88 19 0D2244M 1 ASSY MAGPICKUP 3824 MALE 20 01118 REF BARBEDSTR 1 2 NPTX 5 8 21 065934M 1 CLAMP VINVL 75 X 343Z 2 097411 1 SCREWHHC IM6 L0X 16G88 23 071623 4 SCREWSHC 10 15 556129 2 006742 1 VALVE PCV FORDG amp L B 022097 1 WASHER LOCK M6 1 4 26 1820 2 MACHINED MANFOLD EXHAUST 5 4L 27 0F1818 2 GASKET EXHAUST MANIFOLD 28 002473 1 WASHER FLAT 14M6 ZINC 29 048081 1 HOSE CLAMP 5 8 30 209 1 ENGINE ADAPTER 54 68 31 077996 2 CAP HOSE gt 046526 6 WASHERLOCK MIO 070008 8 WASHERFLAT VBSS 31 070006 24 WASHERLOCK NBSSTL 000608 8 SCREWHHC 5 16 18 X 12 SSTL 36 0514 1 DECAL REFER TO OWNERS MANUAL 3 0544 1 PLATE MAG PICK UP ADAPTOR 41 047290 1 HOSE 38 IDSINGLE BRAID 15 LG 2 059057 1 HOSE 3 4 IDSAE 30R2 NOTE I N8IS FOR HOLDING SENSOR TO I N5 REVISION G 8018 G DATE 4 27 06 PAGE 2 OF 2 GROUP E O AIR CLEANER T TO O TO p 31 RE e 795 26 ENGINE 36 HARNESS ASSEMBLY P N OF8313 OFA rf va SOLENOID MUST BE INSTALLED WITH FLOW ARROW POINTING IN TO INTAKE MANIFOLD 32 DIRECTION SHOWN IN DETAIL ABOVE z lt 5 LL z EXPLODED VIEW Pas T NAM NAM FAS Eos AES Wy NN AAN N fa A
51. LDLSS 600250 Y0X 1 4 28 WASHER FLAT 38MI0ZINC TERMCOVER CB SCREWHHC 1 4 28 X 12 G5 WASHER LOCK M6 1 4 WASHER FLAT 14M6 ZINC SCREWSHC 0 1 5 256129 WASHER LOCK MIO IrOmmgogoo 89 C Hunzmxvovzzrz rommogou tH QTY NHUUWOOOUNSBRABRANHH HMNNHHHHN GROUP A DESCRIPTION UL CIRCUIT BREAKER S004F COVER C5 8004F DECAL DANGER HGHVOLTAGE CIRCUIT BREAKERS 800A FRAIVE INSULATOR CB 800AF SCREWRHM 420X 3 2 WASHER FLAT 1 4 V5 ZINC WASHER LOCK 1 4 NUT HEX 1 4 20STEEL SCREWTHF M6 IXIGNWA ZJ S ELEC 1 2 FOAM SCREWSHC MIO 150X 40G129 WASHER FLAT 3 8 MIOZINC WASHER LOCK 38 NUT HEXMIO L5GBYEL CHR LUG SLDLSS 500750X 2MCMAL CU SCREWSHC MIO 125X 70688 DECAL CUSTOMER CONNECT INSIDE TERMCOVER MTZROTECH AODAF CB NEUTRAL BLOCK 390 200 200A BUS BAR NEUTRAL BLOCK 390 SCREWHHC IMB 1 25 X 45 G88 FT WASHER FLAT 5 16 MB ZINC WASHER LOCK 5 16 NUT HEX MB 1L25 G8 YEL CHR SCREWHHC 1428X 3465 WASHER LOCK 5 1 4 LUG SLDLSS 600 250 1 00 4 28 1 HARDWARE FOR MIG CB TERMINAL COVERS IS SUPPLIED WTHGRCUT BREAKERS 22 3 QTY 2POLE amp 3 POLE CB PAGE 4 OF 4 0827090 ONIM VAA C JO 1 HDVd 90 L ALVA TOULNOD 9 145 09 0 NOISIATH AHIA QHGO IdX4 I I 1 1 a e dnodd EXPLODED VIEW CPL C3 H CONTROL DRAWING 0602780 APPLICABLE TO ITEM RE RBREBQaNo
52. LT WCPLR 81 2 5419 1 ELEMENT AIR FILTER 3 F268 1 TOP PLATE VENTURI 4 1 HOLD DOWNAIR CLEANER PLATED 5 0F6977 1 PLATE AIR CLEAN TOP 54 68 6 087561 1 NUT WING 14 0 NYLK 7 047411 4 SCREWHHC 5 10 16G88 8 022097 4 WASHER LOCK M6 1 4 9 049811 4 WASHER FLAT M6 10 F2 1 GASKET MXER BODY 022473 1 WASHER FLAT 1 4HV5 ZINC REVISION G 8018 C DATE 4 26 06 GROUP D PAGE 2 OF 2 87850 DNIM VIG 142 175 ACIS SLYVd NOWNOO 1 NMOG 39 LSNW z N I 3LON Wu WWLAG dowd IO I HDVd 90 LC r ALYA 8108 D Pa Ya 1 1 33S H3aN3S 91115 110 N A AK RUNES ANS NE LNCS li y 2 CN SENS NL I 5 4 QUE 8 ba SES lt 7 EXPLODED VIEW ENGINE COMMON PARTS L H SIDE 5 4L CPL DRAWING 0F3848 APPLICABLE TO ITEM PART 1 OF3883 2 0 1900 3 a28p 4 2843 5e 005419 6 OF2849 7 0034886 003488 003488 8 057795A 9 QAG283 10 0F2847 123 0F2839 REVISION G 8018 D DATE 4 27 06 DESCRIPTION TUBE HEATER WATER ENGINE 54 FORD IGNITION COIL ASSY FORD GASKET THERMOSTAT HOUSING FORD OIL FILTER FORD V IO ENGINE TUBE OIL LEVEL INDICATOR FORD BELT SERPENTINE 650 1800 RPM SERPENTINE BELT 66 0 2650 RP SERPENTINE BELT 68 3 3600 RP BARBEDEL 903 4 PLASTIC HOSE PREFORMED BLOCK HEATER
53. NC WASHER LOCK 40 NUT HEX 40 32 STEEL ITEM 1 Tr A rommug rA rommug QTY GROUP A DESCRIPTION UL CIRCUIT BREAKER FD 1 1 COVER FDFRMCB DECAL DANGER HIGH VOLTAGE CB 0150A 600 5 FDeLL 0175A 600 5 0225A 600 5 0250A 600 5 INSULATOR CB FD FRAME XML SCREWSHC 1420X4G88 NZ WASHER FLAT 14M6 ZINC WASHER LOCK 6 1 4 NUT HEX 1 420STEEL SCREWTHF 1 16N VA ZJ S ELEC 1 2 FOAM AS DECAL CUSTOMER CONNECT INSIDE UL CIRCUIT BREAKER J D LD 1 1 COVER QR BRKRJ DLD DECAL DANGER HIGH VOLTAGE CB 03004 GXVS J D6 LL 05504 600 5 D6 LL 600 5 D6 LL 08004 600 5 LD6 600 5 LD6LL INSULATOR CIRCUIT BR J DLD SCREWRHM1 4 20X3 WASHER FLAT 1 45 ZINC WASHER LOCK M5 1 4 NUT HEX 1 4 20STEEL SCREWTHF M51X16NWAZJ S TAPE ELEC 1 2FOAM AS REQD DECAL CUSTOMER CONNECTINSIDE 1 ITEMINCLUDED WTH HARNESS 2 ITEMINCLUDED WTH 0D5464 3 ITEMIS PART OF 9R 4 ROUTE ONE SET 11 22 33 44 THROUGH ONE HOLE AND ROUTE THE SECONDSET 11 22 33 44 THROUGH THE OTHER HOLE PAGE2 OF 4 de6ees0 ONIM VYA 40 HDVd 90 0 ALVA NOLLO3NNOO 82 O 1 9 H ES78 D NOISIATH 1 SQv3 LIV Sava riv voor C 22 V dnodd EXPLODED VIEW CPL C3 H CONTROL CB C
54. ONENTS 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 March 1 2005 Costs of normal maintenance i e tune ups associated part s adjustments loose leaking clamps installation and start up Any failure caused by contaminated fuels oils coolants
55. ONNECTION DRAWING 0F3393D APPLICABLE TO ITEM PART 3 A 4173 1 065460 1 4165 REF D OF4186 1 E 086261 4 F 063640 4 G 088150 4 H 002264 4 22471 4 K 029289 2 L 0 1733 1 M 022129 9 N orsi 1 P 0C2454 7 R OF8451 3 S 019897 9 T 2145 6 U 045771 3 8543 3 DW WCB 2 4 A F4175 1 B 065469 1 416655 0 1733 1 042419 4 023897 4 G 022152 4 H 002158 4 2454 7 K 029289 1 L 052617 23 2M 046526 23 WCB 3 P 047822 3 R 022131 3 05 WCB 2 T 003334 6 U 022097 6 022473 6 Ow WCB 23 2x WCB 23 REVISION G 8253 H DATE 5 30 06 DESCRIPTION UL CIRCUIT BREAKER 225 COVER CB C5 225AF DECAL DANGER HIGH VOLTAGE CIRCUIT BREAKERS 200A FRAME COVER CB DISH 225AF RIVET POP 125 27555 SCREWRHM 8 32 X 314 WASHER FLAT 8ZINC WASHER LOCK 81V4 NUT HEX 832 STEEL ELEC 1 2 FOAM DECAL CUSTOMER CONNECT INSIDE WASHER LOCK MB 5 16 INSULATOR CB 225AF SCREWTHF 1 16 2 5 LUG SLDLSS 300MCM6 AL CU SCREWSHC MB 125 X 20G8 WASHER FLAT 5 16 MB ZINC NUT HEX MB 1 25 G8 CLEAR ZINC BUS BAR 200A LUG ADAPTOR TERMINAL COVER CB UL CIRCUIT BREAKER 400 F COVER CB C5 400AF DECAL DANGER HIGH VOLTAGE CIRCUIT BREAKERS 400A FRAME DECAL CUSTOMER CONNECT INSIDE SCREWRHM 10 32 X4 WASHER FLAT 40 ZINC WASHER LOCK 40 NUT HEX 40 32 STEEL SCREWTHF 1 16 2 5 ELEC 1 2 FOAM SCREWSHC MIO 15X25G129 WASHER LOCK MIO BUS BAR CB ADAPTER 225 00 LUG S
56. OX 100KVJ 25 006015 2 NPPLE CLOSE 34X 1375 26 059057 1 HOSE 3 4 IDSAE 30R2 42 LG 27 085461 1 BARBEDSTR 14 NPT 3 8 54 80KWG 100KWNG 081017 1 BARBEDSTR 1 4NPT X 12 68L 100KWNG 28 046580 4 SCREWSHC 1 0 45 G129 29 080204 2 CAMP HOSE 2449 2 31 325 30 02209 4 WASHER LOCK 6 1 4 31 047290 1 HOSE 38 IDSINGLE BRAID 42 LG 052223 1 HOSE 1 2 IDSAE 30R2 FUELOIL 42710 6 8L 100KVJ 2 22808 1 GASKET ADAPTER THROT BODY 6 8L FORD ONLY 33 059057 1 HOSE 3 4 IDSAE 30R2 2 LG 34 064346 1 PIPE TEE 1 1 4 NPT 35 0F4408 1 Y CONNECTOR 500 SERIES BARBS 36 0F6279 1 HARNESS FUEL J UVPER DUAL REG REVISION G 6298 C DATE 9 13 05 GROUP E PAGE 2 OF 2 GROUP E IR CLEANER TO A 1 N N 4 TO C 32 CN N TO ENGINE HARNESS ASSEMBLY S 2 z o 5245 50 L o Bz LE 59 IMPORTANT SOLENOID MUST BE INSTALLED WITH FLOW ARROW POINTING IN DIRECTION SHOWN IN DETAIL ABOVE z lt c 2 9 LL z O EXPLODED VIEW FUEL LP VAPOR C5 CPL REVISION G 6298 C DATE 9 13 05 DRAWING 0F6529 PAGE 1 OF 2 EXPLODED VIEW FUEL LP VAPOR C5 CPL DRAWING 0F6529 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 083212 4 SCREWHHC 5 16 18 X1 1 4G5 2 065908 1 SUPPORT NAT GAS SOLENOID 3 OFG261H 1 REGULATOR ASSM5AL 80KWLPV 5 4L KW 626 1 REGULATOR ASSM5AL 100KWLPV 5 4L 100K OFG26IK 1 REGULATOR ASSM68 100KWLPG 68L 100KVJ OF
57. 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 tools 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 Acomprehensive 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 eq
58. R CONTACTOR SHIELD STARTER SPARK PLUG SHUNT TRIP AUTO MANUAL SELECT SWITCH SCHEMATIC DIAGRAM 4 6L 5 4L amp 6 8L H PANEL DRAWING 0F3901 682950 4 ONIM VYA C dO 1 HDVd 18 1 S 142 TIVLSNI AHIA HHGO IXH dnowdd M3IA 3 ALON 3352 ONILNNOW 31332ND2 G3IN3WWO233 51104 3 ABNVNDSVNW VIC G2 D 651 S39V1d C 5501 53015 NV 4 583 L 8181 398VHOSIG SIV 6402 L TO Z21 989 S32V d 9 39 5510 15 111384 58314 4 15 55322 01 3NVd 3015 NVH 1431 33H1I3 3AUW3S 9 SONINSVA ONILATT 4 WANVYW S 3NMD 32 343434 6 9 15 NV 1943 39 303 013411934 ANNO SI 3 DH 109 01313 9 553229 A04 LNOAS 3ADW3 53 WALNOD 211 5 ASSSNVAL 55322 ANY NOILOSNNOD lt XYW dWV 672 021 398VH2 3 1 NDIIO3NNDO WALNAN NOILOIANNOD LINGNOD 0931 X04 015 3015 f 1 SYSNMO 133HS NUIIVOIJIO3dS 335 NDIIVWHDJNI 2332939898 1119412 E SAANLINALS WOAS 532 91510 X04 53009 79207 NV 31918 19430433 YSHLO ANY SV 713M SV SIBVINVIS OZ VddN NV Vd33N 3789217999 1 344019 HLIM 32 9084 2 NI GATIVLSNI 38 LSAW LINN ONIOIAS3S NV 3ONVN3INIVMW 3 4
59. SING An analog Water Temperature Sender WTS is locat ed in the engine s cooling system This sender is con nected to the panel and allows the panel to monitor and display the temperature of the coolant system The WTS is a resistive device whose resistance chang es based on coolant temperature The resistance of the sender results in a voltage being developed across the sender As the Coolant temperature increases the resistance will decrease causing the voltage to decrease This changing voltage is converted to 4 20mA signal by a signal conditioner module The corresponding 4 20mA signal is read by the control panel and displayed as the coolant temperature The control panel will monitor and display the cool ant temperature anytime the DC input to the control panel is present If the temperature exceeds approximately 140 C 284 F the engine shutdown will be initiated The generator will automatically restart and the display will reset once the temperature has returned to an operating level LOW COOLANT LEVEL A Low Coolant Level LCL sensor is placed in the generators coolant system This sensor allows the panel to detect a Low Coolant Level condition The LCL is a resistive device whose resistance changes rapidly based on the presence or absence of coolant The resistance of the LCL results in a voltage being developed across the LCL This voltage changes as the resistance changes This changing voltage is con
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61. SS ADPTR RHSIDE WCKMAN 1786191 HOLDER FUSE WCKMANN 178 6150 ADPTR LHSIDE WCKMAN 1786192 ASSY PCB G PANEL RELAY 12VDC BLOCK TERM20A 12 X 6X 1100V COMPONENTS NOT INCLUDED IN OF 1826E OR WRE HARNESS BhRNB NEMHENHHNUUUNBNHHHH RELAY SOLENOID T2V0C PNL MNT DPE BREAKER SEE DRAWING BOOST RESISTOR SEE DRAWING COVER CONTROL PANEL SIDE SCREWHHC 1420X 3465 WASHER FLAT 14M6 ZINC WASHER LOCK M6 1 4 WASHER LOCK NB NUT HEX MBQ5 G8 YEL CHR WASHER FLAT MB SCREWPHIT 6 32 X 58ZYC DECAL CPL CONTROL PANEL FUSES DECAL 54 68L TB3 NUT HEX 1 4 20STEEL DECAL CPL 54 68L RELAY BOARD FUSE 15 BLUE FUSE 10ANP RED SEAL WEATHER 45 DIA SCREWPPHMIVb O8X 12 SCREWPHIT 6 32 X 38ZYC WASHER FLAT WASHER LOCK GROUP D PAGE 2 OF 2 696230 ONIM V AA C dO 1 HDVd 90 sc s ALVA GO LSnVHX3 145 18 9 1h S 31344 9 0808 0 AMIA Q3GO Id XH G IO3INVIN 1 3 8 OL Cu LSNVHX3 OL LONG LSNVHX3 OL Mh i xt ISNWHX3 3ais H 1 OL dowd EXPLODED VIEW MUFFLER 5 4L6 8L CPL EXHAUST C5 DRAWING 0F2969 GROUP D APPLICABLE TO ITEM PART QTY DESCRIPTION 1 OF2807C 1 PIPE EXH MAN R H G amp L G B CPL 68 C5 OF2807E 1 PIPE EXH MAN R H54L G B amp 2P SA C5 0 9207 1 PIPE EXHIMANFOLDA4 G RH 2 2808 1 PIPE EXHIMANL H G8 GB CPL 6 8L C5 0F2
62. SYSTEMS 5 1 F el Require mients eios 5 1 Natural Gas Fuel System 5 1 Propane Vapor Withdrawal Fuel System 5 1 LP System 5 1 SPECIFICATIONS 6 1 GeHGEatOE orien orrua Ree RD rou qusaqa sqa 6 1 ose OI RR 6 1 6 1 6 1 Electrical iie tere poe 6 1 Cold Weather Itu s m u LI a 6 2 5 4L amp 6 8L Ignition Description 6 3 Ignition Power up Input 56 Line Input 6 3 Ignition Enable 14 Line Input 6 3 Ignition Shutdown on Loss of Crank or CAM Signals poss Ferte ues ex yea ee eeu qe 6 3 Diagnostic Blink Patterns Red LED Located on the Ignition Control 6 3 GENERAL INFORMATION 7 1 Generator AC Lead Connections 7 1 Four lead Single phase 7 1 Alternator Power Winding Connections 7 1 S phase Alternators tee ens aea nae e 7 1 INSTALLATION 8 1 Installation 8 1 Preparation Before Start up ese eterne e
63. Serial Number QT 5 4L Models STANDBY GENERATOR OWNER S MANUAL A new standard of reliability GENERAC POWER SYSTEMS INC This manual should remain with the unit 409640 ON Hed 90 80 0 80019409 CONTENTS Standby Generator Sets TABLE Table of Contents SECTION PAGE SAFETY 1 1 INTRODUCTION 1 3 Read this Manual 1 3 Operation and 1 8 How to Obtain Service 1 3 IDENTIFICATION RECORD 2 1 Seay sion gay 2 1 EQUIPMENT DESCRIPTION 3 1 Equipment Description etae nerves 3 1 Engine Oil Recommendations 3 1 Coolant Recommendations 3 1 ENGINE PROTECTIVE DEVICES 4 1 Coolant Temperature 4 1 Low Coolant 4 1 Oil Pressure Sensing ee etre 4 1 Overcrank Shutdown nes tene 4 1 Overspeed Shutdown 4 1 RPM Sensor Loss Shutdown 4 1 DC ass 4 1 FUEL
64. Standards KW rating is based on LPG fuel and may derate with natural gas Excitation Brushless Generator Output Voltage kW 60 Hz kW Amp CBSize 120 240V 1 phase 1 0 pf 100 417 500 120 208V 3 phase 0 8 pf 100 347 400 277 480V 3 phase 0 8 pf 100 150 200 Generator Locked Rotor KVA Available Voltage Dip of 35 Single phase or 208 3 190 KVA 4B0V 9 oai meer Ebr 225 ENGINE UL c Generac Modelo trado de cad a V type Cylinders and Arrangement ses 8 Displacemerit cit ini bct ch ads 5 4 Liter i RE 3 55 in icm 4 17 in Compression Ratio 9 to 1 Air Intake Naturally Aspirated ValV6 S68l5 3 hem no cei nnde Hardened Litter Type ciiin Hydraulic Engine Parameters Rated Synchronous 60 Hz 3600 HP at rated 60 Hz 175 Exhaust System Exhaust Flow at Rated Output 60 953 cfm Exhaust Temperature at Rated 10005 F Combustion Air Requirements Natural Gas Flow at rated power 60 7 325 cfm Governor
65. and cord sets must be adequate to handle the maxi mum electrical current ampacity to which they will be subjected Before installing or servicing this and related equipment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in hazardous and pos sibly fatal electrical shock Connecting this unit to an electrical system nor mally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operat ing Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy 90 80 0 100 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 sourc
66. 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 Failure due to misapplication misrepresentation or bi fuel conversion Telephone facsimile cell phone satellite internet or any other communication expenses Rental equipment used while warranty repairs are being performed i e rental generators cranes etc
67. ating con ditions from leaking exhaust gases fuel leakage oil leakage etc Z ELECTRICAL HAZARDS All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the standby generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appropriate covers guards and barriers are in place before operating the gen erator If work must be done around an operating unit stand on an 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
68. attery should be inspected per the Service Schedule section 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 BATTER IES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer 90 80 0 A DIG 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 caus tic 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 the fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster battery to crank and start the generator engine If the battery has completely
69. d 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 for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 1 14 mm 0 045 inch by carefully bending the ground electrode Figure 10 4 Figure 10 4 Setting the Spark Plug Gap SET PLUG GAP AT 1 14 mm 0 045 inch ce COOLANT CHANGE Every year have an Authorized Service Facility drain flush and refill the cooling system See the Specifications section for cooling system recom mendations MISCELLANEOUS MAINTENANCE CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer That dealer will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well 40 80
70. d grounding Control and communication wiring to from the transfer switch must be run in a separate conduit from the AC power leads Battery charger connection to 120 VAC Communication wires connected between transfer switch and generator HTS only Unit secured to pad 90 40 ed 10018154 INSTALLATION Standby Generator Sets Installation INSTALLATION START UP CHECKLIST A warninc Before working on the generator ensure the fol lowing The AUTO OFF MANUAL switch is in the OFF position The 120VAC supply to the battery charger is switched OFF PREPARATION FOR START UP Ensure that the 120VAC circuit breaker to the bat tery charger is open Remove the fuse from the the control panel For the H 100 and R series Open the front door of the control box and remove the 15 Amp ATO fuse in the lower left hand corner of the control box Connect the battery cables to the battery Attach negative battery cable last Close the 120VAC circuit breaker to the battery charger Measure the voltage at the battery before and after the charger is turned on Verify all AC electrical connections are tight at the circuit breaker and transfer switch Visually inspect entire area looking for loose paper plastic wrappings leaves etc Check all hoses clamps fittings for leaks or dam age Check all electrical plugs throughout the genera tor Ensure each plug is seated correctly and fully inserted into its r
71. 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 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 by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the control panel Auto Off Manual switch to the 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
72. dition please note the dangers under Engine Start up and Transfer 90 80 1001900 MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES warninc 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 state of charge and condition Inspect and test fuel system Check transfer switch Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY 1 Test engine governor Adjust or repair if needed 2 Clean inspect generator 3 Flush cooling system FIRST 100 OPERATING HOURS 1 Change engine oil and oil filter After initial change service engine oil and filter at 150 operat ing hours or 6 months whichever comes first EVERY 500 OPERATING HOURS 1 Service air cleaner 2 Check starter 3 Check engine DC alternator 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 Wit
73. ds instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized Service Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and accessories Operating instructions presented in this 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 mode
74. e of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a dry rope or board to free the vic tim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extin guisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or 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
75. eceptacle Verify the AUTO OFF MANUAL switch is in OFF position Open the valve to the engine fuel line Bleed the fuel system of air necessary for long fuel lines Open the generator main line circuit breaker Connect a manometer to the gas line and record the static pressure It must be as listed in the Specifications Insert the fuse into the control panel Move the AUTO OFF MANUAL switch to the MAN UAL position The engine should now crank and start 90 50 L00l e1SU Check voltage at the generator terminals For 3 phase units check phase rotation at the transfer switch terminals The generator phase rotation must match the utility phase rotation Check for coolant fuel oil and exhaust leaks Close the generators main line circuit breaker Turn the generator set off Connect the UTILITY supply to the transfer switch Set the AUTO OFF MANUAL switch to AUTO Disconnect utility power before the transfer switch Engine should start transfer to load Run at least 15 minutes on generator power Make certain all 3 phase loads are functioning correctly correct phase rotation Reconnect Utility power Transfer switch will transfer back to Utility and engine will shut down within the given time parameters set up for the specific transfer switch and controller Install all covers access plates and door panels Put the Owners Manual in a safe and accessible place Make certain the
76. er this heading read instructions that if not strictly complied with will result in personal injury or property damage warninc amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety infor 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 recommen
77. erator to an area where people animals etc will not be harmed This exhaust system must be installed properly in strict compliance with applicable codes and stan dards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical in any room or building hous ing the generator to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts 90 80 0 100 jejes Before performing any maintenance on the gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous oper
78. fer to the wiring diagrams at the back of this manual Voltage codes apply to the type of stator assembly installed on a particular generator FOUR LEAD SINGLE PHASE STATOR Four lead generators see Figure 7 1 are designed to supply electrical loads with voltage code 240V 1 60 Hz Electrical power is produced in the stator power windings These windings were con nected at the factory to the main circuit breaker as shown in Figure 7 1 The rated voltage between each circuit breaker ter minal is 240V The rated voltage between each circuit breaker terminal and the neutral point OO is 120V Figure 7 1 Four lead Single phase Stator m tm E M p E3 I I 120 I VOLTS 33 10 240 33 Tru NOLES I 120 i VOLTS I 11 I H Y Y CIRCUIT BREAKER Standby Generator Sets General Information GENERAL INFORMATION ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS The generator is designed to supply 3 phase electri cal loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit breaker with a Y configuration as shown in Figures 7 2 and 7 3 The rated voltage between circuit breaker terminals E1 E2 1 and E2 E3 is either 480V or 208V depending on the model The rated voltage between each circuit breaker termi
79. hout sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down 710 1 wanNING The exhaust system parts from this product get extremely hot and remain 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 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 Recommendations for recommended oils Figure 10 1 Oil Dipstick and Oil Fill Cap Oil Fill Oil BATTERY FLUID Check battery electrolyte fluid at least once weekly Fluid should cover separators in all battery cells If fluid level is low add distilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY 50 80 0 6001 MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance ENGINE COOLANT Check coolant level in coolant recovery bottle See the Specifications section Add recommended coolant m
80. i freeze Using any high silicate anti freeze boosters or additives will also cause overheating The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment DIG A Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result Ethylene glycol base antifreeze is poisonous Do not use mouth to siphon coolant from the radiator 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 LOOdinb3 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 addi tional automatic engine shutdown information COOLANT TEMPERATURE SEN
81. ixture as necessary Periodically remove radiator pressure cap 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 recovery system for leaks MAINTENANCE OWNER OPERATOR CAN PERFORM CHECK ENGINE OIL LEVEL Refer to the Checking Fluid Levels section CHECK BATTERY Check battery fluid level each week as outlined under Check Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 20 minutes See the Weekly Exercise Cycle section INSPECT COOLING SYSTEM Inspect engine cooling system at least once each month Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness CHECK ENGINE COOLANT LEVEL See the Checking Fluid Levels section 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 exhau
82. k and start as soon as the utility power to the transfer switch is turned off Refer to applicable control panel and transfer switch manuals for more information Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to UTILITY Do not attempt manual operation until all power supplies to the transfer switch have been posi tively turned off or extremely dangerous pos sibly lethal electrical shock will result Transfer switch enclosure doors should be kept closed and locked Only authorized personnel should be allowed access to the transfer switch interior Extremely high and dangerous voltages are present in the transfer switch In order to transfer load from the utility source to the generator follow these directions Turn OFF or disconnect the utility power circuit to the transfer switch using the means provided such as the utility source main line circuit break er Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the standby generator s main line circuit break er to its OFF or OPEN position Start the generator Operation caution Do not crank the engine continuously for longer than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge read ings Whe
83. l coil on plug coils for each spark plug The 5 4L engine uses a 36 1 crank sensor a mag pick up CAM sensor and individual coil on plug coils for each spark plug With a single fire ignition each high voltage coil out put is connected to one spark plug resulting in that spark plug being fired only during the compression cycle Engine Timing versus Engine Speed for the 6 8L engine is RPM NG LP Engine Timing BTDC 1800 rpm 22 degrees 3600 rpm 24 degrees Engine Timing versus Engine Speed for the 5 4L engine is RPM NG LP Engine Timing BTDC 1800 rpm 26 degrees 3600 rpm 26 degrees IGNITION POWER UP INPUT 56 LINE INPUT When battery voltage is applied to this input the igni tion will power up For the ignition to power itself down battery voltage must be removed from this input IGNITION ENABLE 14 LINE INPUT This input must be connected to the 12V battery for the ignition to turn on the coils If this input is con nected to battery ground the ignition will stop firing the coils and will power down within approximately 2 seconds In the event that an ignition fault has occurred however the ignition will wait 60 seconds before powering down This allows time to view the diagnostic LED located on the ignition board m Standby Generator Sets E GENERAL GENERAL INFORMATION Specifi cation S INFORMATION NOTE The ignition cover does not need to be removed to see the
84. l number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit AUTHORIZED SERVICE DEALER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 or locate us on the web at www generac com 90 80 0 100 jejes INFORMATION IDENTIFICATION RECORD DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator The data label which can be found attached to the gen erator s lower connection box lists the unit s serial number and its rated voltage amps wattage capacity phase frequency rpm power factor etc GENERATOR SET DATA MADE IN USA MODEL SERIAL RATED KW RATED KVA PHASE RATED VOLTAGE RATED AMPS POWER FACTOR HERTZ ALT RPM ENGINE RPM PRODUCTION DATE ALTERNATOR SUBTRANSIENT REACTANCE ALTERNATOR TRANSIENT REACTANCE CLASS ROTOR STATOR WINDING INSULATION AT 25 C AMBIENT GENERAC POWER SYSTEMS INC WAUKESHA WI NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Generator Model and Serial Number This number is the key to numerous engineering and
85. lace battery Replace fuse Replenish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Close door on tank Clean or replace as needed Unclog fuel line Clean regap or replace plugs Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch 1 Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Auto reset Wait 5 min and attempt restart Contact the nearest Authorized Dealer for assistance 12 1 50 80 0 0019891 NOTES Standby Generator Sets Notes NOTES NOTES Standby Generator Sets Notes NOTES GROUP A TO ENGINE ADAPTER LOCKTIGHT 2 POLE ONLY o a o amp o CPL ALTERNATOR BRSHLSS 80 100 amp 150KW 2 POLE EXPLODED VIEW DRAWING 0F2987 REVISION G 7794 J DATE 4 3 06 PAGE 1 OF 2 EXPLODED VIEW CPL ALTERNATOR BRUSHLESS 80 100 amp 150KW 2 POLE DRAWING 0F2987 APPLICABLE TO ITEM PART r nni E e REVISION G 7794 J DATE 4 3 06 DESCRIPTION
86. manufacturing details pertaining to your unit Always supply this number when requesting service order ing parts or seeking information PUT Standby Generator Sets E EX GENERAL GENERAL INFORMATION General Information Identification Code Use this code to obtain important information about the generator For example if the code is M Q T 1 0 0 5 4 AJNIS NA M Designates generators capable of paralleling NOTE Only 100kW and 150kW 6 8L units are currently available for this configura tion QT Quiet Test Generator Series 100 kw Rating 5 4 Engine Size in Liters A Voltage Code A 120 240 Single phase 120 208 Three phase 277 480 Three phase J 120 240 Three phase L 346 600 Three phase N Fuel N Natural Gas V Vapor Propane S Enclosure Material A Aluminum S Steel Corrosion Resistant Aluminum Enclosure Material Steel is Standard N Emission Equipment N No Equipment Y Catalytic Converter and Air Fuel Ratio Controller A Industrial Dealer Product Voltage Codes The identification code letter following the unit s engine size is the generator s voltage code Groups and Assembly Numbers The manual drawing listing lists the groups and cor responding assembly numbers for each unit The assembly numbers refer to exploded view drawing numbers that are applicable to the specific generator model These drawings are l
87. n certain that all readings are correct move the transfer switch manual handle to its STANDBY GENERATOR position i e load cir cuits supplied by the generator Set the standby generator s main line circuit break er to its ON or CLOSED position Load circuits are now powered by the standby generator RETRANSFER AND SHUTDOWN For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch To transfer the load back to the utility power source and shut down the generator follow these direc tions Set the standby generator s main line circuit break er to its OFF or OPEN position Manually move the transfer switch handle to its UTILITY NORMAL position i e load circuits connected to the utility Turn ON the utility power supply to the transfer switch using the means provided such as the util ity power source main line circuit breaker Let the generator run at no load for a few minutes to stabilize internal temperatures Shut down the generator OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If the generator has been installed with an automatic transfer switch such as an RTS HTS or GTS type transfer switch the engine may be started and stopped automatically or manually NOTE Refer to the applicable manual for your trans fer switch and to Transfer Switch Start Signal Connections In ad
88. ocated in the back half of this manual 90 70 O 00 119 GENERAL INFORMATION EQUIPMENT DESCRIPTION This equipment is a revolving field alternating cur rent generator set It is powered by a gaseous fueled engine operating at 1800 rpm for 4 pole direct drive units 3600 rpm for 2 pole direct drive units and 2300 3000 rpm for quiet drive gear units See the Specifications section for exact numbers The unit 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 MG1 1 66 The generator is self ventilated and drip proof con structed The voltage waveform deviation total harmonic content of the AC waveform and telephone influ ence factor have been evaluated and are acceptable according to NEMA MG1 32 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE SF Detergent oils keep the engine cleaner and reduce carbon depo
89. operly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications and Coolant sections BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inch 10 to 16 mm ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground Make sure the generator battery is fully charged properly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components INITIAL INSPECTION FOR QT GENSET STARTUP Inspect for the following Freight Damage Manuals present Fluid Levels Oil coolant battery Gear Drive Correct fuel piping Correct muffler installation for external applica tion Adequate air flow clearances and ventilation per installation drawings and applicable codes Correct AC and DC wire size connections an
90. ove 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 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 OVERTIGHTEN 6 Remove OIL FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is listed in the Specifications caution Ak After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance 7 Start engine and check for oil leaks Oil Dipstick Oil Filter CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 0A4637 remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 10 3 Engine Air Filter CLAU See the Service Schedule section for air cleaner maintenance 10 3 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary 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 an
91. ret 8 1 Transler Switch t eee 8 1 CONTENTS Puel System 8 1 Generator Set Lubrication 8 1 Prior to Initial 8 1 Initial Inspection for QT Genset Start up 8 2 Start up Inspectioli sssr eserinin pe eva 8 2 OPERATION 9 1 Generator Control and Operation 9 1 Operating Unit with Automatic Transfer Switch 9 1 Operating Unit with Manual Transfer Switch 9 1 Engine Start up and Transfer 9 1 Retransfer and SIhWUdoWm 1 ll ua ua ss S 9 1 5 5 10 1 Maintenance Performed by Authorized Service Facilities aa esee tene 10 1 Cooling 8 10 1 Checking Fluid Levels is 10 1 Check ER PE HERE wisq 10 1 Battery e erede matre es 10 1 Engine Coolant vertes t Eee 10 2 Maintenance Owner Operator Can Perform 10 2 Check Engine Level 10 2 CHECK BAET ycno a 10 2 Exercise Systemie risna ensena E S 10 2 Inspect Cooling Syst rm suenen nnno 10 2 Check Engine Coolant 10 2 Perform Visual
92. rnia to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before install ing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reli ably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings 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 DIE A 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
93. s Inc Box 8 Waukesha WI 53187 Ph 262 544 4811 Fax 262 544 4851 Bulletin 0171370SVE Printed in U S A 7 05 Printed in U S A
94. sits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Temperature Above 80 F 27 C SAE 30W or 15W 40 SAE 20W 20 or 15W 40 32 to 80 F 0 to 27 C Below 32 F 0 C See Note caution amp Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure 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 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 ant
95. st system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks security damage 50 80 0 10 2 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 inch Adjust belt tension as required INSPECT ENGINE GOVERNOR Visually inspect electronic governor A 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 CHANGING ENGINE OIL Refer to maintenance performed by authorized ser vice facilities for engine oil and filter change frequen cies Drain the oil while the engine is still warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 2 Loosen and rem
96. uipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer 11 1 90 60 WASH LOOPUSSMS MAINTENANCE MAINTENANCE Standby Generator Sets 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 Comp 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 annually Initials 50 hrs 1
97. verted to 4 20mA signal by a signal conditioner mod ule The corresponding 4 20mA signal is read by the control panel and displayed as the low coolant level If the level of the engine coolant drops below the level of the low coolant level sensor the engine shutdown will be initiated Standby Generator Sets Engine Protective Devices GENERAL INFORMATION OIL PRESSURE SENSING An analog Oil Pressure Sender OPS is used for monitoring the engine oil pressure This sender allows the control panel to measure and display the Engine oil pressure The OPS is a resistive device whose resistance changes based on engine oil pressure The resistance of the sender results in a voltage being developed across the sender As the oil pressure increases the resistance will decrease causing the voltage to decrease This changing voltage is converted to 4 20mA signal by a signal conditioner module The corresponding 4 20mA signal is read by the control panel and displayed as the oil pressure The control panel will monitor and display oil pres sure anytime the DC input to the control panel is present Should the oil pressure drop below the 8 psi range the engine shutdown is initiated The unit should not be restarted until oil is added Turn the AUTO OFF MANUAL switch to the OFF position then back to AUTO to restart OVERCRANK SHUTDOWN When the control panel receives a start signal it ini tiates the programmed
98. witch 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 shipped from the manufacturer with break in oil This oil should be changed after 30 hours of operation Check the oil level in the generator gearbox if so equipped prior to initial use and at the intervals indicated by the Service Schedule The recom mended oil is SAE 90 gear lubricant Also if the engine is equipped with a mechanical gov ernor make sure the governor is properly lubricated with clean engine oil PRIOR TO INITIAL START UP caution Prior to initially starting the generator it must be pr

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