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Generac Power Systems 005219-0 Portable Generator User Manual

1. DUREE INCUN 4 SCHEMATIC DIAGRAM REVISION G 3264 C 3 0L COMM PROD LINE PAGE 1 OF2 DATE 8 4 05 DRAWING 0F4265 GROUP G ILI 1 CB Jt ENGINE WIRING LEGEND AFS AIR FUEL SOLENOID ALT D C CHARGE ALTERNATOR 12VDC BATTERY DEG 12V 1 14 CC STARTER CONTACTOR OX INP RET 2 805 CP COIL PACK COOLANT SENSORS 1 4 85 DEG 2 DRIVER ELEC G DEG DRIVER ELEC GOVERNOR DEG OV L5 767 FS FUEL SOLENOID DEG 5V 6 765 FS2 AUX FUEL SOLENOID DISTRIBUTOR 12V 7 GOV ELEC GOVERNOR ACTUATOR HIGH COOLANT TEMP SWITCH Ji CONNECTOR 1 ON PCB CRANK SENSE 110 0 LFP LOW FUEL PRESSURE SWITCH INP 11 601 LOS LOW OIL PRESSURE SWITCH DEG FDBK 12 766 02 OXYGEN SENSOR OX INP 115 804 SM STARTER MOTOR COIL s 114 158 WLS COOLANT LEVEL SWITCH COIL 15 25A DISTRIBUTOR Pur 17 DISTR INPUT 17 DEG 18 769 DEG ENABLE 119 768 LOW OIL PRESS 120 86 CRANK SHIELD 21 SHLD COIL C 22 25C COIL B 123 258 A Ld CS 22 Tn p m 15 dois 25 02 25 14 l 86
2. GROUND E Utility In Transfer Switch O O O6 NEUTRAL f ooo 4 14 WIRES GENERATOR CONNECTION BOX TO GENERATOR CONNECTION BOX Ground Level Concrete Slab STUB UF AREA See Install Dwg for Dimensions COLD WEATHER KIT For cold climates optional cold weather kit part number 0F6148 is recommended The kit includes e Battery Warmer e 4 Junction Box with hardware e 6 qt pack 5W 30 synthetic oil engine RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for natural gas or LP vapor from the factory To reconfigure the fuel system from NG to LP follow these steps 1 Turn the main gas supply off 2 Remove the carburetor fuel hose from the outlet port Port 1 of the demand regulator Figure 6 2 Remove the brass hose fitting from the outlet port Port 1 of the demand regulator Remove pipe plug from Port 2 Install brass hose fitting into Port 2 Install pipe plug into Port 1 Connect carburetor gas hose to brass fitting Tighten all clamps and plugs Make sure fuel supply is of the proper pressure and type for configuration CONDO S0 LL ed 2002905 0 To Generator Control Panel CIRCUIT BREAKER SIZE
3. 1139 44 847 DOOR TYP Pd EXHAUST MUFFLERS ENCLOSED WITHIN SEE NOTE 6 FRONT COVER SEE NOTE 4 AIR INLET LOUVERS CIRCUIT BREAKER SEE NOTE 3 STUB UP AREA 69e 27 247 49 NATURAL GAS LINE 3 4 FEMALE COUPLING LOCATED ON OPPOSITE RH SIDE LIFTING PROVISION 4 PLACES SEE NOTE 5 AND REAR VIEW CENTER OF GRAVITY DIMENSIONS FIELD CUT HOLE FOR OUTSIDE CONDUIT LEFT SIDE VIEW CONNECTION ONLY SEE NOTE 4A REVISION G 5155 A DATE 5 3 05 PAGE 2 OF 2 GROUP el OPTION 1 SINGLE PHASE R 100 CONTROL PANEL 240V LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER B NEUTRAL BLOCK DIRECT DRIVE 45 GENERATOR OUTPUT CUSTOMER CONNECTION El 240 1 190VAC NB 120 PAGE 1 DF 4 21 WIRING DIAGRAM REVISION G 6245 A R 100 CPL ALTERNATOR DATE 08 17 05 PAGE 1 OF 4 DRAWING 0F6839 REVISION G 6245 A GROUP G OPTION 2 THREE PHASE R 100 CONTROL PANEL 6 WIRE 120 208V LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER B NEUTRAL BLOCK ge ON DIRECT DRIVE AS 1 Ee GENERATOR OUTPUT CUSTOMER CONNECTION E
4. E 805 OPTIONAL 3 HCT EMISSION 85 0 CONTROL 2 WLS 85 5 gt gt 56 l 1 1t9 14 Jj al r s am sma E 4 REVISION 3264 DATE 8 4 05 PAGE 2 OF 2 SCHEMATIC DIAGRAM 3 0L COMM PROD LINE DRAWING 0F4265 EXPLODED VIEW INSTALL DWG 3 0L 30KW amp 3 9L 40KW DRAWING 0F6286 GROUP G APPLICABLE TO WEIGHT DATA 3 OL 30KW 649KG 1431 LB 3 9L 40KW 752KG 1658 LB WOODEN SHIPPING SKIDS INCREASE OVERALL WEIGHT 42KG 98 LB NOTES 12 MINIMUM RECOMMENDED CONCRETE PAD SIZE 1460 57 5 WIDE X 2560 100 872 LUNG REFERENCE INSTALLATION GUIDE P N OF S298 FOR CONCRETE PAD REINFORCEMENT AND PAD DEPTH GUIDELINES 02 GENERATOR MUST BE LOCATED A MINIMUM DISTANCE OF 5 FEET FROM A WALL OR FENCE ALLOW A 5 FOOT MINIMUM PERIMETER OF OPEN SPACE AROUND THE ENTIRE GENERATOR REFERENCE INSTALLATION GUIDE P N 0 5298 FOR OUTDOOR ROOF MOUNTED APPLICATIONS 3 gt CIRCUIT BREAKER INFORMATION SEE SPECIFICATION SHEET WITHIN OWNERS MANUAL 4 INSIDE STUB UP AREA FOR AC LOAD LEAD CONDUIT CONNECTION NEUTRAL CONNECTION BATTERY CHARGER 120 VOLT AC 5 MAX CONNECTION AND ACCESS TO TRANSFER SWITCH CONTROL WIRES
5. 10 2 Changing Engine 10 2 Changing the Engine Air Cleaner 10 3 Spark Plugs eee o 10 3 Coolant Change eoe ctetuer rore oe EE son s 10 3 Miscellaneous Maintenance 10 3 Cleaning the Generator 10 3 Battery PC 10 3 Battery Maintenance 10 4 Battery Replacement 5 ot eer 10 4 SERVICE SCHEDULE 11 1 30 kW 150 kW Standby Gas Engine Driven Generator Sets 11 1 TROUBLESHOOTING 12 1 Troubleshooting 12 1 NOTES EXPLODED VIEWS amp PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS WARRANTY 90 80 0 ed 100199000 Standby Generator Sets SAFETY RULES Important Safety Instructions 7 N SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas Safety should be stressed to all operators potential operators and service and repair technicians for this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of Californ
6. 742 ML af 1 4 5 Ml N 282272 N 45 42 47 MM 1 7 42 i eee 2 Quo 7 20 20 6 ALVA 76 9 9 EXPLODED VIEW MUFFLER EXHAUST 3 0L CPL 30KW C2 DRAWING 0F3523 APPLICABLE TO PART REVISION G 6494 B DATE 9 22 05 QTY NROOBRNNNN A N Hi E I E E S DESCRIPTION MUFFLER 7 X9 2 2 IN25 PIPE EXHAUST MUFFLER MUFFLER BRACKET STIFFENER MUFFLER STRAP BOLT U 3 8 16 262 EXHAUST BLANKET 800MM C2 EXHAUST BLANKET 750 2 EXHAUST PIPE 3 0L C2 CPL RH EXHAUST PIPE 3 0L C2 CPL LH GASKET EXHAUST RING WASHERLOCK 38SS SCREWHHC 3 8 16 13455 EXHAUST FLANGE 2 PIPE SCREWHHC 1 0 16G88 WASHER LOCK 14 WASHER FLAT 144 ZINC BOLT 0 5 1618 225 NUT HEX 5 16 24STEEL WASHER LOCK 5 16 WASHER FLAT 38SS PIPE EXHAUST ELBOW3 0L C2 GROUP F PAGE 2 OF 2 GROUP INSULATION AND RETAINERS LOCATED ON THE NEAR SIDE RETAINER 696263 7 INSULATION AND RETAINERS LOCATED ON THE FAR SIDE TYPICAL MOUNTING OF ACOUSTIC O 2 REF INSULATION DETAIL AND B FOR SPLITTER VARIATIONS TO BASE FRAME 2 EXPLODED VIEW ENCLOSURE C2 REVISION G 6440 B DATE 10 10 05 DRAWING 7 0F7887 PAGE 1 OF2 EXPLODED VI
7. FOUR LEAD SINGLE PHASE STATOR Four lead generators see Figure 7 1 are designed to supply electrical loads with voltage code A 240V 1 60 Hz Electrical power is produced in the stator power windings These windings were con nected at the factory to the main circuit breaker as shown in Figure 7 1 The rated voltage between each circuit breaker ter minal is 240V The rated voltage between each circuit breaker terminal and the neutral point OO is 120V Figure 7 1 Four lead Single phase Stator m tm oen E M p E3 1 120 I 10115 33 10 240 33 NOLES 120 i 10115 1 11 L I H Y Y CIRCUIT BREAKER Standby Generator Sets General Information GENERAL INFORMATION ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS The generator is designed to supply 3 phase electri cal loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit breaker with a Y configuration as shown in Figures 7 2 and 7 3 The rated voltage between circuit breaker terminals 1 2 1 E2 E3 is either 480V or 208V depending on the model The rated voltage between each circuit breaker termi nal and the neutral point 00 is either 277V 120V depending on the model Figure 7 2 Stator Power Winding Connections 3
8. Reconnect wire Clean regap or replace plugs Close door on tank Clean or replace as needed Unclog fuel line Clean regap or replace plugs Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch 1 Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Auto reset Wait 5 min and attempt restart Contact the nearest Authorized Dealer for assistance 12 1 50 80 0 100149191 NOTES Standby Generator Sets Notes NOTES 9165530 ONIM VAGA C JO 1 4 SO T TI ALYA X313 95 9 O 149 4 2119 0 NOISIATY 4 V dnodd EXPLODED VIEW CPL C2 amp C4 FLEX HSB DRAWING 0F3391D APPLICABLE TO ITEM PART QTY DESCRIPTION 1 1 7 1 2 F3188 1 STAND RHCONTROL 3 F3129 1 STANDLHCONTROL 4 02348 1 BUSHING SNAP 5 2 5 31 5e CF6366B 1 2 XFMR DUAL 120 197 FOR 120240V amp 277480 UNITS OF6366A 1 XFMRDUAL 104 16V FOR 120208V UNITS 6 043180 2 4 WASHERFLATMT 7 022261 2 4 WASHERLOCK 8 ge 0 3990 2 4 SCREWPHIT M407 X10ZYC 9 057701 REF BLOCK TERM2DA8X 6X 1100
9. SPACER FLEX PLATE 3 0L FORD 3600 RP 25450506 daggasesaggSsuUsu GROUP D PART 4 QTY DESCRIPTION 027482 1 WASHER SHAKEPROCF EXT 5 1651 061012 1 PLUG STDPIPE 1 8 SOCKET HEAD 036751 1 SWTCHH TEMP 2450 X 3 8NPT 083472 3 RIVETPOP I25X 400AL E6729 1 STARTER LW 0E6X8 1 COVER FLYWHEEL ACCESS 3 0L HSB E6667 1 ENGINE ADAPTER 3 0L FORD 03908 1 FLEX PLATE 2POLE 3 0L FORD 3600 RP 0 5048 1 FLEXPLATE HSB 3 0L FORD 1800 RPM 085579 1 BUSHING REDUCER 1 4 1 8 048584 1 SWTCHOIL PRESSURE 10 PSI 2POL 7649 1 CLAMP HOSE 38 87 060860 1 HOSE DRAINASSY 28 083896 6 WASHER LOCK 14M6 SS 084929 6 WASHER FLAT 1 455 F33 4 6 WASHER FLAT 45 X 100 026151 1 RUBBER 057823 1 CLAMP HOSE 340 56 1 06 013790 1 BARBEDEL 9038 X38 077411 4 SCREWHHC 1 0 16G88 022097 4 WASHER LOCK 1 4 22473 4 WASHER FLAT 14M6 ZINC 057765 1 ADAPTER MI4 L50X 38 NPT 040976 8 SCREWSHC 1 25 20G129 022129 12 WASHERLOCK 5 16 022145 5 WASHER FLAT 5 16 057772 1 WASHER NYLON 565 057645 3 SCREWHHC MIO L5X 50G88 029913 12 SCREWSHC 1 25 3555 059980 4 SCREWHHC 1 5 25 6109 1800 Y 005417 REF SCREWHHC 1 0 256109 016526 WASHER LOCK 1800 Y 046526 9 WASHER LOCK MIO 3600 Y 059982 4 SCREWSHC MI2 175X 45 G109 008780 2 SCREWHHC 12 175 X 65688 051769 2 WASHERLOCKMI2 049808 2 WASHER FL
10. 10 022155 4 WASHERLOCK 6 11 00228 4 SCREWPHIT 632 X 1 2ZYC 12 1 DECAL UTIL SENSE CUST CONN 13 049457 1 DECAL NEUTRAL 14 057073 2 JUNCTIONBLOCK 38 16 15 025466 REF BUS BAR NEUTRAL BLOCK 390 1695 047822 REF LUGSLDLSS 600 250 1 0 1428 17 02237 2 WASHERLOCK 3 8 18 022241 2 NUT HEX 38 16 STEEL 19 7 WASHER LOCK 20 0 2266 6 SCREWPHIT IV508X 16ZYC 2 0 254 8 SCREWTHF 1 16 ZJ S 23 022473 8 1 4 022097 4 WASHER LOCK M514 26 024698 REF BLOCK TERM20A 6 1100 7 1 DECAL CUST CONN 120V UTILITY 28 025433 1 LUGSLDLSS 6 14 X 13 64 29 004409 1 SCREWHHIT 2032 38 2 30 067210A 1 DECAL GROUNDLUG 31 026029 4 SCREWHHITM5 10X16ZYC gt 081008 1 GROMVETL125X25X 75 077013 1 CONDUTFLEX2O ID 36 LG x 051713 2 WASHER FLAT 35 026156 1 PLATE WRE SNGL GALV 36 029289 1 TAPE ELEC 1 2 FOAM AS REQ D 37 4 SCREWHHC M amp 10X 16688 3g 0641538 2 WIRE J UVPER TRANSFORMER NOT SHOWN 1 UL CIRCUIT BREAKER ED A 03328 1 COVEREDCB SHORT STND B 065469 1 DECAL DANGER HIGH VOLTAGE 005552 1 0050A 480 5 ED4LL 005554 0070A 48V S EDALL 005556 0000 3P 480 5 ED4 LL 029698 0125 480 5 ED4LL D 1 INSULATOR ED 3P 048927 4 SCREWRHM 440 322 4 1 2 F 023897 4 WASHERRLAT 0ZINC G 022152 4 WASHER LOCK 10 H 022158 4 NUT HEX 40 32 STEEL J 0 51 7 SCREWTHF 1 16 ZJ S 029289 1 ELEC 1 2 F
11. KW VOLTS AMPS LUG SIZE 30 24010 150 6 to 350 mcm 30 20830 125 6 to 350 mcm 30 48030 50 10 to 1 0 10 Reverse the procedure to convert back to natural gas 11 The Dip switch inside the control panel must be in the LP NG position when switching to differ ent fuels Figure 6 2 Reconfigure the Fuel System FUEL HOSE BRASS HOSE FITTING OUT PORT 2 Port 1 FUEL HOSE I BRASS PLUG f FITTING LL HOUSING PORTS Port 2 PLUG n HOUSING PORTS NG FUEL SYSTEM LP FUEL SYSTEM NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made NOTE For LP vapor application substitue LPG fuel inlet decal P N 050280 for NG fuel inlet decal P N 050279 GENERAL INFORMATION GENERATOR AC LEAD CONNECTIONS See Voltage Codes This generator may be rated at any one of three voltages either single phase or three phase The electrical wires in the units AC con nection lower panel should be installed according to the number of leads and the voltage phase required for the application If there are any questions regard ing lead connection 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
12. MAINTENANCE MAINTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom Task Required Task Required Task Task Required Task mended Comp to be done Comp to be done Comp Required Comp to be done Comp to be done Date 3 months Date Semi Date to be done Date Bi Date monthly Initials Initials annually Initials Annually Initials annually Initials 10 hrs 30 hrs 50 hrs 100 hrs 250 hrs 10 Check the engine accessory drive belts and fan coupling device if equipped for correct tension wear weather cracking and damage Replace as necessary 11 Check the engine valve clearance Adjust as necessary 12 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 13 Test the engine and transfer switch safety devices Correct and or adjust as necessary 14 Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 Replace the engine accessory drive belts 16 Check gearbox oil level if equipped L TL TIT TT oil if equipped 11 3 90 60 V ed LOOPYISMS Standby Generator Sets MAINTENANCE Service Schedule Maint
13. OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized Service Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by an Authorized Service Dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact an Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting an Authorized Service Dealer or the factory about parts and service always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit AUTHORIZED SERVICE DEALER LOCATION
14. 60 Hz kW Amp CBSize 120 240V 1 phase 1 0 pf 30 125 150 120 208V 3 phase 0 8 pf 30 104 125 277 480V 3 phase 0 8 pf 30 45 50 Generator Locked Rotor KVA Available Voltage Dip of 3596 Single phase or 208 3 60 KVA ABON S phiase cte dede idee end 70 KVA ENGINE MH V type Cylinders and 6 Displacement k l ll u ll 3 0 Liter crust nta pudiera editi end EL teram pede 3 55 in 510 hte 3 1 in Compression 9 3 to 1 Air Intake Naturally Aspirated Valve Seats asa anu aan Hardened Eno E Hydraulic Engine Parameters Rated Synchronous 60 Hz 1800 HP at rated KW sss 60 Hz 48 Exhaust System Exhaust Flow at Rated Output 60 7 200 cfm Exhaust Temperature at Rated Output 890 F Combustion Air Requirements Natural Gas Flow at rated power 60 92 cfm Governor H Electronic Frequency Regulation Isochronous Steady
15. Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s 10 Failure due to misapplication misrepresentation or bi fuel conversion 11 Telephone facsimile cell phone satellite internet or any other communication expenses 12 Rental equipment used while warranty repairs are being performed i e rental generators cranes etc 13 Overtime holiday or emergency labor 14 Planes ferries railroad busses helicopters snowmobiles snow cats off road vehicle or any other mode of transportation deemed abnormal 15 Any and all expenses incurred investigating performance complaints unless defective Generac materials and or workmanship were the direct cause of the problem 16 Starting batteries fuses light bulbs engine fluids and overnight freight cost for replacement part s THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to purchaser owner GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF
16. REMOVE FRONT COVER FOR ACCESS 4 FIELD CUT HOLE IS ONLY REQUIRED FOR MOUNTING OF GENERATOR ON AN EXISTING PAD 5 gt REFERENCE OWNERS MANUAL FOR LIFTING WARNINGS 62 REMOVE EITHER LEFT OR RIGHT HAND SIDE PANEL TO ACCESS EXHAUST MUFFLERS EXHAUST AND AIR DISCHARGE LOUVERS FRONT AND SIDES 305 127 MIN 305 11271 13 5 53 DIA MOUNTING HOLE 42 PLACES 12 7 1 29 DIA MASONRY ANCHOR BOLTS RECOMMENDED CONCRETE MOUNTING PAD SEE N TE 15 FRDNT VIEW REVISION G 5155 A DATE 5 3 05 PAGE 10F2 EXPLODED VIEW INSTALL DWG 3 0L 30KW amp 3 9L 40KW DRAWING 0F6286 GROUP G APPLICABLE TO REMOVE COVER FOR ACCESS SERVICE ITEM ACCESSIBILITY CHART TO RADIATOR FILL CAP SERVICE ITEM 01 3 9L 40KW 785 30912 30L 30kV DIL FILL cae Wag 760 29 99 3 9L 40KW BATTERY DIL DIP STICK 12 VOLT DIL FILTER 625 COLD DIL DRAIN HOSE CRANKING RADIATOR DRAIN HOSE 13 5 5309 DIA MOUNTING HOLE 42 PLACES LOCATED ON BOTTOM OF GENERATOR MOUNTING FRAME gee AIR CLEANER ELEMENT 38 367 1915 7 5471 SPARK PLUGS D MUFFLERS 56 FAN BELT 2271 BATTERY REFERENCE OWNERS MANUAL FOR PERIODIC REPLACEMENT PART LISTINGS 100 SEE NOTE 4 3 947 1750 68 97 TER TDP VIEW VISE ACTION LATCH ONE PER DOOR ONE LIFT OFF DOOR PER SIDE OF GENERATOR CONTROL PANEL R100 TYPE BATTERY CHARGER IS 850 33 467 ENCLOSED WITHIN 1950 76 777
17. Service Dealer a standard three part form titled Start up Inspection for Standby Power Systems part no 067377 should be completed by the instal lation technician or engineer See page 1 3 for infor mation on locating the nearest Authorized Service Dealer The installer should complete the form and disseminate copies as follows White copy Mail to Generac Warranty Department PO Box 340 211 Murphy Dr Eagle WI 53119 2062 Pink Copy For service file of installing dealer Yellow Copy For the customer s records Standby Generator Sets OD GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator s manual for this unit OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the generator was installed in conjunction with a transfer switch capable of manual operation only the following procedure applies A manually operated transfer switch is one that will not provide automatic start up and does not include an intelligence circuit ENGINE START UP AND TRANSFER For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch DIG A The Maintenance Disconnect Switch and the AUTO OFF MANUAL switches if so equipped must be set properly or the generator will crank and start as soon as the utility power to the transfer switch is turned off Refer to applicable control panel and tr
18. Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTER IES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer DIE A A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charg ing The slightest spark can ignite the gas and cause an explosion Such an explosion can shat ter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smok ing open flame sparks or any spark producing tools or equipment near the battery AN Battery electrolyte fluid is an extremely caus tic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If the fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster battery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging 90 80 0 7 IOOlUIEW wanNING Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch
19. i e load cir cuits supplied by the generator Set the standby generator s main line circuit break er to its ON or CLOSED position Load circuits are now powered by the standby generator RETRANSFER AND SHUTDOWN For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch To transfer the load back to the utility power source and shut down the generator follow these direc tions Set the standby generator s main line circuit break er to its OFF or OPEN position Manually move the transfer switch handle to its UTILITY NORMAL position i e load circuits connected to the utility Turn ON the utility power supply to the transfer switch using the means provided such as the util ity power source main line circuit breaker Let the generator run at no load for a few minutes to stabilize internal temperatures Shut down the generator OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If the generator has been installed with an automatic transfer switch such as an RTS HTS or GTS type transfer switch the engine may be started and stopped automatically or manually NOTE Refer to the applicable manual for your trans fer switch and to Transfer Switch Start Signal Connections In addition please note the dangers under Engine Start up and Transfer 90 80 1004990 Standby Ge
20. tightness leaks security damage 40 80 0 00 10 2 CHECK FAN BELT Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 inch Adjust belt tension as required INSPECT ENGINE GOVERNOR Visually inspect electronic governor DIG A Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incor rect frequency and or voltage Only qualified service technicians should adjust the governed speed CHANGING ENGINE OIL Refer to maintenance performed by authorized 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 tig
21. tion HIGH COOLANT TEMPERATURE SWITCH This switches contacts close if the temperature should exceed approximately 140 C 284 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 OIL PRESSURE SWITCH This switch has normally closed contacts that are held open by engine oil pressure during cranking and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO Standby Generator Sets Engine Protective Devices GENERAL INFORMATION OVERCRANK SHUTDOWN After a prespecified duration of cranking this func tion ends the cranking if the engine has failed to start The overcrank LED will turn ON Turn OFF the AUTO OFF MANUAL switch then turn switch back to AUTO to reset the generator control board NOTE If the fault is not correct
22. 40KD2 CPL 3 0 9708 1 INSTR HYPOT TEST 4 SEE ENGINE EV REF ENGINE ADAPTER 5 SEE ENGINE EV REF FLEXPLATE 6 025536 1 ASSY FLYWHEEL C2CPL 7 0E57 06 1 REAR BEARING CARRIER 390DRCT 8 027874 1 ASSY BRUSH HOLDER 39QHSB 9 02612 1 GUARD REAR BEARING CARRIER CPL 3 0L 30KW 026123 1 GUARD REAR BEARING CARRIER CPL 3 9L 40KW 10 0 6076 1 REVCOR FAN 12 63 X 2 WPRESSDISK n 003454 1 KEY WOODRUFF E 12 OAF 1 CONDUIT FLEX 1 1 4 30 LG B 04576100BU 4 STUD MI4 2 0 5 0G5 ZINC XKW 045 6100 Q 4 STUD MI4 2 0X 615 G5ZINC 052646 4 WASHER FLAT MIA 15 01323 4 WASHER LOCK MIA 16 051779 4 NUTHEXMI4 20G8YEL 17 QA2601 1 SCREWHHC 6 20 45 G88 18 ovx 1 WASHER FLAT 688 IDX 325 OD 19 0 3398 8 SCREWSHC MIO L5X 16G109 20 046526 8 WASHERLOCK MIO 21 0C3908 4 SCREWHHITMTO7X25BP 2 4 WASHER LOCK IM 23 038150 4 WASHER FLAT 8 ZINC 24 017248 1 BALL BEARING45 MM 25 070892 1 SUP RING MACHINED ROTOR REPLACEMENT PARTS REVISION G 6635 C DATE 10 12 05 PAGE 2 OF 2 918 40 ONIM VANGA C JO 1 4 S0 CC 8 ILYA 16 6 06 Wd 0081 0017 H 989 D 19134 719134 335 4 EXPLODED VIEW R 100 1800 RPM 3 0 3 9L DRAWING 0F7376D APPLICABLE TO ITEM PART QTY DESCRIPTION 1823 03078 0F2606 013181 052777 OF4DASE 0F1262 0F1263 051264 0 1725 067680 0 6875 055911 0 3161 OF5459 OF5462 035052 029673 048467 0F1958 082573 0E4494 0
23. 45 214 86 1 298 120 412 166 ELECTRICAL SYSTEM Battery Charge 12V 30 Amp Static Battery 2 Amp Recommended 24F 525CCA System Voltage cete tre 12 Volts Voltage Regulator Electronic SIME EE Single phase 1 Featule5 c emi 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 1000 ft above 600 Controller u u u seen eee ener e ey n eov sve eun R 100 S0 LL 9 2002905 6 GENERAL INFORMATION Standby Generator Sets Specifications GENERAL INFORMATION Figure 1 Interconnections CONTROL PANEL TO ALTERNATOR N1 2 NEUTRAL N2 es GENERATOR M igi CONNECTION GROUT BOX 183 BREAKER H
24. HAZARDS For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by an Authorized Service Dealer or other competent qualified electrician or installation tech nician who is familiar with applicable codes stan dards and regulations The operator also must comply with all such codes standards and regula tions Installation operation servicing and repair of this and related equipment must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electri cal and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operated and serviced in accordance with the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon monox ide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people animals etc will not be harmed This exhaust system must be installed properly in strict compliance with applica
25. RELAY 2 ENGINE RUN SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISER SWITCH TR TRANSFORMER 6VA UTIL 16 VAC 225 ADD FOR 277 480V UNITS 22 WIRING CHANGE gt TRI R2 MOVE 2 FROM TR TO TR2 I I J OB ADD JUMPER JA N1 8 FROM TO N2 ive 3 J TR2 PCB J2 Pet SNP I ANALOG INP RET 1 d FUEL RUN RELAY 3 14A Sw2 Swi 2 MRE STARI T 3 15 019 015 078 ISA MAN AUTO INPUT T 7 15 16VAC SENSE 1 T 8 224 ALARM RELAY T 9 XFER RELAY 0 23 MAN INPUT 11 239 16VAC SENSE 2 112 225 ANALOG INP 15 GND B 114 0 T 5 15E 2 WIRE START 2 6 178 UCT 2 N 3 GND CB1 Ee m 25 ap 2 15 9 4 Gl 454 ICT 1 UTILITY FROM T SW 25 2 ICT 2 UTILITY FROM T SW 22 56A 23 ICT 3 TRANSFER COIL RELAY 35 19 ICT 4 TRANSFER COIL RELAY 56 18 ICT 5 REMOTE START 15 iss 17 ICT 6 REMOTE START E Sr k sided t Z XL 5A CUSTOMER CONNECTION amp ALTERNATOR LEGEND BA BRUSH ASSEMBLY GENERATOR CB1 MAINLINE CIRCUIT BREAKER 240V OUTPUT TO TRANSFER SWITCH INOTE 1 WIRING SHOWN FOR CB1 NB BA AND ICT INTERCONNECT TERMINAL BLOCK NB NEUTRAL BLOCK IS PHASE d acus e PHASE FOR UCT UTILITY CONNECT TERMINAL BLOCK START RELAY 2 56A
26. To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 or locate us on the web at www generac com 90 80 100 jejes i Standby Gene INFORMATION IDENTIFICATION RECORD DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator The data label which can be found attached to the gen erator s lower connection box lists the unit s serial number and its rated voltage amps wattage capacity phase frequency rpm power factor etc rator Sets E General Information INFORMATION NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Generator Model and Serial Number This number is the key to numerous engineering and manufacturing details pertaining to your unit Always supply this number when requesting service order ing parts or seeking information Data Label GENERATOR SET DATA MADE IN USA MODEL SERIAL RATED KW RATED KVA PHASE RATED VOLTAGE RATED AMPS POWER FACTOR HERTZ ALT RPM ENGINE RPM PRODUCTION DATE ALTERNATOR SUBTRANSIENT REACTANCE ALTERNATOR TRANSIENT REACTANCE CLASS ROTOR STATOR WIN
27. phase 277 480V 6 Lead 1 1 1 INTERNAL CONNECTIONS L L S6 lt S4 NEUTRAL 21 53 S2 Tw Figure 7 3 Stator Power Winding Connections 3 phase 120 208V 6 Lead E1 S4 54 00 NEUTRAL 53 3 52 40 80 0 ed 100 4099 INSTALLATION Standby Generator Sets C y Installation i INSTALLATION INSTALLATION Refer to the separate Installation Guide QT Product Line supplied with the unit PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed ser viced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules as well as all other safety information in this manual before attempting to operate this and related equipment Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information 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 se
28. the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Temperature Above 80 F 27 C SAE 30W or 15W 40 SAE 20W 20 or 15W 40 32 to 80 F 0 to 27 C Below 32 F 0 C See Note caution 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 it is strongly recom mended to use the optional Cold Weather Start Kit part number listed in the Specification Section The oil grade for temperatures below 32 F is 5W 30 synthetic oil Standby Generator Sets Equipment Description GENERAL INFORMATION COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is listed in the specifications Use only deion ized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the recommended coolant mixture When adding coolant always add the recommended 50 50 mixture caution 4 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 be
29. 1 Ee Ee E1 Fl E2 OR 120 NOTE THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES VOLTAGE G 120 208 PAGE 2 OF 4 WIRING DIAGRAM R 100 CPL ALTERNATOR DATE 08 17 05 PAGE 2 OF 4 DRAWING 0F6839 GROUP gc viewer ea age a cc Brag FO gt game de ess Be 71 OPTION THREE PHASE R 100 CONTROL PANEL 6 WIRE 277 480 LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER B NEUTRAL BLOCK DIRECT DRIVE GENERATOR OUTPUT CUSTOMER CONNECTION E1 TO Ee Ee E1 1 E2 NB 277 THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE 227 480VAC PAGE 3 DF 4 AS 2 WIRING DIAGRAM REVISION G 6245 A R 100 CPL ALTERNATOR DATE 08 17 05 PAGE 3 OF 4 DRAWING 0F6839 GROUP Dc wh a eh phe y k vr M HN T el OPTION 4 THREE PHASE R 100 CONTROL PANEL 12 WIRE 120 208 LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER B NEUTRAL BLOCK 1 uet S DIRECT DRIVE AS GENERATOR OUTPUT CUSTOMER CONNECTION E1 E
30. 18 X 12 7 X 283 COMPONENTS INCLUDED IN 0F7376D BBRRHbNNANH RELAY SOLENOID 12VDC MNT SCREWHHC M6 LOX 16 8 8 WASHER FLAT 1 4 6 ZINC WASHER LOCK M6 1 4 NUT HEX 1 0 8 YEL CHR SEAL WEATHER 45 DIA COVER CONTROL PANEL SIDE SCREWHHC M5 0 8X 16 8 8 WASHER WASHER FLAT 10 ZINC GROUP B PAGE 2 OF 2 619840 4 ONIM VYA C dO 1 d5Vd 142 9 0 10 3599 ONILNNOW 4 L gt 2 r 6 C 3NION3 d 1O ID vO SUTI ALYA EXPLODED VIEW MOUNTING BASE 3 0L 30KW C2 CPL DRAWING 0F3513 APPLICABLE TO GROUP C ITEM PART QTY DESCRIPTION 1 0F3270A 1 MIG BASE 30L 30KWC2 2 4 NUT FLANGEDHEXMI2 175 3 05225 4 DAIMPENER VIBRATION 40 BLUE 4 052257 4 SPACER 49 62 187 PADR ZNC 5 4 DAVPENER MBRATION 6 4 WASHER FLAT MI2 7 05280 4 SCREWHHC MI 175X80G88 8 1 ASSY WRE 14 00 9 012909 1 SCREWHHC 1 25 30688 10 047411 1 SCREWHHC 1 0 16 8 8 11 055414 1 LUG SLDLSS 22 28 X 1764CU 12 002447 1 WASHER SHAKEPROOF INT 1 4 13 02209 1 WASHER LOCK 1 4 14 002473 2 WASHER FLAT M6 1 4 ZINC 15 049813 1 NUT HEXIV5 LOG8 YEL CHR 16 1 WASHER SHAKEPROOF INT 38 17 88 2 STAMPING ENG FOOT 3 0L FORD 18 045764 1 SCREWHHIT M 07X8BP 19 029814 4 SCREWHHC MIO 15X 25 G88 20 5 WASHERLOCK 7 16 21 022131 4 WASHER 3 8 ZINC 22 065852 1 SPRING CLIP HOLDER 37 62 23 05898 2 PLATE ALTVARMNT 2 022129 1 WASH
31. 3215 0 5886 051713 049226 OF5752F OF5984 0 5896 0C2265 OF 6305 BESSBYRKHRBNABBRBYREURBNRSE 5 5 0 50 5 REVISION G 6286 B DATE 8 22 05 COIVPONENTS INCLUDED IN 01827E 5 CONTROL PANEL COVER CONTROL PANEL HINGE CONTINUOUS H PANEL RIVET POP 125 X 275 SS 5 05 10MM WASHER FLAT ASSY PCB CPL CTRLR 1800 RPM HOLDER FUSE WCKMANN 178 6150 ADPTR RH SIDE WICKMAN 178 6191 ADPTR LH SIDE WICKMAN 178 6192 ASSY PCB 2 LW UL BATT CHGR ASSY VOLTAGE REGULATOR 60HZ RELAY I2VDC FORMWDIODE BLOCK TERM20A 12 6X 1100V ASSY PCB BOSCH GOV DRIVER DECAL CPL CONTROL PANEL FUSES DECAL CPL 3 9L TB1 SPACER 9 5 3 20 DIO BRIDGE 25A 600 CIRCT BRK 7 X LETA 46 500 PLATE HARNESS CLAMP SWITCH RKR DPST 125V SPD SWITCH RKR DPDT ON OFF ON DECAL CONTROL HSB SCREW HHPM 5 08 X 12 WASHER FLAT WASHER LOCK RES WW 158 5 25WQK CONN SCREWPHTT M350 6 X 10 SCREW PHTT M350 6 X 16 SCREWPHIT 0 7 X 12 ZYC SCREWPHIT 0 7 X 10 ZYC 5 8 12 ZNC NUT HEX 5 08 G8 CLEAR ZINC 5 3055 WASHER NUT HEX MB 0 5 G8 YEL CHR SUPPORT ANGLE PCB FUSE ATOTYPE 15 BLUE 1800RPM R 100 CONTROL NOT SHOWN SEAL COVER 3 18 12 7 X 382 SEAL COVER 3
32. 4 1 Overcrank Sh tdown eret eese trennen 4 1 Overspeed Shutdown ee a 4 1 RPM Sensor Loss Shutdown 4 1 DC FUSE MN dI ET 4 1 FUEL SYSTEMS 5 1 Fidel Requirements u a ua au 5 1 Natural Gas Fuel System 5 1 Propane Vapor Withdrawal Fuel System 5 1 LP Ruel System 5 1 SPECIFICATIONS 6 1 Generator MEM MUT 6 1 Engine p 6 1 Cooling Systemi 6 1 gigas 6 1 Electrical System 6 1 Cold Weather Kitni ad 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 1 eret eee orte thes eon de nhe 7 1 INSTALLATION 8 1 Installation iic 8 1 Preparation Before 8 1 Prior to Initial Start up 8 1 Initial Inspection for QT Genset Star
33. 40 16 VAC F1 13 4 J ANALOG INP RET m gt 22 5 5 TIO 2 N gt 211 lt eo L 49 START RELAY 2 56A 225 FUEL RUN RELAY 3 14A 224 TR1 TR2 2 WIRE START 1 4 183 WIRING CHANGE MOMENT OPEN 5 MOVE 2 FROM 2 WIRE START 2 L 6 178 MAN AUTO INPUT 7 18 15 _ i ADD JUMPER JA 4 CB2 16VAC SENSE 1 8 224 1 FROM TR TO AVR tie ALARM RELAY 9 i a N1 T JA JB TR2 HTI 4 XFER RELAY H0 23 N2 1 zu 211 162 INPUTL11 239 4 FJ TERUEL EE ANALOG INP 13 15 GND B 1418 j 2 2 2 ag 601 SINGLE PHASE STATOR SHOWN FOR 3 5 SEE DWG 0 6839 515 UTILITY FROM T SW UTILITY FROM T SW TRANSFER RELAY COIL TRANSFER RELAY COIL REMOTE START REMOTE START 16VAC SENSE 2 112 225 CUSTOMER CONNECTION WIRING DIAGRAM 3 0L COMMERCIAL PROD LINE DATE 8 8 05 DRAWING 073868 REVISION G 3264 F PAGE 1 OF 2 GROUP G c GM S MEM 1 NGINE WIR N AFS AIR FUEL SOLENOID ALT D C CHARGE ALTE
34. ALVE PCV GROMMET ROCKER COVER 3 0LFORD BARBED EL 90 3 8 X 3 8 PLST CLAMP VINYL 75 X 3432 SCREW HHC M6 1 0 X 16 G8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC HARNESS CPL FUEL J UMPER NOTES 1 2 REGULATOR I N 3 AS SHOWN IN ILLUSTRATION IS SET UP FOR NATURAL GAS APPLICATION TO CONFIGURE REGULATOR FOR LP VAPOR SWITCH HOSE BARB HOSE CLAMP 13 AND HOSE 14 FROM OUT 1 TO OUT 2 REPLACE PIPE PLUG FROM OUT 2 TO OUT 1 USE PIPE SEALANT ON HOSE BARB AND PIPE PLUG MAKE SURE TO KEEP PORTS FREE FROM DEBRIS DURING RECONFIGURATION PROCESS FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL INLET DECAL P N 050280 FOR NG FUEL INLET DECAL P N 050279 ITEM17 WHEN SWITCHING FUEL TYPES THE PROPER DIP SWITCH SITTINGS MUST BE MADE TO THE CONTROL PANEL SEE OWNERS MANUAL FUEL SECTION FOR MORE DETAILS NOT SHOWN USED TO HOLD 31 IN PLACE GROUP E PAGE 2 OF 2 609840 4 ONIAAV IG C dO HDVd 9 MAOL 145 106 LS VHX3 83 1H3nW LSNVHX4 Adis HA OL G IO3INVIA 1 341 H d OL 27 r 754 Iy 4 lt lt i N 4 P it Ns 22 1 N 1 M v i NS N i P it N it i S it 4 M AAT i D 21211 N
35. AT 051430 6 WASHER SHAKEPROCF INT 1 2 045773 2 NUT HEXMI2 L75 G8 YEL CHR 085296 6 SCREWHHC 1 4 20 1255 7 2 HEAT SHELD 260X 80HOT 0 5527 2 MANIFOLD EXHAUST 3 0L FORD E7163 2 GASKET EXHAUST 3 0L FORD OF6810 1 HARN ENG 3 0L 3600 100 NOT SHOWN 3600 OF6841 1 HARNENG 3 0L 18008 100 NOT SHOWN 1800RPM 026809 1 ADAPTER WATER 1 SCREWHHC NB L25X20G88 026833 2 SPACER 44 87 1 070008 2 WASHER FLAT MBSS 070006 12 WASHER LOCK BSS F5114 1 DECAL REFER OWNERS MANUAL 025966 1 REFLECTIVE HEAT SHELD 3 0 FD 022985 3 WASHER FLAT 6 ZINC 057822 1 CLAMP HOSE 8 53 1 00 059057 1 HOSE 3 4IDSAE 30R2 14 LG 057795A 1 BARBEDEL 9034 PLASTIC 057796 1 GROMVET 1 1 SPACER PULLEY 3 0L FORD FD 3600 RPMONLY 020641 2 SCREWHHC MIO L5X 35 G88 026925 1 PLUGSTDPIPE 38STEEL 50 0 3217 1 SPACER DC ALTERNATOR PULLEY FOR 3600 RPMUNITS ONLY PAGE 2 OF 2 GROUP D TO 44 2 THERMOSTAT 39 43 HOUSING MOUNTING BASE C2 COOLING SYSTEM amp FAN DRIVE EXPLODED VIEW DRAWING REVISION G 6283 F DATE 9 27 05 0F6879 PAGE 1 OF2 EXPLODED VIEW C2 COOLING SYSTEM amp FAN DRIVE DRAWING 0F6879 GROUP D APPLICABLE TO ITEM PART QTY DESCRIPTION 1 OF3208A 1 WELDIVENT RAD SUPPORT 3 0L C2 2 085685 6 HOSE 28 132 225 3 OF2608A 1 RADIATOR 598 X 568 X 49 CPL LH 4 OF6761 1 HOSE UPPER RAD CPL C2 3 0L 5 0 3228 1 HOSE LOWER RA
36. BE UPPER COOLANT 46 1 CAP RADIATOR 13PSI 47 8 1 8 SCREWHHFC 1 25 20 3 015 INCLUDED WTHITEM E2 REVISION G 6283 F DATE 9 27 05 PAGE 2 OF 2 GROUP D ENGINE CONTROL PANEL COMPARTMENT THE ITEMS INSIDE THE DASHED RECTANGLE WTS REPLACE WATER LEVEL SENSOR PART NUMBER WLS 0 0561 x P N Pd TYPICAL Salh e ra 9 5 PANEL CONNECTION 2 111 0 P N OF9483 9 3 WIRING DIAGRAM FOR NEW COOLANT LEVEL SENSOR MECHANICAL DIAGRAM FUR NEW COOLANT LEVEL SENSUR INSTALATILUN TH A P N 0E2307 P N 0F6749 SEALANT MUST BE APPLIED TO THREAD PRIOR TO INSTALATION WHERE APPLICABLE P N 0F9483 B EXISTING COOLANT LEVEL SENSOR LOCATION DN UNIT EXISTING COOLANT LEVEL SENSOR WIRE HARNESS CONNECTOR EXPLODED VIEW REVISION ERRATA SHEET FOR 0 0561 DATE 12 7 05 PAGE 1 OF 2 DRAWING 0F9502 GROUP D PAGE EXPLODED VIEW REVISION ERRATA SHEET FOR 0E0561 DATE 12 7 05 PAGE 2 OF 2 DRAWING 0F9502 GROUP PAV SKS JN RS PRESS BS 2 ENGINE HARNESS 1 2 amp 3FOR REGULATOR INFORMATION FUEL NAT GAS amp LP VAPOR 3 0L FORD 4 POLE EXPLODED VIEW DRAWING 0F3521 PAGE 1 OF 2 DATE 11 15 04 EXPLODED VIEW FUEL NAT GAS amp LP VAPOR 3 0L FORD 4 POLE DRAWING 0F3521 APPLICABLE TO ITEM PART o Q DA
37. DCPL 2 3 04 6 8 21706 1 SPACER FAN 30L C2 7 2 1 FAN COOLING 16 DIA 8BLADE 8 045764 1 SCREWHHIT M 07X8BP 9 065852 1 SPRING CLIP HOLDER 37 62 10 060811 4 BRASS 0 3312 1 DUCTINNER DISCHARGE 2 12 02454 13 SCREWTHF 1 16 ZJ S 13 4 SCREWHHC 1 25 20G88 14 2 WASHER LOCK 5 16 15 022145 4 WASHER FLAT 5 16 MB ZINC 17 10 WASHER LOCK 1 4 18 008566 8 SCREWHHFC 10 20 8 8 19 0E3257 4 SCREWHAHIF M amp 10X 16 20 3313 1 DUCT INNER DISCHARGE C2 21 080712 1 BRKT COOLANT RECOVERY TANK 2 076749 1 TANK RECOVERY 23 048081C 1 CLAMP HOSE BAND 1 4 2 OF4051D 3 INSULATION INNER DUCT 25 0F4073C 1 INSUL DUCT SIDE OR INNER DUCT 26 qr3800 3 RETAINER INSULATION 450 27 0 3890 2 RETAINER INSULATION 220 28 F3072 10 INSULATIONRETAINVENT HANGER 29 078115 10 WASHER SELF LOCKING DOIVE 30 08996 1 FOAMSTRIP 34 WDE X 3 16 46 LG 31 052250 2 TAPE FOAM1 1 22 5 LG 32 069860 1 HOSE DRAINASSY 28 08085 1 GUARDFANC2CPL 34 0C7649 1 CLAMP HOSE 38 87 35 055596 1 BARBEDSTR 38 NPTX 38 36 089685 1 GROMMET 75 12 50 37 61 1 ASSY WATER LEVEL SENSOR PL 38 1 GUARDFANC2CPL 39 2 CLAMP VINYL 1 5 2812 40 000079 2 SCREWFHHIT 1 0 25 BP 42 076340 2 SCREWHHFC 1 0 16 G38 43 06657 2 SUPPORT TUBE RADIATOR 4 FGG3L 1 HOSE RADIATOR ENGINE 45 06746 1 TU
38. DING INSULATION AT 25 C AMBIENT GENERAC POWER SYSTEMS INC WAUKESHA WI 90 21 200 GENERAL INFORMATION EQUIPMENT DESCRIPTION This equipment is a revolving field alternating cur rent generator set It is powered by a gaseous fueled engine operating at 1800 rpm 4 pole direct drive units 3600 rpm for 2 pole direct drive units and 2300 3000 rpm for quiet drive gear units See the Specifications section for exact numbers The unit comes complete with a sound attenuated enclosure internally mounted muffler control console main line circuit breaker battery charger and protective alarms as explained in the following paragraph All AC connections including the power leads from the alternator 120 volt battery charger input and control connections to the transfer switch are avail able in the main connection box The generator incorporates the following generator features Rotor and Stator insulation is Class H rated as defined by NEMA MG1 32 6 NEMA 1 1 66 The generator is self ventilated and drip proof con structed The voltage waveform deviation total harmonic content of the AC waveform and telephone influ ence factor have been evaluated and are acceptable according to NEMA MG1 32 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE SE Detergent oils keep
39. ERLOCK 5 16 25 1 WASHER SHAKEPROOF INT 5 16 26 02145 1 WASHER FLAT 5 16 MB ZINC 27 025771 1 NUT HEX MB L25 GBCLEAR ZINC 28 051755 1 SCREWHHC 1 5 16G88 DATE 11 15 04 PAGE 2 OF 2 GROUP TO STARTER CONTACTOR lt 28 rium Q A To due net N 14 0 0 Lu 2 tc lt WIRE EXPLODED VIEW BATTERY REVISION G 6148 B 0F5668 DRAWING PAGE 1 OF2 8 10 05 DATE EXPLODED VIEW BATTERY DRAWING 0F5668 APPLICABLE TO ITEM PART 0 3408 FAL 036833 027482 075763 0C254 REVISION G 6148 B DATE 8 10 05 QTY DESCRIPTION TRAY BATTERY STRAP BATTERY RETAINVENT BATT 12 WASHER FLAT 38 MI0ZINC BATT POST COVER RED BATT POST COVER BLK CABLE BATT BLK 2300 CABLE BATT RED 74 X 35 00 NUT HEXIVE L25G8 YEL CHR WASHER LOCK 5 16 WASHER SHAKEPROOF EXT 5 16STL BOOT BATTERY CABLE SCREWTHF 1 16 NVA ZJ GROUP C PAGE 2 OF 2 918640 ONIM VAGA HOVd v0 SVTI ALYA 106 HH3NV319 lt gt EXPLODED VIEW AIR CLEANER 3 0L FORD C2 DRAWING 0F3516 APPLICABLE TO JO0U RUN H d DATE 11 15 04 PART 519 19 022127 062974 0 8127 035547 087561 0 6586 MNMHHHAHHHH DESCRIPTION PLATE AIRC
40. EW ENCLOSURE C2 DRAWING 0F7887 APPLICABLE TO GROUP F ITEM PART QTY DESCRIPTION 1 000 1 REARWRAP C2 2 02254 68 SCREWTHF 1 16 NWA ZJ S 3 0F5819 2 DOORC2 4 087233 2 RIVET POP 18 5 45055 5 E57 4 SCREWTH FRMMBWCAP SHKPRF W 6 0F5822 009 2 DISCHARGE DUCT LH amp RH SIDE C2 7 2 FRONT CORNERS C2 8 0F5851009 1 DISCHARGE CENTER DUCT C2 9 023313 1 REF DUCT INNER DISCHARGE C2 10 0F3312 1 REF DUCT INNER DISCHARGE TOP C2 n 025848 1 ROOF C2ALUM 12 0F2786 2 SLITTER CA B 02785 1 SPLITTER LOWER C4 03364 1 SPLITTER STINGER C2 5 024880 2 SUPPORT SPLITTER LHC2 16 025049 2 PULL U 2634 1 ASSEMBLY COVER ACCESS 18 022173 3 WASHER FLAT 14M6 ZINC 19 02209 1 WASHER LOCK 1 4 20 022127 1 NUT HEX 1 4 20STEEL 21 023072 16 INSULATIONRETAINVENT HANGER 22 078115 48 WASHER SELF LOCKING DOME 23 04051 2 INSULATION DOOR C2 OF4051A 1 INSULATION ROOF TOP 5 025048 2 LATCHMSE ACTION 5 16 SOCK 26 0 5968 1 GASKET EXTRUDED TRIM 440 67 LG 27 OF3760K 2 INSULATION SPLITTER 28 OF3760E 2 INSULATION SPLITTER 29 OF4051C 2 INSULATION DUCT 3 0 38908 8 RETAINER INSULATION 820 31 0240518 2 INSULATIONDUCT SIDES gt OF3890 4 RETAINER INSULATION 450 0 3890 3 RETAINER INSULATION 740 1 INSULATION LOWER SPLITTER 042568 2 SCREWHHC 1 0 20688 36 0912970004 2 ASSY WRE 14 AWG 348 GRNYEL 3 022117 2 WASHER SHAKEPROOF INT 1 4 38 049813 2 NUT HEX LOGS YEL CHR 39 077992 21 NUT HEX LOCK
41. GENERAC POWER SYSTEMS INC NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitations may not apply to purchaser owner Purchaser owner agrees to make no claims against Generac Power Systems Inc based on negligence This warranty gives purchaser owner specific legal rights Purchaser owner also may have other rights that vary from state to state Generac Power Systems Inc Box 8 Waukesha WI 53187 Ph 262 544 4811 Fax 262 544 4851 Bulletin 0171360SVE Printed in U S A 7 05 Printed in U S A
42. IM5 LOSS NY INS 40 grex 1 ROOF RAIN DEFLECTOR Bre 0C3397 4 FASTENER RATCHET OPTIONAL COMPARTMENT MATERIALS ALL P NS WTH AN 00 SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION USE THE FOLLOWING LEGENDTO IDENTIFY THE CORRECT PART NUMBER 39L ONLY ALUMNUMENCLOSURE NOTE ALL ENCLOSURE PANELS THAT FASTENTO THE BASE FRAME MUST BE SECURED USING 2 amp 5 THREAD FORMING FASTENER AND ITEM 39 LOCK NUT LOCK NUT IS TO INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER 30L ONLY REVISION G 6440 B DATE 10 10 05 PAGE 2 OF 2 CONTROL PANEL LEGEND CONTROL PANEL LEGEND NOTE AL WRES 1 18 A CUSTOMER CONNECTION amp ALTERNATOR LEGEND AVR AUTOMATIC VOLTAGE REGULATOR BCH BATTERY CHARGER BR1 DIODE FIELD BOOST CB2 CIRCUIT BREAKER EXCITATION F1 FUSE BAT POWER 15A TYPE 42 CONNECTOR 2 ON R1 2 120 OHM RES 470 OHM RES R4 FIELD BOOST RESISTOR RL1 RELAY 1 START RELAY RL2 RELAY 2 ENGINE RUN WG UL LISTED UNLESS OTHERWISE NOTED AS SHOWN 512 CUSTOMER CONNECTIONS GROUP G BA BRUSH ASSEMBLY GENERATOR ICT INTERCONNECT TERMINAL BLOCK MCB MAINLINE CIRCUIT BREAKER NB NEUTRAL BLOCK UTILITY CONNECT TERMINAL BLOCK SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISER SWITCH TERMINAL BLOCK TRANSFORMER 6VA 2
43. LEANER ADAPTER ADAPTER CARBURETOR WPVC CONN NUT HEX 1 4 20STEEL STUDTH 1 4 20X 4 1 2 G2ZNC SCREWHHC M508X20G88 ELEMENT AIR CLEANER COVER AIR CLEANER NUT WING 1 4 20 NYLK GASKET BOSCH 32 amp 40 GROUP D PAGE 2 OF 2 578940 C dO HDVd 149 4 106 SLYYd NOWWOO 42169 0 NOISIA3I YIM ANNOYS 29 ad ov JHL NI GALV9OT SI KU FYVMGHYVH SLINN Wd 009 HOS 13441 86 NI GALV9OT SI SLINN 0081 HOS 362 Poo LIX v EXPLODED VIEW ENGINE COMMON PARTS 3 0L FORD CPL DRAWING 0F6845 APPLICABLE TO ITEM PART ares 022131 022131 E8963 E6309 are 026873 9868 023216 FZ216C 0 6308 0084882 00834888 08040 F5753 QTY Boo Noun w NH Pee REVISION G 6917 D DATE 11 21 05 DESCRIPTION ENGINE 3 0L FORD FD MAKE CPL WASHER FLAT 3 8 ZINC 1800 RPMONLY WASHER FLAT 3 8 MIO ZINC 3600 RPMONLY PULLEY CRANKSHAFT 3 0L FORD 1800 RPMONLY PULLEY CRANKSHAFT 3 0L FORD 3600 RPMONLY BRACKET R HSIDE DC ALT BRACKET TENSIONER ALTERNATOR DC WOUT PULLEY PULLEY 80OD DC ALTERNATOR 1800 RP PULLEY 132 OD DC ALTERNATOR 3600 RPM PULLEY WATERPUIVP 3 0L FORD RD OIL FILTER 3 0L FORD BELT SERPENTINE 38 35 LG 1800 RPM BELT SERPENTINE 40 85 LG 3600 RPM SPACER FLEXPLATE HSB 1800
44. NSIDE UL CIRCUIT BREAKER Qj 2P COVERQ 2P FRMCB DECAL DANGER HIGH VOLTAGE CB 0225 240 2 5 Q 22 COVERQ 2P CB DISH RIVET POP 125X 275SS WASHER FLAT 1 445 ZINC WASHER LOCK 14 NUT HEX 1 4 20STEEL INSUL CB2PQJ SCREWTHF M5 I16NVA ZJ S WASHER LOCK 38 SCREWSHC 38 16 X34GB8NZ ELEC 1 2 FOAM AS REQD SCREWRHM1 4 20X3 DECAL CUSTOMER CONNECT INSIDE PNEPNNVEPNNNG E NEUTRAL BLOCK 390 200 4004 BUS BAR NEUTRAL BLOCK 390 SCREWHHC 1 25 45 G88 FT WASHER FLAT 5 16 B ZINC WASHER LOCK 516 NUT HEX MB 125 G8 YEL CHR WASHER FLAT 146 ZINC WASHER LOCK 6 1 4 SCREWHHC 1 4 28 X 34 5 LUG SLDLSS 600 250 1 0X 1 4 28 ITEMINCLUDEDWTHHARNESS TEMINCLUDED WITH 0054648 ITEMQTY DOUBLES FOR 277 480V ITEMUSED WITH 277 480V UNITS ONLY PAGE 2 OF 2 611930 ONIMVUG 1 4 0 01 01 ALYA NOILV LIOXS 194410 HOLVNSALTV 149 AHIA QHGO IdXH O 99 D IH9LDIOO T1 A LU V EXPLODED VIEW CPL ALTERNATOR DIRECT EXCITATION DRAWING 0F4779 APPLICABLE TO GROUP A ITEM PART QTY DESCRIPTION 1 OF3438 1 39030AD1L CPL F340 1 390 40AD2 CPL H EF 1 ASSY RTR 39030KD1 CPL 026190 1 ASSY 39040KD2 CPL 2 0F3139 1 STR 390 30AD1 CPL 023441 1 STR 300 40 2 CPL 026189 1 STR 390 30GD1 CPL 026199 1 STR 390 40GD2 CPL 026655 1 ASSY STR 390 30KD1 CPL 026656 1 ASSY STR 390
45. OAM AS REQD L 1733 1 DECAL CUSTOIVER CONNECT INSIDE 2 UL CIRCUIT BREAKER FD A 0 3138 1 COVER CB CONNBOX B 065469 1 DECAL DANGER HIGH VOLTAGE 005572 1 0150 600 5 FD6LL 005573 0175 600 5 FD6LL 005574 2 600 5 FD6LL 00555 225A 600 5 FD6LL 025576 0250A 600 FD6LL D 020199 1 INSULATOR CB FD FRAME 30ML E 081320 4 SCREWSHC 1 4 20X 4 5 GB8 NZ F 022173 4 WASHERRLAT J HVb ZINC G 022097 4 WASHER LOCK 1 4 H 022127 4 NUT HEX 1 4 20STEEL J 0c2454 7 SCREWTHF 1 16 ZJ S 029289 1 ELEC 1 2 FOAM AS REQD L 0 1733 1 DECAL CUSTOIVER CONNECT INSIDE 3 UL CIRCUIT BREAKER J D LD A 29 1 COVERJ DLDCB SHRT STAND REVISION G 6772 F DATE 11 1 05 A rommgog 00 rA rommgoo OuzzrmO rommgogoo 9 v roOmmggou PART GROUP A QTY DESCRIPTION m DECAL DANGER HGH VOLTAGE 600 J D6LL INSULATOR CIRCUIT BR J DLD SCREWRHM1 4 20X3 WASHER FLAT 146 ZINC WASHER LOCK 1 4 NUT HEX 1 4 20STEEL SCREWTHF 1 16 2 5 TAPE ELEC 1 2 FOAM AS REQD DECAL CUSTOIVER CONNECT INSIDE UL CIRCUIT BREAKER QN COVERQNFRMCB DECAL DANGER HGH VOLTAGE 0150A 2P 240 5 QN2 LL 0175 2 5 QN2LL 2XV BASE QNCIRCUIT BREAKER SCREWHHIT N508X 10 BP COVERQNCB DISH RIVET POP 125 X 275SS SCREWTHF 1 16 2 5 ELEC 1 2 FOAM AS REQD DECAL CUSTOIVER CONNECT I
46. RNATOR 12 0 BATTERY STARTER CONTACTOR COIL PACK CB J CRANK SENSOR ode DRIVER ELEC GOVERNOR FUEL SOLENOID OX INP RET 214805 AUX FUEL SOLENOID DEG GND 5 0 GND GROUND COOLANT SENSORS 1 4 85 GOV ELEC GOVERNOR ACTUATOR DEG OV 15 767 HCT HIGH COOLANT TEMP SWITCH DEG 45V T 6 765 J1 CONNECTOR 1 ON PCB DISTRIBUTOR 12V T 7 LFP LOW FUEL PRESSURE SWITCH AFS OUT 8 808 LOS LOW OIL PRESSURE SWITCH CRANK SENSOR IN L 9 79 02 OXYGEN SENSOR CRANK SENSE RET 210 0 LFP x H2 766 SM STARTER MOTOR WLS COOLANT LEVEL SWITCH DEG FDBK 412 766 OX INP 113 804 COIL Gm COIL A 9 115 25 DISTRIBUTOR RET 16 DISTR INPUT 17 DEG 118 769 DEG ENABLE 119 768 LOW OIL PRESS 120 86 CRANK SHIELD 21 SHLD COIL lt 22318256 42388558 49 AFS 808 15 EMISSION CONTROL L AN gt 2 iz c 49 HT HJ O N 8 pem d 601 56 0 14 n UE eg UAE ure x 4 WIRING DIAGRAM REVISION G 3264 F 3 0L COMMERCIAL PROD LINE PAGE 2 OF 2 DATE 8 8 05 DRAWING 0F3868 GROUP G DIE c 1 NTROL PAN N AVR AUTOMATIC VOLTAGE REGULATOR BATTERY CHARGER BRI BRIDGE RECTIFIER CB2 CIRCUIT BREAKER EXCITATION F1 FUSE BAT POWER 15A ATO TYPE 42 CONNECTOR 2 ON PCB R4 FIELD BOOST RESISTOR RELAY 1 START RELAY RL2
47. Serial Number QT 3 0L 30kW Model 005219 0 STANDBY GENERATOR OWNER S MANUAL A new standard of reliability GUARDIAN Hii by Generac Power Systems Inc 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 826140 ON Hed 90 0 V ed 72019702 SECTION PAGE SAFETY RULES 52000052 1 1 INTRODUCTION 1 3 Read this Manual Thoroughly 1 3 Operation and Maintenance 1 3 How to Obtain Service ee 1 3 IDENTIFICATION RECORD 2 1 Data trae 2 1 EQUIPMENT DESCRIPTION 3 1 Equipment Descriptioh u ot ene ono e thu Ye ovens 3 1 Engine Oil Requirements 3 1 Coolant 3 1 ENGINE PROTECTIVE DEVICES 4 1 High Coolant Temperature Switch 4 1 Low Coolant Level Sensor 4 1 Low Oil Pressure Switch
48. State Regulation sss 1 296 Adjustments 22 ox Selectable Standby Generator Sets Fena INFORMATION Specifications INFORMATION Engine Lubrication System Type of Oil Pump Gear Oil Fille Full Flow Cartridge Crankcase 4 0 5 gts COOLING SYSTEM JU G u Closed Mater PUMP Belt Driven Fan steep eed 2150 Damo c ua dert 18 inches Uc Pusher Air Flow inlet air including alternator and combustion air sees 2460 ft3 min Coolant Capacily 2 5 U S gal Heat Rejection to Coolant 115 000 Btu h Maximum Operating Air Temp on Radiator 60 C 150 Maximum Ambient Temperature 50 C 140 FUEL SYSTEM Type s tontos Natural Gas Propane Vapor Sco mE Down Draft Secondary Fuel Regulator Standard Fuel Shut off Standard Operating Fuel Pressure 5 in 14 in Water Column Fuel Consumption ft3 hr Natural Gas LPV Exercise 25 50 75 100 Cycle Load Load Load Load 70 28 3 111
49. TE 11 15 04 026915 075580 0F6390 039253 022145 022129 045771 042907 0E9295A 026812 025424 0F3869 057823 059194 044117 0D1509 050279 050280 0E6123 0E 6586 0E4395 057753B 0E6382A 0E7121 0E6376A 047487 022097 051751 035685 0A2038 047290 047290 0A4121 0E 6609 049099 055934M 047411 022097 022473 026155 QTY F 4 4 I IND I IND IND 4 IND 1 REF 1 REF 1 REF m RO DESCRIPTION NIPPLE CLOSE 3 4 X 1 375 FLANGE FUEL INLET REGULATOR ASSEMBLY DUAL FUEL SCREW HHC M8 1 25 X 20 G8 8 WASHER FLAT 5 16 M8 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 CLEAR ZINC SCREW HHC M8 1 25 X 16 G8 8 ASSY THROTTLE 27MM ELBOW 90D 3 4NPT NIPPLE PIPE 3 4NPT X 6 SWITCH PRESSURE GAS 5 RISE INCLUDED WITH I N 3 CLAMP HOSE 10 56 1 06 HOSE 5 8 ID LPG amp NG 31 5 LG BARBED STR 3 8 NPT X 5 8 DECAL INLET PRESSURE DECAL FUEL INLET NG NATURAL GAS APPLICATION DECAL FUEL INLET LPG LP VAPOR APPLICATION INTAKE ADAPTER 3 0L FORD BOSCH GASKET BOSCH 32 ACTUATOR BOSCH 32 GOVERNOR HOSE 1 5 ID X 2LG 2084 VENTURI HOLDER W 32MM ACTUATOR O RING 47 625 ID X 2 38 WIDTH VENTURI 27 ID THROTTLE W CHOKE SCREW SHC M6 1 0 X 18 G12 9 WASHER LOCK M6 1 4 SCREW HHC M6 1 0 X 50 68 8 CLAMP HOSE 28 1 32 2 25 WASHER FLAT 3 8 ZINC HOSE 3 8 ID SINGLE BRAID 305mm 12 LONG HOSE 3 8 ID SINGLE BRAID 432mm 17 LONG V
50. ansfer switch manuals for more information Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to UTILITY Do not attempt manual operation until all power supplies to the transfer switch have been posi tively turned off or extremely dangerous pos sibly lethal electrical shock will result Transfer switch enclosure doors should be kept closed and locked Only authorized personnel should be allowed access to the transfer switch interior Extremely high and dangerous voltages are present in the transfer switch In order to transfer load from the utility source to the generator follow these directions Turn OFF or disconnect the utility power circuit to the transfer switch using the means provided such as the utility source main line circuit break er Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the standby generator s main line circuit break er to its OFF or OPEN position Start the generator Operation caution Do not crank the engine continuously for longer than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge read ings When certain that all readings are correct move the transfer switch manual handle to its STANDBY GENERATOR position
51. ation after purchase of the unit This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer 3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed semi annually or following each 50 hours of operation of the unit This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer 4 A mid level inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed annually or following each 100 hours of operation of the unit This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer 5 Acomprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required and to identify any potential problem areas Performed annually or following each 250 hours of operation of the unit This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Author
52. ble codes and stan dards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical in any room or building hous ing the generator to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts 90 80 100 jejes Before performing any maintenance on the gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc A ELECTRICAL HAZARDS generators covered by this manua
53. d runs rough Engine starts then shuts down AUTO OFF MANUAL Switch at OFF engine continues to run No AC output from generator 1 2 15 amp fuse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery 5 amp fuse blown Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Door on tank not closed Flame arrestor air cleaner plugged or damaged Plugged fuel line Defective spark plugs Fuel pressure incorrect Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch Defective AUTO OFF MANUAL switch Open disconnected wire 415A between AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open ww CORRECTION 1 2 Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replace fuse Replenish fuel Replace solenoid
54. d storage batteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury 90 80 O LOOIUIEW Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance BATTERY MAINTENANCE The battery should be inspected per the Service Schedule section The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion
55. d 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 the correct recommended fuel is sup plied to the generator fuel system Thereafter the owner operator must make certain that only the proper fuel is supplied NATURAL GAS FUEL SYSTEM Natural gas is supplied in its vapor state In most cases the gas distribution company provides piping from the main gas distribution line to the standby generator site The following information applies to natural gas fuel systems Gas pressure in a building is usually regulated by national state and local codes To reduce gas pressure to a safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is t
56. e Ee E1 1 E2 NB 120 THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 208VAC PAGE 4 OF 4 WIRING DIAGRAM REVISION G 6245 A R 100 CPL ALTERNATOR DATE 08 17 05 PAGE 4 OF 4 DRAWING 0F6839 Standby Generator Sets Warranty GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR HOME STANDBY LIGHT COMMERCIAL PRODUCT 45kW AND BELOW For a period of two 2 years from the date of sale or start up by Authorized Certified Generac Power Systems Dealer or branch thereof Generac Power Systems Inc will at its option repair or replace any part s which upon examination inspection and testing by Generac Power Systems or an Authorized Certified Generac Power Systems Dealer or branch thereof is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be examined by the nearest Authorized Certified Generac Power Systems Dealer or branch thereof This warranty applies only to Generac Power Systems Generators used in Standby applications as Generac Power Systems Inc has defined Standby provided said generator has been properly installed and inspected o
57. e the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with applicable codes standards and regulations FUEL SYSTEM Make sure the fuel supply system to the genera tor a delivers the correct fuel at the correct pres sure and b is properly purged and leak tested according to code No fuel leakage is permitted See Specifications for more information GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULT mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications and Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with break in oil This oil should be changed after 30 hours of operation Check the oil level in the generator gearbox if so equipped prior to initial use and at the intervals indicated by the Service Schedule The recom mended oil is SAE 90 gear lubricant Also if the engine is equipped with a mechanical gov ernor make sure the governor is properly lubricated with clean engine oil PRIOR TO INITIAL START UP caution Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the
58. ed 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 the panel wiring and components from damaging overload Always remove this fuse before commencing work on the generator The unit will not start or crank if the fuse is blown Replace the fuse with one of the same size type and rating See the exploded views and parts lists at the end of this manual for replacement part number 90 80 O 0 GENERAL INFORMATION FUEL SYSTEM FUEL REQUIREMENTS The standby generator may be equipped with one of the following fuel systems Natural gas fuel system Propane vapor PV fuel system The Manual Drawing Listing that is affixed to the unit includes the Identification Code which may be use
59. ed 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 SO LL V ed 100188 Check voltage at the generator terminals For 3 phase units check phase rotation at the transfer switch terminals The generator phase rotation must match the utility phase rotation Check for coolant fuel oil and exhaust leaks Close the generators main line circuit breaker Turn the generator set off Connect the UTILITY supply to the transfer switch Set the AUTO OFF MANUAL switch to AUTO Disconnect utility power before the transfer switch Engine should start transfer to load Run at least 15 minutes on generator power Make certain all 3 phase loads are functioning correctly correct phase rotation Reconnect Utility power Transfer switch will transfer back to Utility and engine will shut down within the given time parameters set up for the specific transfer switch and controller Install all covers access plates and door panels Put the Owners Manual in a safe and accessible place Make certain the AUTO OFF MANUAL switch is in the AUTO position START UP INSPECTION When a startup is performed by an Authorized
60. enance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom Task Required Task Required Task Task Required mended Comp to be done Comp to be done Comp Required Comp to be done to be done Date 3 months Date Semi Date to be done Date Bi monthly Initials Initials annually Initials Annually Initials annually 10 hrs 30 hrs 50 hrs 100 hrs 250 hrs Start and 18 19 20 21 22 23 24 25 exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary Perform an engine oil analysis send a sample to a lab for results Change the engine oil and filters if the analysis results indicate this is required engine oil engine oil filter s Replace engine spark plugs Clean and re gap or replace as necessary Replace the engine air filter s Perform a 5 minute no load operational run of the unit looking for any post service problems Return the unit to standby setup for operation when required 90 60 V LOOPYISAIS 11 4 MAINTENANCE Task Comp Date Initials TROUBLESHOOTING Standby Generator Sets Troubleshooting TROUBLESHOOTING GUIDE CAUSE PROBLEM Engine won t crank Engine cranks but won t start Engine starts har
61. fore 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 90 80 LOOdinb3 GENERAL INFORMATION ENGINE PROTECTIVE DEVICES The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant tempera ture oil pressure or rpm For that reason the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low the coolant temperature is too high the coolant level is too low or the engine is running too fast NOTE Engine protective switches and sensors are men tioned here for the reader s convenience Also refer to the applicable control panel manual for additional automatic engine shutdown informa
62. g properly Coolant should be at bottom of radiator filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact an Authorized Service Dealer Inspect cooling system and coolant recovery system for leaks MAINTENANCE OWNER OPERATOR CAN PERFORM CHECK ENGINE OIL LEVEL Refer to the Checking Fluid Levels section CHECK BATTERY Check battery fluid level each week as outlined under Check Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 20 minutes See the Weekly Exercise Cycle section INSPECT COOLING SYSTEM Inspect engine cooling system at least once each month Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness CHECK ENGINE COOLANT LEVEL See the Checking Fluid Levels section PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition
63. he responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff sole noid should not exceed approximately 14 inches water column 0 5 psi Optimum pressure at the fuel shutoff solenoid is 11 inches water column 0 4 psi Standby Generator Sets Fuel Systems GENERAL INFORMATION PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid fuel in the supply tank Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state The vapor withdrawal system is generally best suited for smaller engines that require less fuel The installer should be aware of the following The natural gas and LP gas systems are similar However the natural gas system delivers gas at a pressure of approximately five inches water col umn to the carburetor When ambient temperatures are low and engine fuel consumption is high the vapor withdrawal system may not function efficiently Ambient temperatures around the supply tank must be high enough to sustain adequate vaporiza tion or the system will not deliver the needed fuel volume In addition to the cooling effects of ambient air the vaporization process itself provides an additional cooling effect LP FUEL SYSTEM LP is supplied as a liquid in pressure tanks It is usuall
64. hten OIL DRAIN HOSE CAP and re install into its retaining clip 4 Turn OIL FILTER Figure 10 2 counterclockwise and remove Dispose of old filter 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVERTIGHTEN 6 Remove OIL FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters caution After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance 7 Start engine and check for oil leaks Figure 10 2 Oil Filter LA S CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 0A4637 remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover See the Service Schedule section for air cleaner maintenance SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush 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 questionab
65. hut down warninc The exhaust system parts from this product get extremely hot and remain hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system CHECKING FLUID LEVELS CHECK ENGINE OIL Check engine crankcase oil level Figure 10 1 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE MARK See Engine Oil Recommendations for recommended oils Figure 10 1 Oil Dipstick and Oil Fill Cap Oil Dipstick Oil Fill BATTERY FLUID Check battery electrolyte fluid at least once weekly Fluid should cover separators in all battery cells If fluid level is low add distilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY 90 80 0 001 MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance ENGINE COOLANT Check coolant level in coolant recovery bottle See the Specifications section Add recommended coolant mixture as necessary Periodically remove radiator pressure cap to make sure the coolant recovery system is functionin
66. ia to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before install ing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reli ably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If a pro cedure work method or operating technique is used that the manufacturer does not specifically recom mend ensure that it is safe for others Also make sure the procedure work method or operating tech nique utilized does not render the generator unsafe 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
67. icing this and related equipment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in hazardous and pos sibly fatal electrical shock Connecting this unit to an electrical system nor mally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operat ing Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy 90 80 100 Aiejes Standby Generator Sets Important Safety Instructions SAFETY RULES Generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to person nel disable the generator s automatic start circuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and on the transfer switch In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a
68. ion Use calendar time from the previous maintenance interval to determine the next required maintenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten tial problem areas This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the control panel Auto Off Manual switch to the OFF position Remove the 15 amp control panel fuse Turn off the battery charger Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A wear in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ONLY ONCE following the first three months or the first 30 hours of oper
69. is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the 120VAC power supply to the battery is turned OFF or sparking may occur at the bat tery posts as the cables are attached and cause an explosion BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 24F 6 525 0 deg F NOTE The BCI number should be located directly on the battery REPAIR PARTS The latter portion of this manual consists of exploded views parts lists and electrical data pertaining to this generator set The parts lists consist of a an item number b a part number c the quantity required and d a description of the part The item number corresponds to an identical number on the exploded view drawing Periodic Replacement Parts Part Number Oil Filter 0E7415 046627 0 4637 Spark Plug Champion 12 4 Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule SERVICE SCHEDULE 30 KW 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to 150 kW in size The established intervals in the schedule are the maximum recommended when the unit is used in an average service application They will need to be decreased performed more frequently if the unit is used in a severe applicat
70. ized Service Dealer 11 1 90 60 LOOPUSSMS MAINTENANCE MAINTENANCE Standby Generator Sets Service Schedule Maintenance Tasks 1 Disable the unit from operating per the first page warning 2 Check the engine oil level Adjust as necessary 3 Check the engine coolant level Adjust as necessary 4 Check the engine coolant thermal protection level Correct as necessary 5 Check the natural gas delivery system for leaks and correct pressure on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level and specific gravity if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiring for loose connections corrosion and damage Correct as necessary 90 60 V ed LOOPUISAIS Level 1 Level 2 Level 3 Level 4 Level5 Recom Task Required Task Required Task Task Required Task mended be done Comp be done Comp Required Comp lto be done Comp to be done Date 3 months Date Semi Date to be done Date Bi Date monthly Initials Break in Initials annually Initials Annually annually Initials 50 hrs 100 hrs 250 hrs 10 hrs 30 hrs 11 2 Standby Generator Sets
71. l produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the standby generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appropriate covers guards and barriers are in place before operating the gen erator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT If personnel must stand on metal or concrete while installing operating servicing adjusting or repair ing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static electricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maxi mum electrical current ampacity to which they will be subjected Before installing or serv
72. le See the Service Schedule section for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 1 01 mm 0 040 inch by carefully bending the ground electrode Figure 10 3 Figure 10 3 Setting the Spark Plug Gap SET PLUG GAP AT 1 01 mm 0 040 inch 10 3 COOLANT CHANGE Every year have an Authorized Service Facility drain flush and refill the cooling system See the Specifications section for cooling system recom mendations MISCELLANEOUS MAINTENANCE CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer That dealer will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well 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 aci
73. n site by appropriate personnel Scheduled maintenance as outlined by the generator owner s manual is highly recommended This should be performed by an Authorized Certified Generac Power Systems Dealer or branch thereof This will verify service has been performed on the unit throughout the warranty period WARRANTY SCHEDULE YEARS ONE and TWO Limited comprehensive coverage on mileage labor and parts listed e ALL COMPONENTS Start up and or On line Registration or Registration Card along with Proof of Purchase must be performed and or sent in Guidelines Any and all warranty repairs and or concerns must be performed and or addressed by an Authorized Certified Generac Power Systems Dealer or branch thereof A Generac Power Systems Inc Transfer Switch is highly recommended to be used in conjunction with the genset If a Non Generac Power Systems Inc Transfer Switch is substituted for use and directly causes damage to the genset no warranty coverage shall apply All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty Policies and Procedures Flat Rate Manual Units that have been resold are not covered under the Generac Power Systems Warranty as this Warranty is not transferable Unit enclosure is only covered against rust or corrosion the first year of the warranty provision Use of Non Generac replacement part s will void the warranty in its entirety Engine coolant hea
74. nerator Sets MAINTENANCE MAINTENANCE Maintenance MAINTENANCE PERFORMED BY AUTHORIZED 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 the con trol box The 120VAC supply to the battery charger is switched OFF EVERY THREE MONTHS Check battery state of charge and condition Inspect and test fuel system Check transfer switch Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY 1 Test engine governor Adjust or repair if needed 2 Clean inspect generator 3 Flush cooling system FIRST 100 OPERATING HOURS 1 Change engine oil and oil filter After initial change service engine oil and filter at 150 operat ing hours or 6 months whichever comes first EVERY 500 OPERATING HOURS 1 Service air cleaner 2 Check starter 3 Check engine DC alternator COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Qa PON Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to s
75. nonconducting imple ment such as a dry rope or board to free the vic tim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extin guisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris These generator sets may operate using one of several types of fuels 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 unit s fuel system frequently and correct any leaks immediately Fuel supply lines m
76. p After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety infor mation that if not followed could endanger personal safety and or property of others A This symbol points out potential explosion hazard Important Safety Instructions This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency
77. recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications and Coolant sections BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inch 10 to 16 mm ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground Make sure the generator battery is fully charged properly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components INITIAL INSPECTION FOR QT GENSET STARTUP Inspect for the following Freight Damage Manuals present Fluid Levels Oil coolant battery Gear Drive Correct fuel piping Correct muffler installation for QT50 0770 QT100 QT150 Adequate air flow clearances and ventilation per installation drawings and applicable codes Correct AC and DC wire size connections and grounding Control and communication wiring to from the transfer switch must be run in a separate condui
78. t from the AC power leads Battery charger connection to 120 VAC Communication wires connected between transfer switch and generator HTS only Unit secured to pad SO LL 10088 INSTALLATION Standby Generator Sets Installation INSTALLATION START UP CHECKLIST A warninc Before working on the generator ensure the fol lowing The AUTO OFF MANUAL switch is in the OFF position The 120VAC supply to the battery charger is switched OFF PREPARATION FOR START UP Ensure that the 120VAC circuit breaker to the bat tery charger is open Remove the fuse from the the control panel For the H 100 and R 100 Open the front door of the control box and remove the 15 Amp ATO fuse in the lower left hand corner of the control box Connect the battery cables to the battery Attach negative battery cable last Close the 120VAC circuit breaker to the battery charger Measure the voltage at the battery before and after the charger is turned on Verify all AC electrical connections are tight at the circuit breaker and transfer switch Visually inspect entire area looking for loose paper plastic wrappings leaves etc Check all hoses clamps fittings for leaks or dam age Check all electrical plugs throughout the genera tor Ensure each plug is seated correctly and fully inserted into its receptacle Verify the AUTO OFF MANUAL switch is in OFF position Open the valve to the engine fuel line Ble
79. t up 8 1 Start up Inspection cete iere robes eto de Paese 8 2 Standby Generator Sets TABLE CONTENTS Table of Contents CONTENTS OPERATION 9 1 Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch 9 1 Engine Start up and Transfer 9 1 Retransfer and Shutdown 9 1 Operating Unit with Automatic Transfer Switch 9 1 MAINTENANCE 10 1 Maintenance Performed by Authorized Service Facilities 10 1 Cooling soc 10 1 Checking Fluid Levels iet reete 10 1 Check Engine 10 1 Battery Fluid a a n u a 10 1 Engine Coolant sc hie eere 10 1 Maintenance Owner Operator Can Perform 10 2 Check Engine Oil 10 2 Check Battery 10 2 Exercise Systemin onore ek eres dees 10 2 Inspect Cooling System iet eere neenon 10 2 Check Engine Coolant 10 2 Perform Visual 10 2 Inspect Exhaust 10 2 Check Fan 10 2 Inspect Engine Governor
80. ters block heaters heater controls and circulating pumps are only covered during the first year of the warranty provision If applicable THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Any unit built manufactured prior to January 1 2005 Costs of normal maintenance i e tune ups associated part s adjustments loose leaking clamps installation and start up Any failure caused by contaminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted or Rental Unit definition and warranty Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not normally exist Failures caused by any external cause or act of God such as but not limited to collision fire theft freezing vandalism riot or wars lightning earthquake windstorm hail volcanic eruption water or flood tornado hurricane terrorist acts or nuclear holocaust Products that are modified or altered in a manner not authorized by Generac Power Systems in writing Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation or sizing
81. ust be prop erly installed purged and leak tested according to applicable fuel gas codes before placing this equip ment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detectors accordingly Standby Generator Sets INTRODUCTION Thank you for purchasing this model of the standby generator set product line Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest Authorized Service Dealer for start ing operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert person nel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows A After this heading read instructions that if not strictly complied with will result in personal injury or property damage warninc am
82. y 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 O 100545114 SPECIFICATIONS GENERATOR M Synchronous Rotor Insulation Class F or H Stator Insulation soot etre ees Class H Total Harmonic lt 3 5 Telephone Interference Factor 50 Alternator Output Leads 3 phase 4 wire P Sanga s Sealed Ball Flexible Disc Load Capacity Standby Rating 30kW NOTE Generator rating and performance in accordance with ISO8528 5 BS5514 SAE J1349 ISO3046 and DIN 6271 Standards KW rating is based on LPG fuel and may derate with natural gas Excitation Systetmi asia Direct Generator Output Voltage kW

Generac Power Systems 005219-0 Portable Generator User Manual

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