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Generac QT06024AVAX Portable Generator User Manual

1. ee a CR ep 71 OPTION 1 SINGLE PHASE NEXUS CONTROL PANEL 11 11 44 44 DIRECT 181 lt AR 0950 44 1 BLACK 1 1 4 4 RED 4 4 25 52 2 2 4 BRUSHLESS 1 BLACK 6 1 6 6 6 4 RED NOTE USED WITH G4 6L amp 11 11 6 8L UNITS 44 44 ONLY 2d 23 DIRECT DRIVE GEAR 5 C AS DRIVE MLC8 M8 ET 2 L I LE END GENERATOR OUTPUT CUSTOMER CONNECTIONS AR ALTERNATOR ROTOR El TO E23 240VAC OR 220 AS ALTERNATOR STATOR E D novac NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES MLCB MAIN LINE CIRCUIT BREAKER OUTPUT VOLTAGE NB NEUTRAL BLOCK 120 240VAC 60L7 TERMINAL BLOCK M 110 220VAC 50HZ OPTION 2 THREE PHASE NEXUS CONTROL PANEL 120 208V 51 51 53 53 DIRECT 6266 S1 09569 1 BLACK 1 4 RED 4 Al mim BRUSHLESS 1 BLACK ui im 4 RED 225 NOTE USED
2. S15 S15 S16 S16 TB DIRECT 515 515 S16 516 1 BLACK 1 1 4 4 4 Eldar 2 0926 2 Set BRUSHLESS 1 BLACK 29 5 1 8 4 RED NOTE USED WITH G6 8L S3 S3 UNITS ONLY S2 S2 CS 51 51 1 GEARBOX S12 DRIVE 56 516 59 AS S4 MLCB NB 515 i S5 lt us El E2 S16 S15 L 1 GENERATOR OUTPUT CUSTOMER CONNECTIONS E1 TO E2 E2 TO E3 480VAC TO E2 OR TO NB 277VAC NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE 277 480 60HZ IUE Ue Reemi use ti nt e cre J REVISION H 7699 C DATE 10 21 10 PAGE 3 OF 4 WIRING DIAGRAM NEXUS CPL ALTERNATOR DRAWING 0H6342 GROUP G OPTION 7 THREE PHASE SERIES DELTA NEXUS CONTROL PANEL GEARBOX REVERSE ROTATION SA SA 58 58 181 lt AR BA 454 4 4 LC gt B pu 1 BLACK 1 1 4 RED 4 4 2 2 2 BRUSHLESS 5 18 NOTE USED S3 UNITS ONLY N3 N3 25 M2 M2 lt 51
3. gt _ OPERATION 2 ___ _ __ Stationary Emergency Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch Engine Start up and Transfer Retransfer and Operating Unit with Automatic Transfer Switch General Check Engine uu u Changing Engine Oil Cooling Intake Outlet Inspect Cooling System Engine Coolant Change Overload Protection for Engine DC Electrical System 10 2 10 2 Perform Visual Inspection u u uu u usss 10 2 Inspect Exhaust System m Check Fam Belt tert Inspect Engine Changing the Engine Air Filter m X Battery Maintenance Battery Replacement Battery aida Cleaning the Stationary Emergency Generator 10 3 SERVICE 5
4. 9 5 to 1 Air Intake System Turbo Charged After Cooled WAIVE Hardened gt __ Hydraulic Spark Plug 0 17mm 0 028 inch Engine Parameters Rated Synchronous RPM 60 Hz 3600 Exhaust System Exhaust Flow at Rated Output 60 Hz 60kW 494 cfm Exhaust Temp at Rated Output 60KW 1050 F Combustion Air Requirements Natural Gas Flow at rated power 60 Hz 60KW 180 cfm Governor Electronic Frequency Isochronous Steady State Regulation 0 25 Engine Lubrication System Type of Oil Pump Gear Full Flow Spin on Cartridge Crankcase Oil Capacity 5 25 U S qts including filter capacity COOLING SYSTEM TVBO ci etre P ete Pressurized Closed Recovery Water rete aasan Belt Driven X ee 2050 rpm 22 inches Fan Puller Air Flow inlet air including alternator and combustion 3280 ft3 min Coolant
5. 11 1 12 1 Troubleshooting Guide 12 1 EMISSIONS WARRANTY 13 1 NOTES EXPLODED VIEWS amp PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS 01 90 9V0IV91V0 Safety Instructions 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 INTRODUCTION Thank you for purchasing this model of the stationary emergency generator 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 contact the nearest Service Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incor rect
6. 2 5 U S gal Heat Rejection to Coolant 60KW 270 000 Btu h Maximum Operating Air Temp on Radiator 60 C 150 F Maximum Ambient Temperature 50 C 140 F FUEL SYSTEM Type Of EUG sit aida Natural Gas Propane Vapor SY CE Down Draft Secondary Fuel Standard Fuel Shut Off Standard Operating Fuel Pressure 5 in 14 in Water Column Fuel Consumption ft3 hr Natural Gas LPV Exercise 25 5096 7596 10096 Cycle Load Load Load Load 60kW 123 49 3 267 101 483 183 672 255 862 327 ELECTRICAL SYSTEM Battery Charge Alternator 12V 30 Amp Static Battery Charger 2 5 Amp Recommended Group 26 525CCA System 12 Volts Voltage Regulator Electronic Single phase Regulatipn 1 Adjustable Voltage and Gain Power Adjustment for Ambient Conditions Temperature Deration 3 for every 10 C above C 60 25 1 65 for every 10 above F 60 77 Altit
7. 5 2 HOLIMS ZH09 0G 9 YIISNVHL OVAOZZ TWNOIS x OVAOZL 1V VI5 2 ALMILO N3JSNVML 3HIM Z lt 0 r 1 r 1 Lim r 1 1 r 1 2 N gt a gt 3 a Sa C Qu ch M E 8 8 zz EE mo SN Q e o 9 gt 5 181 E Ou I 225 1 1 1 I i I 06 0 lt wer 5 gt 2 QA 9 I I I L 1 L I L I 5 gt g 5 3 I I I 109 ILON vl I 1 5 ey 895 I I I N ILON GI 9 I 5 22142 03 1 I I I lt I X 5 gt 2 C 1 2 ALON T E D D EET rs p I I I I rz 22 215 OE SI dE I I I 189 4223 e 8 72 o I I I lt lt E 2 I I I EZ Ese I 2 C 95 5 SES e sQ 8
8. 6 4 SCHEMATIC DIAGRAM PAGE 2 OF 4 G2 4L G2 NEXUS DRAWING 0H6340 REVISION H 8455 D DATE 3 7 11 PAGE 2 OF 4 GROUP G CYL1 BAK SP1 CVL2 7 2 CSV CYL3 AK SP3 CVL4 SP4 AGE 3 OF 4 LP SCHEMATIC DIAGRAM C2 4L G2 NEXUS DRAWING 0H6340 REVISION H 8455 D DATE 3 7 11 PAGE 3 OF 4 GROUP G e ea LL LK a NOTES 1 WIRE 0 IS CHASSIS GROUND BATTERY UNLESS NOTED OTHERWISE 2 WIRE 13 IS UNFUSED 12VDC BATTERY 3 WIRE 14 IS FUSED 12VDC WHEN GENERATOR IS CRANKING OR RUNNING 4 WIRE 15 IS FUSED 12VDC FOR GENERAL USE 5 WIRE 15A IS FUSED 12VDC FOR THE AIR FUEL SOLENOID OPTION AND FOR THE IGNITION COILS EC CONNECTOR BWR CONNECTOR PIN WIRE FUNCTION PIN TO FUNCTION 1 0 GND NOTE 1 5V POWER FOR BASIC REMOTE 2 14 J2 8 NOTE 3 2 817 Ji 4 REMOTE DISPLAY SYSTEM READY 3
9. 1441 33H113 3ADW3S 9 SONINSVM 1311 403 SIINMO 30 343338 9 1151 3 NV 301V33N39 1 803 03410034 A IND SI AIH 119 01314 553009 4034 IJADO 1M091 3ADW3S S3SIM WALNOO HOLIMS 4335 931 01 553004 NOILOSNNOD XVW dWV S 0 OV 021 3398VHO A3311v8 12 WaLNSN 1103 00 LINGNOD 4931 0901 404 9349 1 3CISNI lt v IVANVA SSSNMO NIHLIM 133HS 11901310345 335 3351388 1119819 79534 10 415 ASHLO S3ONVISIG WAWINIW 403 53400 19001 CMV 316915 1943434 ASHLO SV 71138 SV SUAVUNVIS OZ NV ZE 31 90114 1N33934N9 3 0 440009 GATIVLSNI 38 LSAW LINN 403 JOLVIINID 301 53015 119 WOD 1 341314405 MOTIV 313 40 00 2303 LINN HLIM 43134405 30109 11911915 30 343334 C 8 88 X AGIM 1 Sv 5511 3215 Vd 31342 00 C 1CIM 1VIVII 19 WNWINIW CL D df1OID SION ONIM V G 01 ALYA 09 IV NL ISNI 6 9 NOISIAHA AHIA QHGO Id XH Vv 335 AINO NOILIANNOD CH 3415 SIHL NO 31907 301S1NO 404 103 1313 ONTIANOO 3 VW34 14 v NOILISNNOD f D ALIAVNO 30 331N32 AWWA LdN v T1 T NDLL
10. 5 IN31SAS Q STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator s manual for this unit OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the Stationary Emergency Generator was installed in conjunction with a transfer switch capable of manual operation only the fol lowing 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 literature pertaining to the specific transfer switch A DANGER The Maintenance Disconnect Switch and the AUTO OFF MANUAL switches if so equipped must be set properly or the generator will crank and start as soon as the utility power to the transfer switch is turned off Refer to cable 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 positively turned off or extremely dangerous possibly lethal electrical shock will result 2 switch enclosure doors should be kept closed and locked
11. LOOS SI9ny Specifications SPECIFICATIONS GENERATOR Synchronous 9 9 Class LI Stator Insulation 6 Class H Telephone Interference Factor lt 50 Alternator Output Leads 3 phase 4 wire Sealed Ball Flexible Disc Load Capacity Standby Rating 60kW NOTE Generator rating and performance in accordance with 1508528 5 855514 SAE 41349 1503046 and DIN 6271 Standards KW rating is based on LPG fuel and may derate with natural gas Excitation Direct Generator Output Voltage kW 60 Hz kW Amp Size 120 240V 1 phase 1 0 pf 60 250 300 120 208V 3 phase 0 8 pf 60 208 250 120 240V 3 phase 0 8 pf 60 180 200 277 480V 3 phase 0 8 pf 60 90 100 Generator Locked Rotor KVA Available Voltage Dip of 35 Single phase or 208 3 phase 60kW 120 KVA 480V 3 phase 141 KVA ENGINE uLcm Generac In Line Cylinders and 4 _ C 2 4 Liter 3 41 I 3 94 in Compression
12. 19 765 3 THROTTLE POSITION FEEDBACK SOURCE 18 4 FIELD FIELD BRUSH 20 766 6 THROTTLE POSITION FEEDBACK SIGNAL 19 1 FIELD FIELD BRUSH 21 68 WTS 2 COOLANT TEMP SIGNAL 20 11 CUST CON 120 SOURCE FOR BATTERY CHARGER 22 79 MP2 3 CAM SENSOR 21 NEU CUST CON 120 RETURN FOR BATTERY CHARGER I 23 79 MP1 3 FLYWHEEL SENSOR 22 56 5C STARTER CONTACTOR DRIVER I 24 58 MLC8 OUTPUT VOLTAGE SENSING 8 23 15A EC 3 CYLI CYLA NOTE 5 25 1 CUST CON UTILITY VOLTAGE SENSING 1 26 N2 CUST CON UTILITY VOLTAGE SENSING 2 31 573A WLS A COOLANT LEVEL SIGNAL RETURN 32 573 WLS B COOLANT LEVEL SIGNAL I 33 86 LOS NC LOW OIL PRESSURE SIGNAL I 34 804 EC 6 OXYGEN SENSOR 35 805 EC 5 OXYGEN SENSOR RETURN LEGEND 00 NEUTRAL EC EMISSIONS CONNECTOR 05 OXYGEN SENDER AFS AIR FUEL SOLENOID F1 FUSE INLINE R1 RESISTOR ALT DC CHARGE ALTERNATOR 5 FUEL SOLENOID SC STARTER CONTACTOR BAT BATTERY GOV ELECTRONIC GOVERNOR ACTUATOR SHLD SHIELD BWR BASIC WIRELESS RECEPTACLE J ENGINE CONTROL MODULE CONNECTOR SM STARTER MOTOR CAR COMMON ALARM RELAY LOW FUEL PRESSURE SWITCH SP_ SPARK PLUG I CB CIRCUIT BREAKER LOS LOW OIL PRESSURE SWITCH WLS COOLANT LEVEL SENDER CVL CYLINDER IGNITION COIL MLCB MAIN LINE CIRCUIT BREAKER WTS COOLANT TEMPERATURE SENDER DIODE BRIDGE MOV
13. _ _ _ _ 22222021 WIRING DIAGRAM REVISION H 8455 D G2 4L G2 NEXUS DATE 3 7 11 PAGE 2 OF 4 DRAWING 0H6341 GROUP G 554 Bn NI MIL LECCE COMPONENTS LOCATED ENGINE WIRING DIAGRAM G2 4L G2 NEXUS I HVR LVR 1C N J1 25 1 k GND 2 41 26 2 14 SPLICE 5 3 42 20 3 K 49 ALT I 4 K NEU 92 21 4 K 5 SA J1 13 5 K 178 J1 1 6 K SB 01 24 6 K 183 J1 14 7 kE 7 6 25 J2 12 8 8 194 42 13 g 10 6 2 16 11 4 92 18 12 1 42 19 BWR 1 K 820 J1 12 2 K 817 J1 4 3 K 818 J1 5 4 819 01 17 5 K 0 GND 6 9 2 18 8 L9 42 17 162 116 2 ENGINE BLOCK TOP VIEW 2 45 lt S TRE T 62 4L 92 7 454 J2 6 453 J2 5 452 J2 4 451 J2 23 1161 15 3 15 6 CC GND 0 lt 0 OS D SPLICE 5 14 lt 5 14 05 SPLICE 6 15 lt 15A AFS 2 J2 2 808 lt lt 808 AFS 1 I J1 35 805 gt 805 05 J1 34 804 lt 804
14. GROUP G L1 L2 13 00 o gt a c 59 88 If x lt g 5 Bz as VS Ir 2 5 2 8 2 5 N E gt K O ALON 2 LI L 5 lt H vor lt kE CV I 9 LI 0 a 80 af 85 Ir VS f ALTERNATOR MAIN WIRES L1 00 L3 a O 310N C a ami lt C 9 zr 22 80 ALTERNATOR CONNECTIONS FOR 19 UNITS ALTERNATOR CONNECTION BOX GENERATOR SET 4 VI 708 S08 93 808 VSL 05 OPTIONAL AFS EMISSION CONTROL ALON O 98 V6 THS 64 VELS 89 ALON O e 291 2 992 CL DEL S94 I 9 er 4 LOS MP2 WTS WLS MP1 CB o9 oG ol GOV AGE 1 OF 4 E SCHEMATIC DIAGRAM G2 4L G2 NEXUS DRAWING 0H6340 REVISION H 8455 D DATE 3 7 11 PAGE 1 OF 4 GROUP G SNOILO3NNOO 93 I015 r 1 M39NVHO 2
15. ITEM PART 042574 064094 064096B 0G8690 0G8692 0H2811 0A4707B 0A4707F 0C4975 0 4973 0E5343 0H0457 QTY Q gt Q N a oz REVISION DATE 6 22 09 GROUP D DESCRIPTION ADAPTER 1 8NPTF TO 1 8 BSPT MALE ELBOW 45 49 3 OIL SUPPLY 3LHA 38 GASKET 2 4L G2 GASKET 2 4L G2 TURBOCHARGER G2 2 4L ADAPTER 1 4NPT X M12 1 5 ADAPTER 1 2NPT X M16 1 5 ADAPTER 1 2 NPT X 37JIC 3 4 16 ADAPTER 90D JIC37 1 4NPT X 1 2 NUT HEX FL WHIZ M10 1 50 STUD M10 1 5 X 40 G10 9 PAGE OF LS H0 210 60 21 01 91 160 29 172 HX3 93133nW M8 V 8 2614 CC 5 L A 4 EXPLODED VIEW MUFFLER EXH 2 4L G2 TURBO DRAWING 0H3357 APPLICABLE TO ITEM PART 1 0G86870ST03 2 0G8686 3 0G6150 4 0G0113 5 0F2808D 6 0G0007 7 0H3371 8 0H3372 9 0G8685 10 0 2454 11 022473 12 022097 13 049721 14 080762 15 022241 16 036797 17 070006 18 022259 19 0 6928 20 022237 21 0H1310 22 0F3794 23 0G3770 REVISION H 5192 B DATE 10 12 09 QTY 8 N OO N N N A GROUP DESCRIPTION BRACKET MUFFLER BRACKET STIFFENER MUFFLER 60kW EXHAUST ELBOW EXHAUST PIPE DIFFUSER EXHAUST WELDMENT PIPE EXHAUST 2 4L 60kW UPPER EXHAUST PIPE ASM STRAP MUFFLER SCREW THF M6 1 X 16 N WA Z JS WASHER FLAT 1 4 M6 ZI
16. y NOILOANNOO NS N YA 49 H 2 XN M0I1 93MM0 9N1 M0I1 93MM0 9N1 3015 3NI13103 HLIM 3015 403 99 39M LAN 99 33M LAN V OL LON LON xoa NOILO3NNOO V 4104 976 LI0 810 11 9Z 6 140 22 M0IL 93MM0 pepojdx3 3 296 X9 9 8 M0IL 3MM0 7 d 1 H 2 V EXPLODED VIEW CONBOX C2 CPL DRAWING 0H7326 APPLICABLE TO ITEM PART QTY 1 0H6266 1 2 0H6265 1 3 0H6160 1 4 057073 2 5 056739 1 6 6 0H67330STOR 1 7 0H7668B 1 8 0A2115 2 9 022097 3 10 022473 8 11 0H7115 2 12 0C2454 13 13 0F5458 12 14 042568 2 6 15 0H88390STOR 1 16 002265 4 3 17 0H6169B 1 3 18 023897 4 3 19 036943 2 3 20 022152 2 3 21 022158 2 3 22 055934D 1 2 23 0D5464B 1 24 022237 2 25 022241 2 26 0D3700 6 27 0H6267 1 28 0F5752F 1 29 052777 3 30 043182 3 31 051714 3 32 0D7177V 2 33 051713 2 34 049226 2 35 051716 2 36 056326 1 37 0 0489 1 38 0H7292 1 39 0H7293 1 40 026850 1 41 055414 1 4 42 SEE CHART 1 6 43 0H81040ASOR 1 44 0A9457 1 45 022264 4 46 045764 2 47 067210A 1 1 48 0D7393T REF 149 0D7393U REF 1 50 0F5376S0AR REF 1 51 0F5396S0AR REF 2 52 0A7822 REF 2 53 083896 REF 2 54 045335 REF 55 029289 1 56 066146 1 57 OH6692 1 58 0D6029 5 59 0D
17. 0H3078 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0H30830ST03 1 WELDMENT RADIATOR SUPPORT C2 2 062608 1 RADIATOR 598 X 568 X 49 CPL RH 3 0F5263 1 V BELT 31 64 X 57 3 8 4 046526 5 WASHER LOCK M10 1 5 059981 4 SCREW HHC M10 1 5 X 30 G10 9 6 0D3700 4 NUT FLANGE M6 1 0 NYLOK 7 0 5050 1 SHIELD RADIATOR C4 8 0C9332C 1 OIL LINE REMOTE FILTER ENGINE 9 0F2573 1 PULLEY FAN V GROOVE 9 10 0F4011 1 FAN COOL 22 DIA 10 BLADE LH 11 0H20620ST03 1 ARM BELT TENSIONER 1 12 0H2051 1 SHOULDER BOLT 1 2 X 2 1 4 13 0F2862 1 SPRING TENSION CPL 14 0F2560 1 PULLEY V BELT 4 FLANGED 15 022131 4 WASHER FLAT 3 8 M10 ZINC 16 0E2507 1 PROBE COOLANT LEVEL 3 8 NPTF 0H1827 1 PROBE COOLANT LEVEL 3 8 18NPTF 17 035685 2 CLAMP HOSE 28 1 32 2 25 18 0F2561 1 HUB FLEX PLATE 19 008145 8 WASHER FLEX THIN 20 052250 2 TAPE FOAM 1 X 1 26 75 LG 21 007043 12 DISK FLEX 22 0C93328 1 OIL LINE REMOTE COOLER FILTER 23 022473 8 WASHER FLAT 1 4 M6 ZINC 1 24 0C8146 4 SCREW HHC 5 16 24 X 1 124 25 022097 16 WASHER LOCK M6 1 4 26 076749 1 TANK COOLANT RECOVERY 2 27 048031C 2 REF CLAMP HOSE BAND 1 4 28 031971 1 BEARING 6205 2NSE E SRI2 S 29 0H0271 1 PULLEY 5 125 DIA MACHINED 1 30 042911 1 SCREW HHC M10 1 5 X 30 G8 8 31 0F2872 1 SCREW 1 2 13 X 2 G8 32 022304 1 WASHER FLAT 1 2 ZINC REVISION H 9455 D DATE 8 4 11 ITEM 33 34 35 36 37 38 39 40 69 4 70 71 72 73 74 3 75 76 77 5 78 79 80 PART 022195 0
18. 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 Stationary Emergency Generator Model and Serial Number This number is the key to numerous engineering and manufactur ing details pertaining to your unit Always supply this number when requesting service ordering parts or seeking information Data Label MODEL _____ PROD DATE SERIAL Kw KVAL__ SSS SS CD C EE Ed a J X JALTRPM ENG RPM TYPE CODE ALTSUBTRANSREACTANCE ALT TRANS REACTANCE CLASS a STATOR WINDING INS AT 25 C AMB gt 002110 REV C 2 1 01 50 ed SO0 LApI Equipment Description EQUIPMENT DESCRIPTION This equipment is a revolving field alternating current Stationary Emergency Generator 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 mainline circuit breaker bat tery charger and protective alarms as explained in the following paragraph All AC connections including th
19. 54 57 56 x x MLC8 M8 ce El JE ES GENERATOR OUTPUT CUSTOMER CONNECTIONS AR ALTERNATOR ROTOR El TO E2 AS ALTERNATOR STATOR E2 TO 25 240VAC BRUSH ASSEMBLY FI N OR E2 N OR E3 N 120VAC 2 LNE CIRCUIT BREAKER NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES NB NEUTRAL BLOCK OUTPUT VOLTAGE TERMINAL BLOCK J 120 240 60HZ PAGE 4 OF 4 med A C EM CL nC EMO C fe A 2562 CM ER d Mine 41 REVISION 7699 DATE 10 21 10 PAGE 4 OF 4 WIRING DIAGRAM NEXUS CPL ALTERNATOR DRAWING 0H6342 100 ed
20. CONTROL PANEL INTERFACE USING THE AUTO OFF MANUAL SWITCH A WARNING With the switch set to AUTO the engine may crank and start at any time without warning Such automatic starting occurs when utility power source voltage drops below a preset level or during the normal exercise cycle To prevent possible injury that might be caused by such sudden starts always set the switch to OFF and remove the fuse before work ing on or around the generator or transfer switch Then place a DO NOT OPERATE tag on the generator panel and on the trans fer switch 1 AUTO Position Selecting this switch activates fully auto matic system operation It also allows the unit to automati cally start and exercise the engine every seven days with the setting of the exercise timer see the Setting the Exercise Timer section 2 OFF Position This switch position shuts down the engine This position also prevents automatic operation 3 MANUAL Position Set the switch to MANUAL to crank and start the engine Transfer to standby power will not occur unless there is a utility failure ACTIVATE THE GENERATOR When battery power is applied to the generator during the instal lation process the controller will turn ON and the LCD screen will illuminate However the generator still needs to be activated before it will automatically run in the event of a power outage Activating the generator is a simple one time process
21. Check battery electrolyte fluid based on the Service Schedule 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 CLEANING THE STATIONARY EMERGENCY GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal generator 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 a Service Dealer That dealer will use dry low pressure air to clean internal windings Finally have the insulation resistance of stator and rotor windings checked II insulation resistances are excessively low the genera tor may require drying 01 90 v Service Schedule SERVICE SCHEDULE Weekly W Monthly M Inspect Change Clean Yearly Y AAA Fue 8 1 J w Y w Engine Coolant nes amp Comecions J x Emo Mw j X Emo v j x w x x Mam x T Sp v x j Bat
22. 12 L 1 SPLICE 10 os chacun CPC a 22 ma J WIRING DIAGRAM REVISION H 8455 D G2 4L G2 NEXUS DATE 3 7 11 PAGE 1 OF 4 DRAWING 0H6341 GROUP G 4 COMPONENTS LOCATED ON ENGINE 568 Ji 178 LVR 5 CENTER TERMINAL 2 NOT USED FS2 4 K 817 BWR 2 15 5 818 BWR 3 6 15 SPLICE 2 7 15 181 SPLICE 2 A I 8 0 SPLICE 1 9K 0 SPLICE 1 10 0 1 2 0 11 OA 2 2 12 820 BWR 1 13 SA HVR 5 So LP I 14 183 LVR 6
23. METAL OXIDE VARISTOR DPE EXCITER MAGNETIC PICKUP PACE REVISION H 8455 D DATE 3 7 11 PAGE 4 OF 4 SCHEMATIC DIAGRAM G2 4L G2 NEXUS DRAWING 0H6340 GROUP G muri q LEGEND NOTE ALL WIRES 18 AWG 5 AIR FUEL SOLENOID HIGH VOLTAGE RECEPTACLE 12 300V UL LISTED UNLESS ALT DC CHARGE ALTERNATOR J1 ENGINE CONTROL MODULE 35 CONNECTOR SHOWN OTHERWISE AS ALTERNATOR STATOR J2 ENGINE CONTROL MODULE 23 CONNECTOR I BRUSH ASSEMBLY LOW FUEL PRESSURE SWITCH SIZE BATTERY LOS LOW OIL PRESSURE SWITCH 12 BWR BASIC WIRELESS RECEPTAC
24. 022145 7 54 039414 4 55 060149 1 56 069504 1 57 1 060952 4 REF 58 0G1472A 1 59 061477 4 REF 60 0G8852 1 61 1 052265 1 REF 62 1 052203 1 REF 63 046525 2 64 0G3921A 1 65 029333 REVISION H 7244 D DATE 8 10 10 GROUP D DESCRIPTION ENGINE 2 4L G2 CERTIFIED CLAMP HOSE 6 43 78 CAP ANTIFREEZE RUBBER 9 5DIA GASKET INTAKE MANIFOLD G2 MANIFOLD INTAKE MACHINED WASHER LOCK 8 5 16 SCREW SHC 8 1 25 X 25 TEMPERATURE SENDER DELPHI PLUG STD PIPE 1 4 STEEL SQ HD NUT HEX 8 1 25 G8 CLEAR ZINC WASHER NYLON 565 HOSE DRAIN ASSY 28 CLAMP HOSE 38 87 BARBED EL 90 3 8NPT X 3 8 VS ADAPTER M14 1 50 X 3 8 NPT SCREW SHC 8 1 25 X 30 12 9 MAGNETIC PICKUP MOTOR STARTER SPACER 2 4L G2 FLEX PLATE ADAPTER ENGINE FLEX PLATE 2 POLE 2 4L G2 WASHER FLAT 531 ID X 1 062 OD SCREW HHC M12 1 25 X 20 C10 9 SCREW M10 1 25 X 45 G8 8 WASHER SHAKEPROOF EXT 7 16 STL SCREW 10 1 25 X 30 G8 8 CONDUIT FLEX 25 ID SHIELD INNER HEAT 2 4L TURBO SCREW HHTT M6 1 0 X 12 ZINC PLATE HOT RIVET POP 125 X 0 337 STEEL ASSY DIPSTICK W TEXT GTH 530 ASSY DIPSTICK TUBE 2 4 G2 SCREW 10 1 25 X 20 C8 8 WASHER LOCK M10 WASHER FLAT 3 8 M10 ZINC O RING SIZE 9 0MM X 2 0MM NITR TUBE TURBO OIL RETURN G2 2 4L CONDUIT THERMAL FLEX 13MM ID SCREW 6 1 0 X 16 8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC BRACKET EXH MANIFOLD 2 4 TURBO HEAT SHIELD TURBO 2 4L BRACKET HEAT SHIELD 2 4L SCREW HHC 8 1 25 X 16 C
25. 05 8 1 I J2 9 771 31 18 767 2 CCV J1 19 765 3 92 1 770 5 5 1 20 766 3 4 E REVISION H 8455 D DATE 3 7 11 PAGE3OF4 DRAWING 0H6341 GROUP G c aa a 5 J1 23 4 79 3 Ji 10 L 0 J1 16 4 sSHLD MR MET I 22 79 J H o CAM J1 15 7 P MP2 GND J1 33 m 2 J1 21 TH GND m WTS A 01 31 573A 32 573 0 8 8 2 7 1 1 4 808 3 15A 1 0 2 14 EC 5 _ 805 6 804 OPTIONAL 85 41225225253 29 25 REVISION H 8455 D G2 4L G2 NEXUS GROUP G
26. 15A J2 23 NOTE 5 3 818 1 5 REMOTE DISPLAY ALARM 4 808 4222 AIR FUEL RATIO SOLENOID DRIVER I 4 819 1 17 REMOTE DISPLAY MAINTENANCE 5 805 01 35 OXYGEN SENSOR RETURN 5 0 GND NOTE 1 6 804 41 34 OXYGEN SENSOR ENGINE CONTROL MODULE CONNECTIONS 42 PIN TO FUNCTION PIN WIRE 10 FUNCTION 1 178 CUST CON REMOTE START RETURN 1 770 4 THROTTLE DRIVE HI 4 817 BWR 2 REMOTE DISPLAY SYSTEM READY 808 EC 4 AIR FUEL RATIO SOLENOID DRIVER I 5 818 BWR 3 REMOTE DISPLAY ALARM 3 568 FS2 STARTING FUEL SOLENOID CONTROL I 6 15 F1 NOTE 4 4 451 CVL1 IGNITION COIL DRIVE 1 7 15 F1 NOTE 4 5 452 CYL2 IGNITION COIL DRIVE 2 8 0 GND NOTE 1 6 455 CYL3 IGNITION COIL DRIVE 3 9 0 GND NOTE 1 7 454 CVL4 IGNITION COIL DRIVE 4 10 0 1 2 FLYWHEEL SENSOR 8 14 DB1 FS EC 2 NOTE 3 I 11 2 2 SENSOR 9 771 GOV 1 THROTTLE DRIVE LO I 12 820 BWR 1 5V POWER FOR BASIC REMOTE 11 209 CAR COMMON ALARM RELAY 13 SA MLC8 OUTPUT VOLTAGE SENSING 12 23 CUST CON TRANSFER RELAY COIL CONTROL 14 183 CUST CON REMOTE START 13 194 CUST CON TRANSFER RELAY COIL 15 SHLDA 2 1 CAM SENSOR DRAIN 14 601 LFP LOW FUEL PRESSURE 16 SHLD MP1 1 FLYWHEEL SENSOR DRAIN 15 210 CAR COMMON ALARM RELAY I 17 819 BWR 4 REMOTE DISPLAY MAINTENANCE 16 6 DPE EXCITER RETURN I 18 767 GOV 2 THROTILE POSITION FEEDBACK RETURN 17 162 CB EXCITER OUTPUT BREAKER PROTECTED
27. LG HARN FUEL JUMPER DUAL REG CLAMP HOSE 10 56 1 06 ACTUATOR BOSCH 40 GOVERNOR GASKET BOSCH 32 CLAMP HI TORQUE 1 75 2 625 REDUCER RUBBER 3 0 2 00 CLAMP HI TORQUE 2 75 3 625 MIXER 40 60MM ACTUATOR ASSY O RING 2 3 4 X 3 32 X 2 15 16 VENTURI THROTTLE 32MM WASHER LOCK 6 1 4 GROUP E PAGE 2 OF 2 VI89 H0 DNIA VAG M09 IV 2 41114155 Tans AHIA daldvav OL 240 OL 11 6 6 ALYA 0196 NOISIA3 7 22840 N d 222 M 65 A 6 NI NMOHS NI MIIMI09 HLIM G3TIV1SNI 39 ISNW GlON310S INVLYOdWI SS3NHVH 3NION3 OL LOANNOO EXPLODED VIEW FUEL SYSTEM LP 2 4L 60KW DRAWING 0H7581A APPLICABLE TO ITEM PART QTY DESCRIPTION 1 057147 2 075580 3 026915 4 026812 5 0F8379 6 026915 7 022097 8 0F3691 9 0G9189C 10 046580 11 043107 12 022131 13 022129 14 045771 15 050280 16 0D1509 17 057147 18 0H7436 19 057823 20 064394 21 0E6586 22 086133C 23 0F3857 24 086133E 25 0F3885 26 0G3167 REVISION H 9610 B DATE 9 9 11 penn PB BBD AD a O HOSE 3 4 ID LPG amp MC 45 LC FLANGE FUEL INLET NIPPLE CLOSE 3 4 X 1 375 ELBOW 90D 3 4NPT NIPPLE PIPE 3 4 NPT X 7 NIPPLE CLOSE 3 4 X 1 375 WASHER LOCK 6 1 4
28. The manufacturer also strongly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by a Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a 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 con tribute to the need for maintenance service Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum See a Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the generator electric system has been installed by a Service Dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project H
29. VENTURI THROTTLE 32MM REG ASSY 2 4L 60KW LPV CPL SCREW SHC M6 1 0 X 45 C12 9 SCREW HHC M8 1 25 X 25 C8 8 WASHER FLAT 3 8 M10 ZINC WASHER LOCK M8 5 16 NUT HEX 8 1 25 G8 CLEAR ZINC DECAL FUEL INLET LPG DECAL INLET PRESSURE HOSE 3 4 ID LPG amp NG 41 LG HARN FUEL JUMPER SINGLE REG CLAMP HOSE 10 56 1 06 ACTUATOR BOSCH 40 GOVERNOR GASKET BOSCH 32 CLAMP HI TORQUE 1 75 2 625 REDUCER RUBBER 3 0 2 00 CLAMP HI TORQUE 2 75 3 625 MIXER 40 60MM ACTUATOR ASSY O RING 2 3 4 X 3 32 X 2 15 16 GROUP E PAGE 2 OF 2 GROUP F INSULATION AND RETAINERS LOCATED ON THE NEAR SIDE INSULATION FOR DISCHARGE AREAS ONLY SEE DETAIL A AND 8 FOR SPLITTER VARIATIONS 7 INSULATION AND RETAINERS 7 LOCATED ON THE FAR SIDE MOUNTING OF ACOUSTIC C EXPLODED VIEW ENCLOSURE C2 TO BASE FRAME 19 20 277117 z zt 7 77 Z STATES FOAMIS ON FAR SIDE MOUNTING OF ACOUSTIC INSULATION FOR DOORS 0 STATES FOAM IS ON NEAR SIDE AND REAR WRAP es m gt 5 On SE EE a DRAWING 068688 PAGE 1 OF 2 EXPLODED VIEW ENCLOSURE C2 DRAWING 068688 APPLICABLE TO ITEM PART QTY DESCRIPTION 2 1 0G80180ALOR 1 REAR WRAP C2 G2 60KW 2 002454 58 SCREW THF M6 1 X 16 WA Z JS 2 3 0F58490ALOR 2 DOOR C2 4 087233 2 RIVET POP 1875 X 450 SS 5 0E3257 4 SCREW
30. WITH G4 6L amp S7 57 G6 8L UNITS ONLY 52 52 S9 S9 S3 S3 f 37 2 DIRECT DRIVE 56 6 S10 MLCB NB S11 S12 O O O E ES S7 S12 EXIST ONLY ON A 12 ALTERNATOR GENERATOR OUTPUT CUSTOMER CONNECTIONS E1 TO E2 E2 TO ES 208VAC E1 E1 62 OR E3 TO NB 120VAC NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 208 60HZ PAGE 1 OF 4 2 A Ar Cc xac a eee E gt WIRING DIAGRAM REVISION H 7699 C NEXUS CPL ALTERNATOR DATE 10 21 10 PAGE 1 OF 4 DRAWING 0H6342 GROUP G Rer Les 420 2251 ar e aoe at e e gt ua 2 4 aaa ji mun 71 OPTION 3 THREE PHASE NEXUS CONTROL PANEL 6 WIRE 277 480 S15 S15 S16 S16 DIRECT lt AR L 515 515 L s16 s16 sagt 1 BLACK 1 1 4 RED 4 4 2 2 BRUSHLESS EF 1 BLACK 6 6 152 4 RED R
31. X 3 0 LG TUBE CAC IN G2 TURBO TUBE CAC OUT G2 TURBO SCREW THF M6 1 X 30 N WA DELTA OIL LINE REMOTE ENG COOLER ADAPTOR 1 2 NPT X 37JIC 3 4 16 COOLER OIL 2 4L G2 TURBO ADAPTER 90D JIC37 1 2NPT X 3 4 BEARING SLEEVE 1 2 X 34 X 1 SPACER CPL COOLING FAN 1 8 MOUNT OIL COOLER 2 4L G2 ADAPTER 45D JIC37 1 2NPT X 3 4 MOUNT REMOTE OIL FILTER 2 4 G2 NIPPLE OIL FILTER FILTER 1 5L 2 4L G2 OIL SCREW HHC M8 1 25 X 25 C8 8 ASSY PCB LCL SENSOR USE WITH I N 16 P N 0H1827 ONLY TIE WRAP UL 7 4 X 19 BLK NOT SHOWN NUT FLANGE M6 1 0 NYLOK BEARING PRESS NOTE APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO BEARING SURFACE ON ITEM 37 PRIOR TO PRESSING ITEM 28 ONTO ITEM 37 ALSO APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO THE OUTSIDE OF 28 PRIOR TO INSTALLING ITEM 28 INTO ITEM 38 1 APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS 2 INCLUDED WITH 26 3 APPLY LOCTITE 266 TO I N 75 PRIOR TO ASSEMBLY 4 ITEM 70 IS INCLUDED WITH ITEM 1 5 USE WITH R 200 CONTROL PANEL ONLY PAGE 3 OF 4 EXPLODED VIEW C2 COOLING SYTEM amp FAN DRIVE DRAWING 0H3078 GROUP D APPLICABLE TO THIS PAGE IS LEFT INTENTIONALLY BLANK REVISION H 9455 D DATE 8 4 11 PAGE 4 OF 4 9S H0 172 8 1 MelA dowd 210 LL 60 12 eyeq Y UOISIASY 1 424 EXPLODED VIEW TURBO 2 4L G2 DRAWING 0H3356 APPLICABLE TO
32. ZINC L 022152 4 WASHER LOCK 10 M 022158 4 NUT HEX 10 32 STEEL N 023334 6 SCREW HHC 1 4 28 X 1 2 G5 022473 6 WASHER FLAT 1 4 M6 ZINC Q 0G3259 1 DECAL TERMINAL SHOCK HZD BI ITEMS INCLUDED WITH HARNESS P N 0H6692 ITEMS INCLUDED WITH NEUTRAL BLOCK P N 0D5464B ITEMS INCLUDED WITH 4 2L MODELS ONLY SEE C2 DPE BREAKER SELECTION TABLE QTY REQ FOR 2 POLE BREAKER QTY REQ FOR 3 POLE BREAKER SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS NO COLOR MANUFACTURING FOR CORRECT MATERIAL AND COLOR REFER 5400 BOM CUSTOMER WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER FIRST 6 DIGITS ONLY IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR FOR REFERENCE SEE GUIDELINE 0H7169 1 2 3 4 5 6 REVISION H 9621 F Page 5 of 8 DATE 9 26 11 EXPLODED VIEW CONBOX C2 CPL DRAWING 0H7326 GROUP A APPLICABLE TO ITEM PART QTY DESCRIPTION UL CIRCUIT BREAKER KG A 0H5582 1 CB 0300 3P 600V E KG LL B 0H6740 1 COVER CB E KG C2 CONBOX C 003700 4 NUT FLANGE M6 1 0 NYLOK D 0H5581A 1 INSULATOR CB E KG E 0H6734 1 STANDOFF CB MOUNT CONBOX G 022129 3 WASHER LOCK M8 5 16 H 0 2454 12 SCREW HWHT M6 1 X 16 WA Z JS J 0D2157 4 SCREW SHC M6 1 0 X 50 C8 8 K 049897 3 SCREW SHC 8 1 25 X 20 G8 L 022145 3 WASHER FLAT 5 16 M8 ZINC UL CIRCUIT BREAKER FG A 0H5486 1 CB 0060 3P 480V E FG LL B 0H7356 1 COVER CB C2 CPL C 0H7434 1 COVER CB DISH 3P E FG D OH4698A 1 INSULATOR C
33. a wiring short dircuit If this fuse is blown the generator will not operate Replace these fuses with the same size type and rating 0L 90 8 60010408 Fuel System FUEL SYSTEM FUEL REQUIREMENTS The Stationary Emergency Generator may be equipped with one of the following fuel systems Natural gas fuel system Propane vapor fuel system 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 NOTE The fuel consumption requirements are identified in the Specifications section of the Owner s Manual Refer to the Installation Manual if assistance is required for the sizing of the pipe diameter for the generator Any piping used to connect the generator to the fuel supply should be of adequate size to achieve the 100 load fuel consumption requirements identi fied in the Specifications section regardless of actual load NOTE The recommended fuel pressure is identified in the Specifications section this manual NOTE It is the responsibility of the installer to make sure that only the correct recommended fuel is supplied to the generator fuel system Thereafter the owner operator must make certain that only the proper fuel is supplied 5 1 NATURAL GAS FUEL SYSTEM Natural gas is supplied in its vapor state In most cases the gas distribution compa
34. cranks for more than 10 seconds and the utility voltage rises above 80 of nominal programmed pickup voltage and the unit has not started the crank cycle will abort 2 As soon as the unit starts a 5 second warm up timer is initi ated When the warm up timer expires the control will transfer the load to the generator through the RTS switch if the utility voltage is less than 80 of nominal If the utility voltage is greater than the 80 of nominal at the end of the warm up time the load will not be transferred to the generator and a one minute low speed cool down period will start At the end of the one minute cool down period the generator will stop the unit is running and the switch has transferred the load to the generator the unit will monitor utility voltage When utility voltage returns above the programmable pickup voltage normally 80 of nominal a 15 second Return to Utility timer will start At the end of the return to utility time if the utility voltage is still above the pickup voltage the unit will transfer the load back to the utility source and run the unit through a one minute cool down period When the cool down period is over the unit will shut down and be ready for the next outage 4 If during the cool down period utility voltage should fall below 60 of nominal the 5 second warm up timer is initiated and the unit will transfer the load back to the generator and con tinue to monitor the ut
35. free from debris These generators 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 regulating the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks immediately Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detectors accordingly CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm CALIFORNIA PROPOSITION 65 WARNING This product contains or emits chemicals known to the State of California to cause cancer birth defects and other reproductive harm 0L 90 V00 19165 General 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 generator s lower connection box lists the unit s serial number and its rated voltage amps wattage capacity phase frequency rpm power factor production date etc
36. in the alarm log Alarms are all annunciated on the display Warnings are Non Latching meaning the message automati cally clears when the warning condition goes away Warnings can not be of type Shutdown but they are logged in the alarm log Warnings are all annunciated on the display LOW OIL PRESSURE SHUTDOWN ALARM There is a 10 second delay before oil pressure is monitored HIGH COOLANT TEMPERATURE SHUTDOWN ALARM There is a 10 second delay before engine temperature is moni tored Once running there is a 1 4 second delay before shut down The limit is set at 125 C or 257 F OVERCRANK SHUTDOWN ALARM Occurs if the engine has not started within the specified crank cycle OVERSPEED SHUTDOWN ALARM Warning indicator is measured and calculated by the microproces sor Overspeed is defined as 20 of nominal engine speed for 3 seconds or 25 immediate Nominal engine speed 60 0 Hz RPM SENSOR FAILURE SHUTDOWN ALARM During cranking If the board does not see a valid RPM signal within four 4 seconds of cranking it will shut down and lock out on RPM sensor loss During running If the RPM signal is lost for one full second the board will shut the engine down wait 15 seconds then re crank the engine if in AUTO it will not re crank in MANUAL If no RPM signal is detected within the first four 4 seconds of cranking the control board will shut the engine down and latch out on RPM sensor loss If
37. internal failure that can be detected such as corrupted firmware will cause this shutdown alarm This alarm cannot be Cleared CANBUS ALARM Where applicable if the Canbus communications link fails to com municate a Canbus Alarm will be generated This only applies to systems with external ignition modules The alarm may be generated if 1 The physical link is broken 2 Ignition Module fails or resets 3 The Nexus Controller fails or resets 4 Having the Battery Chargers 120 VAC connected without a battery installed 5 A blown 10 amp Ignition Module fuse approximately 12 inches away from the starter 6 A blown 25 amp system fuse located approximately 12 inches away from the DC alternator NOTE The Canbus Alarm will not clear on its own To clear the alarm press the enter key to acknowledge the alarm The alarm will clear and if the fault is still present the alarm will reoccur IGNITION ALARM When an ignition alarm occurs a generic message Ignition Fault will be displayed as the fault code MAINTENANCE WARNING When a maintenance period expires a warning message will be posted The warning can be reset by hitting the Enter key Resetting will clear the warning and reset the maintenance counters for the condition annunciated The history log will reflect the maintenance warning 110 ALARM CANCEL When the generator is shut down due to a
38. must be turned to OFF and then back to AUTO OVERCRANK SHUTDOWN After a prespecified duration of cranking this function ends the cranking if the engine has failed to start The overcrank message will turn ON Turn OFF the AUTO OFF MANUAL switch then turn switch back to AUTO to reset the generator control board NOTE If the fault is not corrected the overcrank feature will continue to activate Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total OVERSPEED SHUTDOWN A speed circuit controls engine cranking start up operation and shutdown Engine speed signals are delivered to the circuit board whenever the unit is running Should the engine overspeed above a Safe preset value the circuit board initiates an automatic engine shutdown Contact the nearest Authorized Dealer if this failure occurs RPM SENSOR LOSS SHUTDOWN If the speed signal to the control panel is lost engine shutdown will occur DC FUSES A fuse 7 5 amp is located on the control panel It protects the panel 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 A fuse 25 amp is located in the engine wire harness adjacent to the DC alternator It is used to prevent circuit failure due to DC alternator falure It will also protect the system in the event of
39. periods of time without an operator on hand to monitor such engine conditions as coolant temperature 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 mentioned here for the reader s convenience Also refer to the applicable control panel manual for additional automatic engine shutdown infor mation HIGH COOLANT TEMPERATURE SENDER An analog coolant temperture sender located in the engine s cooling system will cause an engine shutdown if the temperature should exceed approximately 125 C 257 F The generator will automatically restart once the temperature has returned to a safe operating level LOW COOLANT LEVEL SENSOR To prevent overheating the engine has a low coolant level sensor II the level of engine coolant drops below the level of the low cool ant level sensor the engine automatically shuts down LOW OIL PRESSURE SWITCH This switch has normally closed contacts that are held open by engine oil pressure during cranking and operating Should oil pres sure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL switch
40. 15 K SHLDA MP2 1 16 SHLD 1 1 17 819 BWR 4 18 767 2 19 765 GOV 3 20 K 766 GOV 6 21 K 68 WTS 2 22 K 79 MP2 3 23 K 79 MP1 3 601 24 K SB 6 15 568 25 M1 HVR 1 0 14 I 26 N2 2 27 28 0 0 29 30 601 601 42 14 55 5 8 J2 3 568 15 15 1181 _ 2 33 86 LOS NC 14 0 0 GND 34 804 6 35 805 5 F 14 14 14 LVR 2 5 14 J2 8 J2 1 770 GOV 4 8 15 ER LOCATED BACK OF CUSTOMER CONNECTION BOX 0 5 568 FSP 5 55 5 4 K 451 CYL1 1 10 5C 10 5 K 452 CYL2 1 SPLICE 4 13 M 16 16 SM 6 K 453 CYL3 1 55 gt 7 K 454 CYL4 1 8 C 14 SPLICE 5 9 771 GOV 1 225 10 0 GND 11 209 CAR 56 42 22 12 K 23 LVR 7 n 18 194 LVR 8 2 14 601 FSP 1 12 15 210 GND 16 6 181 1 17 162 L161 18 4 481 8 11 19 H81 12 20 1 3 25A 17 21 NEU 4 LVR 3 22 K 56 SC a 23 15A 181 splice 6 Paz El SM I O sc L0l 16 i SC 19 13 13 13 WIRE LOCATIONS 7 4 i MAY CHANGE 922222520 ON GROUND BAR GND 57 ON 1 LVR 1 0 LOS C 0 BAT WTS 1 0 BWR 5 0 0 6 922 9
41. 2 53 L M Figure 7 3 Stator Power Winding Connections 3 phase 277 480V 12 Lead 1 2 62 3 E3 lt L M 7 1 01 60 8 00u0029V General Information Figure 7 4 Stator Power Winding Connections 3 phase 120 208V 6 Lead INTERNAL CONNECTIONS 81 81 54 54 E 00 NEUTRAL 3 E3 Figure 7 5 Stator Power Winding Connections 3 phase 120 208V 12 Lead Figure 7 6 Stator Power Winding Connections 3 phase 346 600V 6 Lead E1 51 INTERNAL CONNECTIONS 4 t aj NEUTRAL 93 27 62 8 00 V 7 2 3 PHASE ALTERNATORS DELTA CONFIGURATION The Stationary Emergency Generator is designed to supply 3 phase electrical 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 Delta configuration as shown in Figures 7 7 and 7 8 The rated voltage between circuit breaker terminals E1 E2 E1 E3 and E2 E3 is 240V The rated voltage between E1 or E3 and the neutral point 00 is 120V Figure 7 7 Stator Power Winding Connections 3 phase 120 240V 6 Lead E2 S2 N S6 INTERNAL CONNECTIONS L L S5 S3 Ei si 54 E3 L N 00 NEUTRAL Figure 7 8 Stator Power Winding Connections 3 phase 120 240V 12 Lead HAN 00 NEUTRAL Control Panel
42. 22196 0F8651 052677 0F9867 0F2461 022145 022129 039287 082774 0G0795 0G0816 0H1546 049813 052644 0C8566 002454 090283 080713 055934M 0A5259A 039253 009595 049820 0H30880ST03 099502 008165 029032 0G3762 061285 071296 063985 063989 0C2454B 0G9332A 0C4975 063990 0C4973D 0H2844 0653150 10 063986 069910 069331 069333 0A45310244 043107 0H1851 029333A 0D3700 QTY 2 eco gt 2 ana EF GROUP D DESCRIPTION WASHER LOCK 1 2 NUT HEX 1 2 13 STEEL SCREW HHFC 8 1 25 20 W M6 WASHER NYLON 50 X 87 06 SHAFT FAN DRIVE RETAINER BEARING WASHER FLAT 5 16 M8 ZINC WASHER LOCK 8 5 16 SCREW HHC M8 1 25 X 45 C8 8 KEY WOODRUFF 4 X 19D HOSE LOWER RADIATOR G2 HOSE UPPER RADIATOR G2 USED WITH MANFLD P N 0G0707 HOSE UPPER RADIATOR G2 USED WITH MANFLD P N 0G8488 NUT HEX M6 X 1 0 G8 YEL CHR SPACER 5 X 1 5 X 25 STL ZINC SCREW HHFC M6 1 0 X 20 G8 8 SCREW THF M6 1 X 16 WA Z JS CAP RADIATOR 13 PSI BRACKET COOLANT TANK CLAMP STLIVNL 75 X 343 7 HOSE 2 ID X 3 0 LG SCREW HHC M8 1 25 X 20 C8 8 BRACKET RESERVOIR MOUNTING NUT HEX LOCK 8 1 25 NY INS BRACKET TENSIONER SPRING CLAMP HOSE 24 B1 06 2 00 NUT HEX LOCK 5 16 24 NY INS HOSE 9 32 ID 36 LG CAC 504W X 152H X 50D 2 4L G2 CLAMP CNST TENSION 1 75 2 625 HOSE 2 ID
43. 5 16 18 STEEL 32 0H1712 1 BARBED EL 90 POLY 1 2NPT X 34 33 057822 2 CLAMP HOSE 8 53 1 00 34 059057 1 HOSE 3 4 ID SAE 30R2 7 62 LG 35 0H0027 1 FITTING VENT VALVE COVER 2 4L 047527 3 4 1 BARBED STR 1 2NPT X 3 4 0H1644 4 1 FTG VNT VALVE COVER 0G10080103 4 1 REF GASKET PCV VALVE 36 1 2 0H1787A 1 PIPE INSULATION ELBO 37 2 0 1787 1 PIPE INSULATION 4 5 LG 38 2 0H1801 1 PIPE INSULATION TAPE 7 LG TRIM PIPE INSULATION ELBOW TO FIT INSULATION SHALL COMPLETELY COVER 1 5 32 34 amp 35 APPLY PIPE SEALANT COMPOUND TO THREADS ALTERNATE CONFIGURATION REQUIRES ALL NOTED PARTS 1 2 3 4 NOTE APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO OUTSIDE SURFACE OF FITTING I N 35 THAT PRESSES INTO VALVE COVER REVISION H 3963 PAGE 2 OF 2 DATE 2 27 09 WATER PUMP GROUP D 57 TO THERMOSTAT HOUSING EXPLODED VIEW TO CRANKSHAFT ADAPTER 24 REFER TO BEARING PRESS NOTE C2 COOLING SYTEM amp FAN DRIVE DRAWING REVISION H 9455 D DATE 8 4 11 0H3078 PAGE 1 OF 4 GROUP D ENGINE OIL OUT TO ASSY 0G9331A Lu gt ac e Do T o gt HO 455 meon C B lt A lt gt REVISION H 9455 D DATE 8 4 11 EXPLODED VIEW C2 COOLING SYTEM 8 FAN DRIVE DRAWING
44. 7178T REF 60 0J3060 1 61 0H8006 1 REVISION H 9621 F DATE 9 26 11 GROUP A DESCRIPTION BACK PANEL CONBOX SUPPORT C2 TOP PANEL CONBOX SUPPORT C2 COVER WIRE ENTRY CONBOX JUNCTION BLOCK 3 8 16 RELAY SOLENOID 12VDC PNL MNT BRACKET GIMBAL CONTROL PNL RAW ASSY CTRL PROGRAMMED WASHER FLAT NYLON 0 257 X 0 625 WASHER LOCK 6 1 4 WASHER FLAT 1 4 M6 ZINC KNOB M6 1 0 CONTROL PANEL SCREW HWHT M6 1 X 16 WA Z JS SCREW HHSP 10 X 3 8 HI LOW SCREW M6 1 0 X 20 C8 8 SHIELD HIGH LOW C2 RAW SCREW PHTT M4 0 7 X 12 ZP ASSY PROG 2010 IGN MOD 6 CYL WASHER FLAT 10 ZINC SCREW PPHM 10 32 X 2 WASHER LOCK 10 NUT HEX 10 32 STEEL CLAMP STL VNL 1 06 X 406 2 NEUTRAL BLOCK 390 200 400A WASHER LOCK 3 8 NUT HEX 3 8 16 STEEL NUT FLANGE M6 1 0 NYLOK COVER VOLTAGE SHIELD RES WW 15R 5 25W QK CONN WASHER FLAT M3 WASHER LOCK M3 NUT HEX M3 0 5 G8 CLEAR ZINC DIODE BRIDGE 35A 1000V WASHER FLAT M5 WASHER LOCK M5 NUT HEX 5 0 8 G8 CLEAR ZINC TRIM VINYL BLACK 1 8GP 3 LG DECAL CUSTOMER POWER CONNECT DECAL CUSTOMER CONTROL CONNECT DECAL CONBOX TB1 CONNECTIONS WASHER LOCK EXT 1 4 STL LUG SLDLSS 2 8 X 17 64 CU CIRCUIT BREAKER COVER DPE BREAKER NEXUS RAW DECAL NEUTRAL WASHER LOCK 8 M4 SCREW HHTT M4 0 7 X 8 ZP DECAL GROUND LUG TERM BLOCK UL 12 20AWG TERM BLOCK 4P UL 12 20AWG MX150L SLRRMNT 22 18 8P W O GA MX150L SLRRMNT 22 18 12P W OGA LUG SLDLSS 600 250 1 0X1 4 28 WASHER LOCK 1 4 M6 SS SCREW 1 4 2
45. 8 8 GASKET EXHAUST MANIFOLD SCREW 10 1 5 120 08 8 ALTERNATOR DC PULLEY PULLEY DC ALTERNATOR SPACER DC ALTERNATOR PULLEY SCREW HHC 8 1 25 X 25 G10 9 WASHER FLAT 5 16 M8 ZINC SCREW HHC 8 1 25 X 35 G8 8 SCREW SHC 14 1 5 35 G10 9 ADAPTER 2 4L CRANKSHAFT MACH POLY V BELT G2 CAM SENSOR PIN ASSY COVER CAM GEAR G2 REWORKED BRACKET ASM 2 4L COIL G2 SCREW HHC 8 1 25 65 8 8 SCREW 8 1 25 X 70 68 8 NUT HEX M10 1 25 G8 YEL CHR VR SENSOR ASSY 3 8 24 LOW SENS TIE WRAP UL 7 4 X 19 BLK Page 3 of 4 EXPLODED VIEW ENGINE COMMON PARTS 2 4L G2 TURBO 60K DRAWING 0H7323 APPLICABLE TO ITEM PART QTY 66 068853 4 67 023897 8 68 022152 8 69 034413 8 70 069350 1 71 069329 1 72 0H7435 1 73 069940 2 74 069349 1 15 069330 1 76 084750 4 77 064003 1 78 068854 1 19 0H1432B 1 80 1 0A45310244 4 REF 81 0H6689 1 82 045772 1 1 SUPPLIED WITH ENGINE GROUP D DESCRIPTION COIL 2 4L G2 IGNITION WASHER FLAT 10 ZINC WASHER LOCK 10 SCREW HHM 10 32 X 1 1 4 O RING 2 5 X 2 75 X 1 8 VITON ADAPTOR OIL FILTER 2 4L G2 HARN LOW OIL PRESS SWITCH ASSY ADAPTOR 450 JIC37 1 2 X O RING 1 X 1 25 X 1 8 VITON NUT OIL FILTER ADAPTOR 2 4L G2 PLUG SPARK SHIELD HEAT IGNITION COIL 2 4L SPARK PLUG WIRE SET 2 4L G2 IG MANIFOLD EXH 60K G2 TURBO MA FILTER 1 5L 2 4L G2 OIL NOT SHOWN HARN ENG G2 4L G2 NEXUS NOT SHOWN NUT HEX M10 1 5 G8 YEL CHR 2 APPLY MEDIUM STRENGTH BLUE THREAD LOCK
46. 8 X 3 4 G5 TAPE ELEC 1 2 FOAM 69 HANG TAG 2 WIRE START NOT SHOWN HARN CONBOX NEXUS NOT SHOWN SCREW M6 1 0 X 16 ZYC FUSE ATO TYPE 7 5AMP BROWN GASKET WIRE ENTRY COVER DECAL CAUTION ELEC SHOCK SM Page 4 of 8 EXPLODED VIEW CONBOX C2 CPL DRAWING 0H7326 GROUP A APPLICABLE TO ITEM PART QTY DESCRIPTION UL CIRCUIT BREAKER 225AF A 0G5250 1 CB 175A 2 POLE 240V 225AF B 0H7356 1 COVER CB C2 CPL C 0F4186AGSOR 1 COVER CB DISH 2P G 225AF D OF 8432A 1 INSULATOR CB 2P 225AF E 0H7311 1 STANDOFF CB BOX CONBOX F 045771 2 NUT HEX M8 1 25 G8 CLEAR ZINC G 036261 4 RIVET POP 125 X 275 SS H 002454 12 SCREW HWHT M6 1 X 16 WA Z JS J 053640 2 SCREW RHM 8 32 X 3 1 4 K 038150 2 WASHER FLAT 8 ZINC L 022264 2 WASHER LOCK 8 M4 M 022471 2 NUT HEX 8 32 STEEL N 049897 4 SCREW SHC 8 1 25 X 20 G8 022129 6 WASHER LOCK 8 5 16 R 022145 4 WASHER FLAT 5 16 M8 ZINC 5 058306 2 SCREW SHC M8 1 25 X 25 C12 9 I 08843 2 BUS BAR 200A LUG ADAPTOR U 0F8451 2 LUG SLDLSS 300 MCM 6 AL CU V 0C3259 1 DECAL TERMINAL SHOCK HZD BI UL CIRCUIT BREAKER 400AF A 0F4153 1 CB 0250 480 400AF B 0H6735 1 COVER CB 400AF C2 CONBOX C 0A7822 3 LUG SLDLSS 600 250 1 0X1 4 28 D 0H6734 1 STANDOFF CB MOUNT CONBOX E 042419 4 SCREW RHM 10 32 X 4 F 022097 6 WASHER LOCK 6 1 4 G 052647 6 SCREW SHC M10 1 5 25 C12 9 H 002454 12 SCREW HWHT M6 1 X 16 WA Z JS J 046526 6 WASHER LOCK M10 K 023897 4 WASHER FLAT 10
47. B 3P E TYPE CC FG E 0H7311 1 STANDOFF CB BOX CONBOX F 022471 4 NUT HEX 8 32 STEEL G 036261 4 RIVET POP 125 X 275 SS H 002454 12 SCREW HWHT M6 1 X 16 WA Z JS J 0H5721 4 SCREW PPHM 8 32 X 1 3 4 ZINC K 022264 4 WASHER LOCK 8 M4 L 038150 4 WASHER FLAT 8 ZINC M 052619 3 SCREW HHC M5 0 8 X 20 G8 8 N 023897 3 WASHER FLAT 10 ZINC 049226 WASHER LOCK M5 UL CIRCUIT BREAKER JG A 0H5580 1 CB 0250 3P 600V E JG LL B 0H6739 1 COVER CB E JG C2 CONBOX D 0H5576A 1 INSULATOR CB E 3P JG E 0H6734 1 STANDOFF CB MOUNT CONBOX F 022127 4 NUT HEX 1 4 20 STEEL G 022097 4 WASHER LOCK M6 1 4 H 0C2454 12 SCREW HWHT M6 1 X 16 N WA Z JS J 022770 4 SCREW RHM 1 4 20 X 3 K 022473 4 WASHER FLAT 1 4 M6 ZINC L 049897 3 SCREW SHC 8 1 25 X 20 G8 M 022145 3 WASHER FLAT 5 16 M8 ZINC N 022129 3 WASHER LOCK M8 5 16 UL CIRCUIT BREAKER CC A 0H4748 1 CB 0175A 2P 240V E CC LL 0H4915 1 CB 0150 240V E CC LL B 0H7356 1 COVER CB C2 CPL C 0H7432 1 COVER CB DISH 2P E CC 0H7433 1 COVER CB DISH 3P E CC 5 D 051716 2 3 NUT HEX 5 0 8 G8 CLEAR ZINC E 0H7311 1 STANDOFF CB BOX CONBOX 5 F 022471 2 4 NUT HEX 8 32 STEEL G 036261 4 RIVET POP 125 X 275 SS H 002454 12 SCREW HWHT M6 1 X 16 WA Z JS 5 J 053640 2 4 SCREW RHM 8 32 X 3 1 4 5 K 022264 2 4 WASHER LOCK 8 M4 5 L 038150 2 4 WASHER FLAT 8 ZINC 5 M 052619 2 3 SCREW HHC M5 0 8 X 20 G8 8 5 N 023897 4 6 WASHER FLAT 10 ZINC 5 P 049226 2 3 WASHER LOCK M5 5 QTY REQ FOR 2 POLE BREAKER QTY REQ FOR 3
48. ED NOTE USED WITH G4 6L amp S16 S16 6 8L UNITS 515 515 ONLY 51 51 52 52 53 53 DIRECT DRIVE 1910 5 MLC8 M8 O El E2 GENERATOR OUTPUT CUSTOMER CONNECTIONS AR ALTERNATOR ROTOR E1 TO E2 AS ALTERNATOR STATOR E2 TO 3 480VAC BRUSH ASSEMBLY TO E3 EF EXCITER FIELD 62 OR TO NB 277VAC MLCB MAIN LINE CIRCUIT BREAKER NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES NB NEUTRAL BLOCK OUTPUT VOLTAGE TERMINAL BLOCK 277 480VAC 60HZ OPTION 4 THREE PHASE DELTA NEXUS CONTROL PANEL 7 WIRE 120 240V 51 51 53 53 DIRECT 55 TB1 AR BA 0960 ELA 1 BLACK 226 ES a 4 RED 4 BI 2 2 2 sata BRUSHLESS UBL AGI m 5 ee 5 1 8 4 RED NOTE USED WITH 64 6L amp G6 8L UNITS S1 S1 95 95 52 52 56 56 53 53 84 84 o9 DIRECT DRIVE 6 4 MLC8 M8 El E2 GENERATOR OUTPUT CUSTOMER CONNECTIONS TO E2 E2 TO ES 240VAC El OR TO NB 120VAC NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE 120 240VAC 60HZ PAGE 2 OF 4 I E S a EE CLE AD Evi QM n E O 41 WIRING DIAGRAM REVISION 7699 NEXUS CPL ALTERNATOR DATE 10 21 10
49. F 022473 4 WASHER FLAT 1 4 M6 ZINC G 022097 4 WASHER LOCK M6 1 4 H 002454 12 SCREW HWHT 1 16 WA Z JS J 022127 4 NUT HEX 1 4 20 STEEL REVISION H 9621 F Page 7 of 8 DATE 9 26 11 EXPLODED VIEW CONBOX C2 CPL DRAWING 0H7326 GROUP A APPLICABLE TO THIS PAGE LEFT INTENTIONALLY BLANK REVISION H 9621 F Page 8 of 8 DATE 9 26 11 8 8 90 ONIM VNA TAO I d5Vd 80 11 ALVA II 3SV8 ONILNNOW NOISIATY MHIA QHGO IdXH ANION x OL 2 EXPLODED VIEW MOUNTING BASE 2 4L G2 DRAWING 067578 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 REVISION A DATE 7 11 08 0G37260ST03 052860 052251 052257 052252 052259 052891 0536210410 042909 047411 055414 022447 022097 022473 049813 022261 0F9597A 045764 062963 022302 022131 065852 0F9597 022129 026204 022145 045771 0F9596A 052212 WELDMENT FRAME 2 4L C2 60KW NUT FLANGED HEX M12 1 75 DAMPENER VIBRATION 40 BLUE SPACER 49 X 62 X 1 87 PWDR ZNC DAMPENER VIBRATION WASHER FLAT M12 SCREW HHC M12 1 75 X 80 G8 8 ASSY WIRE 14 00 SCREW HHC 8 1 25 X 30 68 8 SCREW HHC 6 1 0 X 16 G8 8 LUG SLDLSS 2 8 X 17 64 CU WASHER SHAKEPROOF INT 1 4 WASHER LOCK 6 1 4 WASHER FLAT 6 1 4 ZINC NUT HEX M6 1 0 G8 YEL CHR WASHER SHAKEPROOF INT 3 8 SUPPORT LH ENGINE 2 4L SCREW M4 0 7 X 8 BP
50. GO Id XH 5 EN x ve 225 gt DF S gt l Ps r V dnodd OI IZ S JA78 v97H NOISIAS3I EXPLODED VIEW CPL ALTERNATOR DIRECT EXCITATION DRAWING 0F9803 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F9677 1 ROTOR 2390 45KD1 CPL 0G0056 1 ROTOR 2390 35KD1 CPL 0G0959 1 ROTOR 2390 45KD1 CPL G2 061155 1 ROTOR 2390 35KD1 CPL G2 061931 1 ROTOR 25KW 3PH DIRECT 390 1800 0G2101 1 ROTOR 25KW 1 DIRECT 390 1800 0G3734 1 RTR 2390 60KD2 CPL 0G6562 1 RTR 390 35AD1 CPL 0G6564 1 RTR 390 35KD1 CPL 2 0F9664 1 STATOR 390 45K 2P 1PH DIRECT 0G0057 1 STATOR 2390 35AD1 CPL 0G0058 1 STATOR 2390 35KD1 CPL 0G0059 1 STATOR 2390 35GD1 CPL 0G0183 1 STATOR 2309 45KW 2P 3PH 208V 0G0184 1 STATOR 2309 45 KD1 CPL 061932 1 ASSY STR 390 25603 CPL 0G2098 1 ASSY STR 390 25AD1 CPL 0G2099 1 ASSY STR 390 25KD3 CPL 0G2100 1 ASSY STR 390 25JD3 CPL 063736 1 55 STR 2390 60AD2 CPL 0G3737 1 ASSY STR 390 60KW 2P 3PH 208V 063738 1 ASSY STR 390 60KW 2 3PH 480V 0G6104 1 STR 2390 45JD1 CPL 0G6563 1 STR 390 35AD1 CPL 0G6565 1 STR 390 35GD1 CPL 0G6566 1 STR 390 35KD1 CPL 0G6567 1 STR 390 35JD1 CPL 0H0201 1 STR 2390 60JD2 CPL 0H1299 1 ASSY STR 390 36AD1 CPL 0H1300 1 ASSY STR 390 36JD1 CPL 0H1301 1 ASSY STR 390 36 GD1 CPL 3 0C9708 REF INSTR HYPOT TEST NOT SHOWN 4 SEE ENGINE EV REF ENGINE ADAPTER 5 SEE ENGINE EV REF FLEXPLATE 6 0F5767B 1 ASSY FLYWHEEL CPL W 40MM FAN B 7 0E5706 1 REAR BEARING CARR
51. IER 390 DRCT 8 0F7874 1 ASSY BRUSH HOLDER 390 HSB 0F7874A 1 ASSY BRUSH HOLDER 390 HSB 9 0G0587 1 GUARD REAR BEARING CARRIER 10 038150 4 WASHER FLAT 8 ZINC 11 023454 1 KEY WOODRUFF 6 12 077043E 1 CONDUIT FLEX 1 0 ID 35 LG 13 04576100BU 4 STUD M14 2 0 570 G5 ZINC 14 052646 4 WASHER FLAT M14 15 043123 4 WASHER LOCK M14 16 051779 4 NUT HEX M14 2 0 G8 YEL CHR 17 0A2601 1 SCREW M16 2 0 X 45 G8 8 18 072879 1 SPACER 69 X 2 75 X 37 STIZNC 19 0 8408 4 SCREW 10 1 50 16 G10 9 20 046526 4 WASHER LOCK M10 21 003992 4 SCREW HHTT M4 0 7 X 16 BP 22 022264 4 WASHER LOCK 8 M4 23 047248 1 BALL BEARING 45 MM 24 070892 1 SLIP RING MACHINED 25 0G0588 1 GUARD REAR BEARING CARRIER 26 077043A 1 CONDUIT FLEX 38 ID 60 27 056326 1 TRIM VINYL BLACK 1 8GP 16 5 LG REVISION H 6438 M DATE 5 21 10 ROTOR REPLACEMENT PARTS GROUP A PAGE 2 OF 2 840 LVI92 6 934 9Z ZHO J L296 H 142 M0I1 3MM0 199 vr w Pos 85 A ot gt 0179 7 AL rv gt ve 9L SSINYVH ANISNA V 97 4H0 9 Jo LLI97I6 91 160 140 NOILOANNOD 4 1296 UOISIA9Y M0I1 93MM0 9N1 3015 3NI13103 85 LAN 910M
52. ING FLUID TO THE THREADS REVISION H 7244 D DATE 8 10 10 Page 4 of 4 L8SZHO ONIM V IV C JO 09 17 W31SAS 1905 6 6 ALVA 0196 NOISIATA MHIA QHGO IdXH veLe8do 7757 255 19V I955V m 6 SS3NHVH 3NION3 L NI NMOHS NI SNLLNIOd MOHHV LSNW GIONTIOS INVLYOdWI OL dildvav OL 1 dfYOSID EXPLODED VIEW FUEL SYSTEM NG 2 4L 60KW DRAWING 0H7581 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 057147 2 065908 3 039130 4 030131 5 088963 6 026915 7 0A8064 8 064346 9 0G9239C 10 046580 11 043107 12 022131 13 022129 14 045771 15 050279 16 0D1509 17 057147 18 0H7438 19 057823 20 0E4394 21 0E6586 22 086133C 23 0F3857 24 086133E 25 0F3885 26 0G3167 27 0F3691 28 022097 REVISION H 9610 B DATE 9 9 11 Pana gt nen Penna ANA BAND a HOSE 3 4 ID LPG amp NG 43 LG FLANGE FUEL INLET NIPPLE CLOSE 1 25 NPT X 1 625 ELBOW 90D 1 1 4 NPT NIPPLE PIPE 1 25 NPT X 5 5 BL IRN NIPPLE CLOSE 3 4 X 1 375 BSHG RDCR HEX 1 1 4 3 4 PIPE TEE 1 1 4 NPT REG ASSY 2 4L 60KW NG CPL SCREW SHC M6 1 0 X 45 12 9 SCREW HHC M8 1 25 X 25 C8 8 WASHER FLAT 3 8 M10 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 CLEAR ZINC DECAL FUEL INLET NG DECAL INLET PRESSURE HOSE 3 4 ID LPG amp NG 43
53. J o ice 12 12 w Ux 14 ORANGE LVP 2 c 49 BLUE LVP 3 12 TRANSFER RELAY 194 9 1 194 ae 9 23 LVP i TRANSFER RELAY COIL 23 y 52 2 4 T 49 8 d 183 LVP O O 183 REMOTE 6 14 START 178 LVP I I 178 4 MC 4 i V V 29 1 4 NOTE WHITE BLACK YELLOW I FOR FIELD WIRING TO CUSTOMER CONNECTIONS TERMINAL BLOCKS MAXIMUM WIRE SIZE 12 AWG 81 I V 181 X I 11 11 I SA 5 4 44 44 9 9 58 HvP 6 YELLOW 6 16 LE 2 1 BLACK 1 3 al DPA 16 I 4 RED 4 4 11 2 La 9 dul 2 16 9 10 aS gt 4 HVP M I 44 6 6 6 10 6 16 22 C AS 1 12 5 O LVP 1 M1 2 1 1 0 1 3 2 M2 2 2 2 amp DBI MLC8 M8 GND 1 PHASE 182 3 3 K 49 DBI ALTERNATOR STATOR 4 K NEU TB2 4X 4 QOO SHOWN FOR 5 K SA 1 1 5 178 TB3 4X s S PHASE SEE 6 K SB 1 2 6 183 TB3 3X IC 1 2 I DRAWING 0H6342 7 7 23 TB3 2X 1 8 8 K 194 183 1X 9 2 181 5 Bo N GND 10 6 TB1 6X CUSTOMER CONNECTIONS 11 6 4 11
54. LE LOW VOLTAGE PLUG 8 BULKHEAD CAR COMMON ALARM RELAY LVR LOW VOLTAGE RECEPTACLE 8 CIRCUIT BREAKER MLCB MAIN LINE CIRCUIT BREAKER SPLICE CYL_ CYLINDER IGNITION COIL MOV METAL OXIDE VARISTOR NUMBER DB DIODE BRIDGE MAGNETIC PICKUP EMISSIONS CONNECTOR NB NEUTRAL BLOCK F1 FUSE INLINE 25A 05 OXYGEN SENDER WIRE FS_ FUEL SOLENOID R1 RESISTOR SPLICE FSP FUEL SOLENOID PLUG SC STARTER CONTACTOR FSR FUEL SOLENOID RECEPTACLE SM STARTER MOTOR I GND GROUND CONNECTION TERMINAL BLOCK CAGE CLAMP GOV ELECTRONIC GOVERNOR ACTUATOR WLS COOLANT LEVEL SENDER 9 fus HIGH VOLTAGE PLUG 12 BULKHEAD WTS COOLANT TEMPERATURE SENDER COMPONENTS LOCATED IN CUSTOMER CONNECTION BOX 60HZ UNITS 50HZ M VOLTAGE 220VAC TB2 x v TB2 x 9 CI lado I E HVP 1 UTILITY FROM 6 UTILITY FROM 9 6 TRANSFER SWITCH TRANSFER SWITCH 2 240 M2 2 D 5 M2 2 6 FUSED 220VAC 6 y 11 11 3 SOURCE FOR 9 16 n 3 bc II 6 T E BATTERY CHARGER MI Dime 6 T E q 22 NEU 4 PRE CONNECTED 9 NEU 4 5 BATTERY CHARGER NEU 4 4 dal MEG TTE WITH JUMPERS N2 lata 4 le NEUI E AS SHOWN 8 13 13
55. NC WASHER LOCK M6 1 4 SCREW HHC M6 1 0 X 35 G8 8 BLK BOLT U 3 8 16 X 2 62 NUT HEX 3 8 16 STEEL BOLT U 5 16 18 X 2 25 WASHER LOCK M8 55 NUT HEX 5 16 18 STEEL SCREW HHC M8 1 25 X 20 SS WASHER LOCK 3 8 BOLT U 3 8 16 X 2 30 W SADDLE EXHAUST BLANKET 600MM LONG EXHAUST BLANKET 737MM PAGE OF GROUP D Exploded View ENGCOMPRT 2 4L G2 TURBO Drawing No 0H7323 Page 1 of 4 Revision H 7244 D Date 8 10 10 GROUP D INDICATION 28 REMOVE amp REPLACE 1 ram N N 32 Exploded View ENGCONPRT 2 4L G2 TURBO Drawing No 0H7323 Page 2 of 4 Revision H 7244 D Date 8 10 10 EXPLODED VIEW ENGINE COMMON PARTS 2 4L G2 TURBO 60K DRAWING 0H7323 APPLICABLE TO ITEM PART QTY 1 0H1619 1 2 035472 1 064738 1 4 060950 1 REF 5 068488 1 6 022129 30 7 058306 7 8 060502 1 9 026073A 3 10 045771 3 4 057772 1 12 069860E 1 43 0C7649 1 14 043790A 1 15 057765 1 16 049821 17 002244 1 18 067461 1 19 069583 1 20 069420 1 21 OF9965E 1 22 063076 7 23 061394 7 24 052830 2 25 025507 5 26 062963 3 27 077043H 2 28 063995 1 29 090388 7 30 003704 1 31 0F0710 2 32 0H6859H 1 33 068427 1 34 052213 35 046526 6 36 022131 5 37 063823 2 38 067902 1 39 0H2574 1 40 047414 1 41 022097 1 42 022473 1 43 06399105 03 1 4 064000 1 45 06399705 03 1 46 042907 4 471 060951 4 REF 48 0E4507 1 4902 0 9868 1 50 060788 1 51 063247 1 52 0A8258 9 53
56. NCE ALERT CHART CONDITION 1 6 CHERY 2 4 1800 MITSU 2 4 3600 MITSU 4 2 FORD Change oil amp filter alert 3mo 30hrs break in 3mo 30hrs break in 3mo 30hrs break in 3mo 30hrs break in 1yr 100hrs 1yr 100hrs 1yr 100hrs 1yr 100hrs Inspect clean air inlet amp 3mo 30hrs break in 3mo 30hrs break in 3mo 30hrs break in 3mo 30hrs break in exhaust alert 6mo 50hrs 6mo 50hrs 6mo 50hrs 6mo 50hrs Change Inspect air filter 1yr 100hr 1yr 100hr 1yr 100hr 1yr 100hr alert Inspect spark plugs alert 100hrs 100hrs 1yr 100hrs 100hrs 100hrs Change Inspect spark 250hr 250hr 250hr 2VI 250hr plugs alert Inspect Accessory drive 3mo 30hrs break in 3mo 30hrs break in 3mo 30hrs break in 3mo 30hrs break in alert 100hrs 100hrs 100hrs 100hrs Coolant change amp flush 100hrs 100hrs 100hrs 100hrs Inspect battery alert 100hrs 100hrs 100hrs 100hrs 8 7 Control Panel 39NVN3INIVIN 1353 3395 31 11 35I 99X3 183110 5 14510 510410 109195 0 eui esn uO1vu3N39 y ajebineu au dn yoeq duinf 253
57. O3NNDO 899 IWAINLVN 33S 530914 MITA 9 113411 1 8 6 661 ATT MT 4 4015 AJIA 3415 1331 L21 JL n 0001 L9 193 137N1 3IV 2 dAL 000 3IUN 335 ui s N3ADO IND23 9 335 8 1 Gy NIHLIA 3SD12N3 C SpTI 8314404 15 03507033 1 2 1 068 SI N39NVHO AN3ILVE J3NYd 0 1 00 019 3 39 30 3415 N3d YODA 4000 L 9I CI vv 6ETT Lv 9 1 0661 440 1417 A000 33d 2191 NDILOV ASIA ONILNNON 401943 349 WIA JD WOLLO NO 4319007 530914 0 ONIINNON 910 26 20 Lv 41 SdWV ONDINVSD 1109 Ses 392 LIA 4831148 59 11811 IN3W3OV 1834 303 WANVW SY NMO 39N333333 1331 A8311v8 ee 9 aon xs 1738 Ly mon ass 931140 50014 AWS 338 1431 11 313 SI3NV3 IO 1431 50 TIO 1431 331713 110 Lv l 9V ALIAVAD YOO 1HDIA 115 dd dwg 1114 110 LY dAl Wie WILI 33IA33S 001 8 4 891 13982 111181553229 WILI 321 435 0541 53 DNILNNDN gt D
58. OW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact a Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting a dealer about parts and service always supply the complete Model Number Serial Number and Type Code where applicable from the DATA LABEL that is affixed to the unit 0L 90 V00 19165 Safety Instructions SAFETY RULES Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely effi ciently and reliably 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 warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If a procedure work method or operating technique is used that the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique utilized does not render the generator unsafe A DANGER Despite the safe design of this generator operating this equipment imprudently neglect ing its maintenance or being careless can cause possible injury or death Perm
59. 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 breaker Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the generator s main line circuit breaker to its OFF or OPEN position Start the generator 9 1 A CAUTION Do not crank the engine continuously for lon ger than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge readings When certain that all readings are correct move the transfer switch manual handle to the STANDBY or EMERGENCY STANDBY position i e load circuits supplied by the generator Set the generator s main line circuit breaker to its ON or CLOSED position Load circuits are now powered by the generator RETRANSFER AND SHUTDOWN For additional information refer to the applicable control panel manual for this unit as well as any literature pertaining to the specific transfer switch To transfer the load back to the utility power source and shut down the generator follow these directions
60. Owner s Manual Stationary Emergency Generator A CAUTION 2 4L NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS 60kW Models ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST ifi FUMES OUTDOOR INSTALLATION ONLY EPA Certified This manual should remain with the unit ON Utd 0L V0 V ed 9649400 Table of Contents SECTION PAGE INTRODUCTION u 1 1 Read this Manual Thoroughly a 1 1 Operation and Maintenance 1 1 How to Obtain Service 1 1 SAFETY RULES eccesso te GENERAL Identification Record Data Label EQUIPMENT DESCRIPTION Equipment Engine Oil Recommendations Coolant Recommendations ENGINE PROTECTIVE DEVICES Engine Protective Devices sss High Coolant Temperature Sender Low Coolant Level 0 Low Oil Pressure Switch Overcrank Shu
61. PAGE 2 OF 4 DRAWING 0H6342 GROUP G Ya eee 9 ae 71 OPTION 5 THREE PHASE NEXUS CONTROL PANEL GEARBOX REVERSE ROTATION SA SA SB SB TB DIRECT o TB1 lt AR BA se 1 BLACK 1 1 4 RED 4 4 2 2 4 4 9 BRUSHLESS 1 BLACK 6 0 0 6 4 RED NOTE USED WITH G6 8L S3 S3 UNITS ONLY S9 S9 S8 S8 S2 S2 S1 S1 57 57 54 55 GEARBOX 55 5 Id 56 DRIVE S10 AS MLCB NB 51 512 1 0 0 E1 E2 L J LE END GENERATOR OUTPUT CUSTOMER CONNECTIONS AR ALTERNATOR ROTOR E1 TO E2 AS ALTERNATOR STATOR E2 TO 25 208VAC BRUSH ASSEMBLY EF EXCITER FIELD E1 E2 OR E3 TO NB 120VAC MLCB MAIN LINE CIRCUIT BREAKER NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES NB NEUTRAL BLOCK OUTPUT VOLTAGE TERMINAL BLOCK 0 120 208 60HZ OPTION 6 THREE PHASE NEXUS CONTROL PANEL GEARBOX REVERSE ROTATION
62. POLE BREAKER REVISION H 9621 F Page 6 of 8 DATE 9 26 11 EXPLODED VIEW CONBOX C2 CPL DRAWING 0H7326 GROUP A APPLICABLE TO ITEM PART QTY DESCRIPTION UL CIRCUIT BREAKER QN A 0E7284 1 CB 0175A 2P 240V S QN2 LL B 0H7356 1 COVER CB C2 CPL C 0H7429 1 COVER CB DISH 2 5 D 0E3664 1 BASE QN CIRCUIT BREAKER E 0H7311 1 STANDOFF CB BOX CONBOX F 074908 2 SCREW M5 0 8 X 10 BP G 036261 4 RIVET POP 125 X 275 SS H 002454 12 SCREW HWHT M6 1 X 16 N WA Z JS UL CIRCUIT BREAKER ED A 009693 1 0125 480V S ED4 LL 0H6736 1 COVER CB S ED C2 CONBOX C 022158 4 NUT HEX 10 32 STEEL D 0F0492 1 INSULATOR CB S ED 3P E 0H6734 1 STANDOFF CB MOUNT CONBOX F 022152 4 WASHER LOCK 10 G 023897 4 WASHER FLAT 10 ZINC H 0C2454 12 SCREW HWHT M6 1 X 16 WA Z JS J 048927 4 SCREW RHM 10 32 X 4 1 2 UL CIRCUIT BREAKER VL A 0H7519 1 CB 0300A 3P 600V S JG VL LL B 0H6738 1 COVER CB S JG VL C2 CONBOX C 040976 3 SCREW SHC 8 1 25 20 12 9 022129 3 WASHER LOCK M8 5 16 E 0H6734 1 STANDOFF CB MOUNT CONBOX F 022145 3 WASHER FLAT 5 16 M8 ZINC G 023897 4 WASHER FLAT 10 ZINC H 002454 12 SCREW HWHT M6 1 X 16 WA Z JS J 042419 4 SCREW RHM 10 32 X 4 K 022152 4 WASHER LOCK 10 L 022158 4 NUT HEX 10 32 STEEL UL CIRCUIT BREAKER FD A 0D5572 1 CB 0150A 3P 600V S FD6 LL B 0H6737 1 COVER CB S FD6 C2 CONBOX C 081320 4 SCREW SHC 1 4 20 X 4 5 G8 8 NZ D 0 0199 1 INSULATOR FD FRAME 30MIL E 0H6734 1 STANDOFF CB MOUNT CONBOX
63. R PLATE PLASTIC GREY 1 ALUMINUM ENCLOSURE NOTE ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 2 amp 5 THREAD FORMING FASTENER AND 10 LOCK NUT LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER 2 SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS NO COLOR MANUFACTURING FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM CUSTOMER FOR CORRECT MATERIAL AND COLOR OF REPLACEMENT PARTS REFER TO REPLACEMENT SHEET METAL PARTS ORDERING GUIDE 0H7169 INCLUDED IN THE MANUAL OR AVAILABLE ON THE GENERAC WEBSITE REVISION H 7711 E DATE 10 27 10 GROUP F PAGE 2 OF 2 0I IC 6 ALVA ONIM VANGA T JO _ MA 09 172 NL 1609 NOISIAHA teest3 669 1861 599 13315 5811 9X 5811 9 S81 DA 135 39 NV 01X 5 319 r3sN395 1V1931VMI TIAS 1HOI3 SNIddIHS M3000M2 1HOIJM _ 1441 5 1HDI3A 9190 1H513 1 3352 ONILNNOW 3133 M3IA I3N3WND3932 51 109 AANDSYW VIC 21 533914 ONILNANON VIC CG2E ZD SET 53415 IMI9 1 59 1 M0V 194 9 2510 1 1 509 3 1134 ANY 43733 LSNVHXS 5539009 OL d3NVd 3015 GNVH
64. SCREW HHC M10 1 25 X 30 G8 8 WASHER LOCK 7 16 WASHER FLAT 3 8 M10 ZINC SPRING CLIP HOLDER 37 62 SUPPORT RH ENGINE 2 4L WASHER LOCK M8 5 16 WASHER SHAKEPROOF INT 5 16 WASHER FLAT 5 16 M8 ZINC NUT HEX 8 1 25 G8 CLEAR ZINC SPACER LH ENGINE MOUNT SCREW M10 1 25 X 25 C8 8 GROUP C PAGE 2 OF 2 089290 ONIM VAA 1 4 aoe awe MY09 AMALLVE V MATA GION310S YALYVLS OL 01 lt 3NION3 En n EXPLODED VIEW BATTERY 60KW C2 DRAWING 067580 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F3408C 1 BATTERY TRAY C1 amp C2 2 0F3411 1 STRAP BATTERY RETAINMENT 3 025507 REF WASHER SHAKEPROOF EXT 7 16 STL 4 052212 REF SCREW HHC M10 1 25 X 25 G8 8 5 046526 REF WASHER LOCK M10 6 022131 REF WASHER FLAT 3 8 M10 ZINC 7 050331A REF BATTERY POST COVER RED 8 050331 REF BATTERY POST COVER BLACK 9 038805Y 1 CABLE BATTERY BLACK 1 X 18 00 10 03880400AE 1 CABLE BATT RED 1 X 18 00 11 045771 REF NUT HEX 8 1 25 G8 YEL CHR 12 022129 REF WASHER LOCK M8 5 16 13 077483 REF BATTERY 12VDC 75 AH 26 14 0F3976 1 BOOT CONTACTOR CABLES 15 042568 4 SCREW HHC M6 1 0 X 20 C8 8 16 022145 REF WASHER FLAT 5 16 M8 ZINC 17 0D3700 4 NUT FLANGE M6 1 0 NYLOK 18 049811 4 WASHER FLAT M6 REVISION A DATE 8 1 08 GROUP C PAGE 2 OF 2 V96LLI0 VIM610 210 60 9 8 966 Ogni 29 172 pep
65. Setthe generator s main line circuit breaker 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 utility 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 Stationary Emergency Generator has been installed with an automatic transfer switch the engine may be started and stopped automatically or manually NOTE Refer to the applicable manual for your transfer switch and to Transfer Switch Start Signal Connections In addition please note the dangers under Engine Start up and Transfer 0L 90 ed 1002990 Maintenance GENERAL MAINTENANCE A WARNING Before working on the Stationary Emergency Generator ensure the following The AUTO OFF MANUAL switch is the OFF position The control panel fuse has been removed from the control box The 120VAC supply to the battery charger is switched OFF The negative battery cable has been removed CHECK ENGINE OIL Check engine crankcase oil level Figure 10 1 according to the Service Schedule and SIB10 10 L24G Remove oil dipstick and wipe dry with a clean lint free cloth e Install oil dipstick then remove again
66. TH FRM M6 W CAP SHKPRF W 2 6 0F58520ALOR 2 DUCT DSCHRG LH amp RH 2 7 0F98330ALOR 2 FRONT CORNERS C2 2 8 0F58510ALOR 1 DUCT DISCHARGE C2 9 049813 2 NUT HEX M6 X 1 0 G8 YEL CHR 1 10 077992 21 NUT HEX LOCK M6 1 0 SS NY INS 2 11 0F98350ALOR 1 ROOF C2 12 0F2786 2 SLITTER C4 13 0F2785 1 SPLITTER LOWER C4 14 0F3364 1 SPLITTER STINGER C2 15 0F4880 2 SUPPORT SPLITTER LH C2 16 0F5049 2 TAB PULL 17 0F4487A 1 ASSEMBLY COVER ACCESS 18 022473 3 WASHER FLAT 1 4 M6 ZINC 19 022097 1 WASHER LOCK M6 1 4 20 022127 1 NUT HEX 1 4 20 STEEL 21 0F3072 10 INSULATION RETAINMENT HANGER 22 078115 26 WASHER SELF LOCKING DOME 4 40 23 0G5892 2 INSULATION DOOR C2 24 0G5892A 1 INSULATION ROOF TOP 25 0F5048D 2 VISE ACTION LATCH SLOTTED CIR 26 065968 1 GASKET EXTRUDED TRIM 328 LC 27 0G5892D 2 INSULATION SPLITTER 28 0G5892C 2 INSULATION SPLITTER 29 0F4051C 2 INSULATION DUCT 30 0F3890B 4 RETAINER INSULATION 820 31 0F4051B 2 INSULATION DUCT SIDES 32 0F3890 4 RETAINER INSULATION 450 33 078115A 6 WASHER SELF LOCKING DOME 8 32 34 0G5892E 1 INSULATION LOWER SPLITTER 35 042568 2 SCREW 6 1 0 20 G8 8 36 0912970094 2 ASSY WIRE 14 AWG 34 8 GRN YEL 37 022447 2 WASHER SHAKEPROOF INT 1 4 38 069473 1 DEFLECTOR INTAKE 2 4L G2 TURBO 39 0F8869D 1 KEY VISE ACTION LATCH SLOT CIR 40 052250 1 TAPE FOAM 1X1 17 25 LG 41 066760 1 STRIP SEALANT 1 8 X 1 44 52 LG 42 0E5298L 1 FOAM 300 X 300 THERMAL ACO 43 0H1208A 1 RF COVER PLATE PLASTIC BISQUE 0H1208B 1 RF COVE
67. arm will be displayed 8 5 d MISSING CAM PULSE ALARM This is a shutdown alarm The alarm will activate after five 5 seconds of continuously missing cam pulses MISSING CRANK PULSE ALARM This is a shutdown alarm The alarm will activate after 12 con secutive revs where crank pulses are missing LOW FUEL PRESSURE WARNING Fuel pressure is monitored by a digital sensor with a fixed setpoint of below five 5 inches water column GOVERNOR SENSOR FAULT ALARM The governor position is monitored by an analog feedback signal If the throttle position is seen outside of the normal operating range a shutdown alarm is displayed If the throttle is commanded to move and no movement is seen a shutdown alarm is displayed WIRING ERROR ALARM When power is first apllied to the contoller the software will per form a check on the wiring of the transfer output and ensure it does not have high voltage on the wire If this is the case it will signal a miswire alarm and will not run The test can be skipped by use of the escape key UNDERVOLTAGE ALARM If the generator voltage falls below 60 for gt 5 seconds an alarm will be issued Control Panel OVERVOLTAGE ALARM I the generator voltage rises above 110 for gt 3 seconds an alarm will be issued If the generator voltage rises above 130 for gt 0 2 seconds an alarm will be issued INTERNAL FAILURE SHUTDOWN ALARM Any
68. arning Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass NOTE DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT WIRES IS NOT WARRANTABLE This test will be performed each time the controller is powered up Upon first power up of the generator the display interface will begin an installation assistant The assistant will prompt the user to set the minimum settings to operate These settings are simply Current Date Time and Exercise Day Time The maintenance vals will be initialized when the exercise time is entered The exercise settings can be changed at any time via the EDIT menu see Appendix Menu System If the 12 volt battery is disconnected or the fuse removed the Installation Assistant will operate upon power restoration The only difference is the display will only prompt the customer for the current Time and Date IF THE INSTALLER TESTS THE GENERATOR PRIOR TO INSTALLATION PRESS THE ENTER KEY TO AVOID SETTING UP THE EXERCISE TIME THIS WILL ENSURE THAT WHEN THE CUSTOMER POWERS UP THE UNIT HE WILL STILL BE PROMPTED TO ENTER AN EXERCISE TIME SETTING THE EXERCISE TIMER This generator is equipped with an exercise timer Once it is set the generator will start and exercise every seven days on the day of the week and at the time of day specified During this exercise period the unit runs for approxim
69. ately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle unless utility power is lost LOW SPEED EXERCISE The standard start sequence will be initiated All 1800 rpm units will exercise at 1400 RPM All 3600 rpm units will exercise at 1800 RPM If utility is lost during exercise the controller will do the following Wait for the line interrupt period for utility to return If utility returns within the line interrupt period continue to exercise at low RPM 8 3 If utility is still lost after the line interrupt period run the engine up to normal RPM and transfer the load At this time the con troller will exit the exercise routine and assume full automatic operation USER ADJUSTABLE SETTINGS Factory Maximum Default Setting Exercise 23 59 Current 23 59 ay Current Jan Jan Dec 1 month Month ear English 100 FUEL CONVERSION For fuel conversion steps refer to the GenSpec section RECONFIGURING THE FUEL SYSTEM OPERATION This system is intended to supply standby power in the event of a utility failure The control system will monitor the utility voltage to determine if stand by power is required Should the utility voltage fail the generator will start and run normally detaching from the utility and supplying the customer load from the generator When utility power returns the controller will re transfer the c
70. attaching the cover Figure 10 3 See the Service Schedule for air filter maintenance Maintenance Figure 10 3 Engine Air Filter SPARK PLUGS Reset the spark plug gap or replace the spark plugs as neces sary 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Service Schedule section for recommended inspection 3 Check the spark plug gap using a wire feeler gauge See the Specifications section for the required spark plug gap BATTERY MAINTENANCE The battery 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 corro sion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type battery hydrometer A DANGER Storage batteries give off explosive hydrogen sAgas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an e
71. 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 dan gerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS All stationary emergency generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dan gerous voltages to the transfer switch as well as the 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 generator 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 stand ing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT Safety Instructions If personnel must stand on metal or concrete while installing Operating servicing adjusting or repairing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC requires the frame and external electrically con
72. ductive parts of the generator to be con nected 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 or by static electricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maximum electrical current ampac ity 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 normally 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 operating 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 Stationary emergency 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 personnel disable the generator s automatic start cir cuit battery cables
73. e should be between FULL and ADD marks f 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 Cap Oil e Dipstick Oil Filter CHANGING ENGINE OIL CAUTION Hot oil may cause burns Allow engine to cool before draining oil Avoid prolonged or repeat ed skin exposure with used oil Thoroughly wash exposed areas with soap 10 1 Refer to the Service Schedule for engine oil and filter change fre quencies Drain the oil while the engine is still warm from running This means warm up the engine shut it down and drain immediately as follows 1 Remove the drain hose from its retaining clip or cut the zip tie securing the oil drain hose 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil com pletely into suitable container When all oil has drained install and tighten OIL DRAIN HOSE CAP and secure drain hose with a new zip tie or place the hose in its retaining clip 4 Turn OIL FILTER Figure 10 1 counterclockwise and remove Properly dispose of old filter 5 Apply light coating of new engine oil to seal of new oil fil ter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remo
74. e missing or corroded nuts bolts and other fasteners Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every year Check all exhaust system pipes mufflers clamps etc for condition tight ness leaks security damage 01 00 V ed CHECK FAN BELT nspect fan belts every year Replace any damaged deterio rated worn or otherwise defective belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 of an inch Adjust belt tension as required Check fan belt alignment see Figure 10 2 Figure 10 2 Fan Belt INSPECT ENGINE GOVERNOR Visually inspect electronic governor A DANGER 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 incorrect frequency and or voltage Only quali fied service technicians should adjust the gov erned speed CHANGING THE ENGINE AIR FILTER To replace the engine air filter remove the air filter cover and replace the air filter making sure it is positioned properly before re
75. e power leads from the alterna tor 120 volt battery charger input and control connections to the transfer switch are available in the main connection box The Stationary Emergency Generator incorporates the following alternator features e Rotor and Stator insulation class is rated as defined by NEMA MG1 32 6 NEMA MG1 1 66 The generator is self ventilated and drip proof constructed Refer to the Specifications section or the data label for the class ratings The voltage waveform deviation total harmonic content of the AC waveform and telephone influence factor have been evalu ated and are acceptable according to NEMA MG1 32 ENGINE OIL RECOMMENDATIONS The unit has been filled with 5W 20 engine oil at the factory Use a high quality detergent oil classified For Service SJ or SH Detergent oils keep the engine cleaner and reduce carbon deposits When changing the engine oil be sure to use 5W 30 engine oil CAUTION 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 If not already equipped it is strongly recommended to use the optional Cold Weather Start Kit for temperatures below 32 The part number for the Cold Weather Start Kit can be found in the Specifications section or by contacting an authorized dealer The oil grade for temperatures below 32 F is 5W 30 synthetic oil 3 1 COOLANT RECOMMENDATIONS Use a mixtu
76. eme tete eee BED UR Automatic Transfer Operation Sequence of Automatic Operation Crank Cycles and Overcrank Shutdown Auto Start Manual Start Alarm and Warning 5 5 8 4 Low Oil Pressure Shutdown 8 4 High Coolant Temperature Shutdown Alarm 8 4 Overcrank Shutdown Alarm Overspeed Shutdown Alarm RPM Sensor Failure Shutdown Alarm Under frequency Shutdown Low Battery Alarm Low Battery Warning Low Coolant Level Alarm Missing Cam Pulse Alarm Missing Crank Pulse Alarm Low Fuel Pressure Warning Governor Sensor Fault Alarm Wiring Error Alarm Undervoltage Alarm Overvoltage Alarm Internal Failure Shutdown Alarm Canbus lgnitiori Alarm es Maintenance Warning Alarm Common Alarm Relay Maintenance Alerts
77. enerator FOUR LEAD SINGLE PHASE STATOR Four lead alternators see Figure 7 1 are designed to supply elec trical loads with voltage code A 240V 1 phase 60 Hz Electrical power is produced in the stator power windings These windings were connected the factory to the main circuit breaker as shown in Figure 7 1 The rated voltage between each circuit breaker terminal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator 74 I 120 I 10115 1 33 VOLTS 120 V0II 11 LS gt H T Y 1 CIRCUIT BREAKER ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS CONFIGURATION The Stationary Emergency Generator is designed to supply 3 phase electrical 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 through 7 6 The rated voltage between circuit breaker terminals E1 E2 E1 E3 and E2 E3 is 480V 208V or 600V depending on the model The rated voltage between each circuit breaker terminal and the neutral point 00 is 277V 120V or 346V depending on the model Figure 7 2 Stator Power Winding Connections 3 phase 277 480V 6 Lead E1 INTERNAL CONNECTIONS 54 S6 4 00 NEUTRAL 82 2
78. 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 immediately shut down the source of electrical power If this is not pos sible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury 1 3 FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and
79. ge can be accessed at any time with several presses of the dedicated Escape key Each press of the Escape key takes you back to the previous menu until the main menu is reached This page displays the following options HISTORY STATUS EDIT AND DEBUG See the Appendix Menu System LL V0 0 Control Panel ACTIVATION CHART CHOOSE LANGUAGE Display Reads Language English YE ALI Display Reads Activate me ENT or ESC to run in manual TA TY Yes Display Reads To Activate go to www activategen com A WA Use ARROW keys to scroll to desired lan guage Press ENTER to select Press ENTER to begin the activation pro cess II you do not have your activation code go to www activategen com or call 1 888 9ACTIVATE 922 8482 II you already have your activation code wait 3 5 seconds for the next display TROUBLESHOOTING If the wrong language is chosen it can be changed later using the edit menu I ESCAPE is pressed instead of ENTER your generator will only run in manual mode for test purposes and NOT ACTIVATED will be displayed You will need to remove the generator control panel fuse AND disconnect the T1 N1 and N2 connector in the external connection box if equipped or disconnect utility input main breaker to the transfer switch for 3 5 seconds and reconnect then begin with Step 1 ENTER ACTIVATION CODE Pa
80. hed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided This should be considered prior to installing the generator The unit should be positioned to direct exhaust gasses safely away from any building where people animals etc will not be harmed Any exhaust stacks that ship loose with the unit must be installed properly per the manufacturer s instruction and in strict compli ance with applicable codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ventilating air is Critical in any room or building housing the 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 seriously 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 Before performing any maintenance on the generator discon nect its battery
81. ility CRANK CYCLES AND OVERCRANK SHUTDOWN If the unit fails to start during a cranking period it will display the Overcrank Shutdown Alarm The system will control the cranking cycles as follows The first crank cycle is a 16 second crank time followed by a 7 second rest The next 5 cycles will be 7 seconds of cranking time each followed by a 7 second rest time I the unit fails to start by the end of the 6 crank rest cycles the Overcrank Shutdown Alarm will display and the unit will not attempt to crank until the alarm is reset AUTO START This unit is designed to automatically start in the event of a util ity failure or brown out condition Brown out is defined as utility voltage less than 60 nominal while utility is considered good when it is restored to at least the pickup value 80 of nominal These levels are fixed The Line Interrupt period is an adjustable parameter by the dealer If 2 wire start mode is activated the unit will start when 2 wire start is active LLvO 8 4 MANUAL START Allows the user to start and run the generator manually Transfer of the load to the generator will occur if utility is lost while the unit is running in the manual mode only if activated ALARM AND WARNING MESSAGES Alarms are defined as Latching which means they must be cleared before the alarm message on the screen will clear They can be of type Shutdown or not and are logged
82. ir cleaner plugged or damaged 1 Clean or replace as needed 2 Defective spark plugs 2 Clean regap or replace plugs 3 Fuel pressure incorrect 3 Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS 4 Insufficient fuel supply 4 Confirm fuel pressure to regualtor is as recommended in SPECIFICATIONS 5 Fuel system set to wrong fuel type 5 Reconfigure the fuel system See RECONFIGURING THE FUEL SYSTEM in manual Check oil and add oil as needed Engine is overheated Check cooling system for leaks Defective Low Oil Pressure Switch Replace switch Engine starts then shuts down 1 1 2 2 3 3 4 Defective Coolant Temperature Switch 4 Replace switch 5 5 6 6 7 7 Engine oil level is low Defective Control Module circuit board Replace board Coolant Level is Low Repair leak Add coolant Defective Low Coolant Level Switch Replace Switch AUTO OFF MANUAL Switch at 1 Defective AUTO OFF MANUAL switch 1 Replace board engine continues to run 2 Defective Control Module circuit board 2 Replace board No AC output from generator 1 Main line circuit breaker is tripped open 1 Reset to ON CLOSED 2 Generator internal failure 3 Thermal circuit breaker open 3 Auto reset Wait 5 min and attempt restart Contact the nearest Dealer for assistance 12 1 01 60 8 ed 6001481021 608640 ONIM VU C JO NOLLV LLIOX3 194810 HOLVNSALTV 149 MHIA QH
83. it only respon sible and capable persons to install operate or maintain this equipment Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators GENERAL HAZARDS For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by a Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations Installation operation servicing and repair of this and related equipment must always comply with applicable codes stan dards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator 15 installed operat ed and serviced in accordance with the manufacturer s instruc tions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations 0L 90 V00 1915 The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breat
84. k coolantlevelin coolant recovery bottle See the Specifications and Service Schedule sections Add recommended coolant mixture as necessary Periodically remove radiator pressure cap only when engine has cooled down to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radia tor filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact a Service Facility Inspect cooling system and coolant recovery system for leaks COOLANT CHANGE Every year have a service facility drain flush and refill the cooling system See the Specifications and Service Schedule for cooling system recommendations OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via the control panel fuse This overcurrent protection device will open if the circuit is overloaded A CAUTION If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse EXERCISE SYSTEM Starts the Stationary Emergency Generator engine once every seven days and lets it run for 12 minutes PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine genera tor monthly Look for obvious damage loos
85. latching alarm the Auto Off Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding fault alarm message COMMON ALARM RELAY The common alarm relay will be activated if there is a shutdown alarm It will not activate on warnings or indicate that the Auto Off Manual switch is in the OFF position The OFF position will clear the alarms and the relay The relay will not be used to indicate a generator is not activated The common alarm connections are wired to a set of potential free dry contacts on the Nexus controller board These Normally Open contacts close when an alarm condition occurs and are used to activate a remote signaling device The circuit is rated for a maximum of 130mA at 24 VDC The connections are a short set of free hanging wires that exit the engine harness loom directly behind the Nexus Control Panel and are labeled numbers 209 and 210 MAINTENANCE ALERTS Maintenance alerts will be provided for these conditions see the Maintenance Alert Chart SERVICE SCHEDULE Inspect Accessory drive alert 100hrs Coolant change amp flush 100hrs Inspect spark plugs alert 100hrs Change oil amp filter alert 100hrs Inspect battery alert 100hrs Change Inspect air filter alert 100hrs SERVICE SCHEDULE B Change Inspect spark plugs alert 250hr Control Panel MAINTENA
86. ly or carelessly Observe them carefully Their definitions are as follows DANGER INDICATES A HAZARDOUS SITUATION OR ACTION WHICH IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY A WARNING Indicates a hazardous situation or action which if not avoided could result in death or serious injury 4 CAUTION Indicates a hazardous situation or action which if not avoided could result in minor or moderate injury NOTE Notes contain additional information important to a procedure and will be found within the regular text body of this manual These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the service are essential to prevent ing 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 information that if not followed could endanger personal safety and or property of others A This symbol points out potential explosion hazard 1 1 This symbol points out potential fire hazard Q This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equip ment The manufacturer strongly recommends that the operator read this Owner s Manual and thoroughly understand all instruc tions before using this equipment
87. ny provides piping from the main gas distribu tion line to the standby generator site The following information applies to natural gas fuel systems Gas pressure in a building is usually regulated by national state and local codes To reduce gas pressure to a Safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff solenoid must never exceed approximately 14 inches water column 0 5 psi 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 When ambient temperatures are low and engine fuel consump tion is high the vapor withdrawal system may not function efficiently Ambient temperatures around the supply tank must be high enough to sustain adequate vaporization or the system will not deliver the needed fuel volume In addition to the cooling effects of ambient air the vaporization process itself provides an additional cooling effect LL p0 4
88. ojdx3 L RR ONS Z A 0 pS ae 7 5 DADOS 3 N ec M0IIV 5959I4M0 31VN3311V d 4 pn aloN3aassc EXPLODED VIEW AIR CLEANER 2 4L G2 TURBO DRAWING 0H1954 GROUP D APPLICABLE TO ITEM PART QTY DESCRIPTION 1 OF 4269 2 GASKET MIXER BODY 2 0LI0030 1 ADAPTOR MIXER 3 0G39340ST03 1 BRACKET AIR INTAKE 4 035480 1 BOLT U 5 16 18 X 2 06 5 0LI0028 1 ADAPTOR AIR CLEANER 6 0 4271 1 BASE PLATE AIR CLEANER 7 0LI0219 1 PLUG PLASTIC 2 5 BLACK 8 05418 1 ELEMENT AIR FILTER 9 0 4270 1 HOLD DOWN AIR CLEANER PLATED 10 0F6323 1 PLATE AIR CLEANER TOP 11 0H0035 1 HOSE AIR INTAKE 12 0G0153 1 BARBED EL 90 1 2NPT X 3 4 HOSE 13 0D3700 4 NUT FLANGE M6 1 0 NYLOK 14 049811 8 WASHER FLAT M6 15 045757 4 SCREW HHC M6 1 0 X 25 G8 8 16 022097 4 WASHER LOCK M6 1 4 17 047411 4 SCREW HHC M6 1 0 X 16 C8 8 18 022145 2 WASHER FLAT 5 16 M8 ZINC 19 022129 2 WASHER LOCK M8 5 16 20 039253 2 SCREW HHC M8 1 25 X 20 G8 8 21 037561 1 NUT WING 1 4 20 W NY INS ST ZN 22 0D3700 4 NUT FLANGE M6 1 0 NYLOK 23 049811 8 WASHER FLAT M6 24 045757 4 SCREW HHC M6 1 0 X 25 G8 8 25 022097 4 WASHER LOCK M6 1 4 26 047411 4 SCREW HHC M6 1 0 X 16 C8 8 27 086133C 2 CLAMP HI TORQUE 1 75 2 625 28 039253 2 SCREW HHC M8 1 25 X 20 G8 8 29 022129 4 WASHER LOCK M8 5 16 30 022145 4 WASHER FLAT 5 16 M8 ZINC 31 022259 2 NUT HEX
89. re of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is listed in the specifications Use only deionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolant mixture When adding coolant always add the recommended 50 50 mixture A 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 operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment A DANGER 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 0 000I 3 Engine Protective Devices ENGINE PROTECTIVE DEVICES The Stationary Emergency Generator may be required to operate for long
90. rrent date and time and exercise day and time The maintenance intervals will be initialized i e started the first time the clock is set If the clock is never set at power up the mainte nance intervals will be reset every time power is applied I a subsequent power loss loss of battery power occurs the Installation assistant will operate upon power restoration The self test routine will be run and then the customer will be required to re enter the time and date as this is not retained during a power loss The unit will not require re activation DISPLAY INTERFACE MENUS The LCD display is organized as detailed below The Home page this page is the default page which will be displayed if no keys are pressed for 30 seconds This page normally shows the current Status message and the current date and time The highest priority active Alarm and or Warning will be automatically posted on this page as well as flashing the backlight when such an event is detected In the case of multiple Alarms or Warnings only the first message will be displayed To clear an Alarm or Warning see the Protection Systems section Clear Alarm The display backlight is normally off If the user presses any key the backlight will come on automatically and remain on for 30 seconds after the last key was pressed The Main Menu page will allow the user to navigate to all other pages or sub menus by using the Left Right and Enter keys This pa
91. sscode TROUBLESHOOTING Display Reads Passcode XXXXX ef A V le Display Reads SELECT HOUR 0 23 6 a Q Use ARROW keys to scroll and find the first number of your Activation Code Press ENTER to select Repeat this step until all digits have been entered Use ESCAPE to correct previous digits Activation is complete when all digits are entered above and your screen shows this display Follow the controller prompts to continue setting the time function Refer to your Owner s Manual with questions 8 2 What happens if Wrong Passcode Try Again appears Re enter the activation code If a second attempt is unsuccessful check the number against the code given on activategen com If it is correct and the generator will not accept it contact 1 888 9ACTIVATE 922 8482 Control Panel INSTALLATION ASSISTANT Interconnect System Self Test Feature follow the on screen prompts Upon power up this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block I utility voltage is detected the controller will display a warning message and lock out the generator preventing damage to the controller Power to the controller must be removed to clear this w
92. tdown Overspeed Shutdown ess RPM Sensor Loss Shutdown Fuel Requirements Natural Gas Fuel System Propane Vapor Withdrawal Fuel System Liquid SPECIFICATIONS u uu ii ico esee e seca aas Stationary Emergency Generator ENQING us Cooling System Fuel System Electrical System Weather and Maintenance Kits Reconfiguring the Fuel System Fuel System Control Panel GENERAL INFORMATION Alternator AC Lead Connections sse Four lead Single phase 1 Alternator Power Winding Connections 3 phase Alternators Y Configuration 3 phase Alternators Delta Configuration CONTROL Control Panel 1 Using the Auto Off Manual Switch Activate Display Interface Menus Activation Chart Setting the Exercise Timer Low Speed EXGICISB occitano User Adjustable Settings r
93. tery Remove Corrosion Ensure Dryness Clean 8 Tighten x T Check Charge State x Check Etetrayte Level Mw x 1 General Condition Vibration Noise Leakage Temperature X Generator System Complete Tune up and System Inspection To be completed by an Authorized Service Dealer Footnotes Inspect the oil level monthly or every 12 hours during continuous operation Change oil and oil filter after the first 30 hours of operation and then every 100 hours or annually thereafter whichever occurs first Change sooner when operating under heavy load or in a dusty or dirty environment or in high ambient temperatures Replace as necessary 11 1 01 90 8 Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won t crank 1 Control panel 7 5 amp fuse blown 1 Replace fuse 2 Loose or corroded or defective 2 Tighten clean or replace battery cables battery cables as necessary 3 Defective starter contactor 3 Replace contactor 4 Defective starter motor 4 Replace starter motor 5 Dead or Defective Battery 5 Remove change or replace battery Engine cranks but won t start 1 Out of fuel 1 Replenish fuel turn on fuel valve 2 Fuel solenoid FS is defective 2 Replace solenoid 3 Spark plugs defective 3 Clean regap or replace plugs Engine starts hard runs rough 1 A
94. that is guided by the controller screen prompts Once the product is activated the controller screen will not prompt you again even II you discon nect the generator battery To obtain the activation code record the generator serial number and log onto www activategen com or call 1 888 9ACTIVATE and follow the steps to retrieve the activation code After obtaining your activation code please complete the following steps at the generator s control panel in the Activation Chart on the following page NOTE The generator will only run in manual until the passcode has been entered 8 1 Upon power up this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block I utility voltage is detected the controller will display a warning message and lock out the generator preventing damage to the controller Power to the controller must be removed to clear this warning Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass NOTE DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT WIRES IS NOT WARRANTABLE This test will be performed each time the controller is powered up Next the user must enter the minimum settings to operate These settings are cu
95. the RPM signal is detected the engine will start and run normally If the RPM signal is subsequently lost the control board will try two more re cranks before latching out and flashing the RPM Sensor Failure message if it is in AUTO Control Panel Figure 1 Generator Control Panel GENERATOR MAINTENANCE SCHEDULE CHECK ENGINE MESSAGE The control system has detected an emissions related fault This fault cannot be cleared using the control panel interface The unit will continue to operate in automatic mode Contact your local servicing dealer UNDER FREQUENCY SHUTDOWN ALARM After starting if the generator stays under frequency for more than 30 seconds it will shutdown LOW BATTERY ALARM While running if the average battery voltage falls below 11 9 volts for one 1 minute the low battery alarm will be displayed LOW BATTERY WARNING The microprocessor will continually monitor the battery voltage and display the Low Battery Voltage message if the battery voltage falls below 12 2 Volts for one 1 minute No other action is taken on a low battery warning condition The warning will automatically clear if the battery voltage rises above 12 2 volts NOTE The battery sentinel is a separate feature that monitors battery condition LOW COOLANT LEVEL ALARM This is a shutdown alarm The sensor will be continuously moni tored If an error condition is seen for five 5 consecutive sec onds the al
96. ude Deration 1 for every 100 m above m 60KW 915 3 for every 1000 ft above ft 60 3000 Controller PE Nexus 01 60 V 8802908090 Specifications WEATHER AND MAINTENANCE KITS To keep the generator running at its peak the following kits are offered Cold Weather Kit Recommended for climates with temperatures below 32 F Extreme Cold Weather Kit Recommended Block Heater Kit for protection in tempera tures below 32 Scheduled Maintenance Kit Kit includes the recommended parts to maintain the genera tor Refer to the Service Schedule for regular maintenance intervals For additional information or to order any of these kits please contact an Authorized Service Dealer or Customer Service Representative 01 80 V 8802908090 6 2 General Information ALTERNATOR AC LEAD CONNECTIONS The electrical wires in the unit s AC connection lower panel should be installed according to the number of leads and the voltage phase required for the application The voltage and phase are described on the generator data label The number of lead wires can be identified using the Specifications section and the power output rating on the generator data label For example if the generator produces 130kW 277 480 Volt 3 phase power the generator has 12 alternator output leads Figure 7 3 describes the stator power winding connection for the g
97. ustomer load back to utility and shut down the generator AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their UTILITY position i e loads connected to the utility power source 2 Be sure that normal UTILITY power source voltage is avail able to transfer switch terminal lugs N1 and N2 Refer to the Electrical Data section 3 the 5 AUTO OFF MANUAL switch to AUTO 4 Set the generator s main circuit breaker to its ON or CLOSED position With the preceding steps complete the generator will start auto matically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to the Sequence of Automatic Operation section LLvO Q Control Panel SEQUENCE OF AUTOMATIC OPERATION Initial Conditions Generator in Auto ready to run load being sup plied by the Utility Source through the transfer switch 1 When the utility voltage fails falls below 60 of nominal 10 30 second programmable line interrupt delay timer is started The factory set time delay is 10 seconds If at the end of the line interrupt time the utility voltage is above 60 the engine will not crank If the utility voltage is still below the 60 of nominal at the end of the line interrupt time the unit will crank and start If the unit
98. ve OIL FILL CAP and add recommended oil Crankcase oil capacity is listed in the Specifications section A CAUTION After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 7 Start engine and check for oil leaks 8 Shut OFF engine and wait 10 minutes for the oil to settle down into the oil pan Recheck oil level on dipstick DO NOT fill above the dipstick FULL mark 9 Dispose of used oil at a proper collection center COOLING INTAKE OUTLET Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation This includes such obstructions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine gen erator quickly overheats which causes it to shut down See the installation diagram AWARNING The exhaust system parts from this product get extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system INSPECT COOLING SYSTEM Inspect engine cooling system See the Service Schedule Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness v ENGINE COOLANT Chec
99. xplosion Such an explosion can shatter 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 10 3 Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging AWARNING Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the 120VAC power supply to the battery is turned OFF or sparking may occur at the bat tery posts as the cables are attached and cause an explosion BATTERY REPLACEMENT NOTE Unit DOES NOT include battery When supplying or replacing the battery the recommended num ber and type of battery is listed in the Specifications Section NOTE The BCI number should be located directly on the battery BATTERY FLUID

Generac QT06024AVAX Portable Generator User Manual

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