Generac 50kW 0065781 Standby Generator Manual

Generac 50kW 0065781 Standby Generator Manual

Owner’s Manual

For Stationary Industrial Generators

Gas or Diesel

®

DANGER

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

(000103)

WARNING

Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(000182a)

SAVE THIS MANUAL FOR FUTURE REFERENCE

ii

WARNING

CANCER AND REPRODUCTIVE HARM

www.P65Warnings.ca.gov.

(000393a)

WARNING

Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

• Always start and operate the engine in a well-ventilated area.

• If in an enclosed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to

www.P65Warnings.ca.gov/diesel.

(000394) Owner’s Manual for Stationary Industrial Generators

Table of Contents

Section 1 Introduction and Safety

Introduction ................................................ 1

Read This Manual Thoroughly ........................1

Installation, Operation, and Maintenance ............................................... 1

Bi-fuel Fuel System ......................................10

LP Fuel System ............................................10

LP Vapor Withdrawal Fuel System ...............11

LP Liquid Withdrawal Fuel System ...............11

Dual Fuel: NG/LP Fuel System ....................11

Specifications ........................................... 11 How to Obtain Service ............................... 1 Safety Rules ................................................ 2 General Hazards ......................................... 2

Generator .....................................................11

Engine Oil Recommendations ......................11

Coolant .........................................................11

Gearbox Lubrication (If Equipped) ................11

Electrical Hazards ...................................... 3 Starting Aids (If Equipped) ...................... 12 Fire and Explosion Hazards ...................... 4 Battery Hazards .......................................... 4 Standards Index ......................................... 5

Engine Coolant Heater .................................12

Engine Oil Sump Heater ...............................12

Battery Warmer ............................................12

Glow Plugs / Intake Air Heater .....................12

Section 2 General Information

Unit Identification ....................................... 7

Section 3 Operation

Generator Control and Operation ........... 13

Data Label ......................................................7

Model Identification Code ...............................7

Voltage Code ..................................................8

Fuel Type ........................................................8

Engine RPM ....................................................8

Controller Type ...............................................8

Grounding the Generator .............................13

Generator AC Neutral Connections ..............13

Initial Startup ................................................13

Control Panel Interface ............................ 14 Equipment Description .............................. 9

Standard Generator Features .........................9

Generator and Load Compatibility ..................9

Single-Phase “A” or “M” Code Units ...............9

Three-Phase Load Imbalance Limits ..............9

Ambient Condition Derate ...............................9

Engine and Generator Protective Devices (If Equipped) ................................ 9

Emergency Stop Button ...............................15

Common Alarm Horn ....................................15

Key Switch ....................................................15

Fuse Block ....................................................15

Additional Components ........................... 15

Main Line Circuit Breaker (MLCB) ................15

Automatic Transfer Switch ............................15

Automatic Battery Charger ...........................15

Alarm Response Procedures .................. 16

Coolant Temperature Sensor .........................9

Low Coolant Level Sensor ............................10

Oil Pressure Sensor ......................................10

Oil Temperature Sensor (If Equipped) ..........10

Overspeed Shutdown ...................................10

Overcrank Shutdown ....................................10

RPM Sensor Loss Shutdown ........................10

Low Fuel Pressure Warning .........................10

Warnings ......................................................16

Non-Shutdown Alarms ..................................16

Shutdown Alarms .........................................16

Alarm Display Window ..................................16

General Fault Response Procedure .............16

Operating the Unit with an Automatic Transfer Switch ........................................ 16 DC Fuses ................................................... 10 Fuel System .............................................. 10

Diesel Fuel System .......................................10

Natural Gas Fuel System ..............................10

Owner’s Manual for Stationary Industrial Generators iii

Operating the Unit with a Manual Transfer Switch ........................................17

Manual Engine Startup and Transfer ............17

Re-Transfer and Shutdown ..........................18

Shutting Generator Down While Under Load ..............................................................18

Section 4 Maintenance

Maintenance ..............................................19

Service Maintenance Intervals .....................19

Maintenance Schedule .................................19

Notes and Maintenance Item Explanations ..20

Disabling a Generator for Maintenance ..............................................20

To Disable the Generator From Starting ......20

Shutdown and Restart an Operating Generator .....................................................20

Maintenance Tasks ...................................21

Visually Inspect Unit .....................................21

Check Engine Fluids .....................................21

Check Engine Oil Level .................................. 21 Check Coolant Level ...................................... 22 Check/Change Gearbox Oil (If Equipped) ...... 22 Battery Inspection .........................................23

Battery Installation and Replacement ...........23

Preliminary Instructions .................................. 23 12 VDC System .............................................. 23 24 VDC System .............................................. 24 Final Instructions ............................................ 24 Other Maintenance Checks ..........................24

Maintenance and Repair Parts ................24

Extended Run-Time Maintenance Checks .......................................................25

Maintenance Level 1A ..............................26

Maintenance Level 1 - Monthly or Every 24 Hours .........................................27

Maintenance Level 2 - Semi-Annual or Every 125 Hours ...................................28

Maintenance Level 3 - Annual or Every 250 Hours ..................................................29

Maintenance Level 4 - Bi-Annual or Every 500 Hours .......................................30

Section 5 Warranty Information

For Stationary Emergency Spark-Ignited Generators ........................31

For Stationary Emergency Compression-Ignition Generators ..........33

iv Owner’s Manual for Stationary Industrial Generators

Introduction and Safety

Section 1 Introduction and Safety

Introduction

Thank you for purchasing a Generac Power Systems, Inc. product. This unit has been designed to provide high performance, efficient operation, and years of use when maintained properly. The information in this manual is accurate based on products produced at the time of publication. The manufacturer reserves the right to make technical updates, corrections, and product revisions at any time without notice.

How to Obtain Service

NOTE:

Use this page to record important information about the generator set. This label is typically located on the side of the control panel.

Each generator set has a data label containing important information about the unit.

When contacting an IASD about parts or service, always supply the complete model number and serial number of the unit as given on the data label. For quick and easy reference, copy the information printed on the data label located on the generator onto the sample label printed here. See

Figure 1-1

.

Read This Manual Thoroughly

WARNING

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

(000100a) If any section of the manual is not understood, contact your nearest Independent Authorized Service Dealer (IASD), or contact machine.

Generac Customer Service at 1-888 GENERAC (1-888-436-3722), or

www.generac.com

with any questions or concerns. The owner is responsible for proper maintenance and safe use of the equipment.

Save these instructions for future reference. This manual contains important instructions for the generator that should be followed during installation, operation and maintenance of the generator and batteries. Always supply this manual to any individual that will use this

Installation, Operation, and Maintenance

Installation and initial startup of this equipment is not a “do-it-yourself” project. This generator set must be installed by an IASD or other competent, qualified contractor. The initial startup must be performed and documented by an IASD. An IASD can also provide the necessary training for authorized operators. 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 IASD.

Access to the generator shall be through the use of a special tool, or lock and key, or other means of security and shall be controlled by the authority responsible for the location.

Normal maintenance service and replacement of parts are the responsibility of the owner 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 will ensure a minimum number of problems and keep operating expenses at a minimum. See an IASD for service aids and accessories.

GENERATOR UNIT

GEN MODEL: MODEL: SERIAL: ALTERNATE PROD DATE: COUNTRY OF ORIGIN:

GENERATOR DATA

KW KVA HZ PF UPSIZE ALT KW KVA VOLT / AMP ENG RPM ALT RPM BREAKER KW AMP X’D X”D ROTOR STATOR CLASS WINDINGS @ AMBIENT TEMP MANUF.

LOC

Figure 1-1. Data Label (Sample)

003564 Owner’s Manual for Stationary Industrial Generators 1

Introduction and Safety

Safety Rules

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all inclusive. If using a procedure, work method or operating technique that the manufacturer does not specifically recommend, verify that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the equipment unsafe.

Throughout this publication, and on tags and decals affixed to the unit, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

(000001)

General Hazards

DANGER

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

(000103)

DANGER

Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury. (000190)

WARNING

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.

(000111)

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

(000002)

WARNING

Moving Parts. Do not wear jewelry when starting or operating this product. Wearing jewelry while starting or operating this product could result in death or serious injury.

(000115)

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

(000003)

NOTE:

Notes contain additional information important to a procedure and will be found within the regular text of this manual.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

WARNING

Sudden start-up. Always set the safety disconnect switch to MANUAL before working on equipment. Failure to do so could result in death or serious injury.

(000194)

WARNING

Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage.

(000142a)

WARNING

Vision Loss. Eye goggles are required to be worn when using this machine. Failure to wear eye goggles could result in permanent vision loss.

(000101)

WARNING

Loss of life. This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury.

(000209b) 2 Owner’s Manual for Stationary Industrial Generators

WARNING

Hearing Loss. Hearing protection is recommended when using this machine. Failure to wear hearing protection could result in permanant hearing loss.

(000107)

WARNING

Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(000182a)

CAUTION

Equipment or property damage. Do not block air intake or restrict proper air flow. Doing so could result in unsafe operation or damage to unit.

(000229) Introduction and Safety

Electrical Hazards

DANGER

Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury .

(000145)

DANGER

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

(000104)

DANGER

Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.

(000144)

DANGER

Electrocution. Verify electrical system is properly grounded before applying power.

Failure to do so will result in death or serious injury.

(000152)

DANGER

Electrocution. Turn utility supply OFF before serious injury.

(000123)

DANGER

Electrocution. Never connect this unit to the electrical system of any building unless a licensed electrician has installed an approved transfer switch. Failure to do so will result in death or serious injury.

(000150) Owner’s Manual for Stationary Industrial Generators 3

Introduction and Safety

Fire and Explosion Hazards

DANGER

Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury.

(000105)

Battery Hazards

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

(000188)

WARNING

Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury.

(000110)

WARNING

Risk of Fire. Unit must be positioned in a manner that prevents combustible material accumulation underneath. Failure to do so could result in death or serious injury.

(000147)

WARNING

Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire.

(000108)

WARNING

Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

(000137a)

WARNING

Explosion. Batteries emit explosive gases.

Always disconnect negative battery cable first to avoid spark. Failure to do so could result in death or serious injury.

(000238)

WARNING

Explosion. Do not dispose of batteries in a fire. Batteries are explosive. Electrolyte solution can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.

(000162)

WARNING

Risk of burn. Do not open or mutilate batteries. Batteries contain electrolyte solution which can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention. (000163a)

WARNING

Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death, or serious injury.

(000228) Always recycle batteries in accordance with local laws and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. For more information on battery recycling, visit the Battery Council International website at:

http://batterycouncil.org

4 Owner’s Manual for Stationary Industrial Generators

Standards Index

The generator owner must strictly comply with all applicable national, state, or local laws, codes, and regulations pertaining to the installation of engine generator power systems. Always use the current acceptable version or edition of the applicable code or standard which applies to the local jurisdiction. In the absence of pertinent local laws and standards, the following published booklets may be used as a guide: National Fire Protection Association (NFPA) 70: The National Electric Code (NEC)*

1.

NFPA10: Standard for Portable Fire Extinguishers*

2.

3.

NFPA 30: Flammable and Combustible Liquids Code* NFPA 37: Standard for Stationary Combustion Engines and Gas Turbines*

4.

5.

6.

7.

NFPA 54: National Fuel Gas Code* NFPA 58: Standard for Storage and Handling of Liquefied Petroleum Gases* NFPA 68: Standard on Explosion Protection by Deflagration Venting* NFPA 70E: Standard for Electrical Safety in the Workplace*

8.

9.

10.

11.

12.

13.

14.

15.

NFPA 99: Health Care Facilities Code* NFPA 101: Life Safety Code* NFPA 110: Standard for non-emergency and Standby Power Systems* NFPA 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances* NFPA 220: Standard on Types of Building Con struction* NFPA 5000: Building Code* International Building Code** Agricultural Wiring Handbook***

16.

ASAE EP-364.2 Installation and Maintenance of Farm Standby Electric Power**** This list is not all inclusive. Check with the Authority Having Local Jurisdiction (AHJ) for any local codes or standards which may be applicable to the jurisdiction where the generator is installed. The above listed standards are available from the following Internet sources: * ** *** ****

www.nfpa.org

www.iccsafe.org

www.rerc.org

0309 Rural Electricity Resource Council; P.O. Box 309; Wilmington, OH 45177-

www.asabe.org

American Society of Agricultural & Biological Engineers; 2950 Niles Road; St. Joseph, MI 49085 Owner’s Manual for Stationary Industrial Generators Introduction and Safety 5

Introduction and Safety

This page intentionally left blank.

6 Owner’s Manual for Stationary Industrial Generators

General Information

Section 2 General Information

Unit Identification Data Label

Each generator set has a data label containing important information about the generator. The data label lists the unit serial number, rated voltage, amps, wattage capacity, etc.

NOTE:

The figure below is a generic representation only. For actual information on your particular model, refer to the data label(s) affixed to your unit.

Model Identification Code

The model identification code gives important information about the generator set. For example, if the code is:

SG 0100 A G03 6.8 N 23 H B Y Y 3

Then the generator would have the attributes shown in bold below:

S G 0100 A G03 6.8

N 23 H B Y Y 3

Standby M Modular (MPS) P W Prime Prime Modular (MPS) C Z Continuous Protector Series Gaseous engine D Diesel engine B Bi-Fuel.

kW rating (100kW) Voltage code (see

Voltage Code

) Engine designation (for internal use) Engine size (6.8 = 6.8L, 142 = 14.2L) Fuel type (see

Fuel Type

) Engine RPM (see

Engine RPM

) Control Panel (see

Controller Type

) Brushless excitation P Permanent magnet (external) excitation D Direct excitation Standard enclosure (weather protective) N S L E No enclosure, standard — suitable for indoor installation Level 1 sound attenuated Level 2 sound attenuated Level 3 sound attenuated C Containerized Exhaust muffler mounted N L Exhaust muffler not provided Exhaust muffler shipped loose with unit Emission designation (for internal use)

SG0100AG036.8N23HBYY3

Sample

Owner’s Manual for Stationary Industrial Generators 7

General Information

Voltage Code

Voltages Code A

60 Hz 50 Hz

D G H J K L M N P R S Description

120/240 VAC, single-phase, three-lead 120/240 VAC, single- or three-phase, 12-lead (Full capacity single- or three-phase; cannot be reconnected for 277/480 VAC) 120/208 VAC, three-phase, 12-lead 231/400 VAC, three-phase, 12-lead (Adjustable from 380 VAC to 416 VAC) 120/240 VAC, three-phase, 12-lead 277/480 VAC, three-phase, 12-lead 346/600 VAC, three-phase, three-lead 110/220 VAC, single-phase, three-lead (Adjustable to 120/240 VAC) 115/200 VAC, single-phase, 12-lead 100/200 VAC, three-phase, 12-lead (Adjustable to 240 VAC) 231/400 VAC, three-phase, 12-lead (Adjustable from 380 VAC to 416 VAC) 480 VAC, three-phase, three-lead

Fuel Type

Code B D G N S V L P R Q T Description

Bi-Fuel Diesel and Natural Gas Diesel Gasoline Natural Gas (11-14” WC) Natural Gas Low Pressure (7-11” WC) Liquid Propane Vapor Withdraw (LPV) Liquid Propane Withdraw (LPL) Dual Fuel NG (Normal) / LPL Secondary Dual Fuel NG (Normal) / LPV Secondary Dual Fuel NG (Low Pressure) / LPL Secondary Dual Fuel NG (Low Pressure) / LPV Secondary

Engine RPM

Example 15 18 23 30 36 Description

1500 RPM 1800 RPM 2300 RPM 3000 RPM 3600 RPM

NOTE:

Engines operating above 1,500 or 1,800 RPM use a gearbox to reduce the engine RPM to the desired alternator rotor RPM of 1,500 RPM (50 Hz operation) or 1,800 RPM (60 Hz operation).

Controller Type

Code A G H P S

ComAp

Description

G-Panel H-Panel Power Zone Pro Sync Power Zone Pro 8 Owner’s Manual for Stationary Industrial Generators

General Information

Equipment Description

This equipment is a revolving field, alternating current type generator set. The generator is designed to supply electrical power for the operation of compatible electrical loads when the utility power supply is not available or has dropped to an unacceptable level.

The generator’s revolving field is directly connected to and driven by an engine by means of flexible discs or a gearbox. Generators with a four-pole rotor are driven at a rated speed of 1,800 RPM to supply a frequency of 60 Hertz. Four-pole rotors operating at 50 Hertz are driven at 1,500 RPM.

Refer to the data label affixed to the unit for rated AC voltage, wattage, amperage, number of phases, etc. See

Model Identification Code

for an explanation of how to identify the unit’s features.

Standard Generator Features

The generator incorporates the following features:

The rotor insulation system is Class “H” rated, and the stator insulation is Class “H” rated as defined by NEMA MG1-22.4 and NEMA MG1-1.65.

The generator is self-ventilated and drip-proof constructed.

The voltage waveform deviation, total harmonic content of the AC waveform and “telephone influence factor” have been evaluated and are acceptable according to NEMA MG1-22.

All prototype tested models have passed three phase symmetrical short circuit test to ensure system protection and reliability.

Generator and Load Compatibility

The generator must be fully compatible with the rated voltage, phase, and frequency of the connected electrical loads. The generator, connected electrical devices, or both, can be damaged if voltage, phase, and frequency are not compatible.

NOTE:

This manual assumes that the generator set has been properly selected, installed and interconnected by a competent, qualified electrician or installation contractor. Once the installation is complete, do nothing that may result in non-compatibility between the generator and connected electrical loads.

Single-Phase “A” or “M” Code Units

The following statement applies to single-phase units with an “A” or “M” code alternator: The generator is suitable for supplying typical residential loads, such as induction motors (sump pumps, refrigerators, air conditioners, furnaces, etc.), electronic components (TV, computer, monitor, etc.), lighting loads, and microwaves.

Three-Phase Load Imbalance Limits

For three-phase units the maximum load imbalance between phases can not exceed 25% of rated load (current).

Ambient Condition Derate

The maximum ambient temperature for the generator is indicated on the unit data label. Derate values for ambient temperature in excess of that indicated on the data label, as well as altitude, may apply depending on the engine and kW rating of the unit. Contact an IASD for any derate values applicable to this specific generator at its installed location.

Engine and Generator Protective Devices (If Equipped)

The generator set may be required to operate for long periods of time without an operator to monitor conditions such as coolant temperature, oil pressure, voltage, frequency, etc. For this reason, the generator set has numerous sensors to provide the control panel with the information it needs to protect both the engine and generator. The control panel is designed to shut down the engine if potentially damaging conditions occur. These conditions can include low oil pressure, high coolant temperature, low coolant level, engine overspeed, over or under voltage, over or under frequency, etc. These settings are configured at the factory and can be adjusted by an IASD if required.

NOTE:

Engine and generator protective devices are only mentioned here for the owner’s general information. For details, consult the applicable control panel technical manual. The list below is not all inclusive.

Coolant Temperature Sensor

The control panel automatically shuts down the engine if the engine coolant temperature rises above a safe level.

Owner’s Manual for Stationary Industrial Generators 9

General Information

Low Coolant Level Sensor

Should the engine coolant level drop below the level of the low coolant temperature sensor, it is possible for the engine to overheat without automatic shutdown. 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 control panel will shut the engine down.

Oil Pressure Sensor

This sensor monitors engine oil pressure. If oil pressure drops below a safe level, the control system automatically shuts down the engine.

Oil Temperature Sensor (If Equipped)

The control panel automatically shuts down the engine if the oil temperature rises above a safe level.

DC Fuses

Located inside the front panel, the fuses protect the control panel wiring and components from damaging overload. For fuse location and identification, see the corresponding control panel manual.

Fuel System

This generator set is equipped with one of the following fuel systems:

Diesel fuel system

Natural Gas (NG) fuel system

Bi-Fuel Diesel and Natural Gas

LP gas vapor withdrawal fuel system (LPV)

LP liquid withdrawal fuel system (LPL)

Dual fuel system: Natural Gas (primary fuel source), LP gas vapor (secondary fuel source)

Dual fuel system: Natural Gas (primary fuel source, LP liquid (secondary fuel source)

Overspeed Shutdown

A speed circuit controls engine cranking, startup, operation, and shutdown. Engine speed signals are delivered to the control panel whenever the unit is running. Should the engine overspeed above a safe, preset value, the control panel initiates an automatic engine shutdown.

Overcrank Shutdown

After a pre-specified duration of cranking, this function ends the cranking if the engine has failed to start. The default settings are:

The unit will attempt to start (crank) three times.

Each crank cycle lasts either 10 or 15 seconds, followed by a five second rest (to cool the starter).

After three starting attempts the unit will shutdown.

RPM Sensor Loss Shutdown

If the speed signal to the control panel is lost, engine shutdown will occur.

Diesel Fuel System

The manufacturer recommends the use of No. 2 diesel fuel when temperatures are above freezing, and No. 1 diesel fuel when temperatures drop below freezing. Diesel fuel must meet the following requirements: Beginning October 1, 2010, owners and operators that use diesel fuel must use diesel fuel that meets:

• •

Sulfur content of 15 parts per million (ppm) maximum.

Cetane index or aromatic content as follows: A minimum cetane index of 40, or a maximum aromatic content of 35 volume percent.

Natural Gas Fuel System

Natural gas is supplied by a local utility in its vapor state through in ground piping.

Bi-fuel Fuel System

Combines diesel fuel and natural gas fuel systems.

Low Fuel Pressure Warning

Some gaseous units are equipped with a low fuel pressure warning switch which will trigger a Warning alarm if the fuel pressure drops below a minimum setting.

Diesel units with fuel tanks are equipped with High and Low fuel level warning alarms, as well as a low fuel level shutdown alarm.

LP Fuel System

LP is supplied as a liquid in pressurized tanks. It is usually made up of propane, butane, or a mixture of both gases. 10 Owner’s Manual for Stationary Industrial Generators

General Information

LP Vapor Withdrawal Fuel 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. IASD for oil recommendations. Synthetic oils meeting the same service category and viscosity requirements for the application may be used.

Recommended API Service Category for gaseous engines: SJ, SL, SM, or SN.

Recommended API Service Category for diesel engines: CH-4, CI-4, or CJ-4

LP Liquid Withdrawal Fuel System

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 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.

NOTE:

Units with LP gas liquid withdrawal systems incorporate a block heater as standard equipment. The heater is powered by the utility power source during non operating periods to provide heated coolant to aid in the fuel vaporization process.

Coolant

DANGER

Risk of poisoning. Do not use mouth to siphon coolant. Doing so will result in death or serious injury.

(000149)

WARNING

Risk of burns. Do not open coolant system until engine has completely cooled. Doing so could result in serious injury.

(000154)

Dual Fuel: NG/LP Fuel System

Some applications consist of a dual-fuel system. This type of fuel system allows the generator to run on either natural gas (primary) or LP vapor or liquid (secondary). In the event that the primary source (utility supplied) becomes unavailable, the unit automatically switches to the secondary source. It can do so while in operation or while not operating.

NOTE:

Engines using propane as an alternative fuel are limited to a maximum of 100 hours per year solely during emergency operations and must keep records of such use. Further operation requires a performance test to confirm compliance with the emissions standards of §60.4233.

Specifications Generator

Refer to the data plate on the generator for rated watts, amperes, frequency, voltage, phase, and other important information.

CAUTION

Risk of overheating. Do not use any chromate base rust inhibitor with propylene glycol base antifreeze, boosters, or additives. Doing so will cause overheating and possible equipment damage.

(000165a) Use only deionized or distilled water and Ethylene glycol antifreeze (Propylene glycol can also be used but do not mix with Ethylene glycol). When adding coolant, always add the recommended 50-50 mixture.

Gearbox Lubrication (If Equipped)

Use only SAE 90 gear oil with the correct proportion of Lucas Heavy Duty Oil Stabilizer. See the

Maintenance

section for more information.

Engine Oil Recommendations

The engine has been filled with factory engine oil of a grade recommended by the engine supplier. See the applicable engine service manual for engine oil recommendations.

The manufacturer recommends an initial oil and filter change after the first 50 hours (or first three months) of service operation. Use a high quality detergent oil with an appropriate classification and viscosity for the engine type and ambient temperature conditions. Contact your Owner’s Manual for Stationary Industrial Generators 11

General Information

Starting Aids (If Equipped)

One or more of the following starting aids may be provided to ensure quicker, easier starts under varying climactic conditions.

Engine coolant heater

Engine oil heater

Battery warmer

Glow Plugs These aids are powered by a normal (utility) power source during non-operating periods.

Engine Coolant Heater

Heats the engine coolant when the unit is not operating. This action keeps the engine warm even in cold weather, helping to ensure quicker starts. Powered by a circuit normally fed by the utility power supply.

Engine Oil Sump Heater

Keeps the oil in the sump heated to allow easier starting and faster engine warm-up. Powered by a circuit normally fed by the utility power supply.

Battery Warmer

Keeps the battery warm so it can provide full cranking current when starting in cold conditions. Powered by a circuit normally fed by the utility power supply.

Glow Plugs / Intake Air Heater

Internally heat the cylinders of a diesel engine. This assists in achieving a chamber temperature high enough for combustion. Powered by a circuit normally fed by battery power.

12 Owner’s Manual for Stationary Industrial Generators

Operation

Section 3 Operation

Generator Control and Operation

WARNING

Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(000182a) The operation of this generator set should only be performed by an Authorized Operator, that is, someone who has been properly trained by an IASD. Contact your local IASD for assistance in training Authorized Operators.

The following instructions assume that the generator has been properly installed, serviced, tested, adjusted, and otherwise prepared for use by a competent, qualified installation contractor and IASD. Carefully read the Safety Rules and any other safety information before attempting to operate this (and related) equipment.

Grounding the Generator

Ground the generator set in accordance with all codes and regulatory requirements.

DANGER

Explosion and Fire. Do not connect ground wire to any pipe that carries a flammable or explosive substance. Doing so will result in death or serious injury.

(000211)

Generator AC Neutral Connections

Grounding is recommended only at one point in the system. Consult local building codes for proper neutral grounding requirements.

Initial Startup

The initial startup of the generator set must be performed and documented by an IASD.

A B

001064

Figure 3-1. Grounding Electrode Terminal (Typical)

A B

Grounding Electrode Terminal Base Frame Owner’s Manual for Stationary Industrial Generators 13

Operation

Control Panel Interface

The Control Panel Interface mounted on the generator allows the operator to monitor, and if necessary, manually start the generator.

D E H A B G C F

009612

Figure 3-2. H-Panel

G A B D H A B G C F

009613

D

Figure 3-3. G-Panel

D C

009615

Figure 3-5. Power Zone Pro Sync

A B C D E F G H

Emergency Stop Button Common Alarm Key Switch Display Window Arrow Key Pad Communication Port Panel Access Battery Charger

NOTE:

Refer to the accompanying control panel manual for more information.

A B C

Figure 3-4. Power Zone ® Pro

009614 14 Owner’s Manual for Stationary Industrial Generators

Operation

Emergency Stop Button

Pressing the Emergency Stop button while the unit is running will immediately shut the generator down. To restart the unit, the Emergency Stop Button must be manually reset, the alarm acknowledged, the Key Switch turned to the OFF position, and then turned to either the AUTO or MAN position, depending on the desired mode of operation.

CAUTION

Equipment Damage. The emergency stop switch is not to be used to power down the unit under normal operating circumstances. Doing so could result in equipment damage.

(000246b) 001066

Figure 3-6. Panel Fuse Block (Reference Only)

NOTE:

Some units will NOT have a fuse in the F4 slot.

Additional Components

Common Alarm Horn

The Common Alarm and corresponding output are activated whenever a fault condition is set for Alarm and if the fault is Active. The Common Alarm will not activate on Warnings or DTC fault conditions. Pressing the ENTER button on the key pad will acknowledge the alarm and silence the horn. The manufacturer recommends that the local IASD be notified of any alarm condition in order for qualified service personnel to assess and correct the situation.

Key Switch

The Key Switch positions are:

• AUTO:

The generator will automatically start when a properly connected automatic transfer switch senses a loss or reduction of available utility power.

• OFF:

Immediately shuts down the generator and prevents it from starting automatically.

• MAN:

Immediately starts the generator.

Fuse Block

The fuse block is located inside the control panel at the back lower left corner, and provides electrical protection for the DC power, wiring and other electrical components.

Main Line Circuit Breaker (MLCB)

A MLCB is located in the High Voltage Customer Connections panel, typically located to the right of the Control Panel. The MLCB serves as protection for the AC wiring and alternator, while also providing a means of disconnecting the generator.

Automatic Transfer Switch DANGER

Electrocution, equipment and property damage. Handle transfer switches carefully when installing. Never install a damaged transfer switch. Doing so could result in death or serious injury, equipment and property damage.

(000195) A typical automatic transfer switch monitors utility voltage and when that voltage falls outside of specific parameters, it will initiate the generator start command. As long as the generator control is in the AUTO position, it responds to the automatic transfer switch start command.

For information about any connected automatic transfer switch, consult the applicable transfer switch owner’s manual.

Automatic Battery Charger

One of the following types of battery chargers may be provided:

2.5-amp

10-amp

20-amp Owner’s Manual for Stationary Industrial Generators 15

Operation The 2.5-amp charger is 12 VDC only. The 10-amp charger is available either as a 12 VDC or 24 VDC. The 20-amp charger operates as both 12 VDC or 24 VDC. The appropriate battery charger is installed per the engine’s battery system. All chargers are fully automatic float types and are fully fuse protected (input and output). They have automatic current limiting to reduce risk of overcharging, and have automatic maintenance of charge voltage. Therefore, they can be connected to the batteries continuously.

The chargers require the connection of a charged battery in order to turn on. The battery provides boost voltage for the charger, so a completely dead battery will not allow the charger to operate. The boost required is approximately 9 to 11 volts for a 12 VDC system, and 18 to 22 volts for a 24 VDC system. Replace the battery if it is below the boost voltage.

Alarm Response Procedures

The generator is protected by factory set alarms and warnings. The alarms and warnings alert the owner of a fault condition that requires attention and action to keep the generator operating in an efficient and safe running order.

When any alarm is triggered, the Common Alarm Horn sounds and the corresponding fault will be displaed.

NOTE:

Not all faults can be corrected and cleared by the owner/operator. Some Warnings, and most Alarm conditions, must be safely cleared by a qualified dealer or trained technician.

Warnings

Warnings are the lowest level alarm, and are generated to alert the operator that an operating condition has changed and may require action or inspection. Warnings clear once they are no longer active.

Non-Shutdown Alarms

Non-shutdown alarms are more urgent than warnings, and indicate a system parameter which is approaching or has exceeded a safe operating limit. Non-shutdown alarms require some form of action, such as inspection, close monitoring, etc. These types of alarms clear when they are no longer active and have been acknowledged.

Alarm Display Window

For information for your control panel.

regarding alarm codes and troubleshooting procedures, see the applicable manual

General Fault Response Procedure NOTE:

See corresponding control panel manual for detailed alarm descriptions and specific procedures.

1.

2.

3.

4.

5.

6.

Use the keypad or touch screen to navigate to the Alarm Display.

Carefully read each line of the Alarm Warning Page to determine what fault condition is present. If there is more than one fault, the most recent is listed first.

Depending on the fault condition, toggle to the corresponding area.

Observe the information displayed for the affected area.

Determine corrective action necessary.

When the fault condition is cleared, the Alarm Dis play will turn off.

Operating the Unit with an Automatic Transfer Switch

If the generator has been installed along with an automatic transfer switch, the engine may be started and stopped automatically or manually.

NOTE:

Refer to the applicable manual for any transfer switch being used and note the dangers during operation.

Normal operation is the generator in AUTOMATIC working with an automatic transfer switch. When the transfer switch senses a utility failure or loss it will provide a start command to the generator, the generator will automatically start and the transfer switch will transfer power to the load from utility to generator (emergency). It is important that both the generator and any connected automatic transfer switch(es) be properly connected and in AUTOMATIC mode for normal operation.

Shutdown Alarms

Shutdown Alarms protect the generator from damage and indicate a system fault that, if continued without immediate inspection or correction, would result in damage to the unit. Shutdown Alarms are cleared only after the key switch has been placed in the OFF position and they are no longer active.

16 Owner’s Manual for Stationary Industrial Generators

Operating the Unit with a Manual Transfer Switch

If the generator was installed in conjunction with a transfer switch capable of manual operation only, or when an automatic transfer switch has failed and can only be transferred manually, the following procedure applies. A manually operated transfer switch is one that will not provide automatic startup.

DANGER

Electrocution. Do not manually transfer under load. Disconnect transfer switch from all power sources prior to manual transfer. Failure to do so will result in death or serious injury, and equipment damage.

(000132)

DANGER

Electrocution. Only authorized personnel should access transfer switch interior. Transfer switch doors should be kept closed and locked. Failure to do so will result in death or serious injury.

(000213)

Manual Engine Startup and Transfer

Refer to the applicable documentation for the control panel. For additional and specific information about any transfer switch connected to the generator, refer to the applicable transfer switch manual as well.

In order to manually transfer load from the utility source to the generator (emergency source):

1.

2.

3.

4.

5.

6.

7.

With the generator OFF, and the generator MLCB in the OFF (OPEN) position, turn OFF or disconnect the utility power circuit to the transfer switch, using the means provided (such as the utility source MLCB or other means of disconnect).

Manually set the automatic transfer switch (ATS) to its EMERGENCY (STANDBY/GENERATOR) position with load circuits connected to the emergency (generator) power supply.

Set the generator’s MLCB to its OFF (OPEN) position.

Start the generator.

Allow the engine to stabilize and warm up.

Check all applicable instrument and gauge readings. When certain that all readings are correct, set the emergency generator’s MLCB to its ON (CLOSED) position.

Load circuits are now powered by the stationary emergency generator.

Owner’s Manual for Stationary Industrial Generators Operation 17

Operation

Re-Transfer and Shutdown

To manually transfer the load back to the utility power source and shut down the generator:

1.

2.

3.

4.

5.

6.

Set the stationary emergency generator’s MLCB to the OFF (OPEN) position.

Verify utility power to the transfer switch is OFF (open the utility disconnect).

Manually move the ATS to the UTILITY (NORMAL) position, i.e., load circuits connected to the utility.

Turn ON the utility power supply to the transfer switch using the means provided (such as the utility power source MLCB).

Allow the generator to run at no-load for five to ten minutes to stabilize internal temperatures.

Shut down the generator.

Shutting Generator Down While Under Load IMPORTANT NOTE: To turn the generator OFF during utility outages to perform maintenance, or conserve fuel, follow these steps: To turn the generator OFF (while running in AUTO and ONLINE): 1.

2.

3.

4.

Turn the main utility disconnect OFF.

Turn the MLCB on the generator to OFF (OPEN).

Allow the generator to run for five minutes to cool down.

Turn the generator OFF.

To turn the generator back ON: 1.

Put the generator back into AUTO and allow to start and warm-up for a few minutes.

2.

Set the MLCB on the generator to ON.

The system will now be operating in AUTOMATIC mode. The main utility disconnect can be turned ON (CLOSED). To shut the unit OFF, this complete process must be repeated.

18 Owner’s Manual for Stationary Industrial Generators

Maintenance

Section 4 Maintenance

Maintenance

Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be per formed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be per formed by any repair shop or person of the owner’s choosing. To obtain emissions control warranty service free of charge, the work must be performed by an IASD. See the emissions warranty.

Periodic inspection, service, and maintenance of this unit is critical in ensuring its reliable operation. The following is the manufacturer’s recommended maintenance schedule. The established intervals are the maximum required when the unit is used in typical standby service applications (approximately 250 hours per year). The maintenance items will need to be performed more frequently if the unit is used in severe applications (such as long duration outages, very high or very low ambient conditions, or extremely dirty or dusty environments). Use calendar time or hours of operation, whichever occurs first, from the previous maintenance interval to determine the next required maintenance interval. Note that some checks are based only on hours of operation.

There may be times when the generator must operate continuously for long periods of time (for example, extended utility outages). During such extended operational periods some items will require more frequent checking (based on hours). Use the “Extended Run-Time Maintenance Checks” recommendation for such periods of operation.

Be sure to follow all applicable safety and caution statements found in the unit operating manual or engine service/maintenance manual before performing any maintenance checks or service.

Service Maintenance Intervals

Extended Run-Time Maintenance Checks:

performed by an Authorized Operator.

Daily checks which must be performed when the unit is operated continuously for extended periods of time. These checks and routine monthly checks can be

NOTE:

For units equipped with a gearbox, the gearbox oil should be checked monthly or every 100 hours of operation.

1A.

A

one-time

post installation, initial operation, service inspection of the generator set to ensure it is ready to operate, transfer to, and carry the load when required, and to identify any potential problem areas.

Performed ONLY ONCE following the first three months or first 50 hours of operation after installation and startup of the unit.

The various service maintenance intervals are designated by interval numbers:

1.

2.

A frequent, periodic inspection of the generator set to ensure it is ready to operate when required and to identify any potential problem areas.

operation of the unit.

Performed monthly, or every 24 hours (interrupted) of

An operational service inspection of the generator set to ensure it is ready to operate and carry the load when required, and to identify any potential problem areas.

Performed semi-annually (6 months) or every 125 hours of operation of the unit.

3.

4.

A mid-level service inspection of the generator set to ensure it is ready to operate and carry the load when required, and to identify any potential problem areas.

Performed annually or every 250 hours of operation of the unit.

A comprehensive service inspection of the generator set to ensure it is properly serviced and ready to operate and carry the load when required, and to identify any potential problem areas.

Performed biannually (every 24 months or 500 hours).

NOTE:

Maintenance levels 2, 3, and 4 require the use of the applicable engine service manual and must be performed by a qualified service technician.

Maintenance Schedule

The following pages contain the maintenance schedule describing the checks/tasks which need to be accomplished at each designated maintenance interval. Some maintenance level tasks are combined. For example, if the six month tasks are due, both the monthly and the six month task should be completed at the same time. Similarly, when the annual tasks are due, the monthly and semi-annual tasks should also be completed. There is space on the sheets for recording the date and signature of the person completing the task, as well as recording the engine hours and other pertinent information. At the bottom of each sheet, space is also provided to record any fluids added, parts replaced or corrective action taken. All of this recorded information provides a detailed maintenance history of the unit. This maintenance history may be required for warranty validation purposes, and is a good idea to maintain throughout the lifetime of the unit.

It is recommended by the manufacturer that service procedures beyond the normal monthly checks be performed by an IASD.

Generator Installation and Operating Manual 19

Maintenance

Notes and Maintenance Item Explanations

Maintenance Item

Oil and Oil Filter Gearbox Oil (If Equipped) Coolant Quality Flexible Hoses Accessory drive belts

Description

Change oil and filter shortly after start up or commissioning of the unit. The recommendation is that this be done after the first 50 hours of operation or after the first three months of service. Perform oil and filter changes every 250 hours (or yearly) thereafter. If an oil analysis program is used (annually), the acceptable oil change interval can be extended to 500 hours or every two years, based on the results of the analysis.

Change gearbox oil every two years or 600 hours of operation. Check gearbox oil level monthly or every 100 hours of operation.

Check coolant annually for proper thermal protection levels. Drain, flush, and refill the cooling system with fresh coolant every two years regardless of operating hours.

Change coolant, fuel (gaseous supply hoses from regulator to mixer), oil, charge air cooling, and block heater hoses, flexible joints, etc.) every two years regardless of operating hours.

Replace accessory drive belts every two years regardless of operating hours. If necessary, check and replace automatic tensioner (if used).

Remove, clean, inspect, and reset magnetic pickups to the correct operational output voltage every two years.

Magnetic Pickup(s) mounted on flywheel housing Crank and/or Cam Pickup for ignition system Visually inspect (outside) for cleanliness and tightness.

NOTE:

Certain applications may require more frequent maintenance checks and more frequent operation under load.

NOTE:

This schedule does not reflect all of the possible requirements of an individual engine manufacturer service schedule, particularly if the unit is used in other than a standby power application.

NOTE:

For more information about service schedules and support for your application, please contact your local IASD.

Disabling a Generator for Maintenance

There are two conditions when maintenance checks may have to be performed on the unit: 1.

When the unit is in standby mode (automatic) and NOT running. To disable the unit from starting in this condition, in order to perform maintenance checks or service, follow the steps in

To Disable the Generator From Starting

.

2.

When the unit is running and providing power to the load. To shut down the unit safely, without damaging loads or the generator, follow the steps for shutting down a unit while in operation. See

Shutdown and Restart an Operating Generator

placed in standby.

. Before shutting down an operating unit for maintenance, always warn personnel that power will be shut down temporarily, so equipment that might be damaged can be properly turned OFF or

To Disable the Generator From Starting

To prevent injury, BEFORE performing any maintenance, disable the generator set from starting and/or connecting to the load:

1.

2.

3.

4.

Set the control panel AUTO/OFF/MANUAL switch to the OFF position.

Remove the control panel fuse (see wiring diagram).

Turn OFF power to the battery charger (remove battery charger ATC style fuse or open the battery charger circuit breaker located in the load control panel).

Disconnect the negative battery cable.

NOTE:

The battery charger must be turned OFF BEFORE disconnecting the battery cable to prevent an over-current condition from burning out sensitive control panel components and circuits.

NOTE:

Following any maintenance, reverse these steps so the unit is returned to standby setup for normal operation.

Shutdown and Restart an Operating Generator

If the unit is operating and required checks must be performed:

1.

Verify power to the load can be interrupted (warn any equipment users that there will be a temporary power disruption). There may be other procedures 20 Generator Installation and Operating Manual

Maintenance

2.

3.

4.

5.

6.

7.

8.

9.

10.

that must be done before shutting a unit down, depending on application.

Open the utility MLCB.

Open the generator MLCB.

Allow the unit to cool down (running at no-load) for approximately five minutes to prevent damage to critical engine components.

Set the control panel AUTO/OFF/MANUAL switch to the OFF position. There may be safety tag-outs or lockouts required at this point, depending on application.

Perform the necessary maintenance checks or tasks (based on the hourly requirements).

When all checks have been completed and any discrepancies corrected, set the control panel AUTO/OFF/MANUAL switch to the AUTO position.

When the generator is running, and all engine/ generator parameters (voltage, frequency, coolant temp, oil pressure, etc.) have been verified as correct, close the generator MLCB. The unit will accept and carry the load.

Make a last visual inspection of the generator set to make sure it is operating properly.

Close the utility MLCB.

Maintenance Tasks Visually Inspect Unit

Perform a visual inspection of the unit periodically. If problems are found contact your local IASD. Look for the following:

Any debris, trash, grass or weed growth, which would obstruct the flow of cooling air into and out of the unit ventilation louvers.

Visually inspect hoses and hose connections for signs of leakage. This includes all coolant hoses, fuel hoses, exhaust system connections, intake system connections, etc. Also look at the engine block and gearbox (if equipped) for signs of fluid leakage.

Visually inspect the engine accessory drive belts for evidence of obvious wear, fraying or deterioration, and obvious running could indicate a loose belt.

looseness. A “squealing” sound heard during starting and

Check Engine Oil Level

An Authorized Operator should check the levels of engine oil and engine coolant monthly (or every 24 hours of operation). The oil level should be maintained between the FULL and ADD marks on the engine dipstick. Recommended fluids are listed in

Engine Oil Recommendations

.

To check the engine oil:

1.

2.

3.

4.

5.

6.

7.

Locate the engine oil dipstick.

The most accurate oil level readings are measured when the engine is cold. If the engine was running, wait at least ten minutes before proceeding.

Remove the dipstick and wipe it dry with a clean, lint free cloth.

Slowly insert the clean dipstick into the tube. Visually confirm that the dipstick is fully seated in the dipstick tube. A visual inspection is required because some dipsticks will require more effort than others to fully seat.

After ten seconds remove the dipstick.

Look at the oil level on both sides of the dipstick. The lower of the two readings will be the correct oil level measurement.

Add oil (if necessary) to adjust the level. After adding or changing the oil, the engine should run for one minute before checking the oil level. Remember to wait ten minutes to allow the engine to cool and oil to fully drain into the oil pan.

Typical causes of inaccurate oil level readings:

Reading the high level of the dipstick.

Reading the dipstick before the oil fully drains into the oil pan.

Inserting and removing the dipstick too quickly.

The dipstick is not fully seated in the dipstick tube.

Check Engine Fluids

The following checks can be performed by a trained Authorized Operator. Observe all safety precautions outlined in

Introduction and Safety

.

Generator Installation and Operating Manual 21

Maintenance

Check Coolant Level DANGER

Risk of poisoning. Do not use mouth to siphon coolant. Doing so will result in death or serious injury.

(000149)

NOTE:

Do NOT overfill the gearbox. If too much fluid is added let the excess drain from the level check plug hole and collect it in a suitable container or with rags.

A B WARNING

Risk of burns. Do not open coolant system until engine has completely cooled. Doing so could result in serious injury.

(000154)

C

001063

CAUTION

Risk of overheating. Do not use any chromate base rust inhibitor with propylene glycol base antifreeze, boosters, or additives. Doing so will cause overheating and possible equipment damage.

(000165a) Visually check the coolant expansion tank and verify the coolant level is between the “Cold” and “Hot” level markings. To add coolant to the system add it to the expansion tank when the engine is cool (not at operating temperature, not running). Add only a 50/50 mixture of the correct antifreeze and distilled or deionized water to the coolant system.

Check/Change Gearbox Oil (If Equipped)

Check monthly, or every 100 hours of operation. Biannually (or every 600 hours), an authorized service technician should completely drain and refill the gearbox. Gear oil used is 80W-90. Lucas Heavy Duty Oil Stabilizer should be added as follows by Fluid volume:

390 Gearbox - Approximately 32 oz. total. 26 oz. gear oil and 6 oz. Lucas Heavy Duty Oil Stabilizer.

520 Gearbox - Approximately 55 oz. total. 44 oz. gear oil and 11 oz. Lucas Heavy Duty Oil Stabilizer.

To check gearbox oil level:

1.

2.

3.

4.

5.

Disable the generator from starting.

Remove the oil level check plug. See

Figure 4-1

.

The oil level should be at the bottom edge of the oil level check plug hole.

To add oil, remove the oil filler/vent cap, and fill through the vent line.

Replace the vent cap and oil level check plug and tighten.

Figure 4-1. Gearbox Oil Servicing Points

A B C Oil Filler/Vent Cap Oil Level Check Plug Oil Drain Plug To change the gearbox oil:

1.

Disable the generator from starting.

2.

3.

Remove the oil drain plug and drain the oil into an appropriate container. Properly dispose of or recycle the oil.

Reinstall the oil drain plug.

4.

5.

6.

To add oil to the gearbox, remove the oil level check plug and oil filler/vent cap.

Add the recommended oil/stabilizer mix until it just starts to flow from the oil level check plug opening.

Install and tighten the oil filler/vent cap and oil level check plug.

Return the generator to operating condition. Start the unit and check for leaks.

22 Generator Installation and Operating Manual

Battery Inspection

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

(000188)

WARNING

Sudden start-up. Always set the safety disconnect switch to MANUAL before working on equipment. Failure to do so could result in death or serious injury.

(000194) Maintenance An Authorized Operator should inspect the engine bat tery system monthly. At this time, the battery fluid level should be checked and distilled water added if needed. Battery cables and connections also should be inspected for cleanliness and corrosion.

Once every six months, an Authorized Service Technician should inspect the battery system. At this time the battery condition and state of charge should be checked using a battery hydrometer. The battery should be recharged or replaced as required.

NOTE:

A negative ground system is used. Battery connections are shown on the wiring diagrams. Verify the battery is correctly connected and terminals are tight. Observe battery polarity when connecting the battery to the generator set.

WARNING

Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

(000137a)

WARNING

Explosion. Batteries emit explosive gases.

Always disconnect negative battery cable first to avoid spark. Failure to do so could result in death or serious injury.

(000238)

WARNING

Explosion. Do not dispose of batteries in a fire. Batteries are explosive. Electrolyte solution can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.

(000162)

WARNING

Risk of burn. Do not open or mutilate batteries. Batteries contain electrolyte solution which can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention. (000163a)

Battery Installation and Replacement

When required, the battery must be replaced with one of equivalent size, voltage, and CCA (cold crank amp capacity). Consult the Unit Specification Sheet or contact the local IASD for proper battery sizing.

A new battery must be filled with the proper electrolyte and be fully charged before installing.

Preliminary Instructions 1.

Set the AUTO/OFF/MANUAL switch on the generator control panel to OFF.

2.

3.

4.

Turn off utility power supply to the battery charger circuit.

Remove the 10A fuse from the generator control panel.

Remove the ATC style fuse from the battery charger.

Battery cables are connected to the generator connection points at the factory. Connect the cables to the battery posts as shown in

Figure 4-2

and

Figure 4-3

.

12 VDC System 1.

Connect the red battery cable from the starter contactor to the positive (POS or +) battery post.

WARNING

Vision Loss. Eye protection is required to avoid spray from spark plug hole when cranking engine.

Failure to do so could result in vision loss.

(000181)

WARNING

Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death, or serious injury.

(000228) Generator Installation and Operating Manual 23

Maintenance

B 2.

Connect the black battery cable to the frame ground to the negative (NEG or -) battery post.

A B A

Figure 4-2. 12 VDC System

C D E F

001061

E F 2.

3.

4.

Install the 10A fuse in the generator control panel.

Turn on the utility power supply to the battery charger circuit.

If the unit was previously operational, turn the AUTO/OFF/MANUAL switch on the generator control panel to AUTO.

WARNING

Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death, or serious injury.

(000228) Always recycle batteries in accordance with local laws and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. For more information on battery recycling, visit the Battery Council International website at:

http://batterycouncil.org

CAUTION

Equipment damage. Do not make battery connections in reverse. Doing so will result in equipment damage.

(000167a) A B C D E F

Figure 4-3. 24 VDC System

Black Lead to Frame Black (-) Red or Black Jumper Wire 13 (if used) Red Lead from Starter Contactor Red (+) 001062

24 VDC System 1.

Connect the red battery cable from the starter contactor to the positive (POS or +) post of battery A.

2.

Connect the black battery cable to the frame ground to the negative (NEG or -) post of battery B.

NOTE:

On 24V gaseous units, center tap wire number 13 between the batteries as shown in

Figure 4-3

.

3.

Connect either a black or red jumper cable from the negative (NEG or -) post of battery A to the positive (POS or +) post of battery B.

Final Instructions 1.

Install the ATC style fuse in the battery charger.

24

Other Maintenance Checks

The following inspections should be performed by an IASD, or an Authorized Operator. These maintenance items require a high level of experience and skill to evaluate and correct.

Inspect engine accessory drive belts

Inspect hoses and connections

Inspect fuel supply system

Inspect exhaust system

Maintenance and Repair Parts

All non-emissions related service maintenance or repairs should be completed by an authorized service technician to maintain the warranty status of a unit. Emissions related maintenance and repairs may be performed by a person or repair shop of the owner’s choosing.

Generator Installation and Operating Manual

Maintenance

Extended Run-Time Maintenance Checks

These maintenance tasks can be performed by an IASD or an Authorized Operator. Comply with all safety notices contained in the owner’s manual.

IASD/Authorized Operator Maintenance Tasks.

Perform steps 1 through 8 and 11 every 24 continuous operating hours.

1.

2.

3.

4.

5.

6.

7.

8.

Before shutting the unit down, perform a thorough visual inspection for leaks, loose components or connections, excessive apparent wear or damage. Any discrepancies noted should be further inspected and corrected while the unit is shut down.

Shut the unit down per the procedure in the owner’s manual.

Check the engine oil level. The level should be between the low and full markings on the dipstick. Adjust as necessary.

Check the engine coolant level. Make sure the level in the coolant catch tank is between the cold and hot level markings. Adjust as necessary. Use only a 50/50 mixture of appropriate coolant.

Visually inspect the engine accessory drive belts and fan coupling device (if equipped) for correct tension and any signs of abrasion, wear, deterioration or damage. Correct as necessary.

Visually inspect all hoses and connections (exhaust, intake, coolant, block heater, fuel lines and filters, oil filters, etc) for leaks, tightness, signs of deterioration, wear, or damage. Correct as necessary.

Check the air inlets and outlets (enclosure or building vents) for debris or blockage. Correct as necessary.

Visually inspect the fuel supply system for signs of leaks or damage. Correct as necessary.

9.

Gearbox Equipped Only:

Check the gearbox oil level every 100 operating hours. Adjust as necessary.

10.

Weekly When Operating:

Check the battery electrolyte level (if accessible). Adjust as necessary (add only distilled or deionized water to replenish battery cells).

11.

Return the unit to operational condition and restart. Check unit voltage and frequency. Visually inspect the unit for leaks, loose connections or components. Place the unit back in service.

Date inspection Completed: Unit Hour-Meter Reading: Task Completed Date/Initials IASD/Authorized Operator signature signifying inspection complete: Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

Generator Installation and Operating Manual 25

Maintenance

Maintenance Level 1A

One Time at 50 Hours / 3 Months.

These maintenance tasks must be performed by an IASD. Comply with all safety notices contained in the owner’s manual. Some of these tasks require the use of the applicable engine service manual.

3.

4.

5.

1.

2.

6.

7.

8.

IASD Tasks. Perform these tasks in addition to the regularly scheduled Monthly maintenance tasks Disable the unit from operating per the procedure found in the owner’s manual. Check engine valve clearance (valve lash) as specified in the engine service manual. NOTE: This is NOT required for engines with hydraulic lifters. Check the engine service manual.

Change the engine oil.

Change the oil filter(s).

Check the engine accessory drive belts and fan coupling device (if equipped) for correct tension, wear or abrasion, deterioration, or damage. Correct as necessary.

Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and filters, oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.

Check wiring connections (at MLCB, customer connections, control terminal strips, battery, etc) for loose connections, corrosion or damage. Correct as necessary.

Return the unit to operational condition and test. Place the unit in automatic and open the service disconnect to force the unit to start and transfer to the load. Exercise the unit against the load for 15 minutes, visually inspecting for leaks, loose connections or components, and any abnormal operating conditions. Record the unit voltage, frequency, kW and kVA while running. Restore utility power and monitor transfer to utility, cool-down and shutdown. Correct any discrepancies.

Voltage: Frequency: kW: kVA: Task Completed Date/Initials

9.

If the control has alarm and/or event or run logs, record the alarm and event logs to a history file for the unit.

10.

Return the unit to operational condition.

Date inspection Completed: Unit hour Meter Reading: IASD signature signifying inspection complete: Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

26 Generator Installation and Operating Manual

Maintenance

Maintenance Level 1 - Monthly or Every 24 Hours

These maintenance tasks can be performed by an IASD or an Authorized Operator. Comply with all safety notices contained in the owner’s manual.

IASD/Authorized Operator Maintenance Tasks

1.

2.

3.

4.

5.

6.

7.

8.

Disable the unit from operating per the instructions in the owner’s manual.

Check the engine oil level. The level should be between the low and full markings on the dipstick. Adjust as necessary.

Gearbox Equipped Only:

Check the gearbox oil level. Adjust as necessary.

Check the engine coolant level. Verify the level in the coolant catch tank is between the cold and hot level markings. Adjust as necessary. Use only a 50/50 mixture of appropriate coolant.

Check the battery electrolyte level (if accessible). Adjust as necessary (add only distilled or deionized water to replenish battery cells).

Check the battery terminal posts, connections, cables and charger connections, and battery hold-downs for signs of corrosion, looseness, etc. Remove, clean and tighten connections as necessary.

Check operation and condition of the battery charger. Check operation and condition of optional block heater, oil sump heater, and battery warmer (if equipped). Correct discrepancies as necessary.

Check the air inlets and outlets (enclosure or building vents) for debris or blockage. Correct as necessary.

9.

Visually inspect the fuel supply system for signs of leaks or damage. Correct as necessary.

10.

Perform a 5 minute, no-load operational test of the unit. Check unit voltage and frequency. Visually inspect the unit for leaks, wear, damage, loose connections or components, and corrosion. Correct as necessary.

Voltage: Frequency: Task Completed Date/Initials

11.

If the control has alarm and/or event or run logs, record the alarm and event logs to a history file for the unit.

12.

Return the unit to operational condition.

Date inspection Completed: Unit hour Meter Reading: IASD/Authorized Operator signature signifying inspection complete: Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

Generator Installation and Operating Manual 27

Maintenance

Maintenance Level 2 - Semi-Annual or Every 125 Hours

These maintenance tasks must be performed by an IASD. Perform these tasks every six months or every 125 hours of operation. Perform these tasks in addition to the regularly scheduled Monthly maintenance tasks. Comply with all safety notices contained in the owner’s manual. Some of the tasks will require the use of the applicable engine service manual.

IASD Tasks

1.

2.

3.

4.

5.

Disable the unit from operating per the procedure found in the owner’s manual. Check the engine accessory drive belts and fan coupling device (if equipped) for correct tension, wear, abrasion, deterioration, or damage. Correct as necessary.

Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and filters, oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.

Load test the battery or test electrolyte levels (specific gravity) with a hydrometer.

Return the unit to operational condition and test. Place the unit in automatic and open the service disconnect to force the unit to start and transfer to the load. Exercise the unit against the load for 15 minutes, visually inspecting for leaks, loose connections or components, and any abnormal operating conditions. Record the unit voltage and frequency while running. Restore utility power and monitor transfer to utility, cool-down and shutdown. Correct any discrepancies.

Voltage: Frequency: kW: kVA: Task Completed Date/Initials

6.

7.

If the control has alarm and/or event or run logs, record the alarm and event logs to a history file for the unit.

Return the unit to operational condition.

Date inspection Completed: Unit hour Meter Reading: IASD signature signifying inspection complete: Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

28 Generator Installation and Operating Manual

Maintenance

Maintenance Level 3 - Annual or Every 250 Hours

These maintenance tasks must be performed by an IASD. Perform these tasks every 12 months or every 250 hours of operation. Perform these tasks in addition to the regularly scheduled Monthly and Semi-Annual maintenance tasks. Comply with all safety notices contained in the owner’s manual. Some of the tasks will require the use of the applicable engine service manual.

IASD Tasks

1.

2.

3.

4.

5.

6.

7.

8.

Disable the unit from operating per the procedure found in the owner’s manual. Some of the following tasks will require the use of the applicable engine service manual.

Change the engine oil.

Change the engine oil filter(s).

Inspect the air filter. Replace as necessary.

Gaseous Units Only:

Inspect, clean, and gap the spark plugs. Replace as necessary.

Gaseous Units Only:

Inspect ignition wires for damage, deterioration and tightness. Replace as necessary.

Diesel Units Only:

Test the fuel quality. If required, strip any water/sediment from the tank. Filter or polish the fuel and add any additional additives required to maintain fuel quality.

Diesel Units Only:

Change the primary and secondary fuel filters (if equipped). Clean any water separator or mechanical strainer (if equipped). Prime and bleed the fuel system per the engine service manual procedures.

9.

Check the engine accessory drive belts and fan coupling device (if equipped) for correct tension, wear or abrasion, deterioration, or damage. Correct as necessary.

10.

Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and filters, oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.

11.

Visually inspect the radiator and charge air core (if equipped) for any build up of dirt, debris, or oil contamination (external). Clean, correct as necessary.

12.

Check the coolant thermal protection level. Correct as necessary.

13.

Check all wiring connections in the high voltage and low voltage connection panels. Check for loose connections, corrosion, arcing or damage. Check torque on all main load lugs at generator connections (MLCB) and transfer switch connections (refer to applicable transfer switch manual). Correct as necessary.

14.

Return unit to operational condition and test. Place unit in automatic and open the service disconnect to force the unit to start and transfer to the load. Exercise unit against the load for 1 hour (60 minutes). Visually inspect for leaks, loose connections or components, and any abnormal operating conditions. Record unit voltage, frequency and kW while running. Restore utility power and monitor transfer to utility, cool-down and shutdown. Correct any discrepancies.

Voltage: Frequency: kW: kVA:

15.

If control has alarm and/or event or run logs, record the alarm and event logs to a history file.

16.

Return the unit to operational condition and place back in automatic operation.

Date inspection Completed: Unit hour Meter Reading: Task Completed Date/Initials IASD signature signifying inspection complete: Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

Generator Installation and Operating Manual 29

Maintenance

Maintenance Level 4 - Bi-Annual or Every 500 Hours

These maintenance tasks must be performed by an IASD. Perform these tasks every 24 months or every 500 hours of operation. Perform these tasks in addition to the regularly scheduled Monthly, Semi-Annual and Annual maintenance tasks. Comply with all safety notices contained in the owner’s manual. Some of the tasks will require the use of the applicable engine service manual.

IASD Tasks

1.

Disable the unit from operating per the procedure found in the owner’s manual. Some of the following tasks will require the use of the applicable engine service manual.

2.

Check engine valve clearance (valve lash) as specified in the engine service manual.

NOTE:

This is NOT required for engines with hydraulic lifters. Check the engine service manual.

3.

4.

5.

6.

Gearbox Equipped Only:

Change the gearbox oil. Can be extended to 600 hours.

Replace the engine air filter(s).

Gaseous Units Only:

Replace the spark plugs. Gap per the engine specifications.

Replace the engine accessory drive belts. Inspect and lubricate (if required) the belt tensioning device (if equipped) and replace if necessary.

7.

8.

Drain and flush the cooling system. Refill with fresh coolant of appropriate type (50/50 mixture).

Replace all flexible hoses: Coolant hoses including the block heater hoses and vaporizer hoses (if equipped); charge air system connection hoses/joints/couplings, and any flexible fuel or oil lines.

9.

Replace fuel filter. Verify the fuel system is bled and primed before running unit (diesel only).

10.

Remove, clean, inspect, reinstall and reset to correct voltage level the flywheel magnetic pickup(s) (if equipped).

11.

Return the unit to operational condition and test. Place the unit in automatic and open the service disconnect to force the unit to start and transfer to the load. Use an appropriate load bank to supplement load to full rated load (100% kW at rated kVA) if possible. Exercise the unit against the load for 2 hours (120 minutes). Visually inspect for leaks, loose connections or components, and any abnormal operating conditions. Record the unit voltage, frequency, kW and kVA while running. Remove the load bank load, restore utility power and monitor transfer to utility, cool-down and shutdown. Correct any discrepancies. Voltage: Frequency: kW: kVA: Task Completed Date/Initials

12.

If control has alarm and/or event or run logs, record the alarm and event logs to a history file.

13.

Return the unit to operational condition and place back in automatic operation.

Date inspection Completed: Unit hour Meter Reading: IASD signature signifying inspection complete: Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

30 Generator Installation and Operating Manual

Warranty Information

Section 5 Warranty Information

For Stationary Emergency Spark-Ignited Generators United States Environmental Protection Agency Warranty Statement (Stationary Emergency Spark-Ignited Generators)

Warranty Rights, Obligations and Coverage

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or component on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replacement parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system may include parts such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac will warrant the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect, unapproved modification, or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the date of sale to the ultimate purchaser. For engines greater than or equal to 130 HP the warranty period is three years or 2500 hours of operation, whichever comes first, from the date of the engine being placed into service. For high-cost warranted components, the Emission Control System warranty is valid for 5 years or 3500 hours of operation, whichever comes first.

Purchaser's/Owner's Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following: 1) The engine must be installed and configured in accordance to Generac's installation specifications. 2) The completion of all maintenance requirements listed in your Owner's Manual. 3) Any engine setting adjustment must be done in accordance and consistent with the instructions in the Owner's Manual. 4) Any emission control system or component must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize emissions at all times.

Generac may deny any and/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system or component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/owner shall be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System Warranty related information, Generac Power Systems, Inc., PO. Box 8, Waukesha, WI 53187, or call 1-800-333-1322, email emissions@generac.com, or visit www.generac.com.

Important Note

This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Generac pursuant to federal law. Note that this warranty shall not apply to 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). This warranty is in place of all other warranties, expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Emission Related Parts Include the Following (if so equipped)

1) Fuel Metering System 1.1) Gasoline Carburetor Assembly and Internal Components A) Fuel Filter, B) Carburetor, C) Fuel Pump 1.2) Carburetion Assembly and Its Components A) Fuel Controller, B) Carburetor and Its Gaskets, C) Mixer and Its Gaskets, D) Primary Gas Regulator, E) Liquid Vaporizer 1.3) Fuel Regulator 2) Air Induction System Including A) Intake Pipe/Manifold, B) Air Cleaner 3) Ignition System Including A) Spark Plug, B) Ignition Module, C) Ignition Coil, D) Spark Plug Wires 4) Exhaust System A) Catalyst Assembly*, B) Exhaust Manifold, C) Muffler, D) Exhaust Pipe, E) Muffler Gasket 5) Crankcase Breather Assembly Including A) Breather Connection Tube, B) PCV Valve 6) Oxygen Sensor 7) Diagnostic Emission-Control System *High-Cost Warranted Component Part No. 10000012792 Generator Installation and Operating Manual 31

Warranty Information

United States Environmental Protection Agency Compliance Requirements (Stationary Emergency Spark-Ignited Generators)

Purchaser's/Owner's Record Keeping Responsibilities

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in this Owner's Manual, you are required to meet the following notification and record keeping requirements to demonstrate compliance: 1) Maintain documentation that the engine is certified to meet emission standards. 2) Record keeping of maintenance conducted. 3) Record keeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel solely during emergency operations provided the engine is not certified to operate on propane. 4) Meet all compliance notifications submitted to the purchaser/owner and maintain all supporting documentation. 5) Record keeping of hours of operation, including what classified the operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130 HP, record keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, record keeping of hours of operation begins January 1, 2009; engines are equipped with non-resettable hour meters to facilitate record keeping.

Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements. Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air Quality Management or Air Pollution Control District for specific requirements.

Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing, provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emergency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be used for maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal, State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may operate up to 50 hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for maintenance and testing.

The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/owner of emergency engines, any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year, as permitted in this section is prohibited.

If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance to the specifications and guidelines in this Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be considered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.

Emission-Related Installation Instructions

Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow these instructions when installing a certified engine in a piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.

32 Part No. 10000012792 Generator Installation and Operating Manual

For Stationary Emergency Compression-Ignition Generators

To receive information about how to make an emissions related warranty claim and how to make arrangements for authorized repairs, call 1-800-333-1322 or go to

www.generac.com

.

Warranty Information Generator Installation and Operating Manual 33

Warranty Information

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34 Generator Installation and Operating Manual

Part No. 0J5019 Rev. W 05/20/2019 ©2019 Generac Power Systems, Inc.

All rights reserved Specifications are subject to change without notice.

No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc.

Generac Power Systems, Inc.

S45 W29290 Hwy. 59 Waukesha, WI 53189 1-888-GENERAC (1-888-436-3722)

www.generac.com

United States Environmental Protection Agency Warranty Statement (Stationary Emergency Spark-Ignited Generators)

Warranty Rights, Obligations and Coverage

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or compo nent on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replace ment parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system may include parts such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac will warrant the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect, unapproved modifica tion, or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the date of sale to the ulti mate purchaser. For engines greater than or equal to 130 HP the warranty period is three years or 2500 hours of operation, whichever comes first, from the date of the engine being placed into service. For high-cost warranted components, the Emission Control System war ranty is valid for 5 years or 3500 hours of operation, whichever comes first.

Purchaser's/Owner's Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following: 1) The engine must be installed and configured in accordance to Gen erac's installation specifications. 2) The completion of all maintenance requirements listed in your Owner's Manual. 3) Any engine setting adjustment must be done in accordance and consistent with the instructions in the Owner's Manual. 4) Any emission control system or com ponent must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize emissions at all times.

Generac may deny any/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system or component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/owner shall be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being trans ported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System Warranty related information, Generac Power Systems, Inc., PO. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www.generac.com.

Important Note

This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Gen erac pursuant to federal law. Note that this warranty shall not apply to 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). This warranty is in place of all other warranties, expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Emission Related Parts Include the Following (if so equipped)

1) Fuel Metering System 1.1) Gasoline Carburetor Assembly and Internal Components A) Fuel Filter, B) Carburetor, C) Fuel Pump 1.2) Carburetion Assembly and Its Components A) Fuel Controller, B) Carburetor and Its Gaskets, C) Mixer and Its Gaskets, D) Primary Gas Regulator, E) Liquid Vaporizer 1.3) Fuel Regulator 2) Air Induction System Including A) Intake Pipe/Manifold, B) Air Cleaner 3) Ignition System Including A) Spark Plug, B) Ignition Module, C) Ignition Coil, D) Spark Plug Wires 4) Exhaust System A) Catalyst Assembly*, B) Exhaust Manifold, C) Muffler, D) Exhaust Pipe, E) Muffler Gasket 5) Crankcase Breather Assembly Including A) Breather Connection Tube, B) PCV Valve 6) Oxygen Sensor 7) Diagnostic Emission-Control System *High-Cost Warranted Component EmsnWrnty001 Revision F (04/15)

United States Environmental Protection Agency Compliance Requirements (Stationary Emergency Spark-Ignited Generators)

Purchaser's/Owner's Record Keeping Responsibilities

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in this Owner's Manual, you are required to meet the following notification and record keeping requirements to demonstrate compliance: 1) Maintain documentation that the engine is certified to meet emission standards. 2) Record keeping of maintenance conducted. 3) Record keeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel solely during emergency operations provided the engine is not certified to operate on propane. 4) Meet all compliance notifications submitted to the purchaser/owner and maintain all supporting documentation. 5) Record keeping of hours of operation, including what classified the operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130 HP, record keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, record keeping of hours of oper ation begins January 1, 2009; engines are equipped with non-resettable hour meters to facilitate record keeping.

Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements. Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air Quality Management or Air Pollution Control District for specific requirements.

Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing, provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emer gency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be used for maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal, State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may operate up to 50 hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for maintenance and testing.

The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/owner of emergency engines, any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year, as permitted in this section is prohibited.

If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance to the specifications and guidelines in this Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be con sidered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Igni tion Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.

Emission-Related Installation Instructions

Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow these instructions when installing a certified engine in a piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.

EmsnWrnty001 Revision F (04/15)

Warranty United States Environmental Protection Agency & California Warranty Statement (Compression- Ignition Generators) Warranty Rights, Obligations and Coverage

The United States Environmental Protection Agency (EPA) and the California Air Resources Board (CARB) together with Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new non-road diesel engine. New non-road diesel engines must be designed, built and equipped to meet stringent anti-smog standards for the state of California and the federal government. Generac will warrant the emis sion control system on your non-road diesel engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modifica tion or improper maintenance of your non-road diesel engine.

Your emission control system may include such parts as the fuel injection system and the air induction system. Also included may be hoses, belts, con nectors and other emission-related assemblies. Generac will repair your non-road diesel engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

Emission control systems on 1996 and later model year non-road diesel engines are warranted for five years, or 3,000 hours of use, whichever occurs first. In the absence of an hourmeter, the said coverage is five years. If, during said warranty period, any emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.

This warranty is applicable to compression-ignition generator models; equal to and smaller than an SD60 starting 1/1/2011, equal to and smaller than an SD30 starting 1/1/2012, and not applicable to any compression-ignition generator models starting 1/1/2013.

Purchaser’s/Owner’s Warranty Responsibilities

As the non-road diesel engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory sup plied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance of your non-road diesel engine. However, Generac cannot deny warranty solely due to lack of receipts or for your failure to ensure the completion of all scheduled maintenance.

As the non-road diesel engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or responsibility if your non-road diesel engine, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications., or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.

Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with federal or California emission requirements.

You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs. The warranty repairs should be com pleted in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility. To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number: 1-800-333-1322.

IMPORTANT NOTE: This Warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS Warranty), which is provided to you by Generac pursuant to federal and California law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new non-road diesel engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac describe important rights and obligations with respect to your new non-road diesel engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be pre sented showing the date of sale to the original purchaser/owner.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address: Attention Warranty Department, Generac Power Systems, Inc., 211 Murphy Drive, Eagle, WI 53119.

Important Note

Note that this warranty shall not apply to 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). This warranty is in place of all other warranties, expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any implied warranties which are allowed by law, shall be lim ited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

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Warranty United States Environmental Protection Agency & California Warranty Statement (Stationary Compression-Ignition Generators) Emission Control System Warranty

Emission Control System Warranty (ECS Warranty) for 1996 and later model year non-road diesel engines: (A) Applicability: This warranty shall apply to 1996 and later model year non-road diesel engines. The ECS Warranty shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for five years, or 3,000 hours of use, thereafter, whichever occurs first.

(B) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new non-road diesel engine or equipment, and to each subsequent purchaser/owner, that each non-road diesel engine is … (1) Designed, built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to their respective author ity, and (2) Free from defects in materials and workmanship, which, at any time during the ECS Warranty Period, may cause a warranted emission-related part to fail to be identical in all material respects to the part as described in the engine manufacturer’s application for certification.

(C) The ECS Warranty pertains only to emissions-related parts on your non-road diesel engine, as follows: (1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s Manual shall be war ranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emis sions-related part.

(4) Repair and replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner by a Generac Authorized Warranty Service Facility.

(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable.

(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under war ranty of any emissions-related part covered by the ECS Warranty.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emissions-related parts sufficient to meet the expected demand for such emission-related parts.

(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS warranty maintenance or repairs and will be provided without charge to the owner. Such use will not reduce Generac’s ECS Warranty obligations.

Emission Related Parts Include the Following (if so equipped)

(A) F UEL M ETERING S YSTEM : (1) F UEL INJECTION SYSTEM (B) A IR I NDUCTION S YSTEM : (1) I NTAKE MANIFOLD AND GASKET (2) T URBOCHARGER SYSTEMS ( IF SO EQUIPPED ) (3) C HARGE AIR COOLING SYSTEMS ( IF SO EQUIPPED ) (C) E XHAUST S YSTEM : (1) E XHAUST MANIFOLD AND GASKET ( TURBOCHARGED ENGINES ONLY ) (2) C ATALYTIC C ONVERTER ONLY (D) M ISCELLANEOUS I TEMS USED IN ABOVE SYSTEMS : (1) H OSES , CONNECTORS , ASSEMBLIES , CLAMPS , FITTINGS , TUBING , SEALING GASKETS OR DEVICES , AND MOUNTING HARDWARE A 09/11 ev.

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Warranty United States Environmental Protection Agency Warranty Statement (Stationary Emergency Compression-Ignition Generators) Warranty Rights, Obligations and Coverage

Your emission-related warranty covers only components whose failure would increase an engine’s emissions of any regulated pollutant where they are designed, built, and equipped to be free from defects in materials and workmanship under applicable regulations of sec tion 213 of the clean air act. To receive information about how to make an emission-related warranty claim, and how to make arrange ments for authorized repairs call 1/1/2013.

1-800-333-1322

or

www.generac.com

. Emission- related warranty claims may be denied without proof of proper maintenance or use, accidents beyond the control of the manufacturer, or act of God. Proper maintenance is specified in the Owner’s Manual. Usage is limited to stationary emergency operations and 100 hours per year for maintenance and readiness testing. The warranty period begins when the engine is placed into service. Warranty periods for compression ignition engines greater than 25 horsepower is five years. This warranty is applicable to compression-ignition generator models; equal to and larger than an SD80 starting 1/1/2011, equal to and larger than an SD35 starting 1/1/2012, and all compression-ignition generator models starting

Important Note

This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Generac pursuant to federal law. Note that this warranty shall not apply to 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). This warranty is in place of all other warranties, expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

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