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Generac Power Systems 1.6L 18 kW Portable Generator User Manual

1. 10 1 Cooling SY Stem 10 1 Overload Protection for Engine DC Electrical 10 1 Checking Fluid Levels 10 1 Check Engine oret rte 10 1 Battery 10 2 Engine Coolant een ee onera brace Ia 10 2 Maintenance Owner Operator Can Perform 10 2 Check Engine Oil 10 2 Check Battery a 10 2 Exercise SVSUGD uu saus 10 2 Inspect Cooling Syslem eren hene 10 2 Check Engine Coolant 10 2 Perform Visual 2 10 2 Inspect Exhaust System 10 2 Check Bela iiie err reet Reve 10 2 Inspect Engine 10 2 Changing Engine 10 3 Changing the Engine Cleaner 10 3 Spark prp 10 3 Coolant Change abp Sam SEE Eon eie Us 10 3 Miscellaneous Maintenance 10 4 Cleaning Generator 10 4 ous E UE 10 4 Battery Maintenance sis u 10 4 Battery Replacement 10 4 Repai
2. 8 1 Generator Set Lubrication 8 1 Prior to Initial Start up onore eae ere eere aue 8 1 Engine Coolant u 8 1 Belt IensiOn 8 1 d 8 1 Initial Inspection Genset Start up 8 1 Start up Ch eekliSE u ep noe enei 8 2 Preparation for Start p ederet ere 8 2 TABLE Standby Generator Sets TABLE CONTENTS Table of Contents CONTENTS OF OPERATION 9 1 Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch 9 1 Engine Start up and Transfer 9 1 Retransfer and Shutdown 9 1 Operating Unit with Automatic Transfer Switch 9 1 MAINTENANCE 10 1 Maintenance Performed by Service Facilities 10 1 Every Three Montlis net eere eoa rennen Once Every Six Montlis erret ONCE ANNUI First 30 Operating First 100 Operating Hours Every 500 Operating Hours 10 1 Every 800 Operating
3. IN3W313 N3NV3T1O OL lt lt 392 wood ISOH NIvad 30191094 403 3AUW33 14 FSOH NIVAC TID 30118 30 asta 92 1113 TIU 553009 3914938 dAl LEETYS 0881 Lv6 1 13 11118155322 W31I 321 435 001 D 0099 10 70
4. _ ju 21 00 T isa 14109914 ISA 12 15 38 I 15 EC oem 0 1 m 15 1 CENTER TERMINAL INPUT USED UTILITY FRUM T SW UTILITY T SW TRANSFER RELAY COIL TRANSFER RELAY COIL REMOTE START REMOTE START NOTE THIS PAGE APPLIES TO STATOR UNITS BUILT AFTER JUNE 2006 hoc 8 1 51 601 eol 44 837 SINGLE PHASE STATOR SHOWN FOR 3 PHASE SEE DWG 0 6839 BI N K Y 4 m i 0 SCHEMATIC DIAGRAM REVISION G 7908 A 1 6L 2 POLE DATE 04 20 06 PAGE 2 OF 3 DRAWING 0G0925 GROUP G ENGINE WIRING LEGEND 5 AIR FUEL SOLENOID ALT D C CHARGE ALTERNATOR BAT 12VDC BATTERY CP COIL PACK CS CAM SENSOR DCVR DC VOLTAGE REGULATOR FS FUEL SOLENOID FSe AUX FUEL SOLENOID GND GROUND HCT HIGH COOLANT TEMP SWITCH Ji CONNECTOR 1 PCB LFP LOW FUEL PRESSURE SWITCH LOS LOW OIL PRESSURE SWITCH MP1 MAGNETIC PICKUP OXYGEN SENSOR SC STARTER CONTACTOR SM STARTER MOTOR STM STEPPER MOTOR WLS COOLANT LEVEL SWITCH WIRE SPLICE TOMER NNECTION
5. 1879 PAGE 4 OF 5 REVISION H 0767 D DATE 07 23 07 510 S11 512 O O IO O GENERATOR DUTPU CUSTOMER C ECTION E1 Fe Ee 1 Sxe08VAC EI ES 1 OR NB 120 THE 8th DIG F THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 208VAC PAGE 4 OF 6 WIRING DIAGRAM R SERIES CPL ALTERNATOR DRAWING 0 6839 GROUP G apa pi ii pi i i ip 71 5 THREE PHASE DELTA R SERIES CONTROL PANEL 7 WIRE 120 240 LEGEND ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER B NEUTRAL BLOC 1 BLACK 4 RED AR gt 1 4 S38 2 4 6 amp s amp 1 51 1
6. 51108 AANOSVYW VIG 2 0 532914 ONILNNOW VIC GES S 33A nU1 419 15 553009 01 34 05070 3 2130 1311 SONINSVM 1 404 NV NO 401 9 403 03410034 A IND SI 3 DH 119 1313 7553909 403 S3ADO LINDJA S389IM 1091403 HOLIMS 34SNV31 OL 8553209 NOILOSNNOD lt XVW dWY 672 081 A3311v8 NDILO3NNDO WALNAN NOILOSNNOD LINGNOD 0931 4901 ov 403 9349 15 3015 54 LASHS 11901412345 335 NOTLVYWAOANI 232398 1109812 10 3415 ASHLO 543 1510 WAWINIW 204 53400 09001 NV 31915 1943034 ANY SV 71138 59 8 OZ VddN ANY ZE 31849211449 HLIM 30 9440009 NI 0311 15 38 15 LINN SIHL ANY SSNVNALNIVW 403 4019435 0 34 1 53015 119 NO WOOd 1 91214415 MOTIV S3NI 134109 31389ND2 3D LINN HLIM 031 ddfhS 30109 NDILIVTIVISNI 3ON333338 1 CS 922 681 X C 0 182 THOT 3ZIS 094 31340 00 WNWINIW D 0049 9 9 2 SALON 10 81 00 ALYA V 91190 ONIA VIG C JOZ 10 81 00 V NOISIATY 180 19
7. T 6 W4 CB J AFS DUT 1 808 START RELAY 2 56 FUELCRUN RELAY 3 14 WIRE START 1 4 183 MOMENT OPEN 5 1815 8 WIRE STARTC2 76 178 INPUT 7 1815A 16 SENSEC 1 ii 8 224 808 f em ALARM RELAY 9 M XFER RELAY 710 e3 MAN INPUT 111 239 16VAC SENSEC 2 12 25 EMISSIONS ENABLE T13 0 z 29 SN I 9 uJ 5 oc roro UTILITY FROM T SW UTILITY FROM T SW TRANSFER RELAY TRANSFER RELAY COIL REMOTE START REMDTE START REVISION G 7908 A DATE 04 20 06 GROUP G NOTE ALL WIRES ARE 18 AWG UL LISTED UNLESS OTHERWISE NOTED AS SHOWN 512 C AWG CUSTOMER CONNECTIONS 180 VAC UTILITY SUPPLY UCTI 2 GND DNLY po p CONNECT FOR OPTIONAL EMISSIONS SINGLE PHASE STATOR SHOWN FOR 3 PHASE SEE DWG OF 6839 NOTE THIS PAGE APPLIES TO UNITS BUILT IN THE FIRST HALF DF 2006 PAGE 1 DF 3 SCHEMATIC DIAGRAM 1 6L 2 POLE PAGE 1 OF3 DRAWING 0G0925 GROUP G CONTROL PANEL LEGEND AVR AUTOMATIC VOLTAGE REGULATOR BCH BATTERY CHARGER BR1 DIODE lt FIELD BOOST
8. 60 Hz 1800 pieta ipie 30 Exhaust System Exhaust Flow at Rated Output 60 2 168 cfm Exhaust Temp at Rated Output sss 810 F Combustion Air Requirements Natural Gas Flow at rated power 60 76 Governor rein Ere tendido egi Electronic Frequency Regulation Isochronous Steady State Regulation sss 2596 Adjustments Speed ctas intento v onde De en Selectable Standby Generator Sets Specifications GENERAL INFORMATION Engine Lubrication System Type of Oil PUMP iseseisana Gear Oil Filter Full Flow Cartridge Crankcase Oil Capacity sss 4 U S gts COOLING SYSTEM e Closed Water PUMP u Belt Driven 9 1550 muB m 17 7 inches erret E ERU ERR Pusher Air Flow inlet air including alternator and COMBUSTION IN s cucurrit 890 ft3 min Coolant 2 0 U S gal Heat Rejection to Coolant 117 000 Btu h Maximum Operating Air Temp on Radiator 60 C 150 F Maximum Ambient Tem
9. filter s filter s 18 Replace the engine fuel filter s on diesel engine driven units and re prime the fuel system 19 Check the engine spark plugs on gas engine driven units Clean and re gap or replace as necessary 20 Perform a 5 minute no load operational run of the unit looking for any post service problems 21 Return the unit to standby setup for operation when required 100 Hrs 11 3 90 50 2 00 Standby Generator Sets Troubleshooting TROUBLESHOOTING TROUBLESHOOTING GUIDE E PROBLEM Engine cranks but won t start Engine starts hard runs rough Engine starts then shuts down AUTO OFF MANUAL Switch at OFF engine continues to run No AC output from generator CAUSE Engine won t crank 1 2 15 amp fuse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery 5 fuse blown Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Door on tank not closed Flame arrestor air cleaner plugged or damaged Plugged fuel line Defective spark plugs Fuel pressure incorrect Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is
10. 3 33N31SV4 N3dO 10 61 9 9 0 EXPLODED VIEW AV R 200 1800 RPM 1 6L DRAWING 0645780 APPLICABLE PART QTY DESCRIPTION COMPONENTS INCLUDED IN 0G4578E 1 0F1823A 1 ENCL HSB CONTROL PANEL 2 0F3078 1 COVER CONTROL PANEL 3 0F 2606 1 HINGE CONTINUOUS H PANEL 4 036261 6 RIVET 125 X 275 SS 5 0 7358 4 SCREW PPPH HI LO 44 24 X 3 8 6 052777 3 WASHER 7 0G3958C 1 ASSY PCB R 200A CNTRL 1800 8 0F1262 REF HOLDER FUSE WICKMANN 178 6150 9 0F1263 REF ADPTR RH SIDE WICKMAN 178 6191 10 0F1264 REF ADPTR LH SIDE WICKMAN 178 6192 11 0F1725C 1 ASSY PCB 2AMP 12V UL BATT CHGR 12 067680 1 ASSY VOLTAGE REGULATOR 60HZ 13 0E6875A 2 RELAY 12VDC FORM W DIODE 14 055911 REF BLOCK TERM 20A 12 X 6 X 1100V 15 0F5459 1 DECAL CPL CONTROL PANEL FUSES 18 0F5462 1 DECAL CPL 3 9L TB1 19 0 5062 4 SPACER 9 5H 3 2 ID 20 029673 1 DIO BRIDGE 25A 600V 21 054502 1 CIRCT BRK 3 X 1 ETA 46 500 P 22 0F1958 1 PLATE HARNESS CLAMP 23 082573 1 SWITCH RKR DPST 125V SPD 24 0E4494 1 SWITCH RKR DPDT ON OFF ON 25 0F3215 1 DECAL CONTROL HSB 26 0F6305 2 SEAL COVER 3 18 X 12 7 X 382 27 0F6305A 1 SEAL COVER 3 18 X 12 7 X 283 28 0F5886 3 SCREW HHPM 5 0 8 X 12 29 051713 14 WASHER FLAT M5 30 049226 14 WASHER LOCK M5 31 0 5752 1 RES WW 15 5 25 CONN 32 5884 2 SCREW PHTT M3 5 0 6 X 10 33 0 5896 2 SCREW M3 5 0 6 X 16 34 0C2265
11. CIRCUIT BREAKER EXCITATION EMISSIONS CONNECTOR FUSE BAT POWER 15A TYPE Je CONNECTOR 2 UN PCB J3 CONNECTOR ON PCB R4 FIELD BOOST RESISTOR 25 OHM RL1 RELAY 1 START RELAY RL2 RELAY 2 ENGINE RUND GEE 6 W4 SW1 AUTD FF MANUAL SWITCH NOTE ALL WIRES ARE s ae MINA BER T D OTHERWISE NOTED AS SHOWN TRI TRANSFORMER 1 SIZ CAWG 16 15 F1 1154 13 4 15 iu Un SW2 71 L1 120 TS 15 UTILITY PCB J3 suPLY NOT USED 1 MI USED 2 BAK T 3 1 4 CUSTOMER CONNECTIONS R4 13 5 BR1 lt 4 AFS DUT 1 808 eoe START RELAY 2 564 FUELCRUN RELAY 7 3 1441 EC 2 WIRE STARTCD 4 183 2 MOMENT 5 18 15 1 808 808 WIRE STARTC2 76 178 gt 4 misa 0 ed cg eesebrnrte EI ele 4 16 SENSECD 8 224 mu ALARM RELAY 9 Ne XFER 710 23 14 MAN INPUT T11 239 TB1 16 SENSEC 112 225 4 EMISSIONS ENABLE 13 0 2 2 GND B 9 p oe ST 1 1 2 1646 656 11 81 FQ 6 QE z m
12. pM u JENERATOR DUTPU CUSTDMER 1 E1 NB 120 NB s PAGE 1 OF 5 WIRING DIAGRAM REVISION H 0767 D R SERIES CPL ALTERNATOR DATE 07 23 07 PAGE 1 OF 6 DRAWING 0F6839 GROUP G m CELL a ee LC 71 2 THREE PHASE R SERIES CONTROL PANEL 6 120 208 LEGEND ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER B NEUTRAL BLOC 1 BLACK 4 RED x p x 1 4 S38 2 949 6 amp s amp 1 S1 11 i QoQ 53 44 9769 s 52 5 DIRECT DRIVE 5 S4 STIS 8 122 NB 1 Ee GE RATOR DUTPU CUSTOM
13. 064581 1 HARN ENG 1 6L R200 1800RPM 611 SHOWN 1800 54 0602070100 1 OIL FILTER 1 6L 55 077043H 1 CONDUIT FLEX 25 ID 6 LG 56 06386205703 1 STRUT RH 1 6L ENG ADAPT PLATE 57 055596 1 BARBED STR 3 8 NPT X 3 8 58 007649 2 CLAMP HOSE 38 87 59 005210 1 HOSE 3 8 ID LOW PRES OIL WATER 11 LG 60 051756 6 SCREW HHC M10 1 5 X 20 G8 8 61 063433 BRACKET FAN ALT ADAPTER 1 6L 62 049541 1 SCREW HHC M10 1 5 X 35 G8 8 REVISION A DATE 11 3 06 PAGE 2 OF 2 06790 ONIM C JO 1 L0 91 7 ALVA AT8W3SSV NOISIATY MHIA bu 438 COSINVN 9 0L xousda 11 PANY E SS3NHVH SHIM 2 4 9 EXPLODED VIEW GOVERNOR ASSEMBLY DRAWING 064930 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 098290 1 ASM MOTOR STEPPER 2 098941A 1 HOUSING GOVERNOR CONNECTOR 3 098958A REF CONNECTOR INTERFACE ASSEMBLY 4 098942A 1 COVER CONNECTOR HOUSING 5 098225 2 SCREW FHM 2 X 5 8 SELF TAP 6 043146 3 SCREW HHC 6 1 0 X 10 68 8 7 022097 5 WASHER LOCK 6 1 4 8 084543A 1 SCREW PHM 0 5 X 12MM 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX 10 32 NYL INS 11 0E1326 1 ASSY CARBURETOR LINKAGE ROD 12 064451 1 BRACKET STEPPER MOTOR COOLANT 13 064526 1 SCREW TAP HWH 6 25 X 3 8 ZINC 14 029333A 10 TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCRE
14. ENGINE PROTECTIVE DEVICES The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant tempera ture oil pressure or rpm For that reason the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low the coolant temperature is too high the coolant level is too low or the engine is running too fast NOTE Engine protective switches and sensors are men tioned here for the reader s convenience Also refer to the applicable control panel manual for additional automatic engine shutdown informa tion HIGH COOLANT TEMPERATURE SWITCH This switches contacts close if the temperature should exceed approximately 140 C 284 F initiating an engine shutdown The generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level LOW COOLANT LEVEL SENSOR Should the engine coolant level drop below the level of the high coolant temperature switch it is possible for the engine to overheat without automatic shut down To prevent such overheating the engine has a low coolant level sensor If the level of engine coolant drops below the level of the low coolant level sensor the engine automatically shuts down LOW PRESSURE SWITCH This switch has normally closed contacts that
15. 4 1 Overspeed Shutdown sannita ntenni 4 1 RPM Sensor Loss Shutdown 4 1 06 unai u E A 4 1 FUEL SYSTEMS 5 1 Fuel Redquiremients au 5 1 Natural Gas Fuel System 5 1 Propane Vapor Withdrawal Fuel System 5 1 LP Fuel System 5 1 SPECIFICATIONS 6 1 Generator uu s a u u MNT 6 1 lorum 6 1 Cooling System 6 1 SYSTEM ve 6 1 Electrical Systems dass 6 1 Cold Weather u a u 6 2 Reconfiguring Fuel 6 2 GENERAL INFORMATION 7 1 Generator AC Lead Connections 7 1 Four lead Single phase Stator 7 1 Alternator Power Winding Connections 7 1 S phase Alternators 5 7 1 5 1 8 1 Installation 8 1 Preparation Before Start up 8 1 Transfer Switch uk us 8 1
16. These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety infor mation that if not followed could endanger personal safety and or property of others Important Safety Instructions This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by 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
17. line circuit breaker battery charger and protective alarms as explained in the following paragraph All AC connections including the power leads from the alternator 120 volt battery charger input and control connections to the transfer switch are avail able in the main connection box The generator incorporates the following generator features Rotor and Stator insulation is Class rated as defined by NEMA 1 32 6 NEMA 1 1 66 The generator is self ventilated and drip proof con structed The voltage waveform deviation total harmonic content of the AC waveform and telephone influ ence factor have been evaluated and are acceptable according to NEMA MG1 32 ENGINE OIL RECOMMENDATIONS The unit has been filled with 5W 30 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 syn thetic oil is recommended caution Ak Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure NOTE For temperatures below 32 F it is strongly recom mended to use the optional Cold Weather Start Kit part number listed in the Specification Section The oil grade for temperatures below 32 F is 5W 30 synthetic oil Standby Generator Sets Equipment Descriptio
18. 5 55 O O O L LCB NB O O O O E2 Xu GENERATOR CUSTOMER E1 1 gt 480 E1 E3 El NB 277VAC THE 8th DIG F THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE K 227 480 PAGE 3 OF 5 2 a e um o m m Um E m n ee Um a T cue emm i D ee t eL LS E 441 WIRING DIAGRAM REVISION H 0767 D R SERIES CPL ALTERNATOR DATE 07 23 07 PAGE 3 OF 6 DRAWING 0 6839 GROUP G aa k a em ee ge me eS 71 ES CONTROL PANEL 12 1 180 208 lt gt br 2 CIRCU EUTRAL HAA NA 1 gt 1 4 RED AR gt 93 16049 9567 B1 SS S1 11 53 44 51 11 53 44 S7 51 58 52 59 53 vu eS AS 54 55 56
19. NO 1 n Wn OL J u 1 wy OL lt TM AL i is gt ad 1 YN ML j y a wee 9 s gt Sav Tiv 8 r HdE 272 J 310d OL V AR 72 e 3HIM ONISN3S M H Sava1 rv SNISN3S C savai riv V dnodd EXPLODED VIEW CONNECTION BOX C1 CPL DRAWING 064980 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 UL BREAKER 2 0D5543 1 CB 0090A 2P 240V S BQ2 LL 0D5544 1 CB 0100A 2P 240V S BQ2 LL 0A2077 1 CB 0125A 2P 240V S BQ2 LL B 064499 1 COVER 20 25K 2 0 2265 2 SCREW 4 0 7 X 12 ZYC D 0C2264 2 WASHER LOCK 8 M4 E 0E7890 1 BRKT CB MTG BACK F 0G4497 1 CIRCUIT BREAKER SUPPORT BQ G 052619 2 SCREW 5 0 8 X 20 G8 8 H 023897 4 WASHER FLAT 10 ZINC J 049226 2 WASHER LOCK M5 K 051716 2 HEX 5 0 8 G8 CLEAR ZINC L 0E3257 7 SCREW HWHTF M6 1 0 X 16 2 UL BREAKER BQ3 A 049135 1 CB 0070A 3P 240V S BQ3 LL 062812 1 CB 0080A 3P 240V S BQ3 LL 040532 1 CB 0100A 3P 240V S BQ3 LL B 064500 1 20 25 0 2265 2 SCREW 4 0 7 X 12 2 0 0C2264 2 WASHER LOCK 8 M4 E 0E6002 1 BRKT CB MTG BACK F 0G4497 1 CIRCUIT BREAKER SUPPORT BQ G 052619 3 SCREW 5 0 8 X 20 G8 8 H 023897 6 WASHER
20. QTY DESCRIPTION 1 063343 1 MOUNTING BASE 1 6L 2007 C1 2 027482 2 WASHER SHAKEPROOF EXT 5 16 STL 3 070936 2 DAMPENER VIBRATION 4 070936C 2 VIB ISO 70 75 DURO 5 039253 8 SCREW 8 1 25 X 20 68 8 6 022145 12 WASHER FLAT 5 16 ZINC 7 022129 12 WASHER LOCK M8 5 16 8 045771 4 NUT HEX M8 1 25 G8 YEL CHR 9 071956 4 WASHER FLAT 8 10 051730 4 SCREW 8 1 25 X 60 G8 8 11 021991 1 EARTH STRAP 13 026850 1 WASHER SHAKEPROOF EXT 1 4 STL 14 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 15 055414 1 LUG SLDLSS 2 8 X 17 64 CU 16 047411 1 SCREW HHC 6 1 0 X 16 G8 8 17 022097 1 WASHER LOCK 6 1 4 18 022473 5 WASHER FLAT 1 4 M6 ZINC REVISION A DATE 9 7 06 GROUP C PAGE 2 OF 2 GROUP 5 HARNESS WIRE 10 SEE NOTE EXPLODED VIEW BATTERY C1 1 6L REVISION A 004067 DRAWING PAGE 1 OF 2 10 27 06 DATE EXPLODED VIEW BATTERY C1 1 6L DRAWING 064067 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F3408C 1 BATTERY TRAY C1 amp C2 2 0F3411 1 STRAP BATTERY RETAINMENT 3 025507 1 WASHER SHAKEPROOF EXT 7 16 STL 4 059980 1 SCREW HHC M10 1 5 X 25 G10 9 5 046526 1 WASHER LOCK M10 6 077483 REF BATTERY 12VDC 75 AH 26 7 050331 POST COVER RED 8 050331 REF BATTERY POST COVER BLK 9 038805J 1 CABLE BATTERY BLACK 1 X 30 00 10 038804M 1 CABLE BATTERY RED 1 X 21 00 11 045771 REF NUT HEX 8 1 25 G8 YEL CHR
21. amp ALTERNATOR LEGEND BRUSH ASSEMBLY GENERATOR ICT INTERCONNECT TERMINAL BLOCK MCB MAINLINE CIRCUIT BREAKER CB J NEUTRAL BLOCK UCT UTILITY CONNECT TERMINAL BLOCK DEG 12V OX INP RET DEG GND COOLANT TEMP GOV GOV 5V DISTRIBUTOR 12V COOLANT LEVEL CRANK SENSOR CRANK SENSE RET LFP IN GOV FDBK OX INP COIL COIL A DISTRIBUTOR RET DISTR INPUT DEG PWM DEG ENABLE LOW OIL PRESS CRANK SHIELD COIL lt 2 Tee COIL MP1 808 3 808 15 OPTIONAL EMISSION CONTROL DC VR 18345 02 48 0 4913 14 56 SC TI Im Ne 56 3 51 56 Cy 6105 85 HcT st m sasa 0 APPLIES ALL L PAGE 3 OF 3 1 SCHEMATIC DIAGRAM REVISION G 7908 A 1 6L 2 POLE DATE 04 20 06 PAGE OF 3 DRAWING 0G0925 GROUP G DIE EM MERCI ee ME C C XS eh USED NOT USED BLACK W1 RED We WHITE W3 GREEN W4 F1 AFS OUT 708 START RELAY T 2 S6A RELAYT 3 14A EA 2 WIRE STARTC 1 4 183 a MOMENT 5 15 WIRE STARTC2 7 6 178 MAN AUTO INPUT 7 15A 16 SENSE
22. Low Defective Low Coolant Level Switch Defective AUTO OFF MANUAL switch Open disconnected wire 415A between AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open CORRECTION 1 2 Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replace fuse Replenish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Close door on tank Clean or replace as needed Unclog fuel line Clean regap or replace plugs Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch 1 Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Setto GENERATOR position Auto reset Wait 5 min and attempt restart Contact the nearest Dealer for assistance 12 1 90 60 0 20014909 NOTES Standby Generator Sets Notes NOTES NOTES
23. NOLLVTIVLSNI JION 33S 1103 2 LINGNOD 3918410 304 102 01314 14 S33 14JnW LSNVHXS NDIL23NND2 INIT 13014 ASIA INUSj SNDISN3WIQ 40 331N32 147061 084 MIT AL dAl 3IHN 335 830914 DNLL3I1 MAIA 3015 1 913 LOST 6 6 NIN 91 E Sesi 91 158 T 335 49383934 1119812 310 33S 43 00 INOJ 53415 NV LNOYs SS3AnU L 8682 962 AY ANY 9004 L 209v 691 0861 3SD13N3 SI 9 443114 0023 13NVd 1041 09 c 291 YOLVASNSD 30 3015 440 1417 008 33d 2191 12 ASIA 6 6611 6 3LON 33S 15 401 9 20 4401108 1319201 S32V ld 3 IDH VIC QES 59 115811 1494 303 9 2 MODO 1 914 419 ONDINV3O 1109 a00 NAHL 1138 NV4 92 L DA AN311v8 SOflld 80 2 1113 wood
24. QoQ 53 44 i 6 769 85 s2 56 53 54 x 00 NB O 1 GE RATOR DUTPU CUSTOMER C E1 TO 240 1 Fl 120 TE THE 8th DIG F THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE jJ 120 240 PAGE 5 OF 5 Hed 2 ee a ea ee i 441 WIRING DIAGRAM REVISION H 0767 D R SERIES CPL ALTERNATOR DATE 07 23 07 PAGE 5 OF 6 DRAWING 0 6839 GROUP G WIRING DIAGRAM R SERIES CPL ALTERNATOR DRAWING 0F6839 NALLY BLANK INTENT PAGE 6 OF 6 aE REVISION H 0767 D DATE 07 23 07 AVR AUTOMATIC VOLTAGE REGULATOR BCH BATTERY CHARGER BR1 DIODE FIELD BOOST CBe CIRCUIT BREAKER 7A EXCITATION EMISSIONS CONNECTOR F1 FUSE BAT POWER 154 ATO TYPE Je CONNECTOR UN PCB 43 CONNECTOR PCB R4 FIELD BOOST RESISTOR 15 OHM RL1 RELAY 1 lt 5 RELAY RL CRELAY 2 CENGINE SCR SCR BRIDGE MODULE W PCB SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISER SWITCH TB TERMINAL BLOCK TR1 TRANSFORMER F1 13 JEE NOT USED T 1 e RAK 3 W1 4 WER 5
25. Standby Generator Sets Notes NOTES NOTES Standby Generator Sets Notes NOTES NOTES Standby Generator Sets Notes NOTES 800790 ONIA MASZ MAOZ MA8 SLYYd NOWWOO LTV 2 es 28 U 21 1JVHSXNVHO 8 OL ONISNOH OL lay gt 2 gt 25 S T r Ve mr di V 4109 EXPLODED VIEW COMMON PARTS 18KW 20KW 25KW amp 30KW DRAWING 064008 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 064827 1 ASSY 104 KD1 18KW 062927 1 RTR 102 20 0AD1 CPL 2006 20KW 062827 1 ASSY 25KW P 2006 25KW 0G3451C 1 RTR 102 30KD2 2006 CPL CHI 30KW 2 0G0820A 1 HOUSING BLOWER LG PILOT 3 0G4452 1 BLOWER HOUSING SCREEN 4 020746 4 SCREW PPHM M5 0 8 X 8 ZINC 5 049226 4 WASHER LOCK M5 6 051713 4 WASHER FLAT M5 7 022129 4 WASHER LOCK 8 5 16 8 064825 1 ASSY STR 104 18AD1 EFF 18KW 064826 1 ASSY STR 104 18601 EFF 18KW 062926 1 STR 102 20 0AD1 CPL 2006 20KW 0G3682 1 STR 102 20 0GD1 CPL 2006 20KW 0G5584 1 STR 102 20 0JD1 CPL 2006 20KW 0G3685 1 STR 102 20 0KD1 CPL 2006 20KW 0G2826 1 ASSY STR 102 25AD1 2006 25KW 063683 1 STR 102 25 0GD1 CPL 2006 25KW 066573 1 STR 102 25 0 JD1 CPL 2006 25KW 0G3686 1 STR 102 25 0KD1 CPL 2006 25KW 063452
26. by a Service Dealer 4 A mid level inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed annually this requires approximately 4 0 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by a Service Dealer 11 1 90 50 2 00 5 Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp be done Comp to be done Comp Required Comp to be done Date Date Semi to be done Date monthly Initials Break in Initials annually Initials Annually Initials 10 Hrs 30 Hrs Disable the unit from operating per the first page warning Check the engine oil level Adjust as necessary Check the engine coolant level Adjust as necessary Check the engine coolant thermal protection level Correct as necessary Check the natural gas delivery system on gas engine driven units Tighten connections as necessary Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger fo
27. erator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT If personnel must stand on metal or concrete while installing operating servicing adjusting or repair ing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static electricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maxi mum electrical current ampacity to which they will be subjected Before installing or servicing this and related equipment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in hazardous and pos sibly fatal electrical shock Connecting this unit to an electrical system nor mally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distrib
28. materials or work manship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum See a Service Dealer for ser vice aids and accessories Operating instructions presented in this manual assume that the standby 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 HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact a Service Dealer for assistance Service technicians are factory trained and are capa ble of handling all service needs When contacting a Service Dealer about parts and service always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit 10 80 8 pOOKaeS INFORMATION IDENTIFICATION RECORD DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator The data label which can be found attached to the gen erator s lower connection box lists the units serial number and its rated voltage amps wattage capacity phase frequency rpm power factor etc PUE Standby Generator Sets E Eu GENERAL GENERAL INFORMATION Genera
29. the correct recommended fuel is sup plied to the generator fuel system Thereafter the owner operator must make certain that only the proper fuel is supplied NATURAL GAS FUEL SYSTEM Natural gas is supplied in its vapor state In most cases the gas distribution company provides piping from the main gas distribution line to the standby generator site The following information applies to natural gas fuel systems Gas pressure in a building is usually regulated by national state and local codes To reduce gas pressure to safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff sole noid should not exceed approximately 14 inches water column 0 5 psi Optimum pressure at the fuel shutoff solenoid is 11 inches water column 0 4 psi Standby Generator Sets Fuel Systems GENERAL INFORMATION PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid fuel in the supply tank Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state The vapor withdrawal system is generally best suited for smaller engines that require less fuel The install
30. the panel wiring and components from damaging overload Always remove this fuse before commencing work on the generator The unit will not start or crank if the fuse is blown Replace the fuse with one of the same size type and rating See the exploded views and parts lists at the end of this manual for replacement part number 90 80 O 0010 4643 GENERAL INFORMATION FUEL SYSTEM FUEL REQUIREMENIS The standby generator may be equipped with one of the following fuel systems Natural gas fuel system Propane vapor PV fuel system The Manual Drawing Listing that is affixed to the unit includes the Identification Code which may be used to identify the type of fuel system installed on the unit Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is 5 inches to 14 inches water column 0 18 to 0 5 psi and for liquid propane 5 inches to 14 inches of water column 0 18 to 0 5 psi NOTE Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below five inches water column for natural gas or 5 inches water column for propane vapor for all load ranges NOTE It is the responsibility of the installer to make sure that only
31. throughout the genera tor Ensure each plug is seated correctly and fully inserted into its receptacle Verify the AUTO OFF MANUAL switch is in OFF position 40 10 9 ed 200118150 Open valve to engine fuel line Bleed the fuel system of air necessary for long fuel lines Open the generator main line circuit breaker Connect a manometer to the gas line and record the static pressure It must be as listed in the Specifications Insert the fuse into the control panel Move the AUTO OFF MANUAL switch to the man ual position The engine should now crank and start Check voltage at the generator terminals For 3 phase units check phase rotation at the transfer switch terminals The generator phase rotation must match the utility phase rotation Check for coolant fuel oil and exhaust leaks Close the generators main line circuit breaker Turn the generator set off Connect the UTILITY supply to the transfer switch Set the AUTO OFF MANUAL switch to AUTO Disconnect utility power before transfer switch Engine should start transfer to load Run at least 15 minutes on generator power Make certain all 3 phase loads are functioning correctly correct phase rotation Reconnect Utility power Transfer switch will transfer back to Utility and engine will shut down within the given time parameters set up for the specific transfer switch and controller Install all covers access plates and door panels Put the Owne
32. to this generator set The parts lists consist of a an item number b a part number c the quantity required and d a description of the part The item number corresponds to an identical number on the exploded view drawing Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule SERVICE SCHEDULE The following is a recommended maintenance schedule for small standby and residential generator sets The established intervals in the schedule are the maximum recommended when the unit is used in an average service application They will need to be decreased performed more frequently if the unit is used in a severe applica tion Use calendar time or accumulated run time from the previous maintenance interval to determine the next required maintenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten tial problem areas Performed monthlu this requires approximatelu 5 man hours per unit to complete This inspection may be performed bu the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or conne
33. 00 ft above 600 Controller oe eee tee o nouo ususi Ro R 200 1090 V geooedgueo GENERAL INFORMATION Standby Generator Sets ws Specifications INFORMATION Figure 6 1 Interconnections CONTROL PANEL TO ALTERNATOR NEUTRAL SI GENERATOR CONNECTION BOX CIRCUIT BREAKER o o o GROUND 320 Vat on gg OO FRAME RAIL Ground Level Concrete Slab STUB UP AREA See Install for Dimensions COLD WEATHER KIT For cold climates optional cold weather kit part number 0F6148 is recommended The kit includes Battery Warmer 4 Junction Box with hardware 6 qt pack 5W 30 synthetic oil engine RECONFIGURING THE FUEL SYSTEM NOTE All models are configured to run on natural gas from the factory To reconfigure fuel system from NG to LP follow these steps 1 Turn the main gas supply 2 Remove the carburetor fuel hose from the outlet port of the demand regulator see Figure 6 2 3 Disconnect the power wires from the fuel sole noid located on top of the regulator assembly 4 Loosen the spring clamp on the small fuel enrich ment line and remove the hose from the hose barb 5 Remove the black pipe assembly from the outlet port of the demand r
34. 0111 FROM T SW ee 56A ICT 3 TRANSFER COIL RELAY 33 94 ICT 4 TRANSFER RELAY NB S6 83 START Y T 15 78 6 START eg pe Ion CUSTOMER CONNECTION amp ALTERNATOR LEGEND BA BRUSH ASSEMBLY GENERATOR CB1 MAINLINE CIRCUIT BREAKER 240V DUTPUT TRANSFER SWITCH ICT INTERCONNECT TERMINAL BLOCK NB NEUTRAL BLOCK UCT UTILITY CONNECT TERMINAL BLOCK 1 WIRING SHOWN FOR 1 BA AND 5 IS TYPICAL FOR SINGLE PHASE 3 PHASE SEE DWG OF 6839 NOTE 2 jTHIS PAGE APPLIES TO UNITS BUILT jAFTER JUNE 2006 PAGE 2 OF 3 uD ee es ee SE SSES SS Sao J SCHEMATIC DIAGRAM REVISION G 7908 A 1 6L 2 POLE DATE 04 20 06 PAGE 2 OF 3 DRAWING 0G1042 GROUP G r ENGINE WIRING LEGEND 2 AFS AIR FUEL SOLENOID CB J ALT D C CHARGE ALTERNATOR BAT 12VDC BATTERY DEG 12V 1 CS CAM SENSOR INP RET T e 805 CP PACK DEG GNDT3 DCVR DC VOLTAGE REGULATOR COOLANT TEMP 4 85 FS FUEL SOLENOID GOV 0 5 FSe AUX FUEL SOLENOID cov sv 6 HCT HIGH COOLANT TEMP SWITCH DISTRIBUTOR 18V 7 194 41 CONNECTOR 1 PCB COOLANT LEVEL 8 573 LFP LOW FUEL PRESSURE SWITCH CRANK SENSOR 9 79 LOS LOW OIL PRESSURE SWITCH CRANK SENSE RET 10 0 1 MAGNETIC PICKUP INP 11 601 ue OXYGEN SENSOR G
35. 1 06 2 00 9 0G4070 1 HOSE REAR COOLANT 1 6L 10 0G4072 1 TUBE ENGINE COOLANT 1 6L 11 0G4071 1 HOSE UPPER RADIATOR 1 6L 12 046627 1 CAP RADIATOR 13 052250 2 TAPEFOAM 1 X 1 24 LG 14 022473 8 WASHER FLAT 1 4 M6 ZINC 15 022097 8 WASHER LOCK M6 1 4 16 0 8566 4 SCREW HHFC M6 1 0 X 20 G8 8 17 045771 4 NUT HEX M8 1 25 G8 CLEAR ZINC 18 0C2454A 28 SCREW THF M6 1 X 12 N WA 245 19 042568 4 SCREW HHC M6 1 0 X 20 G8 8 20 0G3573 1 GUARD FANLH C1 21 0G3574 1 GUARD FAN RH C1 23 0G3420 1 RADIATOR BLOCK OFF 24 080713 1 BRACKET COOLANT TANK 25 076749 1 TANK COOLANT RECOVERY 26 048031 2 CLAMP HOSE BAND 14 27 029032 1 HOSE 9 32 ID 437 LG 28 0G4451 REF BRACKET STEPPER MOTOR COOLANT 29 055934N 2 CLAMP VINYL 1 31 X 281 Z 30 0F9504 1 GROMMET 5 8 X 1 1 8 X 5 16 31 0G0568 1 ASSY FAN BEARING SUPPORT 32 0G3433 1 BRACKET FAN ALT ADAPTER 1 6L 33 0E2507 1 PROBE COOLANT LEVEL 3 8 NPTF 34 0A2628 1 PULLEY FAN 95 DIA 35 029333A 1 TIEWRAP UL 7 4 X 19 BLK 1 36 042907 4 SCREW HHC M8 1 25 X 16 688 37 027482 4 WASHER SHAKEPROOF EXT 5 16 STL 38 022129 4 WASHER LOCK 8 5 16 39 039253 4 SCREW HHC M8 1 25 X 20 G8 8 1 APPLY LOCTITE 242 TO 36 BEFORE THREADING INTO 31 REVISION A DATE 2 26 07 GROUP C PAGE 2 OF 2 168690 ONIM VAGA 1 4 90 L 6 ALYA 797 3SV8 ONILNNOW AHIA QHGO Id XH V EXPLODED VIEW MOUNTING BASE 1 6L DRAWING 063531 APPLICABLE TO ITEM PART
36. 1 STR 102 30AD2 2006 CPL 30KW 0G3684 1 STR 102 30 0GD2 CPL 30KW 0G3687 1 STR 102 30 0KD2 CPL 30KW 0G5909 1 ASSY STR 102 30AD2 10 30KW 066103 1 STR 102 30 0JD2 9 0A5382A 1 BEARING CARRIER REAR LG PILOT 10 075591 2 ASSY HOLDER BRUSH 11 051787 4 SCREW HHC M4 0 7 X 16 G8 8 12 0A5601A 1 COVER REAR BEARING 13 075554B 4 BOLT STATOR X 16 LG 20KW amp 25KW 075554E 4 SCREW 8 1 25 X 463 G5 ZP 30KW 14 0A9375 4 SCREW RHM 10 24 X 2 15 022152 4 WASHER LOCK 10 16 064196 1 FLYWHEEL RINGGEAR ASSY 1 6L 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 049814 4 SCREW HHC M10 1 5 X 25 G8 8 19 0G0965B 1 PLATE FLEX 1 6L R12 7 20 053607 1 SCREW HHC M12 1 75 X 35 G8 8 21 051769 1 WASHER LOCK M12 22 023365 4 WASHER SHAKEPROOF INT 8 1 23 0F3353 6 SCREW HHC M10 1 0 X 20 G10 9 24 072578 1 SPACER ROTOR SHAFT 25 0G3787 10 WASHER 41 ID 94 OD 12 THK 26 0A8830 4 WASHER FLAT 34 ID X 75 OD 27 077043E 1 FLEX CONDUIT 1 BLACK NOT SHOWN 28 0G2070 1 PLATE SPACER 14GA 1 6L REVISION H 0854 G DATE 8 7 07 1 APPLY LOCTITE 242 BEFORE THREADING SCREW INTO CRANKSHAFT GROUP A PAGE 2 OF 2 086790 DNIM V AA Z dO 1 L0 S 6 ALVA 140 12 NOILOANNOO H LVOT H NOISIATH MHIA 21 A ose 9 g 6 vl 6 4 ut V Ol 310d
37. 10 2 PIN SPRING 1 4 X 3 4 19 005479 1 SCREW HHC M12 1 5 X 40 G10 9 20 059980 7 SCREW HHC M10 1 5 X 25 G10 9 21 046526 22 WASHER LOCK M10 22 022131 18 WASHER FLAT 3 8 M10 ZINC 23 063922 9 NUT HEX 10 1 5 CLASS 10 ZINC 24 0G0464 1 GASKET INTAKE MANIFOLD 1 6L 25 0G0465 1 GASKET EXHAUST MANIFOLD 1 6L 26 052858 14 NUT LOCK FL 8 1 25 27 051735 1 SCREW HHC M10 1 5 X 70 G8 8 28 063920 4 SCREW 10 1 5 X 110 610 9 29 0A7387 4 SCREW 10 1 5 X 40 G10 9 30 039414 1 SCREW HHC 8 1 25 X 35 68 8 31 022129 4 WASHER LOCK 8 5 16 32 022145 3 WASHER FLAT 5 16 M8 ZINC 33 029333A 1 TIE WRAP UL 7 4 X 19 BLK 34 057821 3 SCREW HHC 8 1 25 X 40 68 8 35 045771 3 NUT HEX M8 1 25 G8 CLEAR ZINC 36 022507 2 SCREW 1 4 20 X 1 2 G5 37 022097 2 WASHER LOCK M6 1 4 38 022473 5 WASHER FLAT 1 4 6 ZINC 39 090388 3 SCREW HHTT M6 1 0 X 12 ZINC 40 0A5768 5 WASHER FLAT M10 HEAVY DUTY 41 0 6751 1 SWITCH 245 D X 3 8 NPT 42 035579 1 BSHG 1 4 1 8 43 038584 1 SWITCH OIL PRESSURE 10PSI 2POL 44 001852 1 ADAPTER DRAIN OIL 45 070928 1 CLAMP HOSE OIL DRAIN 46 069860C 1 HOSE OIL DRAIN ASSY 21 47 069811 1 CAP HEX 1 4 NPT BRASS 48 0G38580ST03 1 STRUT LH 1 6L ENG ADAPT PLATE 49 025065 1 NIPPLE PIPE 3 8 NPT X 1 1 2 50 027738A 1 PIPE TEE 3 8 NPT 51 0E3257 3 SCREW HWHTF 6 1 0 X 16 52 0A8830 29 WASHER FLAT 34 ID X 75 OD 53 064582 1 HARN ENG 1 6L R200 3600 G11 NOT SHOWN 3600
38. 12 022131 1 WASHER FLAT 3 8 M10 ZINC 13 027482 1 WASHER SHAKEPROOF EXT 5 16 STL 14 0F3976 1 BOOT CONTACTOR CABLES 15 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 16 022145 REF WASHER FLAT 5 16 M8 ZINC NOTE WHEN INSTALLING BATTERY TUCK BATTERY S LIFTING STRAP ALONG THE LEFT SIDE OF BATTERY SIDE OPPOSITE RADIATOR BEFORE CONNECTING THE BATTERY CABLES REVISION A DATE 10 27 06 GROUP C PAGE 2 OF 2 GROUP D BELT TENSION 30 35 BROKEN IN BELT EXPLODED VIEW ENGINE COMMON PARTS 1 6L REVISION A DRAWING 0G3425 PAGE 1 OF 2 DATE 11 3 06 EXPLODED VIEW ENGINE COMMON PARTS 1 6L DRAWING 063425 GROUP D APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0G0207 REF ENGINE GENERAC 1 6L NG 2 0G0834 1 ENGINE PLATE 1 6L 3 060820 HOUSING BLOWER MACHINED 1 6L 4 0E9747 1 STARTER 12 VOLT 5 060839 2 ENGINE MOUNTING FOOT STAMPING 6 0G0781 1 EXHAUST MANIFOLD 1 6L MACHINED 7 0G0722 1 INTAKE MANIFOLD MACHINED 1 6L 8 0G4059 1 SHIELD 1 6L EXHAUST HEAT 9 064604 1 ALTERNATOR ADAPTER MACHINED 10 063424 1 PULLEY CRANKSHAFT MACHINED 3600RPM 064863 1 PULLEY CRANKSHAFT CASTING 1800RPM 11 0G0786 1 WASHER PULLEY 12 0G4605 1 BRACKET TENSIONER DC ALT 13 0 9617 1 SPACER ALTERNATOR 14 0A1354B 1 DC ALTERNATR HAN KOK 15 060823 1 V BELT 3 8 X 30 6 3600RPM 064949 1 V BELT 3 8 X 31 6 1800 16 063900 1 1 5 SHALLOW 17 002244 1 ASSY MAGPICKUP 3 8 24 MALE 18 0367
39. 294 LG 15 078115 18 WASHER SELF LOCKING DOME 16 0G4029 2 INSULATION SIDE DOOR C1 17 0G4029A 1 INSULATION ROOF C1 18 0F3890 5 RETAINER INSULATION 450 19 0E3257 4 SCREW HWHTF M6 1 0 X 16 20 0912970090 2 ASSY WIRE 14AWG GRNIYEL 32 25 LG 21 0640298 1 INSULATION REAR 1 22 0F3890B 4 RETAINER INSULATION 820 1 REFER TO CHART BELOW FOR COLOR AND MATERIAL TYPE 2 ALUMINUM ENCLOSURE NOTE ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 10 amp 19 THREAD FORMING FASTENER AND ITEM 3 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 SUFFIX 1 MATL SUFFIX 2 COLOR AL ALUMINUM 01 TAN ST STEEL 08 GRAY GENERIC SUFFIX 1 SUFFIX 2 EXAMPLE ie OF19870AL 01 REVISION A DATE 10 23 06 GROUP F PAGE 2 OF 2 468690 4 DNIA VIG C JO 1 9 4 90 1 6 ALVA 19 WALSAS LSNVHX4 AHIA QHGO Id XH dowd EXPLODED VIEW EXHAUST SYSTEM 1 6L DRAWING 063535 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0 7366 1 MUFFLER 1 2 0 7647 1 MUFFLER SADDLE 3 0 8095 1 PIPE EXHAUST OUTLET 4 0G3576 1 EXHAUST PIPE LOWER 1 6L 5 0E3257 4 SCREW HWHTF 6 1 0 X 16 6 0 7644 2 MUFFLER 7 0 6119 1 BOLT U 5 16 18 X 2 1 4 8 036434 3 BOLT U 5 16 18 X 2 09 9 036449 3 SADDLE 2 INCH 10 022129 6 WASHER LOCK 8 5 16 11 022259
40. 4 SCREWPHTT 4 0 7 X 12 ZYC 35 0C3990 2 SCREWPHTT M4 0 7 X 10 ZYC 36 091526 8 SCREW 5 0 8 X 12 ZNC 37 051716 7 NUT HEX 5 0 8 G8 CLEAR ZINC 43 043182 7 WASHER LOCK M3 44 051714 7 NUT HEX M3 0 5 G8 YEL CHR 45 0F3192 1 SUPPORT ANGLE PCB 46 0E7403C 1 FUSE ATO TYPE 15 AMP BLUE 47 064583 1 HARN CTRL PNL 200 LOW KW SHOWN 48 0 2627 1 COVER H PANEL COMPONENTS INSTALLED PER THIS DRAWING A 056739 1 RELAY SOLENOID 12VDC PNL MNT B 022287 2 SCREW HHC 1 4 20 X 3 4 G5 C 022473 4 WASHER 1 4 6 ZINC D 022097 2 WASHER LOCK M6 1 4 E 022127 2 NUT HEX 1 4 20 STEEL F 0F6145 AIR SEAL WEATHER 45 DIA G 063545 1 DANGER HIGH VOLTAGE SPANISH REVISION H 0467 C DATE 6 19 07 GROUP B PAGE 2 OF 2 877690 ONIM VYANA C JO I k9 19 WALSAS AHIA QHGO IdXH dad ONILNNOW 7s 8 5S AV1SOWH3HI OL 7 OL b 8 40018 NO agn L s 131 H31VM JO OL O OL 10 92 ALYA V 5 EXPLODED VIEW COOLING SYSTEM 1 6L C1 DRAWING 063428 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 063418 1 RADIATOR SUPPORT LH SIDE 1 6L 2 063421 1 VENTURI 1 6L 3 0G3419 1 RADIATOR SUPPORT RH SIDE 1 6L 4 0 9837 1 RADIATOR 1 61 5 063553 1 FAN COOL 450MM DIA 7 BLADE 6 0E3257 2 SCREWHWHTF M6 1 0 X 16 7 064080 1 HOSE LOWER RADIATOR 1 6L 8 099502 6 CLAMP HOSE 24 B
41. 6 NUT HEX 5 16 18 STEEL 12 038750 1 SCREW 6 1 0 X 30 68 8 13 063575 1 EXHAUST PIPE UPPER 1 6L SS 14 0F3794A 1 EXHAUST BLANKET 500 LONG 15 022097 1 WASHER LOCK M6 1 4 16 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 17 022473 6 WASHER FLAT 1 4 M6 ZINC REVISION A DATE 9 12 06 GROUP F PAGE 2 OF 2 GROUP G ER PTION 1 SINGLE PHASE R SERIES CONTROL PANEL 240V LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATUR MLCB MAIN CIRCUIT BREAK NEUTRAL BLOC 1 4 RED AR gt 1 2 46 r 956 gt 1 11 11 6 44 44 Q7Q 11 44 AS BS EC 1 LCB NB
42. 7 ITEM 1 16 17 18 19 20 1 21 1 22 23 24 25 1 26 3 27 28 29 1 30 1 31 1 32 1 33 1 34 1 35 1 36 1 37 1 38 1 39 40 4 4 4 4 46 47 1 49 1 50 1 2 51 1 52 53 PART 0E0591 059402 037561 0E1028F 0E1028E 059401 091526 049226 026915 062522 022127 0E1339 050279 050280 030795 0 6155 0 1104 0 0668 0E0590A 0E0590 005133 0 0665 0 1108 033138 022152 0 0645 034339 059194 057823 026073A 048031L 048031J 061985 0 3994 0 0568 0 0527 025105 0 0991 048031P QTY GROUP E DESCRIPTION ADAPTER CARB TO AIR CLNR FILTER ELEMENT NUT WING 1 4 20 NYLK ASSY CARBURETOR 1 6L 3600RPM ASSY CARBURETOR 1 6L 1800RPM CARBURETOR GASKET SCREW PPHM N5 0 8 X 12 ZNC WASHER LOCK M5 NIPPLE CLOSE 3 4 X 1 375 STUD TH 1 4 20 X 3 G2 ZNC FULL NUT HEX 1 4 20 STEEL PIN SPRING 3 16 X 5 8 DECAL FUEL INLET NG DECAL FUEL INLET LPG SCREW 5 16 18 X 1 G5 HARNESS FUEL JUMPER SINGLE REG GASKET AIR CLEANER ADAPTER O RING 2 028 1 38 X 1 50 X 06 VENTURI 20MM 3600RPM VENTURI 18MM 1800RPM O RING 29 82 X 2 62 SCREW THROTTLE PIN STOP THROTTLE ARM REWORK SCREW HHM 10 32 X 5 8 WASHER LOCK 10 LEVER THROTTLE STOP BARBED EL 90 3 8 NPT X 5 8 HOSE 5 8 ID LPG amp NG 12 LG CLAMP HOSE 10 56 1 06 PLUG STD PIPE 1 4 STEEL SQ HD CLAMP HOSE BAND 1 0 CLAMP HOSE BAND 63 HOSE BARB REDUCR TEE 3 4 3 8 PCV VALVE 2 5L FORD SHAFT THROTT
43. CD y 8 224 ALARM RELAY 9 XFER RELAY 710 23 MAN INPUT 11 239 16 SENSEC2 t12 225 13 0 6 8414 0 4 IN CONNECT FOR OPTIONAL EMISSIONS ONLY 144 2 14 ei 15 a 02 154 56 56 a a 154 INOTE 1 WIRING SHOWN FOR 1 NB BA AND STATOR IS TYPICAL FOR SINGLE PHASE FOR 3 PHASE SEE DWG OF 6839 NOTE 2 THIS PAGE APPLIES TO UNITS BUILT IN THE FIRST HALF OF 2006 PAGE 1 OF 3 REVISION G 7908 A DATE 04 20 06 N1 FRFCT 1 UTILITY FROM T SW Ne ACT 2 UTILITY FROM T SW ee NTR PAN N AVR AUTOMATIC VOLTAGE REGULATOR BCH BATTERY CHARGER BR1 BRIDGE RECTIFIER CB2 CIRCUIT BREAKER EXCITATION F1 FUSE BAT POWER 154 TYPE Je CONNECTOR 2 UN PCB J3 CONNECTOR PCB VARISTOR 680V R1 8 820 OHM RES R3 470 RES R4 FIELD BOOST RESISTOR RL1 RELAY 1 START RELAY RELAY 2 CENGINE RUN SCR SCR BRIDGE 5 1 AUTO OFF MANUAL SWITCH 5 2 SET EXERCISER SWITCH TR1 TRANSFORMER 1 6 UTIL 16 VAC Ne 15 15 Sw2 15 919 1 swi 5 0 15 194 839 o 194 54 S CT 3 TRANSFER COIL RELAY 33 CT 4 TRANSFER COIL RELAYNB 5 START CT 6 REMOTE START SS CUSTOMER CONNECTION amp ALTERNATOR LEGEND BA BRUSH ASSEMBLY GE
44. ER CONNECTION E1 E1 E3 Fl E2 GR E3 TO NB 120VAC TE THE 8th DIG F THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 0 PAGE 2 OF 5 ye cc I ae hh ee Y 241 WIRING DIAGRAM REVISION H 0767 D R SERIES CPL ALTERNATOR DATE 07 23 07 PAGE 2 OF 6 DRAWING 0 6839 GROUP G a LT 71 PTIDN 3 THREE PHASE R SERIES CONTROL PANEL 6 WIRE 277 480V LEGEND ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER B NEUTRAL BLOC 1 BLACK 4 RED AR gt 1 x jess x 2 46 m C SNP 9559 st5 1 S 6 516 44 1 76 52 DIRECT DRIVE
45. ERATOR AC LEAD CONNECTIONS See Voltage Codes This generator may be rated at any one of three voltages either single phase or three phase The electrical wires in units AC con nection lower panel should be installed according to the number of leads and the voltage phase required for the application If there are any questions regard ing lead connection refer to the wiring diagrams at the back of this manual Voltage codes apply to the type of stator assembly installed on a particular generator FOUR LEAD SINGLE PHASE STATOR Four lead generators see Figure 7 1 are designed to supply electrical loads with voltage code 240V 1 60 Hz Electrical power is produced in the stator power windings These windings were con nected at the factory to the main circuit breaker as shown in Figure 7 1 The rated voltage between each circuit breaker ter minal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator m tm oen E M p E3 1 120 10115 33 1 00 240 33 Tru NOLES 1 120 i 10115 11 I H Y Y CIRCUIT BREAKER Standby Generator Sets General Information GENERAL INFORMATION ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS The generator is designed to supply 3 phase electri cal loads Electric po
46. FLAT 10 ZINC J 049226 3 WASHER LOCK 5 K 051716 3 HEX 5 0 8 G8 CLEAR ZINC L 0E3257 7 SCREW HWHTF M6 1 0 X 16 REVISION H 1047 E DATE 9 5 07 ITEM 3 A r lt lt T m 9 O gt PART 005548 005549 005551 005552 005556 005557 009693 064502 066715 038150 022264 022471 038278 022097 005621 064498 0 3257 0 7283 063474 074908 0 3257 0 3664 064112 0 1354 063473 0 6366 0 6366 063524 057701 0 3824 057073 057329 004698 0 4464 025433 063472 0 3257 0 2212 022264 022241 022237 0 2265 023762 039457 0G4577E 0G4578E 047411 022097 049813 065249 WICB 0G5735 053640 038150 022264 022471 0F8432A 065734 0 3257 049897 022129 022145 058306 045771 0 8451 0 8843 23 mmmn gt N N N gt N N AND GROUP A DESCRIPTION UL BREAKER ED CB 0030A 3P 480V S ED4 LL CB 0035A 3P 480V S ED4 LL CB 0045A 3P 480V S ED4 LL CB 0050A 3P 480V S ED4 LL CB 0090A 3P 480V S ED4 LL CB 0100A 3P 480V S ED4 LL CB 0125A 3P 480V S ED4 LL CB COVER 20 30K 3P ED SCREW RHM 8 32 X 4 1 2 WASHER FLAT 8 ZINC WASHER LOCK 8 M4 NUT HEX 8 32 STEEL SCREW SHC 1 4 28 X 3 4 G8 8 NZ WASHER LOCK M6 1 4 WASHER STEP 1 200 9 320 BRASS CI
47. LE 1 5L THROTTLE VALVE PLATE 27MM SCREW RHMS 6 32 X 1 4 ZINC SEAL SHAFT COVER CLAMP HOSE BAND 88 1 INCLUDED IN ITEM 19 CARBURETOR ASSY 2 APPLY LOCTITE TO 51 BEFORE THREADING INTO IN 49 3 FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL INLET DECAL P N 050280 FOR NG FUEL INLET DECAL P N 050279 ITEM 27 NOTES 1 REGULATOR 3 AS SHOWN IN ILLUSTRATION IS SET UP FOR NATURAL GAS APPLICATION 2 TO CONFIGURE REGULATOR FOR LP VAPOR REFER TO THE RECONFIGURING THE FUEL SYSTEM SECTION OF THIS MANUAL PAGE 2 OF 2 GROUP INSULATION AND RETAINERS LOCATED ON THE NEAR SIDE INSULATION AND RETAINERS LOCATED ON THE FAR SIDE O TYPICAL MOUNTING OF ACOUSTIC INSULATION EXPLODED VIEW ENCLOSURE C1 CPL DRAWING 063534 PAGE 1 OF 2 DATE 10 23 06 REVISION A EXPLODED VIEW ENCLOSURE C1 CPL DRAWING 063534 APPLICABLE TO ITEM PART QTY DESCRIPTION 11 063337 1 ROOF 1 6L C1 1 2 063336 1 REAR INTAKE WRAP 1 61 C1 2 3 077992 16 NUT HEX LOCK M6 1 0 SS NY INS 1 4 063341 2 RIGHT SIDE DOOR 1 61 1 1 5 063335 1 FRONT DISCHARGE WRAP 1 6L 1 6 0F4487A 1 ASSY ACCESS COVER 7 022127 1 NUT HEX 1 4 20 STEEL 8 022097 1 WASHER LOCK M6 1 4 9 022473 1 WASHER FLAT 1 4 M6 ZINC 10 0C2454 16 SCREW THF M6 1 X 16 N WA 21 45 11 0F5048D 2 VISE ACTION LATCH SLOTTED CIR 12 0F5049 2 TAB PULL 13 0F8869D 1 KEY VISE ACTION LATCH SLOT CIR 14 089961 1 FOAM STRIP 3 4 WIDE X 3 16 THK
48. NERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by a Service Dealer That dealer will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying BATTERY All lead acid storage batteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric soluti
49. NERATOR CB1 MAINLINE CIRCUIT BREAKER 240V OUTPUT TO TRANSFER SWITCH ICT INTERCONNECT TERMINAL BLOCK NB NEUTRAL BLOCK UCT UTILITY CONNECT TERMINAL BLOCK SCR SCHEMATIC DIAGRAM PAGE 1 OF 3 1 6L 2 POLE DRAWING 0G1042 GROUP G ES ee Lc EPI DM 1 NOT USED NOT USED BLACK W1 RED We WHITE W3 GREEN W4 AFS START RELAY FUELCRUN gt RELAY 2 WIRE STARTCD MOMENT WIRE START MAN AUTD INPUT 16 SENSECD 7 8 224 ALARM RELAY 9 XFER RELAY 710 23 7 15 15 15 Sw2 15E o Lo 15 NTROL AVR AUTOMATIC VOLTAGE REGULATOR BCH BATTERY CHARGER BR1 BRIDGE RECTIFIER CIRCUIT BREAKER EXCITATION F1 FUSE BAT POWER 15 ATO TYPE Je CONNECTOR 2 UN PCB J3 3 UN PCB R4 FIELD BOOST RESISTOR RL1 RELAY 1 5 RELAY RELAY 2 CENGINE RUN 5 1 AUTO OFF MANUAL SWITCH 5 2 SET EXERCISER SWITCH TR1 TRANSFORMER 1 6VA 240 16 VAC e SW1 9 15 239 018 194 NOTE 1 zc r MAN INPUT 11 239 16VAC SENSEC2 12 225 J EMISSIONS ENABLET13 0 GND B 114 0 CONNECT FOR OPTIONAL EMISSIONS ONLY 14 1 14 UCT 1 L1 UCT 2 N UCT 3 GND CB1 Ose N C 15 G 9 zisa t ICT 1 UTILITY FROM T SW 2 66228 1 82
50. OV 12 sc STARTER OX INP 113 804 SM STARTER COIL 14 15R STM STEPPER MOTOR COIL 2 15 25 WLS COOLANT LEVEL SWITCH DISTRIBUTOR RET 16 0 DISTR INPUT 17 402 DEG PWM 18 DEG ENABLE 19 LOW DIL PRESS T20 86 CRANK SHIELD T21 SHLD COIL lt C Tee COIL B Te3 e5B 194 4 MP1 402 DUT 5 0 805 EMISSIDN 85 o In 105 86 OPTIONAL HCT CONTROL WLS 5735 gt DC VR NOTE THIS PAGE APPLIES TO ALL UNITS ae ttu eret Ea SCHEMATIC DIAGRAM REVISION G 7908 A 1 6L 2 POLE DATE 04 20 06 PAGE 3 OF 3 DRAWING 0G1042 911990 ONIM VG 149 NOLLVTIVLSNI 61211 166 821 6667 13315 7971 66111 ves 082142 tsz83 zee 13315 9 1 W3IA IS pen 5811 SE 1 5411 59 C13SN39 NV 01 5 31943 L3sN39 T JION 335 TIJS LHDI3M DNIddIHS SNIddIHS 1 913 DNILNDDN 31340 00 9190 1HDI3A 9
51. RCUIT BREAKER SUPPORT ED SCREW HWHTF 6 1 0 X 16 UL BREAKER QN CB 0150A 2P 240V S QN2 LL CONBOX FRONT COVER 1 6L QN 2P SCREW HHTT 5 0 8 X 10 BP SCREW HWHTF 6 1 0 X 16 BASE QN CIRCUIT BREAKER BREAKER SUPPORT BRACKET 30KW REGULATOR DC ALT CONBOX TOP PANEL SUPPORT XFMR 208 TO 16V 6VA 208V ONLY XFMR 240 TO 16V 6VA 240 480V COVER BELL HOUSING CONBOX BLOCK TERM 20A 8 X 6 X 1100V DECAL UTIL SENSEICUST CONN JUNCTION BLOCK 3 8 16 LUG SLDLSS 350 6X13 32 AL CU BLOCK TERM 20A 6 X 1100V DECAL CUST CONN 120V UTILITY LUG SLDLSS 6 14 X 13 64 CU CONBOX BACK amp SIDES 1 6L SCREW HWHTF M6 1 0 X 16 SCREW PHTT M4 0 7 X 16 ZYC WASHER LOCK 8 4 NUT HEX 3 8 16 STEEL WASHER LOCK 3 8 SCREW PHTT M4 0 7 X 12 ZYC WASHER SHAKEPROOF EXT 10 STL DECAL NEUTRAL ASSY R 200 3600 1 6L ASSY R 200 1800 1 6L SCREW HHC M6 1 0 X 16 G8 8 WASHER LOCK M6 1 4 NUT HEX M6 X 1 0 G8 YEL CHR UL BREAKER CB 150A 2 POLE 240V 225AF TERMINAL COVER CB CB COVER 30K G 225AF SCREW RHM 8 32 X 3 1 4 WASHER FLAT 8 ZINC WASHER LOCK 8 4 NUT HEX 8 32 STEEL INSULATOR CB 2P 225AF CIRCUIT BREAKER SPPRT G 225AF SCREW HWHTF M6 1 0 X 16 SCREW SHC 8 1 25 20 G8 WASHER LOCK 8 5 16 WASHER FLAT 5 16 M8 ZINC SCREW SHC 8 1 25 25 G12 9 NUT HEX 8 1 25 G8 CLEAR ZINC LUG SLDLSS 300 MCM 6 AL CU BUS BAR 200A LUG ADAPTOR PAGE 2 OF 2 0949720 ONIM VNA C JO 1 1911 0081 00774 AV
52. Serial Number 1 6L 18 kW Models STANDBY GENERATOR OWNER S MANUAL A new standard of reliability N Not intended for use in critical life support applications N CAUTION A ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY This manual should remain with the unit 2500 ON Hed Catalog Number OMASPEA018 1 10 60 SECTION PAGE SAFETY RULES 1 1 INTRODUCTION 1 3 Read this Manual 1 3 Operation and 1 3 How to Obtain iota ete eere sa 1 3 IDENTIFICATION RECORD 2 1 Data Label 2 1 EQUIPMENT DESCRIPTION 3 1 Equipment Description rene tnn 3 1 Engine Oil Recommendations 3 1 Coolant 3 1 ENGINE PROTECTIVE DEVICES 4 1 High Coolant Temperature Switch 4 1 Low Coolant Level 4 1 Low Oil Pressure 4 1 Overcrank Shutdown eere
53. TRODUCTION Thank you for purchasing this model of the standby generator set product line Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest 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 person nel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows A A After this heading read instructions that if not strictly complied with will result in serious person al injury including death or property damage amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis
54. W HHC 1 4 20 X 1 2 G5 16 0E1694 1 SPRING ANTI LASH REVISION A DATE 2 16 07 GROUP D PAGE 2 OF 2 0 6790 DNIA VIG C JO I 10 61 ALVA 149 19 19 Ad VON WALSAS 1919 V NOISIATA MHIA NOLLVWHOSNI 9 21 9 61 N l 31ON 33S ASSV 1 1 1 4 6c i SS3NHVH OL LO3NNOO OL 3AO8V NOILVYLSNTII NI NMOHS NOLLO3UIG NI S9NILNIOd MOHHV Q3TIVLSNI LSNW GION31OS INVLYOdWI Ol 41 Sc ve 5 3SOH SNLLSIX3 d ai dowd EXPLODED VIEW FUEL SYSTEM 1 6L C1 CPL DRAWING 064970 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 026812 2 ELBOW 90D 3 4 NPT 2 075580 1 FLANGE FUEL INLET 3 061397 1 FUEL REG REWORK 1 6L 3600 07 3600RPM 0613978 1 FUEL REG REWORK 1 6L 1800 07 1800RPM 4 039253 2 SCREW HHC 8 1 25 X 20 68 8 5 022145 2 WASHER FLAT 5 16 ZINC 6 022129 4 WASHER LOCK 8 5 16 7 045771 2 NUT HEX M8 1 25 G8 YEL CHR 1 8 0F1570 1 BODY CARBURETOR ASSEMBLY 9 0A6344 1 BARBED EL 90 1 8 NPT X 3 8 10 0C5210 1 HOSE 3 8 ID LOW PRES OIL WATER 16 LG 11 025424 1 NIPPLE PIPE 3 4 NPT X 6 12 0C5210 1 HOSE 3 8 ID LOW PRES OIL WATER 12 LG 13 0A5547 1 COVER AIR CLEANER 14 063178 1 HOSE BREATHER 1 6L 15 0D1509 1 DECAL INLET PRESSURE REVISION A DATE 2 19 0
55. age battery must be properly ventilated Do not allow smok ing open flame sparks or any spark producing tools or equipment near the battery Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster battery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging waRNING 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 recom mended number and type of battery is listed in the Specifications Section NOTE The BCI number should be located directly on the battery REPAIR PARTS The latter portion of this manual consists of exploded views parts lists and electrical data pertaining
56. alified service technicians should adjust the governed speed MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance CHANGING ENGINE OIL Refer to maintenance performed by service facilities for engine oil and filter change frequencies Drain the oil while the engine is still warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil completely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and re install into its retaining clip 4 Turn OIL FILTER Figure 10 2 counterclockwise and remove Properly dispose of old filter Figure 10 2 Oil Filter DIPSTICK 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters caution AN After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 7 Start engine and check for oil leaks CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner simply remove the air cleaner cover and replace the air filter making sure it is pos
57. and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via a 15 amp fuse These overcurrent protection devices will open if the circuit is overloaded caution A If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse CHECKING FLUID LEVELS CHECK ENGINE OIL Check engine crankcase oil level Figure 10 1 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Engine Oil Recommen dations for recommended oils 10 90 ed MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance Figure 10 1 Oil Dipstick and Oil Fill Cap OIL FILL CAP Yu 24 DIPSTICK X 9 4 o AWS LA BATTERY FLUID C
58. and test fuel system Check transfer switch Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY 1 Test engine governor adjust or repair if needed 2 Clean inspect generator 3 Flush cooling system FIRST 30 OPERATING HOURS 1 Change engine break in oil and filter FIRST 100 OPERATING HOURS 1 Change engine oil and oil filter After initial change service engine oil and filter at 100 operat ing hours or six months whichever comes first 2 Retorque cylinder head 3 Retorque intake and exhaust manifold EVERY 500 OPERATING HOURS 1 Service air cleaner 2 Check starter 3 Check engine DC alternator EVERY 800 OPERATING HOURS Retorque cylinder head Retorque intake and exhaust manifold Check engine compression Check valve clearance 10 1 COOLING SYSTEM intake and outlet openings in generator partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See the installation diagram warninc amp The exhaust system parts from this product get extremely hot
59. are held open by engine oil pressure during cranking and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO Standby Generator Sets Engine Protective Devices GENERAL INFORMATION OVERCRANK SHUTDOWN After a prespecified duration of cranking this func tion ends the cranking if the engine has failed to start The overcrank LED will turn ON Turn OFF the AUTO OFF MANUAL switch then turn switch back to AUTO to reset the generator control board NOTE If the fault is not corrected the overcrank feature will continue to activate Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total OVERSPEED SHUTDOWN A speed circuit controls engine cranking start up operation and shutdown Engine speed signals are delivered to the circuit board whenever the unit is running Should the engine overspeed above a safe preset value the circuit board initiates an automatic engine shutdown Contact the nearest Authorized Dealer if this failure occurs RPM SENSOR LOSS SHUTDOWN If the speed signal to the control panel is lost engine shutdown will occur DC FUSE This fuse is located inside of the control panel It protects
60. cting to the load by setting the control panel AUTO OFF MANUAL switch to the OFF position e Remove the 5 amp and 15 amp control panel fuses Turn off the battery charger turn OFF utility supply to ATS Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ONLY ONCE following the first three months or 30 run time hours of operation after purchase of the unit and requires approximately 2 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by a Service Dealer 3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed semi annually this requires approximately 1 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only
61. deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks security damage CHECK FAN BELT Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 of an inch Adjust belt tension as required INSPECT ENGINE GOVERNOR Visually inspect electronic governor A DAN A Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incor rect frequency and or voltage Only qu
62. egulator 6 Remove the NG fuel jet loosen counter clock wise from the outlet port 7 Remove the LP fuel jet loosen counter clockwise from the jet keeper port on the side of the regula tor housing Install this jet into the outlet port in the regulator casting 10 70 820290090 Utility In Transfer Switch 79 S 4 14 WIRES GENERATOR CONNECTION BOX gt ee TO GENERATOR CONNECTION BOX To Generator Control Panel NOTE The jet sizes are stamped on the individual jets The larger jet size is used for running on NG 8 Install the previously removed NG jet into the jet keeper port on the side of the regulator housing 9 Install the previously removed black pipe onto the outlet port of the demand regulator 10 Reverse steps 1 4 in this procedure to reactivate the demand regulator Figure 6 2 Reconfigure the Fuel System FUEL HOSE SPRING CLAMP FUEL ENRICHMENT LINE BLACK PIPE ASSEMBLY FUEL JET JET KEEPER e e A A Serious injury or damage may occur if not con figured properly Please consult an Authorized Dealer with any questions GENERAL INFORMATION GEN
63. entilation per installation drawings and applicable codes Correct AC and DC wire size connections and grounding Control and communication wiring to from the transfer switch must be run in a separate conduit from the AC power leads 10 10 ed INSTALLATION Standby Generator Sets nea Installation Battery charger connection to 120 Communication wires connected between transfer switch and generator HTS only Unit secured to pad START UP CHECKLIST warninc Before working generator ensure fol lowing The AUTO OFF MANUAL switch is in the OFF position The 120VAC supply to the battery charger is switched OFF PREPARATION FOR START UP Ensure that the 120VAC circuit breaker to the bat tery charger is open Remove the fuse from the the control panel Open the front door of the control box and remove the 15 Amp ATO fuse in the lower left hand corner of the control box Connect the battery cables to the battery Attach negative battery cable last Close the 120VAC circuit breaker to the battery charger Measure the voltage at the battery before and after the charger is turned on Verify all AC electrical connections are tight at the circuit breaker and transfer switch Visually inspect entire area looking for loose paper plastic wrappings leaves etc Check all hoses clamps fittings for leaks or dam age Check all electrical plugs
64. er should be aware of the following The natural gas and LP gas systems are similar However the natural gas system delivers gas at a pressure of approximately five inches water col umn to the carburetor When ambient temperatures are low and engine fuel consumption is high the vapor withdrawal system may not function efficiently Ambient temperatures around the supply tank must be high enough to sustain adequate vaporiza tion or the system will not deliver the needed fuel volume In addition to the cooling effects of ambient air the vaporization process itself provides an additional cooling effect LP FUEL SYSTEM LP is supplied as a liquid in pressure tanks It is usually made up of propane butane or a mixture of the two gases Propane tends to vaporize readily even at temperatures as low as 20 F 29 C However butane reverts to its liquid state when temperatures drop below 32 F 0 C LP in a liquid withdrawal system must be converted to its gaseous state before it is introduced into the engine carburetor A vaporizer converter is generally used to accomplish this In such a converter heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state 90 80 100545114 GENERAL INFORMATION SPECIFICATIONS GENERATOR ann Synchronous Rotor Insulatiori iuueni ttt tct Class F S
65. he generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extin guisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris These generator sets may operate using one of several types of fuels All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulat ing the storage and handling of fuels Inspect the units fuel system frequently and correct any leaks immediately Fuel supply lines must erly installed purged and leak tested according to applicable fuel gas codes before placing this equip ment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detectors accordingly Standby Generator Sets IN
66. heck battery electrolyte fluid based on the Maintenance Schedule Fluid should cover separa tors in all battery cells If fluid level is low add dis tilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications Add recommended coolant mixture as necessary Periodically remove radiator pressure cap only when engine has cooled down to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radiator filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact a Service Dealer Inspect cooling system and coolant recovery sys tem for leaks MAINTENANCE OWNER OPERATOR CAN PERFORM CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels CHECK BATTERY See Checking Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary 10 90 10 2 EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 20 minutes For more detailed exercise information see the respective sec tions in the Control Panel Technical Manual that is supplied with the unit INSPECT COOLING SYSTEM Inspect engine cooling system See Maintenance Schedule Check hoses for damage
67. ictly to local state and national electri cal and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operated and serviced in accordance with the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon mon oxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided 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 compliance with appli cable 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 venti lating air is critical in any room or building hous ing the generator to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installa
68. itioned properly before reattaching the cover Figure 10 3 See the Service Schedule for air cleaner mainte nance 10 3 Figure 10 3 Engine Air Cleaner Air Cleaner 292 X XXX e 05050 o Doors Removed for Clarity SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary Figure 10 4 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Service Schedule section for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 inch by carefully bending the ground electrode Figure 10 4 Figure 10 4 Setting the Spark Plug Gap SET PLUG GAP AT 0 76 mm 0 030 inch COOLANT CHANGE Every year have a service facility drain flush and refill the cooling system See Specifications for cool ing system recommendations 10 90 ed MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance MISCELLANEOUS MAINTENANCE CLEANING THE GE
69. l Information NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Generator Model and Serial Number This number is the key to numerous engineering and manufacturing details pertaining to your unit Always supply this number when requesting service order ing parts or seeking information Data Label CAT CUST PROD DATE KW KVA PHASE HERTZ VOLT AMP PWR FACT ALT RPM ENG RPM ALT SUBTRANS REACTANCE ALT TRANS REACTANCE CLASS ROTOR STATOR WINDING INS AT 25 C AMB RAN MANUFACTURINGINFORMATION VY 2 10 60 900 GENERAL INFORMATION EQUIPMENT DESCRIPTION This equipment is a revolving field alternating cur rent generator set It is powered by a gaseous fueled engine operating at 1800 rpm 4 pole direct drive units 3600 rpm for 2 pole direct drive units and 2300 3000 rpm quiet drive gear units See Specifications section for exact numbers The unit comes complete with a sound attenuated enclosure internally mounted muffler control console
70. mp Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications and Coolant sections BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inch 10 to 16 mm ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground Make sure the generator battery is fully charged properly installed and interconnected and ready for use NOTE Battery charger must be connected to 120 VAC 15 amp circuit to operate Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components INITIAL INSPECTION FOR GENSET STARTUP Inspect for the following Freight Damage Manuals present Fluid Levels Oil coolant battery Gear Drive Correct fuel piping Adequate air flow clearances and v
71. n GENERAL INFORMATION COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is listed in the specifications Use only deion ized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the recommended coolant mixture When adding coolant always add the recommended 50 50 mixture caution AN Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chro mium hydroxide green slime forms and will cause overheating Engines that have been oper ated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment DIG A Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result AN Ethylene glycol base antifreeze is 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 10 90 200003 GENERAL INFORMATION
72. on that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury BATTERY MAINTENANCE The battery should be inspected per the Scheduled Maintenance section The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 10 90 LOWEN 10 4 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer A A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charg ing The slightest spark can ignite the gas and cause an explosion Such an explosion can shat ter the battery and cause blindness or other injury Any area that houses a stor
73. ower source and shut down the generator follow these direc tions Set the standby generator s main line circuit break er to its OFF or OPEN position Manually move the transfer switch handle to its UTILITY NORMAL position i e load circuits connected to the utility Turn ON the utility power supply to the transfer switch using the means provided such as the util ity power source main line circuit breaker Let the generator run at no load for a few minutes to stabilize internal temperatures Shut down the generator OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If the generator has been installed with an automatic transfer switch such as an RTS HTS or GTS type transfer switch the engine may be started and stopped automatically or manually NOTE Refer to the applicable manual for your trans fer switch and to Transfer Switch Start Signal Connections In addition please note the dangers under Engine Start up and Transfer 90 80 0 1001990 MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance MAINTENANCE PERFORMED BY SERVICE FACILITIES warninc amp Before working on the generator ensure the fol lowing The AUTO OFF MANUAL switch is in the OFF position The 15A fuse has been removed from trol box The 120VAC supply to the battery charger 15 switched OFF EVERY THREE MONTHS Check battery condition Inspect
74. perature 50 C 140 F FUEL SYSTEM Type u ua naa Natural Gas Propane Vapor Down Draft Secondary Fuel Regulator Standard Fuel Shut off Solenoid sss Standard Operating Fuel Pressure 5 in 14 in Water Column Fuel Consumption ft3 hr Natural Gas LPV Exercise 2590 5090 7590 100 Cycle Load Load Load Load 56 24 104 43 158 66 210 87 265 110 ELECTRICAL SYSTEM Battery Charge Alternator 12V 15 Amp Static Battery Charger 2 Amp Recommended Battery Group 26 525CCA System Voltage uentris 12 Volts Voltage Regulator Electronic SENSING asuy Single phase ll 196 V F Adjustable Adjustable Voltage and Gain LED Indicators Power Adjustment for Ambient Conditions Temperature Deration 3 for every 10 C above 25 1 65 for every 10 above 77 Altitude Deration 1 for every 100 m above 183 3 for every 10
75. r loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiring for loose connections corrosion and damage Correct as necessary 10 Check the engine accessory drive belts for wear weather cracking and damage Replace as necessary 11 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 12 Test the engine and transfer switch safety devices Correct and or adjust as necessary e N gt a 90 90 ed 200 25 5 11 2 Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp be done Comp Comp Required Comp to done Date 3 months Date i Date be done Date monthly Initials Break in Initials Initials Annually Initials 10 Hrs 13 Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 14 Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 the engine oil
76. r PACS su upam a a qay qe 10 4 SERVICE SCHEDULE 11 1 TROUBLESHOOTING 12 1 Troubleshooting 12 1 NOTES EXPLODED VIEWS amp PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS 20 70 V ed Standby Generator Sets SAFETY RULES Important Safety Instructions 7 SAVE THESE INSTRUCTIONS manufacturer suggests that these rules for safe operation N be copied and posted in potential hazard areas Safety should be stressed to all operators potential operators and service and repair technicians for this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before install ing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reli ably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might invol
77. rocedures For follow up maintenance information service intervals please refer to the Maintenance section and the Service Schedule TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems For additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with applicable codes standards and regulations FUEL SYSTEM Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and b is properly purged and leak tested according to code No fuel leakage is permitted See Specifications for more information GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULT mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications and Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with break in oil This oil should be changed after 30 hours of operation PRIOR TO INITIAL START UP caution a
78. rs Manual in a safe and accessible place Make certain the AUTO OFF MANUAL switch is in the AUTO position Standby Generator Sets OD GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator s manual for this unit OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the generator was installed in conjunction with a transfer switch capable of manual operation only the following procedure applies A manually operated transfer switch is one that will not provide automatic start up and does not include an intelligence circuit ENGINE START UP AND TRANSFER For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch A DIG A The Maintenance Disconnect Switch and the AUTO OFF MANUAL switches if so equipped must be set properly or the generator will crank and start as soon as the utility power to the transfer switch is turned off Refer to applicable control panel and transfer switch manuals for more information Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to UTILITY Do not attempt manual operation until all power supplies to the transfer switch have been posi tively turned off or extremely dangerous pos sibly lethal electrical shock will result Transfer switch enclosure doors should be kep
79. t closed and locked Only authorized personnel should be allowed access to the transfer switch interior Extremely high and dangerous voltages are present in the transfer switch In order to transfer load from the utility source to the generator follow these directions Turn OFF or disconnect the utility power circuit to the transfer switch using the means provided such as the utility source main line circuit break er Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the standby generator s main line circuit break er to its OFF or OPEN position Start the generator Operation caution 4 Do not crank the engine continuously for longer than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge read ings When certain that all readings are correct move the transfer switch manual handle to its STANDBY GENERATOR position i e load cir cuits supplied by the generator Set the standby generator s main line circuit break er to its ON or CLOSED position Load circuits are now powered by the standby generator RETRANSFER AND SHUTDOWN For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch To transfer the load back to the utility p
80. tator cet ette Class F Total Harmonic Distortion lt 5 Alternator Output Leads 3 phase 4 wire in etd reni a Hn aid ei Sealed Ball eec Flexible Disc Load Capacity Standby 18 kW NOTE Generator rating and performance in accordance with 508528 5 BS5514 SAE J1349 1503046 and DIN 6271 Standards KW rating is based on LPG fuel and may derate with natural gas Excitation a i sec mn asnuq luna s Direct Generator Output Voltage kW 60 Hz kW Amp CB Size 120 240V 1 phase 1 0 pf 18 75 90 120 208V 3 phase 0 8 pf 18 63 70 Generator Locked Rotor KVA Available Voltage Dip of 3596 Single phase or 208 3 35 KVA ENGINE IL cm Generac In Line Cylinders and 4 Displacement u e ttp ce tec 1 6 Liter BO 3 15 in Jp cm CC 3 13 in Compression Rallo nett 9 75 to 1 Air Intake Naturally Aspirated Vale inerte teta ndr Replaceable Lifter caeca acetate tas Hydraulic Engine Parameters Rated Synchronous
81. tion or permit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts 10 80 8 ed Before performing any maintenance on gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc Z ELECTRICAL HAZARDS All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the standby generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appropriate covers guards and barriers are in place before operating the gen
82. ution system when the generator is operat ing Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy 10180 8 Standby Generator Sets Important Safety Instructions SAFETY RULES Generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to person nel disable the generator s automatic start circuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and the transfer switch In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a dry rope or board to free the vic tim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS Keep a fire extinguisher near t
83. ve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If a pro cedure work method or operating technique is used that the manufacturer does not specifically recom mend ensure that it is safe for others Also make sure the procedure work method or operating tech nique utilized does not render the generator unsafe A AN Despite the safe design of this generator operating this equipment imprudently neglect ing its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to install operate or main tain this equipment Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators GENERAL HAZARDS For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by 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 standards laws and regulations Adhere str
84. wer is produced in the alterna tor power windings These windings were connected at the factory to the main circuit breaker with a Y configuration as shown in Figures 7 2 and 7 3 The rated voltage between circuit breaker terminals 1 2 1 and E2 E3 is either 480V or 208V depending on the model The rated voltage between each circuit breaker termi nal and the neutral point 00 is either 277V or 120V depending on the model Figure 7 2 Stator Power Winding Connections 3 phase 277 480V 6 Lead S1 E1 1 INTERNAL CONNECTIONS L L 56 lt gt 84 NEUTRAL 21 53 S2 Tw Figure 7 3 Stator Power Winding Connections 3 phase 120 208V 6 Lead E1 S4 54 00 NEUTRAL 53 E3 53 52 40 80 0 INSTALLATION Standby Generator Sets C y Installation i INSTALLATION INSTALLATION Refer to the separate Installation Guide supplied with the unit PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed ser viced tested adjusted and otherwise prepared use by a competent qualified installation contractor Be sure to read the Safety Rules as well as all other safety information in this manual before attempting to operate this and related equipment Before starting the generator for the first time the installer must complete the following p

Generac Power Systems 1.6L 18 kW Portable Generator User Manual

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