Generac 25 kW 0050311 Standby Generator Manual

Generac 25 kW 0050311 Standby Generator Manual

Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number 005030-0 (15kW) 005028-0 (20kW) 005031-0 (25kW)

This manual should remain with the unit.

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

INTRODUCTION

Thank you for purchasing this model of the QuietSource™ standby generator series.

Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ ten. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.

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READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, con tact the nearest Authorized Service Dealer for start ing, operating and servicing procedures.

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

DANGER After this heading, read instructions that, if not strictly complied with, will result in serious person al injury, including death, or property damage.

After this heading, read instructions that, if not strictly complied with, may result in personal injury or property damage.

After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

NOTE: After this heading, read explanatory statements that require special emphasis.

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

Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows: !

This symbol points out important safety informa tion that, if not followed, could endanger personal safety and/or property of others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recom mends that the operator reads this Owner's Manual and thoroughly understands all instructions before using this equipment. The manufacturer also strong ly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.

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OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by an Authorized Service Dealer. Normal maintenance service adjust ments and replacement of parts are the responsibility of the owner/operator and, as such, are not consid ered 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 ensures a minimum number of problems and keep operating expenses at a minimum. See an Authorized Service Dealer for service aids and accessories.

Operating instructions presented in this manual assume that the standby electric system has been installed by an Authorized Service Dealer or other competent, qualified contractor. Installation of this equipment is not a “do-it-yourself” project.

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HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, contact an Authorized Service Dealer for assistance.

Service technicians are factory-trained and are capa ble of handling all service needs.

When contacting an Authorized Service Dealer about parts and service, always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit.

AUTHORIZED SERVICE DEALER LOCATION

To locate the nearest GENERAC AUTHORIZED SERVICE DEALER, please call this number:

1-800-333-1322

OR Locate us on the web at:

www.generac.com

Table of Contents Liquid-cooled 15, 20 and 25 kW Generators

INTRODUCTION ................................................

IFC Read this Manual Thoroughly......................................IFC

Operation and Maintenance ........................................IFC

How to Obtain Service ................................................IFC

Authorized Service Dealer Location ............................IFC

SAFETY RULES ....................................................

2 Standards Index..............................................................3

Section 1 — GENERAL INFORMATION ............4

1.1

1.2

1.3

1.4

Generator ..............................................................4

Transfer Switch ....................................................4

ATS Mode (Automatic Operation) ..........................4

Engineered Transfer Switch (2-wire Start GTS Mode) ............................................................4

Generator AC Connection Systems........................4

1.5

1.6

1.7

1.8

1.9

Main Circuit Breaker ............................................5

Generator Fuel System ..........................................5

Engine Protective Devices ......................................5

Unpacking ............................................................6

1.10 Lifting the Generator ............................................6

1.11 Specifications ........................................................7

1.12 Fuel Consumption ................................................7

1.13 Reconfiguring the Fuel System for LP Vapor..........7

1.14 Engine Oil Recommendations ..............................8

1.15 Coolant Recommendations....................................8

1.16 Before Installation ................................................8

Section 2 — INSTALLATION ............................9

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

Standby Generator Installation ............................9

Generator Location................................................9

Generator Mounting and Support ........................9

Basic Standby Electric System ............................10

Emergency Circuit Isolation Method....................10

Total Circuit Isolation Method ............................10

Grounding the Generator ....................................10

Generator AC Neutral Connections......................11

2.9

Automatic Transfer Switch (ATS Mode) ..............11

2.10 Engineered Transfer Switch (2-wire Start GTS Mode) ..........................................................12

2.11 Battery Installation ..............................................13

2.12 Preparation Before Start-Up ................................14

Section 3 — OPERATION ................................15

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

Control Console Components..............................15

Manual Transfer and Startup ..............................15

Engine Governor Gain Adjustments ....................16

Manual Retransfer and Shutdown ......................17

Automatic Operation ..........................................17

Weekly Exercise Cycle..........................................17

Control Board DIP Switch Settings ....................18

Voltage Regulator Adjustment..............................18

Section 4 — MAINTENANCE ..........................19

4.1

4.2

4.3

4.4

4.5

4.6

Maintenance Performed by Authorized Service Facilities ..................................................19

Exhaust Manifold Procedure ..............................19

Intake Manifold Procedure ..................................19

Cylinder Head Procedure ....................................20

Cooling System....................................................20

Overload Protection for Engine DC Electrical System ................................................20

4.7

4.8

Checking Fluid Levels ........................................20

Maintenance Owner/Operator Can Perform ........................................................21

4.9

Miscellaneous Maintenance ................................22

4.10 Scheduled Maintenance ......................................24

Section 5 — TROUBLESHOOTING ..................27

Section 6 — NOTES ........................................28

Section 7 — ELECTRICAL DATA ....................30

Section 8 — EXPLODED VIEWS AND PARTS LISTS ..............................38

Section 9 — INSTALLATION DIAGRAM ..........55

Section 10 — WARRANTY ...............................56

1

Important Safety Instructions Liquid-cooled 15, 20 and 25 kW Generators

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SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment.

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Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this

Owner’s Manual

and with the unit. The gen erator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fun damental rules or precautions.

The manufacturer cannot anticipate every possible cir cumstance 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 manufac turer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique chosen does not render the generator unsafe.

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SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.

WARNING:

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

WARNING:

DANGER

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This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate or main tain this equipment.

Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot during operation. Exercise care near running gen erators.

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GENERAL HAZARDS

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• For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by an Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regu lations.

• Installation, operation, servicing and repair of this (and related) equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes.

Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed, operated and serv iced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regula tions.

• The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided.

• Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

• Adequate, unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to ensure correct generator operation. Do not alter the instal lation or permit even partial blockage of ventilation provi sions, as this can seriously affect safe operation of the gen erator.

• Keep the area around the generator clean and uncluttered.

Remove any materials that could become hazardous.

• When working on this equipment, remain alert at all times.

Never work on the equipment when physically or mentally fatigued.

• Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only fac tory-approved parts.

• Before performing any maintenance on the generator, dis connect its battery cables to prevent accidental start-up.

Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.

• Never use the generator or any of its parts as a step.

Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

2

Important Safety Instructions Liquid-cooled 15, 20 and 25 kW Generators

ELECTRICAL HAZARDS

• All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock.

Utility power delivers extremely high and dangerous volt ages to the transfer switch as well as the standby generator.

Avoid contact with bare wires, terminals, connections, etc., on the generator as well as the transfer switch, if applicable.

Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.

DANGEROUS ELECTRICAL SHOCK MAY RESULT.

• If personnel must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden plat form. Work on the equipment only while standing on such insulative mats.

• The National Electrical Code (NEC), Article 250 requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground and/or grounding rods. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static elec tricity. Never disconnect the ground wire.

• Wire gauge sizes of electrical wiring, cables and cord sets must be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.

• Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are positively turned off at their source. Failure to do so will result in haz ardous and possibly fatal electrical shock.

• Connecting this unit to an electrical system normally sup plied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating. Failure to isolate the two electric system power sources from each other by such means will result in dam age to the generator and may also result in injury or death to utility power workers due to backfeed of electrical ener gy.

• Generators installed with an automatic transfer switch will crank and start automatically when NORMAL (UTILITY) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, disable the generator’s automatic start circuit (battery cables, etc.) before working on or around the unit. Then, place a “Do Not Operate” tag on the genera tor control panel and on the transfer switch.

• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not pos sible, attempt to free the victim from the live conductor.

AVOID DIRECT CONTACT WITH THE VICTIM.

help.

Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical • Never wear jewelry when working on this equipment.

Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

FIRE HAZARDS

• Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insu lation. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department.

EXPLOSION HAZARDS

• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

• These generator sets may operate using one of several types of fuels. All fuel types are potentially FLAMMABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the unit’s fuel system frequently and correct any leaks immediately. Fuel supply lines must be properly installed, purged and leak tested according to applicable fuel-gas codes before placing this equipment into service.

• Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air; install leak detectors accordingly.

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STANDARDS INDEX

In the absence of pertinent standards, codes, regulations and laws, the published information listed below may be used as installation guide for this equipment.

1.

2.

3.

4.

5.

6.

7.

8.

9.

NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS TURBINES, available from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210.

NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES, available same as Item 1.

NFPA No. 54, NATIONAL FUEL GAS CODE, available same as Item 1. NFPA No. 58, AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLE UM GAS, available same as Item 1.

NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELEC TRIC CODE, available same as Item 1.

Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New York, N.Y. 10038.

AGRICULTURAL WIRING HANDBOOK, available from the Food and Energy Council, 909 University Avenue, Columbia, MO 65201.

ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085.

NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQ UIDS CODE, available same as Item 1.

3

Section 1 - General Information Liquid-cooled 15, 20 and 25 kW Generators

1.1

GENERATOR

This equipment is a liquid-cooled, engine-driven gen erator set. The generator is designed to supply elec trical power that operates critical electrical loads during utility power failure. The unit has been facto ry-installed in a weather resistant, all metal enclosure and is intended for outdoor installation only. Use this generator as a source of electrical power for the oper ation of 120 and/or 240VAC, single-phase loads.

These models are available. They are rated as follows:

Model 005031-0:

phase power.

Provides 25,000 watts (25 kW) of single-

Model 005028-0:

phase power.

Provides 20,000 watts (20 kW) of single-

Model 005030-0:

phase power.

Provides 15,000 watts (15 kW) of single If a transfer switch is not included, one may be pur chased separately from an Authorized Dealer.

1.3

AUTOMATIC TRANSFER SWITCH (ATS MODE)

When this generator, along with an HS Type automat ic transfer switch has been installed and connected, a circuit board in the generator control panel con stantly monitors the utility voltage and controls the operation of the transfer switch.

In ATS Mode utility voltage sensing, weekly exercis ing, and load transferring is under the control of the generator. Should the utility voltage drop below a preset value, and remain at this low voltage for a preset amount of time, the generator cranks and starts. After the gen erator starts, the transfer switch transfers the load circuits to the generator so the generator can power them. When the utility source voltage has been restored, the transfer switch re-transfers the load cir cuits back to the utility source voltage and the gener ator shuts down.

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If this generator is used to power electrical load circuits normally powered by a utility power source, it is required by code to install a trans fer switch. The transfer switch must effectively isolate the electric system from the utility distri bution system when the generator is operating (NEC 701). Failure to isolate an electrical system by such means results in damage to the genera tor and may also result in injury or even death to utility power workers due to backfeed of electrical energy.

1.2

TRANSFER SWITCH

This generator system is intended to be used with a matched automatic transfer switch. It may be supplied in either a NEMA 1 enclosure or a NEMA 3R enclo sure. The NEMA 1 enclosure is intended for indoor use only. The NEMA 3R enclosure is weather proof and can be used indoors or outdoors. Follow these rules: • Install the transfer switch on a firm, sturdy sup porting structure.

• To prevent switch distortion, level the switch if nec essary. This can be done by placing washers between the switch enclosure and the mounting surface.

• Never install the switch where water or any corro sive substance might drip onto the enclosure.

• Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and cor rosive vapors.

Model

005031-0 005028-0 005030-0

Rating

25,000 W 20,000 W 15,000 W

Phase

1 1 1

1.4

ENGINEERED TRANSFER SWITCH (2-WIRE START GTS MODE)

When required, the pre-packaged standby generator can be installed with an engineered W-type transfer switch which controls utility voltage sensing, weekly exercising and load transferring.

UTILITY voltage sensing, weekly exercising and load transferring is then under the control of the Engineered W-type transfer switch (GTS Mode).

1.5

GENERATOR AC CONNECTION SYSTEMS

The generator was shipped from the factory with its stator AC output leads connected in a single-phase, 3-wire generator AC connection system (Figure 1.1).

The stator assembly in this system consists of a pair of stationary windings, with two leads brought out of each winding. Each single winding can supply 120 VAC, 60 Hertz. When the two windings are connected in series, a 240 VAC, 60 Hertz AC output results.

Typically the two “hot” leads in the circuit are Wires No. 11 and 44. The “Neutral” leads are the junction of Wires 22 and 33.

Figure 1.2 - Main Circuit Breaker

Actual Current C/B Rating*

104.2 A 83.3 A 62.5

125 A 100 A 70 A

* Amp Rating of C/B structured under model.

% over rating

120% 120% 112%

Circuit Breaker

125A BQ2 100A BQ2 70A BQ2 4

Section 1 - General Information Liquid-cooled 15, 20 and 25 kW Generators

Figure 1.1 - Generator AC Connection System

(BLACK) (WHITE) 0 NEUTRAL (BLACK)

1.6

MAIN CIRCUIT BREAKER

The generator’s main circuit breaker is included with the unit as shipped from the factory. The breaker for each unit is described in Figure 1.2.

1.7

GENERATOR FUEL SYSTEM

This unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is pre ferred, refer to Section 1.13, Reconfiguring the Fuel System for LP Vapor.

Fuel pressure for a natural gas set up should be psi) at all load ranges.

five inches to 14 inches of water column (0.18 to 0.5

Fuel pressure for an LP vapor set up should be psi) at all load ranges.

11 inches to 14 inches of water column (0.4 to 0.5

NOTE: A seperate gas line and regulator may be needed to assure proper gas pressure to the generator.

Improper gas pressure can cause hard starting and affect engine durability.

!

Gaseous fuels such as natural and LP (propane) gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explo sion. No leakage of fuel is permitted. Natural gas, which is lighter than air, tends to collect in high areas. LP gas is heavier than air and tends to settle in low areas.

1.8

ENGINE PROTECTIVE DEVICES

The engine has several safety switches which cause the engine to automatically shut down under the fol lowing conditions: low oil pressure, high coolant tem perature, engine overspeed, low coolant level or over crank (Figure 1.3).

Figure 1.3 - Engine Protective Devices

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1.8.1 LOW OIL PRESSURE SWITCH

This switch is normally-closed (N.C.) but is held open by engine oil pressure during engine running. Should operating oil pressure drop below about 8-10 psi (55-68 kPa), the switch contacts close and the engine shuts down automatically (Figure 1.4).

Figure 1.4 - Low Oil Pressure Switch

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1.8.2 HIGH COOLANT TEMPERATURE SWITCH

Normally open (N.O.) thermostatic switch has sens ing tip which is immersed in captive coolant. Should coolant temperature exceed about 230°F (110°C), the switch contacts close, which causes the engine to shut down automatically (Figure 1.5).

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Section 1 — General Information Liquid-cooled 15, 20 and 25 kW Generators

Figure 1.5- High Coolant Temperature Switch

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1.8.3 LOW COOLANT LEVEL SWITCH

Should engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shutdown.

To prevent such overheating without automatic shut down, the engine has a low coolant level sensor. If the engine coolant drops too low, the engine automatical ly shuts down (Figure 1.6).

Figure 1.6 - Low Coolant Level Sensor

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1.8.4 OVERSPEED SHUTDOWN

Should AC frequency exceed about 72 Hz, circuit board action will automatically shutdown the engine.

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1.8.5 OVERCRANK SHUTDOWN

The engine control board uses a cyclic cranking process when attempting to start the engine. The first crank cycle is a 15-second crank followed by a seven second rest. This is followed by five more crank cycles each with a seven second crank followed by a seven-second rest.

If the engine fails to start after all six attempts, the start attempt is stopped and the overcrank LED turns on.

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1.8.6 LOW BATTERY

The engine control board continually monitors the battery voltage and turns on the low battery LED if the battery voltage falls below 12 VDC for one minute.

Low battery voltage is a non-latching alarm, which will automatically clear if the battery voltage rises above 12 VDC. If battery voltage goes below 6 VDC during cranking, the low battery voltage alarm is latched, cranking is terminated, and the low battery LED stays on.

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1.8.7 15A DC FUSE

This fuse is located inside the control panel. It pro tects the panel wiring and components from damag ing overload. The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rating.

1.9

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UNPACKING 1.9.1 UNPACKING PRECAUTIONS

Handle shipping cartons and crates with care. Use care to avoid damage from dropping, bumping, colli sion, etc. Store and unpack cartons with the proper side up, as noted on the shipping carton.

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1.9.2 INSPECTION

Upon delivery, carefully inspect the generator for any damage that may have occurred during shipment. If loss or damage is noted at the time of delivery, have the person(s) making delivery note all damage on the freight bill or affix their signature under the consign or’s memo of loss or damage.

1.10 LIFTING THE GENERATOR

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When lifting or hoisting equipment is used, be careful not to touch overhead power lines. The generators weight of more than 900 pounds requires proper tools, equipment, and qualified personnel to be used in all phases of handling and unpacking.

6

Section 1 — General Information Liquid-cooled 15, 20 and 25 kW Generators

1.11 SPECIFICATIONS

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1.11.1 ENGINE

Make ......................................................................................Ford

Displacement ............................................153 inches 3 (2.5 liters) Cylinder Arrangement......................................................4, in-line Valve Arrangement................................................Overhead Cam Firing Order........................................................................1-3-4-2 Number of Main Bearings............................................................5

Compression Ratio..........................................................9.37 to 1 No. of Teeth on Crank ............................................................36-1 Ignition Timing (Waste Spark System) at 1800 rpm (NG) ..........................................36 degrees BTDC at 1800 rpm (LP vapor) ................................28` degrees BTDC Spark Plug Gap ............................................................0.044 inch Recommended Spark Plugs Motorcraft ................................................................AWSF-52-C Oil Pressure....................................................................30-50 psi Crankcase Oil Capacity......................4.5 U.S. quarts (4.26 liters) Recommended Engine Oil........................................SAE 15W-40 Type of Cooling System ..................Pressurized, closed recovery Cooling Fan ..............................................................Pusher Type Cooling System Capacity ......................2 U.S. gallons (7.6 liters) Recommended Coolant ............Use a 50-50 mixture of ethylene glycol base and deionized water.

!

Home standby control board assembly part number 0E9704 must be used on 1800 rpm gen erators.

1.12 FUEL CONSUMPTION

15 kW Models Using Natural Gas ........................................236 cu. ft. per hour Using LP Gas ..................................................92 cu. ft. per hour 20 kW Models Using Natural Gas ........................................307 cu. ft. per hour Using LP Gas ................................................122 cu. ft. per hour 25 kW Models Using Natural Gas ........................................441 cu. ft. per hour Using LP Gas ................................................175 cu. ft. per hour NOTE: Fuel consumption is given at rated maximum con tinuous power output when using natural gas rated at 1000 Btu per cubic foot; or LP gas rated 2520 Btu per cubic foot. Actual fuel consumption obtained may vary depending on such variables as applied load, ambient temperature, engine condi tions and other environmental factors.

Fuel pressure for a natural gas set up should be psi) at all load ranges.

five inches to 14 inches of water column (0.18 to 0.5

Fuel pressure for an LP vapor set up should be psi) at all load ranges.

11 inches to 14 inches of water column (0.4 to 0.5

1.13 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR

NOTE: All models are configured for natural gas (NG) from the factory.

To reconfigure the fuel system from NG to LP vapor, follow these steps: 1. Turn the main gas supply off.

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1.11.2 GENERATOR

Model Rated Max. Cont.

AC Power Output (kW)* Rated Voltage (volts) No. of Rotor Poles Driven Speed of Rotor (rpm) Rotor Excitation System Type of Stator Rotor Insulation Stator Insulation Single-phase 005031-0 25 120/240 4 1800 Direct excited brush type 4 Wire Class F Class H Single-phase 005028-0 20 120/240 4 1800 Direct excited brush type 4 Wire Class F Class H Single-phase 005030-0 15 120/240 4 1800 Direct excited brush type 4 Wire Class F Class H * Rated power of generator is subject to and limited by such factors as ambient temperature, altitude, engine condition, and other fac tors. Engine power will decrease about 3.5% for each 1000 feet above sea level and will decrease an additional 1% for each 10°F above 60°F. Maximum output power of the generator is limited by maximum engine power.

7

Section 1 — General Information Liquid-cooled 15, 20 and 25 kW Generators

2. Remove the carburetor fuel hose from the outlet port (Port 1) of the demand regulator (Figure 1.8).

3. Remove the brass hose fitting from the outlet port (Port 1) of the demand regulator.

4. Remove pipe plug from Port 2.

5. Install brass hose fitting into Port 2.

6. Install pipe plug into Port 1.

7. Connect carburetor gas hose to brass fitting.

8. Tighten all clamps and plugs.

9. Make sure fuel supply is of the proper pressure and type for configuration (not to exceed 14 inch es water column).

10. Move DIP switch position 4 on the control board to the off position (LP vapor, see Figure 3.2 and Section 3.7).

11. Reverse the procedure to convert back to natural gas.

Figure 1.8 — Reconfigure the Fuel System

Port 1 Port 2 PLUG FUEL HOSE BRASS HOSE FITTING OUT PORT 1 FUEL HOSE BRASS HOSE FITTING OUT PORT 2 PLUG FUEL INLET NG FUEL SYSTEM LP FUEL SYSTEM NOTE: Port 1 is for NG only and Port 2 is for LP vapor only. No provision for dual fuel has been made.

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DANGER Serious injury or damage may occur if not con figured properly. Please consult an Authorized Service Dealer with any questions.

1.14 ENGINE OIL RECOMMENDATIONS

The unit has been filled with 15W-40 engine oil at the factory. Use a high-quality detergent oil classified “For Service CC, SD, SE, SF.” Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change:

Temperature Above 80° F (27° C) 32° to 80° F (-1° to 27° C) Below 32° F (0° C) Oil Grade (Recommended) SAE 30W or 15W-40 SAE 20W-20 or 15W-40 SAE 10W or 15W-40

8 NOTE: Synthetic oil is highly recommended when the generator will be operating in ambient tempera tures which regularly exceed 90° F and/or fall below 30° F.

!

Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure.

1.15 COOLANT RECOMMENDATIONS

Use a mixture of half low silicate ethylene glycol base anti-freeze and half deionized water. Cooling system capacity is about 8 U.S. quarts (7.6 liters). Use only deionized water and only low silicate anti-freeze. If desired, add a high quality rust inhibitor to the rec ommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture.

!

Do not use any chromate base rust inhibitor with ethylene glycol base anti-freeze or chromi umhydroxide (“green slime”) forms and will cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base anti-freeze. Using any high silicate anti-freeze boosters or additives will also cause overheating. DO NOT use any solu ble oil inhibitor for this equipment.

1.16 BEFORE INSTALLATION

Before installing this equipment, check the ratings of both the generator and the transfer switch. Read “Emergency Isolation Method” and “Total Circuit Isolation Method” in the installation manual (Part No.

079699).

The generator’s rated wattage/amperage capacity must be adequate to handle all electrical loads that the unit will power. It may be necessary to group the critical (essential) loads together and wire them into a separate “emergency” distribution panel.

This generator can be installed in conjunction with an engineered transfer switch, if necessary (see Section 2.10).

The standard prepackaged transfer switch (ATS mode) does not have sensing or controlling circuit boards. Instead, the generator control console hous es a “Printed Circuit Board Assembly”, which con trols all phases of operation, including engine start up and load transfer.

Section 2 — Installation Liquid-cooled 15, 20 and 25 kW Generators

2.1

STANDBY GENERATOR INSTALLATION

DANGER Connecting this generator to an electrical sys tem normally supplied by an electric utility shall be by means of a transfer switch, so as to isolate the electric system from the utility distri bution system when the generator is operating.

Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy.

If an open bottom is used, the engine-genera tor must be installed over non-combustible materials and should be located such that com bustible materials are not capable of accumu lating under the generator set.

Only qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system. The installation must comply strictly with all codes, standards and regula tions pertaining to the installation.

!

After the system has been installed, do nothing that might render the installation in noncompli ance with such codes, standards and regula tions.

NOTE: For more information about the installation of a standby system contact an Authorized Service Dealer.

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2.1.1 NFPA STANDARDS

The following published standards booklets pertain ing to standby electric systems are available form the National Fire Protection Association (NFPA), Batterymarch Park, Quincy, MA 02269: • NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS TURBINES.

• NFPA No. 76A, ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES.

• NFPA No. 220, STANDARD TYPES OF BUILDING CONSTRUCTION • NFPA No. 68, GUIDE FOR EXPLOSION VENTING • NFPA No. 70, NATIONAL ELECTRICAL CODE.

• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE.

• NFPA No. 10, INSTALLATION, MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS.

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2.1.2 OTHER PUBLISHED STANDARDS

In addition to NFPA standards, the following infor mation pertaining to the installation and use of standby electric systems is available: • Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New York, N.Y. 10038.

• AGRICULTURAL WIRING HANDBOOK, obtainable from the Food and Energy Council, 909 University Avenue, Columbia, MO, 65201.

• ASAE EP-364.2, INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRIC POWER, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085.

• A52.1, AMERICAN NATIONAL STANDARD FOR CHIMNEYS, FIREPLACES AND VENTING SYS TEMS, available from the American National Standard Institute, 1430 Broadway, New York, N.Y.

10018.

2.2

GENERATOR LOCATION

Install the generator set, in its protective enclosure outdoors, where adequate cooling and ventilating air always is available. Consider these factors: • Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or drift ing, consider using a windbreak to protect the unit.

• Install the generator on high ground where water levels will not rise and endanger it.

• Allow sufficient room on all sides of the generator for maintenance and servicing. A required mini mum allowance of space to any solid structure is three feet. Five feet allowance of space is recom mended.

• Where strong prevailing winds blow from one direction, face the generator air inlet openings into the prevailing winds.

• Install the generator as close as possible to the transfer switch. This reduces the length of wiring and conduit.

• Install the generator as close as possible to the fuel supply, to reduce the length of piping. HOWEVER, REMEMBER THAT LAWS OR CODES MAY REG ULATE THE DISTANCE.

2.3

GENERATOR MOUNTING AND SUPPORT

Retain the generator compartment to a concrete slab with 1/4-inch masonry type anchor bolts. Be sure the bolts are long enough to retain the compartment. The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides.

9

Section 2 — Installation Liquid-cooled 15, 20 and 25 kW Generators

2.4

BASIC STANDBY ELECTRIC SYSTEM

Figure 2.1 shows a schematic diagram of a basic standby electric system. Both the UTILITY power supply and the STANDBY GENERATOR output are connected to an approved transfer switch. The trans fer switch is required by electrical code and serves the following functions: • Permits the LOAD circuits to be connected to only one power supply at a time.

• Prevents electrical backfeed between the generator and the UTILITY power circuits.

Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker.

Figure 2.1 – Basic Standby Electric System

NOTE: The manufacturer recommends the use of a Generac Power Systems transfer switch in con junction with this generator.

2.5

EMERGENCY CIRCUIT ISOLATION METHOD

This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator. If the generator is powering only crit ical loads, within its wattage/amperage capacity, dur ing utility power outages, consider using the emer gency circuit isolation method.

Critical electrical loads are grouped together and wired into a separate “Emergency Distribution Panel.” The generator only supplies electrical circuits connected to the emergency distribution panel during utility power outages. Load circuits powered by that panel must be within the wattage/amperage capacity of the generator set. The transfer switch must meet the following requirements: 10 • It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit.

• It must be installed between the building’s main distribution panel and the emergency distribution panel.

2.6

TOTAL CIRCUIT ISOLATION METHOD

When a generator capable of powering all electrical loads in the circuit is to be installed, the “Total Circuit Isolation Method” may be used. The following apply to the transfer switch in this type of system.

• Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service.

• The transfer switch is installed between the utility service entrance and the building distribution panel.

2.7

GROUNDING THE GENERATOR

A GROUNDING LUG (Figure 2.2) is provided on the generator mounting base for the purpose of ground ing the frame and the external electrically conductive parts of the equipment to an approved earth ground and/or grounding rods where required by the National Electrical Code. Consult a qualified electri cian for grounding requirements in the area.

Grounding procedures must meet local regulations.

DANGER Do not connect the ground wire to any pipe that carries a flammable or explosive substance – FIRE or an EXPLOSION may result.

Proper grounding helps protect personnel against electrical shock in the event of a ground fault condi tion in the generator or in connected electrical devices. In addition, grounding helps dissipate static electricity that often builds up in ungrounded devices.

Figure 2.2 – Generator Grounding Lug (typical)

Section 2 — Installation Liquid-cooled 15, 20 and 25 kW Generators

2.8

GENERATOR AC NEUTRAL CONNECTIONS

The manufacturer uses an UNGROUNDED AC neu tral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the exces sive current opens the load circuit breaker or col lapses the generator field. The actual result depends on the electrical characteristics of the particular installed generator.

The HS Type transfer switch is controlled by the gen erator circuit board via control wires 23 and 194.

Wire 23 connects the relay driver output (collector of an NPN transistor) on the generator circuit board to the "low side" (Terminal 23) of the transfer relay coil in the transfer switch. Wire 194 connects positive battery voltage from the generator circuit board to the "high side" (Terminal 194) of the transfer relay coil in the transfer switch.

2.9

AUTOMATIC TRANSFER SWITCH (ATS MODE)

When this generator, along with an HS Type automat ic transfer switch has been installed and connected, a circuit board in the generator control panel con stantly monitors the utility voltage and controls the operation of the transfer switch.

To implement this mode of operation, Position 2 of the eight-position DIP switch, which is located on the generator circuit board (see Figure 3.2), must be in the OFF position. In ATS Mode utility voltage sensing, weekly exercising, and load transferring is under the control of the generator. Should the utility voltage drop below a preset value, and remain at this low voltage for a preset amount of time, the generator cranks and starts. After the gen erator starts, the transfer switch transfers the load circuits to the generator so the generator can power them. When the utility source voltage has been restored, the transfer switch re-transfers the load cir cuits back to the utility source voltage and the gener ator shuts down.

!

If generator wires 23 and 194 are not wired to the correct terminals in the transfer switch, the circuit board in the generator control panel will be damaged.

In order for the generator utility voltage sensing and battery charging functions to work, it is necessary to provide a 5 amp fused 240Vac utility source connec tion from the transfer switch main N1 and N2 termi nals to the generator control panel N1 and N2 termi nals (See Figure 2.3).

Transfer Switch terminals N1 and N2 (also called Utility 1 and Utility 2) are the input utility AC power connections to the Transfer Switch. Transfer Switch terminals T1 and T2 (also called Load 1 and Load 2) are the transfer switch AC output power terminals that go to the load circuit distribution panel. Transfer Switch terminals E1 and E2 are the AC power termi nals that come from the generator's main alternator.

Figure 2.3 - Connection Diagram (ATS Mode)

FUSE N1 N2 FUSE FROM UTILITY N1 N2 MAIN LINE CIRCUIT BREAKER OR FUSE T1 T2 194 23 HS TYPE TRANSFER SWITCH E1 E2 TO LOAD FEEDER CIRCUITS LOAD DISTRIBUTION PANEL GENERATOR 194 23 178 183 N2 N1 E1 E2 11

Section 2 — Installation Liquid-cooled 15, 20 and 25 kW Generators

2.10 ENGINEERED TRANSFER SWITCH (2-WIRE START GTS MODE)

When required, the pre-packaged standby generator can be installed with an engineered W Type transfer switch which controls utility voltage sensing, weekly exercising and load transferring.

When Position 2 of the eight-position DIP switch, which is located on the generator circuit board (See Figure 3.2), is in the ON position then utility voltage sensing, weekly exercising and load transferring is under the control of the Engineered W Type transfer switch (GTS Mode).

Generator DIP Switch Position 2 ON = 2-Wire Start GTS Mode • The generator control board will NOT monitor the utility.

• The generator control board will NOT perform a weekly exercise. (The five red LEDs will flash one at a time in GTS mode.) • The generator control board will NOT activate the transfer output.

The generator control board WILL monitor all engine conditions and shut down on all the faults listed in this document.

For the W Type transfer switch to control utility volt age sensing, weekly exercising and load transferring, suitable wiring must also be connected from the transfer switch 178 and 183, 2-Wire Start terminals to the corresponding generator 178 and 183 2-Wire Start terminals. Recommended wire gauge sizes for the 2-Wire Start wiring depend on the length of the wire (see wiring length chart).

MAXIMUM WIRE LENGTH

460 feet (140m) 461 to 730 feet (223m) 731 to 1,160 feet (354m) 1,161 to 1,850 feet (565m)

RECOMMENDED WIRE SIZE

No. 18 AWG.

No. 16 AWG.

No. 14 AWG.

No. 12 AWG.

Route the 2-Wire Start control wires through suitable, approved conduit which is separate from the AC power leads. Connection of wire 178 to wire 183 by relay contact closure action (volt free switch contacts) in the transfer switch must result in generator engine cranking and startup (See Figure 2.4).

!

Do NOT connect battery voltage, utility voltage (N1/N2) or load voltage (T1/T2) to either the 178 or the 183 2-Wire start terminals as this will damage the generator control board.

In order for the generator battery charging function to work, it is necessary to provide a 5 amp fused 240Vac utility source connection from the transfer switch main N1 and N2 terminals to the generator control panel N1 and N2 terminals (See Figure 2.4).

Figure 2.4 - Connection Diagram (GTS Mode)

FROM UTILITY TO LOAD FEEDER CIRCUITS FUSE N1 N2 FUSE N1 N2 W-TYPE TRANSFER SWITCH 178 183 MAIN LINE CIRCUIT BREAKER OR FUSE T1 T2 E1 E2 LOAD DISTRIBUTION PANEL GENERATOR 194 23 178 183 N2 N1 E1 E2 12

Section 2 — Installation Liquid-cooled 15, 20 and 25 kW Generators

Transfer Switch terminals N1 and N2 (also called Utility 1 and Utility 2) are the input utility AC power connections to the Transfer Switch. Transfer Switch terminals T1 and T2 (also called Load 1 and Load 2) are the transfer switch AC output power terminals that go to the load circuit distribution panel. Transfer Switch terminals E1 and E2 are the AC power termi nals that come from the generator's main alternator.

When in GTS mode, the control board will respond as follows based on the generator AUTO/OFF/MANU AL switch position.

OFF — The generator will not start and run in this position MANUAL — The generator control board will start and run the generator whenever the switch is in the manual position.

AUTO — The generator control board will monitor the 2-Wire start circuit (terminals 178 and 183 in the generator control panel). When a 2-Wire start signal is issued by the W type engineered transfer switch, via a relay contact closure that connects wire 178 to wire 183, the generator control board will immedi ately start and run the generator. When the 2-Wire start signal is removed the control board will imme diately stop the generator.

2.11 BATTERY INSTALLATION

DANGER

!

Standby generators installed with automatic transfer switches will crank and start automati cally when NORMAL (UTILITY) source voltage is removed or is below an acceptable preset level.

To prevent such automatic start-up and possible injury to personnel, do not connect battery cables until certain that normal source voltage at the transfer switch is correct; the generator main line circuit breaker is switched to OFF; the AUTO/OFF/MANUAL switch on the control con sole is switched to OFF; the 15A and 5A fuses have been removed from the control console; utility fed supply to battery charger (terminals N1 and N2) is removed; and the system is ready to be placed into operation. Ensure that the 5A and 15A fuses in the control panel are removed when connecting or disconnecting battery cables.

Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.

!

Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid is spilled, flush the affected area immediately with clear water.

!

Do not dispose of the battery in a fire. The bat tery is capable of exploding.

Do not open or mutilate the battery. Released electrolyte can be toxic and harmful to the skin and eyes.

The battery represents a risk of high short cir cuit current. When working on the battery, always remove watches, rings or other metal objects, and only use tools that have insulated handles.

‹

2.11.1 VENTED BATTERIES

!

The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. The following proce dures are to be observed: • Wear full eye protection and protective clothing, • Where electrolyte contacts the skin, wash it off immediately with water, • Where electrolyte contacts the eyes, flush thor oughly and immediately with water and seek med ical attention, and • Spilled electrolyte is to be washed down with an acid-neutralizing agent. A common practice is to use a solution of one pound (500 grams) bicarbon ate of soda to one gallon (4 liters) of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

Lead acid batteries present a risk of fire because they generate hydrogen gas. The fol lowing procedure are to be followed: • DO NOT SMOKE when near batteries, • DO NOT cause flame or spark in battery area, and • Discharge static electricity from body before touch ing batteries by first touching a grounded metal surface.

Servicing of batteries is to be performed or super vised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized person nel away from batteries.

13

Section 2 — Installation Liquid-cooled 15, 20 and 25 kW Generators

The recommended battery is Group 26, 12VDC, 550 CCA/75 AH minimum. All batteries must be at 100 percent state-of-charge before they are installed on the generator.

When using maintenance-free batteries, it is not nec essary to check the specific gravity or electrolyte level.

Have these procedures performed at the intervals specified in Section 4, “Maintenance.” A negative ground system is used. Battery connections are shown on the wiring diagrams. Make sure all batter ies are correctly connected and terminals are tight.

Observe battery polarity when connecting batteries to the generator set.

NOTE: Damage will result if the battery connections are made in reverse.

2.12 PREPARATION BEFORE START-UP

The instructions in this section assume that the standby generator has been properly installed, serv iced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor. Be sure to read the “Safety Rules” on pages 2 and 3, as well as all other safety information in this manual, before attempting to operate this (and related) equip ment.

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2.12.1 PRIOR TO INITIAL START-UP

!

Prior to initially starting the generator, it must be properly prepared for use. Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure.

Before starting the generator for the first time, the installer must complete the following procedures. For follow-up maintenance information and/or service intervals, please refer to Section 4, “Maintenance.” ‹

2.12.2 TRANSFER SWITCH

If this generator is used to supply power to any elec trical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents elec trical backfeed between two different electrical sys tems, (for additional information, see the applicable transfer switch manual for this unit). The transfer switch, as well as the generator and other standby components, must be properly located and mounted in strict compliance with applicable codes, standards and regulations.

14 ‹

2.12.3 FUEL SYSTEM

Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and volume and, (b) is properly purged and leak tested according to code. No fuel leakage is permitted.

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2.12.4 GENERATOR SET LUBRICATION

Check the engine crankcase oil level before operating and add oil to the proper level – the dipstick “FULL” mark. Never operate the engine with the oil level below the dipstick “ADD” mark. See “Specifications” and “Engine Oil Recommendations”.

NOTE: This engine is shipped from the manufacturer with 15W-40 oil. This oil should be changed after 30 hours of operation.

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2.12.5 ENGINE COOLANT

Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See “Specifications” and “Coolant”.

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2.12.6 BELT TENSION

Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of approximately 22 pounds (10 kg), applied midway between pulleys, deflects the belt about 3/8- to 5/8 inches (10 to 16 mm).

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2.12.7 ELECTRICAL SYSTEM

Make sure the generator is properly connected to an approved earth ground and/or ground rod.

Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use.

Check to ensure that there are no loose electrical con nections. Restrain any loose wires to keep them clear of any moving generator set components.

Section 3 - Operation Liquid-cooled 15, 20 and 25 kW Generators

3.1

CONTROL CONSOLE COMPONENTS

The components of a home standby generator control console (Figure 3.1) are as follows:

Figure 3.1 - Generator Control Console

OVER CRANK OVER SPEED LOW COOL. LEVEL HI COOL. TEMP.

LOW OIL PRESS.

LOW BATTERY SYSTEM READY LED INDICATORS: FLASHING GREEN LED = NO UTILITY SENSE 5 FLASHING RED LED'S = EXERCISER NOT SET (IN AUTO MODE ONLY) SOLID GREEN LED = SYSTEM READY, UTILITY POWER ON RED LED'S = INDIVIDUAL FAULT (SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS) AUTO OFF OFF ON SET EXERCISE TIME MANUAL TO SET EXERCISER TIME 1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.

2) HOLD "SET EXERCISE TIME" SWITCH IN "ON" POSITION FOR THREE SECONDS AND RELEASE. (SEE OWNER'S MANUAL FOR COMPLETE DETAILS) THE EXERCISER IS NOW SET. ALL FIVE RED LED'S WILL FLASH FOR 10 SECONDS THEN THE UNIT WILL START, RUN THROUGH THE EXERCISE CYCLE AND SHUTDOWN.

0F2629 CAUTION RISK OF ELECTRICAL SHOCK. DO NOT REMOVE COVER. NO USER SERVICEABLE PARTS INSIDE. REFER SERVICING TO QUALIFIED SERVICE PERSONNEL.

CAUTION FOR STAND-BY SERVICE CONNECT OUTPUT OF GENERATOR TO SUITABLY RATED TRANSFER SWITCH IN ACCORDANCE WITH CANADIAN ELECTRICAL CODE, PART I.

TENTION: POUR L'ALIMENTATION DE RESERVE, CONNECTER LA SORTIE DE ATRICE A UN COMMUTATEUR DE CALIBRE APPROPRIE, CONFORMENENT AU CANADIEN DE L'ECTRICITE, PREMIERE PARTIE.

WARNING CAN AUTOMATICALLY START AT ANYTIME WITHOUT NOTICE.

Y REMOVE FUSE ON CONTROL PANEL AND NEGATIVE BATTE SERVICING.

WARNING THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR OUTDOOR INSTALLATION ONLY!

USE OF SYNTHETIC OIL IS RECOMMENDED 0E7193 ‹

3.1.1 AUTO/OFF/MANUAL SWITCH

Use this three-position switch as follows: • Set the switch to AUTO for fully automatic opera tion. See “Automatic Operation” (Section 3.6).

• Set switch to MANUAL position to crank and start the generator engine.

• Set switch to OFF position to shut down an oper ating engine. With OFF selected, operation will not be possible.

DANGER

!

With switch set to AUTO, engine can crank and start suddenly without warning. Such automat ic start up normally occurs when utility source voltage drops below a pre-set level. To prevent possible injury that might be caused by such sudden starts, set AUTO/OFF/ MANUAL switch to OFF before working on or around the unit.

Then, place a “DO NOT OPERATE” tag on con trol console.

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3.1.2 FAULT INDICATOR LEDS

(SEE CHART ON PAGE 16)

These red LEDs turn ON when one or more of the fol lowing engine faults occurs and the engine shuts down.

• Low Oil Pressure • Overcrank • Low Battery • Overspeed/Engine Speed Signal Fault • High Coolant Temperature/Low Coolant Level See Section 1.7 for further explanation of engine pro tection functions.

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3.1.3 15 AMP FUSE

This fuse protects the control console’s DC control circuit against electrical overload and is located inside the control panel. If the fuse has melted open because of an overload, engine cranking and startup cannot occur. If the fuse needs to be replaced, use only an identical 15-amp replacement fuse (type ATO).

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3.1.4 5 AMP FUSE

This fuse protects the battery charger against electri cal overload and is located inside the control panel. If the fuse needs to be replaced, use only an identical 5 amp replacement fuse (type ATO).

NOTE: This fuse will not remove the + battery input power from the PCB when it opens. This means the exercise timer will not be reset.

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3.1.5 SET EXERCISE TIME SWITCH

This switch allows programming the generator to start and exercise automatically. “See Weekly Exercise Cycle” (see Figure 3.3 and Section 3.6).

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3.1.6 SYSTEM READY LED

The System Ready LED (green) has two main pur poses. First, the LED will be ON when the AUTO/OFF/MANUAL switch is in the AUTO position, utility is present, and there are no system alarms.

This ON state indicates the system is fully ready for automatic operation.

The system ready LED will be OFF when the switch is in the MANUAL or OFF positions.

The system ready LED is also used to indicate the presence of utility sensing at the PCB when the switch is either in the AUTO or MANUAL modes. The LED will flash at the rate of 1/2 second on, 1/2 second off if the utility sensing level is below the transfer back threshold.

This secondary function is only available with DIP switch two in the OFF position (ATS - automatic transfer switch application).

3.2

MANUAL TRANSFER AND START-UP

To transfer electrical loads to the Standby (EMER GENCY) power source side and start the engine man ually, refer to the Owner’s Manual of the particular transfer switch.

15

Section 3 - Operation Liquid-cooled 15, 20 and 25 kW Generators Condition

Generator Switch is in the OFF Mode.

System Ready for Automatic Start Generator Switch is in the MANUAL Mode Weekly Exerciser is not set Battery Voltage <12.2V

for >1 minute Battery Voltage <6V Unit Shutdown due to Low Oil Pressure Unit Shutdown due to High Coolant Temperature or Low Coolant Level Unit Shutdown due to Engine Overspeed Unit Failed to Start during it’s Crank Cycle Utility Voltage is <45% of Nominal Engine Speed Signal Fault Control Board is in GTS Mode

System Ready (Green)

OFF ON OFF X X OFF OFF OFF OFF OFF Flashing 1 sec rate OFF OFF

Low Bat (Red)

X X X

Low Oil (Red)

OFF OFF OFF

High Temp (Red)

OFF OFF OFF

Over Speed (Red)

OFF OFF OFF

Over Crank (Red)

OFF OFF OFF Flashing Flashing Flashing Flashing Flashing (-----------------------------------1 sec rate---------------------------------------) ON (Non-latching) ON X ON X X X X X X ON ON Flashing The five RED LED’s will turn on one at a time ON

Switch Position Manual Auto Off

O O O O O O O O O O O O O O O O O O O O O O O O O O

3.3

ENGINE GOVERNOR GAIN ADJUSTMENTS

X = indicates that the LED can be ON or OFF depending on the operating conditions.

Figure 3.2 — Control Board Dip Switch Location

Engine speed governing is also controlled by the engine control board. The engine governor has been set by the factory during final testing of the generator and should not be adjusted.

If, however, adjustments are necessary, the following procedure should be followed (Figure 3.2 and Section 3.7): 1. Move DIP switch 8 to the TEST mode (OFF posi tion).

2. Set all three potentiometers (pots) fully counter clockwise.

3. Under no load condition, increase the GAIN pot as much as possible without causing instability.

4. Apply 1/4, 1/2, 3/4 and full load to the unit.

Decrease the GAIN pot if there is instability at any load point.

5. Under full load condition, increase the stability pot until the unit returns to 60 Hertz (or 50 Hertz in 50 Hertz applications).

16

Section 3 - Operation Liquid-cooled 15, 20 and 25 kW Generators

6. Reduce load to 3/4, 1/2, 1/4 and no load.

Decrease the stability pot if there is instability at any load point.

7. Adjust differential pot to make the recovery to load changes even faster and minimize load change undershoot and overshoot. If it is set too high, it may introduce oscillations at some load.

It can be set to zero (full CCW) if a small amount causes oscillations at some load.

8. Leave DIP switch 8 in TEST mode.

3.4

When utility power source voltage has been restored, electrical loads may be transferred back to that source and the generator can be shut down as fol lows:

MANUAL RETRANSFER AND SHUTDOWN

• Verify that utility power supply voltage to the trans fer switch has been positively turned Off, using whatever means provided (such as utility main line circuit breaker).

• Set the generator’s main circuit breaker to its Off or Open position.

• Let the generator engine run at no-load for a few minutes, to stabilize internal unit temperatures.

• On the generator console, set the Auto/Off/ Manual switch to Off. Wait for engine to come to a complete stop.

• For transfer to utility position, refer to the Owner’s Manual of the particular transfer switch.

• Turn on the utility power supply to the transfer switch, using whatever means provided (such as a utility main line circuit breaker). The utility power source now powers the loads.

3.5

AUTOMATIC OPERATION

To set the system for fully automatic operation, pro ceed as follows: • Check that load circuits are connected to the utility power supply.

• Set the AUTO/OFF/MANUAL switch to its AUTO position.

• Set the generator main circuit breaker to its ON or CLOSED position.

3.6

WEEKLY EXERCISE CYCLE

The engine control board will start and run the gen erator once every seven days for approximately 12 minutes. If utility should fail during this exercise period, the engine control board will transfer the load to the generator output and continue to run until util ity returns.

On the day, and at the time of day chosen for the gen erator to exercise, set the weekly exercise cycle as fol lows: 1. Place the AUTO/OFF/MANUAL switch in the AUTO position (Figure 3.3).

2. Press and hold the “Set Exercise Time” switch for five seconds, then release.

At this time all five red LEDs will flash for approxi mately 10 seconds, then the engine will start and run for it’s 12 minute exercise period, then shut down.

The generator will now start and run each week at the same time.

Figure 3.3 - “Set Exercise Time” Switch

SOLID GREEN LED SYSTEM READY, UTILITY POWER ON RED LED'S = INDIVIDUAL FAULT (SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS) AUTO OFF OFF ON SET EXERCISE TIME MANUAL TO SET EXERCISER TIME 1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.

2) HOLD "SET EXERCISE TIME" SWITCH IN "ON" POSITION FOR THREE SECONDS AND RELEASE. (SEE OWNER'S MANUAL FOR COMPLETE DETAILS) THE EXERCISER IS NOW SET. ALL FIVE RED LED'S WILL FLASH FOR 10 SECONDS THEN THE UNIT WILL START, RUN THROUGH THE EXERCISE CYCLE AND SHUTDOWN.

0 If DC power to the control board is lost, the weekly exercise setting will be lost. This is indicated by all five red LEDs continually flashing. In this state the generator will still start and run in MANUAL mode, or automatically start and run if utility is lost while in AUTO mode, but it will not perform a weekly exercise cycle.

If a failure occurs while running in this mode, the five red LEDs will stop flashing, the individual fault LED will turn on and the engine will shut down. Once the AUTO/OFF/MANUAL switch has been switched to OFF, the individual fault LED will turn OFF and the five red LEDs will begin flashing to show exercise has still not been set.

17

Section 3 - Operation Liquid-cooled 15, 20 and 25 kW Generators

3.7

CONTROL BOARD DIP SWITCH SETTINGS

Located on the control board is an eight position DIP switch (see Figure 3.2). The eight different switches, are used to configure the control board for the spe cific engine and governor being used and are pre-set at the factory.

!

If the DIP switch settings are not set correctly, the generator may not start or operate correct ly.

240 VAC can be present within the control panel.

If it is necessary to select an alternate switch position, move the AUTO/OFF/MANUAL switch to the OFF position. Remove the 15 amp fuse in the generator control panel. Move the DIP switch position that needs to be changed to its new position. Wait five sec onds, then re-install the 15 amp fuse.

The ON position is marked on the switch and is shown in Figure 3.2.

Switch Position 1 — Selects the generator alternator output frequency and is factory pre-set for 60 Hz.

Switch Position 2 switch and is factory pre-set for an automatic trans fer switch (ATS).

— Selects the type of transfer Switch Position 3 control used, and is factory pre-set for stepper motor operation.

— Selects the type of governor Switch Position 4 — Selects the type of fuel being used and is factory pre-set for natural gas (NG).

Switch Position 5 — Selects the engine displacement and is factory pre-set for a 2.5 liter (2.5L) engine.

Switch Position 6 — Selects the number of engine cylinders and is factory pre-set for four cylinders.

Switch Position 7 throttle).

— Selects the direction of rotation of the governor stepper motor and is factory pre-set for CCW rotation (rotation is observed looking at the stepper shaft as it moves from closed throttle to open Switch Position 8 — Selects whether the control is in the Normal Mode of operation or Test Mode. In the Normal Mode of operation, pre-determined governor gains are used and the gain trimpots on the control board (Gain, Stability, and Differential) are not active and have no effect on the gains. In Test Mode the gain trimpots are active and can be adjusted. See Section 3.3.

18

3.8

VOLTAGE REGULATOR ADJUSTMENT

Four adjustment potentiometers are provided on the voltage regulator installed in the control panel (Figure 3.4). These are (a) voltage adjust, (b) gain, (c) stabili ty and (d) underfrequency adjust. The voltage regula tor potentiometers have been factory set and SHOULD NOT be adjusted. If however, adjustments are necessary, contact the local Dealer to implement the following procedure.

High voltage is present inside the control panel during this procedure.

1. Disconnect all electrical loads from the generator (initial adjustments are done under no-load con ditions).

Figure 3.4 — Voltage Regulator

2. Connect an accurate AC voltmeter and AC fre quency meter to the generator’s AC output leads.

3. On the voltage regulator, set the potentiometers as follows: A. Turn the Voltage Adjust pot fully counterclock wise (CCW).

B. Set the GAIN pot to its centered (mid) position.

C. Set the STABILITY pot to its centered (mid) position.

D. ADJUST pot.

4. Start the engine. Let it stabilize and warm up at no-load.

5. Verify that the three voltage regulator’s LED’s are ON.

6. Check the reading on the AC frequency meter.

Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators

7. Turn the voltage regulator’s VOLTAGE ADJUST pot to obtain a line-to-line voltage of: A. 240 VAC if the generator has been configured for 60 Hertz operation.

B. 200 VAC if the generator has been configured for 50 Hertz operation.

8. If the RED REGULATOR LED is flashing, adjust the STABILITY pot in either direction until the flashing stops.

9. Apply an electrical load and check the engine speed recovery.

A. Adjust the UNDERFEQUENCY ADJUST pot CCW to reduce load during engine recovery.

B. For flat regulation (no voltage decrease as fre quency drops) set the UNDERFREQUENCY ADJUST pot fully CW.

C. To obtain a constant voltage regulation as fre quency decreases, set the UNDERFREQUENCY ADJUST pot fully CCW.

10. With the electrical load still applied, check the REGULATOR LED for flashing. If the LED is flashing, adjust the STABILITY pot until the flash ing stops.

11. If better response is needed, adjust the GAIN pot clockwise (CW) as needed. Then (if needed) cor rect for stability by adjusting the STABILITY pot.

12. Turn OFF the electrical loads.

13. Verify that all the voltage regulator’s LED’s are ON.

14. Turn OFF the generator.

4.1

MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A. EVERY THREE MONTHS

1. Check battery condition.

2. Inspect and test fuel system.

3. Check transfer switch.

4. Inspect exhaust system.

5. Check engine ignition system.

6. Check fan belts.

B. ONCE EVERY SIX MONTHS

1. Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature).

C. ONCE ANNUALLY

1. Test engine governor; adjust or repair, if needed.

2. Clean, inspect generator.

3. Flush cooling system.

D. FIRST 100 OPERATING HOURS

1. Change engine oil and oil filter. After initial change, service engine oil and filter at 150 oper ating hours or six months, whichever comes first.

2. Retorque cylinder head (see torque specs).

3. Retorque intake and exhaust manifold (see torque specs).

E. EVERY 500 OPERATING HOURS

1. Service air cleaner.

2. Check starter.

3. Check engine DC alternator.

F. EVERY 800 OPERATING HOURS

1. Retorque cylinder head (see torque specs).

2. Retorque intake and exhaust manifold (see torque specs).

3. Check engine compression.

4. Check valve clearance.

4.2

EXHAUST MANIFOLD PROCEDURE

1. If necessary, clean gasket surfaces on exhaust manifold and cylinder head.

2. Install exhaust manifold and exhaust manifold gasket.

3. Install fasteners.

NOTE: Exhaust manifold fasteners must be tightened in two stages.

4. Tighten fasteners to 20-30 N-m (15-22 lb-ft) dur ing the first stage.

5. Retighten fasteners to 60-80 N-m (44-59 lb-ft) during the second stage.

4.3

INTAKE MANIFOLD PROCEDURE

1. Clean and inspect the mounting surfaces of the intake manifold and the cylinder head. Both sur faces must be clean and flat (Figure 4.1).

2. Clean and lightly oil the manifold bolt/stud threads.

Figure 4.1 — Intake Manifold Installation

19

Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators

3. Install a new lower intake manifold gasket.

4. Position the lower intake manifold to the cylinder head.

5. Install retaining bolts/studs finger tight.

6. Tighten all bolts/studs to specifications in the tightening sequence shown: • First pass = 7=10 N-m (5-7 lb-ft).

• Final pass = 26-38 N-m (19-28 lb-ft).

4.4

CYLINDER HEAD PROCEDURE

1. Position head gasket on the block (Figure 4.2).

2. Position cylinder head to cylinder block.

3. Install 10 cylinder head bolts in numerical sequence. Tighten to 70 N-m (52 lb-ft) in sequence. Retighten to 70 N-m (52 lb-ft) in sequence. Then turn all head bolts an additional 90 - 100 degrees in sequence.

Figure 4.2 — Cylinder Head Installation

The exhaust system parts from this product get extremely hot and remains hot after shutdown.

High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.

4.6

OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM

Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board.

Battery voltage is delivered to that circuit board via a 15 amp fuse. These overcurrent protection devices will open if the circuit is overloaded.

!

If a circuit breaker opens or a fuse element melts, find the cause of the overload before resetting the circuit breaker or replacing the fuse.

4.7

CHECKING FLUID LEVELS

‹

4.7.1

CHECK ENGINE OIL

Check engine crankcase oil level (Figure 4.3) at least every 20 hours of operation, or prior to use.

• Remove oil dipstick and wipe dry with a clean, lint-free cloth.

• Install oil dipstick, then remove again.

• Oil should be between FULL and ADD marks.

• If oil level is below the dipstick ADD mark, remove oil fill cap. Add the recommended oil to bring oil level up to the FULL mark. DO NOT FILL ABOVE THE “FULL” MARK. See “Engine Oil Recommen dations” for recommended oils.

Figure 4.3 - Oil Dipstick and Oil Fill Cap

Oil Fill Cap Engine Air Cleaner

4.5

COOLING SYSTEM

Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation. This includes such obstruc tions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See the installation diagram.) 20

Oil Dipstick Oil Filter

Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators

‹

4.7.2

BATTERY FLUID

Check battery electrolyte fluid based on the Maintenance Schedule. Fluid should cover separa tors in all battery cells. If fluid level is low, add dis tilled water to cover tops of separators. DO NOT USE TAP WATER IN BATTERY.

‹

4.7.3

ENGINE COOLANT

Check coolant level in coolant recovery bottle. See Specifications.

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap (only when engine has cooled down) to make sure the coolant recovery system is functioning properly.

Coolant should be at bottom of radiator filler neck.

If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact an Authorized Service Dealer. Inspect cooling system and coolant recov ery system for leaks.

4.8

MAINTENANCE OWNER/ OPERATOR CAN PERFORM

‹

4.8.1 CHECK ENGINE OIL LEVEL

Refer to “Checking Fluid Levels”.

‹

4.8.2 CHECK BATTERY

• See “Checking Fluid Levels”.

• Check battery cables for condition, tightness, cor rosion or damage. Clean, tighten or replace as necessary.

‹

4.8.3 EXERCISE SYSTEM

Start the generator engine at least once every seven days and let it run at least 12 minutes. See “Weekly Exercise Cycle”.

‹

4.8.4 INSPECT COOLING SYSTEM

• Inspect engine cooling system. See “Maintenance Schedule”.

• Check hoses for damage, deterioration, leaks, etc.

Correct any discrepancies found.

• Check hose clamps for tightness.

‹

4.8.5 CHECK ENGINE COOLANT LEVEL

See “Checking Fluid Levels”.

‹

4.8.6 PERFORM VISUAL INSPECTION

Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded nuts, bolts and other fas teners. Look for fuel, oil or coolant leaks.

‹

4.8.7 INSPECT EXHAUST SYSTEM

Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage.

‹

4.8.8 CHECK FAN BELT

• Inspect fan belts every three months. Replace any damaged, deteriorated, worn or otherwise defec tive belt.

• Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 of an inch. Adjust belt tension as required.

‹

4.8.9 INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

!

DANGER Do not attempt to adjust the governor. Only qualified service facilities should adjust the governor. Excessively high operating speeds are dangerous and increase the risk of personal injury. Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life. Correct rated frequency and voltage are supplied only at the proper governed speed. Some connected electrical load devices may be damaged by incorrect frequency and/or voltage. Only quali fied service technicians should adjust the gov erned speed.

‹

4.8.10 CHANGING ENGINE OIL

Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies.

Drain the oil while the engine is still warm from run ning. This means warm up the engine, shut it down and drain immediately as follows: 1. Remove OIL DRAIN HOSE from its retaining clip.

2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container.

3. When all oil has drained, install and tighten OIL DRAIN HOSE CAP, and re-install into its retaining clip.

4. Turn OIL FILTER (Figure 4.1) counterclockwise and remove. Properly dispose of old filter.

21

Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators

5. Apply light coating of new engine oil to seal of new oil filter. Install FILTER and tighten by hand only.

DO NOT OVER TIGHTEN.

6. Remove OIL FILL CAP. Add recommended oil (see SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK “FULL” MARK. Crankcase oil capacity is 4.0 U.S. quarts (3.8 liters).

!

After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK “ADD” MARK.

7. Start engine and check for oil leaks.

‹

4.8.11 CHANGING THE ENGINE AIR CLEANER

To replace the engine air cleaner, (part number 059402), simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover (Figure 4.1).

See the “Service Schedule,” for air cleaner mainte nance.

‹

4.8.12 SPARK PLUGS

Reset the spark plug gap or replace the spark plugs as necessary (Figure 4.4). See Section 6.

1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and com mercial solvent. Do not blast the spark plugs to clean.

2. Remove the spark plugs and check the condition.

Replace the spark plugs if worn or if reuse is questionable. See the “Service Schedule,” Section 6, for recommended inspection.

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 1.07-1.17 mm (0.042 0.046 inch) by carefully bending the ground elec trode (Figure 4.2).

Figure 4.4 – Setting the Spark Plug Gap

SET PLUG GAP AT 1.07 - 1.17 mm (0.042 - 0.046 inch)

‹

4.8.13 COOLANT CHANGE

Every year, have an Authorized Service Facility drain, flush and refill the cooling system. See “Specifications” for cooling system recommenda tions.

4.9

MISCELLANEOUS MAINTENANCE

‹

4.9.1 CLEANING THE GENERATOR

Keep the generator as clean and as dry as possible.

Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance.

Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dry, low pressure air to remove any accumulations of dirt. The generator is housed inside an all-weather enclosure, clean the enclosure with a soft, damp cloth or sponge and water.

Once each year have the generator cleaned and inspected by an Authorized Service Dealer. That deal er will use dry, low pressure air to clean internal windings. Parts inside the control console should be cleaned and inspected at this time as well.

Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low, the generator may require drying.

‹

4.9.2 BATTERY

All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery. If such information is not available, observe the following precautions when handling a battery: • DO NOT use jumper cables and a booster battery to crank or start the generator engine.

• DO NOT recharge a weak battery while it is installed in the generator. Remove battery from generator and recharge in a well-ventilated area, away from fuel vapors, sparks, heat or flames.

• Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns. DO NOT permit fluid to contact eyes, skin, clothing, painted surfaces, wiring insulation, etc. If any bat tery fluid is spilled, flush the affected area with clear water immediately.

• Always wear safety glasses, rubber apron and gloves when handling a battery.

• Batteries give off explosive hydrogen gas while charging. The gas can form an explosive mixture around the battery for several hours after charging.

Any spark, heat or flames can ignite the gas and cause an explosion which can shatter the battery, causing blindness or other serious injury.

22

Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators

‹

4.9.3 BATTERY MAINTENANCE

The battery should be inspected per Section 4.7, Scheduled Maintenance. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. Do not use tap water in batteries.

3. Have the state of charge and condition checked.

This should be done with an automotive-type bat tery hydrometer.

DANGER

!

!

Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.

Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid is spilled, flush the affected area immediately with clear water.

Do not use any jumper cables or booster bat tery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging.

!

Be sure the AUTO/OFF/MANUAL switch is set to the OFF position, before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.

Be sure the utility power supply to the battery charger is turned off, or sparking may occur at the battery posts as the cables are attached and cause an explosion.

‹

4.9.4 BATTERY REPLACEMENT

When replacing batteries, use the same number and the type of battery that follows:

BCI Group No.

26-60R

CCA

525 @ 0 deg. F NOTE: The BCI number should be located directly on the battery.

Part Name

PERIODIC REPLACEMENT PARTS

Part Number

Oil Filter Radiator Cap Air Cleaner Spark Plug Battery Motorcraft FL-400-S (supplied with engine) # 046627 # 059402 Motorcraft AWSF-52-C (supplied with engine) # 077483 23

Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators

4.10 SCHEDULED MAINTENANCE

The following is a recommended maintenance schedule for small standby and residential generator sets. The established intervals in the schedule are the

maximum

recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application.

Use calendar time from the previous maintenance interval to determine the next required maintenance interval.

Service Maintenance Interval Information:

The various service maintenance intervals are designated by interval numbers as follows: 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten tial problem areas.

Performed monthly this requires approximately .

5 man-hours per unit to complete.

This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning:

• • • • To prevent injury, perform the following steps in the order indicated before starting any maintenance: Disable the generator set from starting and/or connecting to the load by setting the control panel AUTO/OFF/MANUAL switch to the OFF position.

Remove the 5 amp and 15 amp control panel fuses.

Turn off the battery charger (turn OFF utility supply to ATS).

Remove the negative battery cable.

The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condi tion from burning out sensitive control panel components and circuits.

Following all maintenance, reverse these steps to assure the unit is returned to standby setup for normal operation when required.

2 A break-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.

Performed ONLY ONCE following the first three months of operation after purchase of the unit and requires approximately 2.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer.

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

Performed semi-annually this requires approximately 1.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer.

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

Performed annually this requires approximately 4.0 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer.

24

Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators Maintenance Tasks

1. Disable the unit from operating per the first page warning.

2. Check the engine oil level.

Adjust as necessary.

3. Check the engine coolant level. Adjust as necessary.

4. Check the engine coolant thermal protection level.

Correct as necessary.

5. Check the natural gas delivery system on gas engine driven units.

Tighten connections as necessary.

6. Check the air inlets and outlets for debris. Clean as necessary.

7. Check the battery electrolyte level if accessible. Adjust as necessary.

8. Check the battery posts, cables, and charger for loose connections, corrosion, and proper operation. Correct as necessary.

9. Check the unit wiring for loose connections, corrosion, and damage.

Correct as necessary.

10. Check the engine accessory drive belts for wear, weather cracking, and damage. Replace as necessary.

11. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary.

12. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary.

Level 1

Recom mended to be done monthly Task Comp.

(Date Initials)

Level 2

Required to be done 3 months/ Break-in Task Comp.

(Date Initials)

Level 3

Required to be done Semi annually Task Comp.

(Date Initials)

Level 4

Required to be done Annually Task Comp.

(Date Initials) 25

Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators Maintenance Tasks

13. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary.

14. Start and exercise the unit at full rated load (use a load bank if the site load is not enough) for at least 2 hours looking for leaks, loose connections or components, and abnormal operating conditions.

Correct as necessary.

15. Change the engine oil.

16. Replace the engine oil filter(s).

17. Replace the engine air filter(s).

18. Replace the engine fuel filter(s) on diesel engine driven units and re-prime the fuel system.

19. Check the engine spark plugs on gas engine driven units. Clean and re-gap or replace as necessary.

20. Perform a 5 minute no-load operational run of the unit looking for any post service problems.

21. Return the unit to standby setup for operation when required.

Level 1

Recom mended to be done monthly Task Comp.

(Date Initials)

Level 2

Required to be done 3 months/ Break-in Task Comp.

(Date Initials)

Level 3

Required to be done Semi annually Task Comp.

(Date Initials)

Level 4

Required to be done Annually Task Comp.

(Date Initials) 26

Section 5 — Troubleshooting Liquid-cooled 15, 20 and 25 kW Generators

TROUBLESHOOTING POINTS PROBLEM

Engine won’t crank.

CAUSE

1. 15 amp fuse blown.

2. Loose or corroded or defective battery cables.

3. Defective starter contactor.

4. Defective starter motor.

5. Dead or Defective Battery.

6. 5 amp fuse blown.

Engine cranks but won't start Engine starts hard, runs rough.

1. Out of fuel.

2. Fuel solenoid (FS) is defective 3. Open Wire #14A from Engine Control circuit board.

4. Spark plugs defective.

1. Flame arrestor (air cleaner) plugged or damaged.

2. Plugged fuel line.

3. Defective spark plugs.

Engine starts then shuts down.

1. Engine oil level is low.

2. Engine is overheated.

3. Defective Low Oil Pressure Switch 4. Defective Coolant Temperature Switch 5. Defective Control Module circuit board.

6. Coolant Level is Low.

7. Defective Low Coolant Level Switch AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch engine continues to run 2. Open/disconnected wire #15A between AUTO/OFF/MANUAL switch and Control Module circuit board.

3. Defective Control Module circuit board No AC output from generator.

1. Main line circuit breaker open.

2. Circuit breakers & fuses open.

3. Transfer switch set to NORMAL position 4. Generator internal failure.

5. Thermal circuit breaker open.

CORRECTION

1. Replace fuse.

2. Tighten, clean or replace battery cables as necessary.

3. Replace contactor.

4. Replace starter motor.

5. Remove, change or replace battery.

6. Replace fuse.

1. Replenish fuel.

2. Replace solenoid.

3. Reconnect wire.

4. Clean, regap or replace plugs.

1. Clean or replace as needed.

2. Unclog fuel line.

3. Clean, regap or replace plugs.

1. Check oil and add oil as needed.

2. Check cooling system for leaks.

3. Replace switch.

4. Replace switch.

5. Replace board.

6. Repair leak - Add coolant.

7. Replace Switch.

1. Replace switch.

2. Reconnect/close wire.

3. Replace board.

1. Reset to ON or CLOSED.

2. Reset and replace, if necessary.

3. Set to GENERATOR position.

4. Contact an Authorized Service Dealer.

5. Auto-reset - Wait 5 min. and attempt restart.

27

28

Section 6 — Notes Liquid-cooled 15, 20 and 25 kW Generators

Section 6 — Notes Liquid-cooled 15, 20 and 25 kW Generators

29

30

Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2183-B

Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2183-B

31

32

Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2184-B

Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2184-B

33

34

Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1286-B

Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1286-B

35

36

Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1287-B

Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1287-B

37

38

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Mounting Base — Drawing No. 0F0104-B

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Mounting Base — Drawing No. 0F0104-B ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

PART NO.

060619 046526 022131 021991 038805G 050331 050331A 038804J 045771 022129 027482 075763 0E9748A 0F0795 0C2454 065852 045764 0F1705 0E8834 0E9911 049813 022097 026850 055414 022473 047411 052860 052251 052257 052252 052259 052891 0536210261 074906 077483 0F0796 025507

QTY.

1 1 1 1 4 2 1 4 4 4 4 4 4 4 4 1 1 REF 3 3 1 1 1 1 1 REF REF 1 REF REF 1 1 1 3 33 1 1

DESCRIPTION

SUPPORT BATTERY TRAY HOLD DOWN BATTERY ASSEMBLY BATTERY TRAY NUT HEX M6 X 1.0 G8 YEL CHR WASHER LOCK M6-1/4 WASHER SHAKEPROOF EXT 1/4 STL LUG SLDLSS #2-#8 X 17/64 CU WASHER FLAT 1/4-M6 ZINC SCREW HHC M6-1.0 X 16 G8.8

NUT FLANGED HEX M12-1.75

DAMPENER VIBRATION 40 BLUE SPACER .49 X .62 X 1.87 PWDR/ZNC DAMPENER VIBRATION WASHER FLAT M12 SCREW HHC M12-1.75 X 80 G8.8

ASSY WIRE #0 12.00" SCREW HHTT M6-1.0 X 20 BP BATT 12VDC 75-AH 26 (NOT SHOWN) BRACKET CONTROL PANEL SUPPORT WASHER SHAKEPROOF EXT 7/16 STL SCREW SHC M10-1.50 X 40 G12.9

WASHER LOCK M10 WASHER FLAT 3/8-M10 ZINC EARTH STRAP CABLE BATT BLK #1 X 41.50

BATTERY POST COVER (BLACK) BATTERY POST COVER (RED) CABLE BATT RED #1 X 40.50

NUT HEX M8-1.25 G8 YEL CHR WASHER LOCK M8-5/16 WASHER SHAKEPROOF EXT 5/16 STL BOOT BATTERY CABLE ASSY MTG BASE 2.5L AL ENCL SUPPORT CONTROL PANEL 2.5L

SCREW THF M6-1 X 16 N WA Z/JS SPRING CLIP HOLDER .37-.62

SCREW HHTT M4-0.7 X 8 BP 39

40

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Enclosure — Drawing No. 0F1645-H

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Enclosure — Drawing No. 0F1645-H ITEM PART NO.

QTY.

DESCRIPTION

0F0783 0F0781 0F0780 0C2454 0F0779 0E0072AB 0E0072AC 0E0072AD 0E5912 0F0787 089961 0A2115 0E0072AE 0F0165A 0F0165 022097 022473 0E7570 0E7571 070015 0E7662 0F0164A 0F0164 0D2023 078115 0F2179 0F0788 0E7829B 0D3037A 0C7781 0F0786 0E0072Q 0D3037 0E0072Y 0E0072AF 0E0072AA 0F0782 026850 0912970064 0912970063 049813 0F0784 0F0785 0E8665 0E8837 0A3359 0E8404 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 42 43 44 45 46 47 48 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 * ALL ITEMS NOTATED WITH "AI" ARE COMPONENTS OF 0F2179 1 1 1 34 1 1 1 1 2 1 2 4 1 1 1 13 13 2 4 4 10 1 1 1 1 1 1 4 1 1 3 8 1 1 2 1 2 1 2 1 1 1 1 1 4 2 2 DUCT INTAKE MID AL 2.5L

DUCT DISCHARGE RH AL 2.5L

DUCT DISCHARGE LH AL 2.5L

SCREW TH-FRM M6-1 X 16 N WA Z/JS SUPPORT RADIATOR 2.5L AL AI INSULATION SIDE REAR CORNER POST RH AI INSULATION INTAKE DUCT TOP PANEL AI INSULATION LH SIDE REAR CORNER POST PANEL (BOTTOM) DOOR SIDE HSB AL SUPPORT RH SIDE AL 2.5L

FOAM STRIP 3/4" WIDE X 3/16" THK (40" LG) WASHER NYLON .257

AI NSULATION LH SIDE REAR CORNER POST PANEL (TOP) HINGE TYPE B W/STUDS, SOCKET HINGE TYPE B W/STUDS, PIN WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC GAS SPRING BALL STUD GAS SPRING MOUNT NUT HEX 5/16-18 LOCK SCREW WING M6-1.00 X 25 HINGE TYPE A W/STUDS, SOCKET HINGE TYPE A W/STUDS, PIN GASKET CLIP-ON SELF GRIPPING (84" LG) WASHER SELF LOCKING DOME KIT SAE FOAM 2.5L QUIET SOURCE ROOF 2.5L FORD AL AI DOOR PANEL LATCH 1/4 TURN NONLOCKING PAWL DOOR HSB SUPPORT LH SIDE AL 2.5L

AI INSULATION RAD SUPPORT PANEL LATCH QUARTER TURN LOCKING AI INSULATION SIDE BRACE PANEL RH AI INSULATION SIDE BRACE PANEL LH AI INSULATION ROOF PANEL DUCT DISCHARGE MID AL 2.5L

WASHER SHAKEPROOF EXT 1/4 STL ASSY WIRE 14AWG 7.5 #0 GRN/YEL ASSY WIRE 14AWG 7.5 #0 GRN/YEL NUT HEX M6 X 1.0 G8 YEL CHR CORNER POST REAR LH SIDE AL CORNER POST REAR RH SIDE AL BRACKET STIFFENER LH FRONT DOOR BATTERY COMPARTMENT SCREW BHSC M6-1.0 X 16 SS BRACKET STIFFENER RH FRONT 41

42

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Control Panel (15kW and 20kW) — Drawing No. 0F2267-D

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Control Panel (15kW and 20kW) — Drawing No. 0F2267-D PART NO.

0F0790 0F0789 0F0791 0E9704 067680 0E6875A 0C3910 048468 0D5070A 057073 040213 0C2265 029673 0F0793 0E7890 0D5541* 0D5544** 0F1264 0F1263 0F1262 0E7403A 0E7403C 0E2514 020911 023897 022152 051716 082573 0E4494 0C4167 0C2699 0C2212 047411 022097 022473 0E7358 064733 0F0798A 0E6881 048352 0C1127 0C1229 0F2632 0F2629 0E7193 0F6146

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 35 36 37 38 39 40 41 42 43 44 45 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 * 15KW ** 20KW

QTY.

1 1 1 1 1 2 1 1 1 1 2 18 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 4 2 2 1 1 REF.

4 1 4 4 4 4 2 1 REF 1

DESCRIPTION

TOP, CONTROL PANEL BACK & BOTTOM, CONTROL PANEL PANEL, FRONT 2.5L CONTROL PNL ASSY PCB HSB CONTROLLER 2.5L

ASSY VOLTAGE REGULATOR 60HZ RELAY, 12VDC C FORM W/DIODE XFMR 240/16V 1VA&56VA CIRCT BRK 8 X 1 ETA 46-500-P ASSY PCB 2A 12V UL BATT CHRGR JUNCTION BLOCK 3/8-16 PCB SUPPORT SNAP-IN 1/4" SCREW PHTT M4-0.7 X 12 ZYC DIO BRIDGE 25A 600V BRACKET, CB SIEMENS BQ BRKT CB MTG BACK CB 0070A 2P 240V S BQ2 LL CB 0100A 2P 240V S BQ2 LL ADPTR,LH SIDE WICKMAN 178.6192

ADPTR,RH SIDE WICKMAN 178.6191

HOLDER, FUSE WICKMANN 178.6150

FUSE ATO TYPE 5 AMP (TAN) FUSE, ATO TYPE 15 AMP (BLUE) FITTING CONDUIT STR 1-1/2" SCREW PPHM M5-0.8 X 30 ZINC WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX M5-0.8 G8 YEL CHR SWITCH ROC DPST 125V SPD SWITCH ROC DPDT ON-OFF-ON BLOCK TERM 20A 14 X 6 X 1100V SCREW PHTT #6-32 X 3/8 ZYC SCREW PHTT M4-0.7 X 16 ZYC SCREW HHC M6-1.0 X 16 G8.8

WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW PPPH HI-LO #4-24 X 3/8 RES MTG BRACKET HARNESS, C-PNL 2.5L QS 15&20KW (NOT SHOWN) SOCKET, RELAY RES 5R 5% 25W DECAL AVR COVER DECAL WARNING ELECTRICAL SHOCK DECAL TERMINAL BLOCK DECAL CONTROL HSB DECAL, WARNINGS HSB HANG TAG 2 WIRE START (NOT SHOWN) 43

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Control Panel (25kW) — Drawing No. 0E7615-C 3 40 32 33 34 32 33 34 27 28 42 43 1 4 6 38 12 23 24 35 13 31 39 12 2 12 9 16 24 25 26 14 12 12 15 11 17 21 20 18 30 12 12 41 2 8 5 7

44

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Control Panel (25kW) — Drawing No. 0E7615-C ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 37 38 39 40 41 42 43 44

PART NO.

0F0790 0F0789 0F0791 0E9704 067680 0E6875A 0C3910 054450 0D5070A 057073 040213 0C2265 029673 0F0793 0E7890 0A2077 0F1264 0F1263 0F1262 0E7403A 0E7403C 0E2514 020911 023897 022152 051716 082573 0E4494 0C4167 0C2699 0C2212 047411 022097 022473 0E7358 0F0798 0E6881 0C1127 0C1229 0F2632 0F2629 0E7193 0F6146

QTY.

1 1 1 1 1 2 1 1 1 1 2 16 1 1 1 1 1 1 2 1 1 1 2 4 2 2 1 1 REF.

4 1 4 4 4 4 1 REF 1 1 1 1 1 1

DESCRIPTION

TOP, CONTROL PANEL BACK & BOTTOM, CONTROL PANEL PANEL, FRONT 2.5L CONTROL PNL ASSY PCB HSB CONTROLLER 2.5L

ASSY VOLTAGE REGULATOR 60HZ RELAY, 12VDC C FORM W/DIODE XFMR 240/16V 1VA&56VA CIRCT BRK 5.5 X 1 ETA 46-500-P ASSY PCB 2A 12V UL BATT CHRGR JUNCTION BLOCK 3/8-16 PCB SUPPORT SNAP-IN 1/4" SCREW PHTT M4-0.7 X 12 ZYC DIO BRIDGE 25A 600V BRACKET, CB SIEMENS BQ BRKT CB MTG BACK CB 0125A 2P 240V S BQ2 LL ADPTR,LH SIDE WICKMAN 178.6192

ADPTR,RH SIDE WICKMAN 178.6191

HOLDER, FUSE WICKMANN 178.6150

FUSE ATO TYPE 5 AMP (TAN) FUSE, ATO TYPE 15 AMP (BLUE) FITTING CONDUIT STR 1-1/2" SCREW PPHM M5-0.8 X 30 ZINC WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX M5-0.8 G8 YEL CHR SWITCH ROC DPST 125V SPD SWITCH ROC DPDT ON-OFF-ON BLOCK TERM 20A 14 X 6 X 1100V SCREW PHTT #6-32 X 3/8 ZYC SCREW PHTT M4-0.7 X 16 ZYC SCREW HHC M6-1.0 X 16 G8.8

WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW PPPH HI-LO #4-24 X 3/8 HARNESS CTRL PNL 2.5L FORD AL (NOT SHOWN) SOCKET, RELAY DECAL AVR COVER DECAL WARNING ELECTRICAL SHOCK DECAL TERMINAL BLOCK DECAL CONTROL HSB DECAL, WARNINGS HSB HANG TAG 2 WIRE START (NOT SHOWN) 45

46

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Engine — Drawing No. 0E9918-F

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Engine — Drawing No. 0E9918-F ITEM PART NO.

QTY.

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 27 28 29 30 31 32 33 34 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 0E9681 039253 097962 022145 022097 022129 043107 022131 046526 052625 0E9708 0E9738 0E9929 0F0230 0E9834 0E9909 0E9739 049814 0F0001 0D3488B 0A8584 0E0561 0A6751 035579 026925 0E9611 0E9611A 0E9834A 0D5417 0E5048B 0E9655 057192 060619 0E8940 0E9680 0E9609 1 6 1 1 4 2 1 1 1 1 4 4 8 11 16 11 19 22 2 2 1 1 1 1 REF 1 8 1 1 1 1 1 1 1 1 1

ITEM PART NO.

QTY.

ENGINE 2.5L FORD PULLEY, 2.5L FORD WATER PUMP SCREW HHC M10-1.5 X 25 G8.8

CLUTCH, COOLING FAN 2.5L FORD SERPENTINE BELT - 40.85" LENGTH SWITCH,OIL PRESSURE,10PSI,2POL ASSY WATER LEVEL SENSOR C/E PL SW-TMP 245DEG 3/8NPT BUSHING REDUCER 1/4 TO 1/8 PLUG STD PIPE 3/8 STEEL SQ HD MANIFOLD, INTAKE (MACHINED) (STEPPER MOTOR) MANIFOLD INTAKE MACH BOSCH32 (BOSCH GOV.) (NOT SHOWN) GASKET, 2.5L FORD INTAKE MAN.

SCREW HHC M8-1.25 X 20 G8.8

SCREW SHC M6-1.0 X 25 G12.9 ZP WASHER FLAT 5/16-M8 ZINC WASHER LOCK M6-1/4 WASHER LOCK M8-5/16 SCREW HHC M8-1.25 X 25 G8.8

WASHER FLAT 3/8-M10 ZINC WASHER LOCK M10 SCREW SHC M10-1.5 X 35 G12.9

ENGINE FOOT, 2.5L FORD DIPSTICK, 2.5L FORD BRACKET, DIPSTICK TUBE FAN 16" COOLING HARNESS, 2.5L FORD ENGINE (NOT SHOWN) HARNESS,2.5L FORD (BOSCH GOV.) (NOT SHOWN) SCREW HHC M10-1.0 X 25 G10.9

FLEXPLATE 2.5L FORD ADAPT CASTING MACH 2.5L FORD SCREW SHC M10-1.5 X 30 G12.9

SCREW SHC M10-1.50 X 40 G12.9

SPACER FLEXPLATE HSB GASKET, 2.5L FORD EXHAUST MAN.

MANIFOLD, EXHAUST ( MACHINED) 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61* 62 63 64 65 66 67 68 69 0E9930 049821 0E9747 043116 022473 045772 064416 0F0252 0E9868 0F0035 026082 0E9928 0F0383 057823 0E9737 0F0393 045757 069860C 048031J 055596 077456 052677 049813 0E9738A 0F1132 0F1133 059355 076749 029032 0F1433 070007 070005 080826 045771 048031C 1 3 1 5 6 2 2 1 1 1 1 1 1 3 3 3 1 2 1 8 1 1 1 * NOTE: TORQUE TO 44 FT/LBS.

1 1 1 1 1 2 1 1 2 1 REF 1

DESCRIPTION

HEAT SHIELD, EXHAUST MANIFOLD SCREW SHC M8-1.25 X 30 G12.9

STARTER, 12 VOLT SCREW HHC M6-1.0 X 12 G8.8

WASHER FLAT 1/4-M6 ZINC NUT HEX M10-1.5 G8 YEL CHR SCREW HHC M10-1.5 X 45 G8.8

SPRING BUSHING ALTERNATOR, D.C

BRKT,D.C. ALTERNATOR(MACHINED) SCREW HHC 3/8-16 X 2-1/4 G5 TENSIONER, D.C. ALTERNATOR HOSE,2.5L FORD COOLANT BY PASS CLAMP HOSE #10 .56-1.06

LOWER HOSE ADAPTER,2.5L FORD O-RING 1-3/16 X 1-7/16 X 1/8 SCREW HHC M6-1.0 X 25 G8.8

HOSE OIL DRAIN ASSY 21" HOSE CLAMP BAND 5/8" BARBED STR 3/8NPT X 3/8 ADAPTER M12-1.75 3/8NPT WASHER NYLON .50 X .87 X .06

NUT HEX M6 X 1.0 G8 YEL CHR DIPSTICK TUBE, 2.5L FORD COVER, R/H SIDE ENGINE ADAPTOR COVER, L/H SIDE ENGINE ADAPTOR SCREW SHC M10-1.50 X 50 G12.9

TANK COOLANT RECOVERY HOSE 9/32 ID (39"LG) BRACKET,2.5L FORD WATER BOTTLE WASHER FLAT M6 SS WASHER LOCK M6 SS SCREW HHC M6-1.0 X 12 SS NUT HEX M8-1.25 G8 YEL CHR CLAMP HOSE BAND 1/4 47

48

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Fuel System — Drawing No. 0E9980-D

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Fuel System — Drawing No. 0E9980-D ITEM PART NO.

QTY.

0E8456 075580 0E9967 039253 022145 022129 045771 0F1570 0A6344 0F3994 0E1056 0F0397 0A5547 048031C 0D1509 0E0591 059402 037561 0E1028A 059401 091526 049226 026307 062522 022127 022259 050279 0A6125 0C2454 0E1104 0E0668 0E0590A 0C5133 0E0665 0E1108 033138 022152 0E0645 034339 059194 057823 0F0382 1 2 3 4 5 6 7 8 * 9 10 16 * 17 18 19 20 11 12 13 14 15 21 * 22 * 23 24 25 26 27 28 29 30* 31* 32* 33* 34* 35* 36* 37* 38* 39* 40 41 42 * INCLUDED IN ITEM 19 (CARBURETOR ASSY ) 1 1 1 4 2 6 2 1 1 REF.

1 1 1 2 1 1 1 1 1 1 4 4 1 1 1 2 1 2 3 1 1 1 1 1 1 1 1 1 1 1 2 1

DESCRIPTION

BRACKET FUEL REGULATOR FLANGE FUEL INLET ASSY FUEL REG 2.5L FRD N/G-L/P SCREW HHC M8-1.25 X 20 G8.8

WASHER FLAT 5/16 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 YEL CHR BODY CARBURETOR ASSEMBLY BARBED EL 90 1/8 NPT X 3/8 PCV VALVE 2.5L FORD FUEL HOSE ASSM. NAT. GAS/L.P.V.

HOSE CRANKCASE BREATHER COVER AIR CLEANER CLAMP HOSE BAND 1/4 DECAL INLET PRESSURE ADAPTER CARB. TO AIR CLNR FILTER ELEMENT NUT WING 1/4-20 NYLK CARBURETOR ASSY. 2.5L FORD CARBURETOR GASKET SCREW PPHM M5-0.8 X 12 ZNC WASHER LOCK M5 ELBOW 90D STREET 3/4 STUD TH 1/4-20 X 3 G2 ZNC FULL NUT HEX 1/4-20 STEEL NUT HEX 5/16-18 STEEL DECAL FUEL INLET NG STUD 5/16-18 X 1.25 F THR SCREW TH-FRM M6-1 X 16 N WA Z/JS GASKET, AIR CLEANER ADAPTER O-RING 2-028 1.38 X 1.50 X .06

VENTURI 20MM 0-RING 29.82 X 2.62

SCREW THROTTLE PIN STOP THROTTLE ARM REWORK SCREW HHM #10-32 X 5/8 WASHER LOCK #10 LEVER,THROTTLE STOP BARBED EL 90 3/8 NPT X 5/8 HOSE 5/8 ID LPG & NG (24" LG) CLAMP HOSE #10 .56 - 1.06

HOSE 3/8" 90 DEG 2.5L PVC 49

50

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Alternator — Drawing No. 0E8660-C

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Alternator — Drawing No. 0E8660-C ITEM PART NO.

10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 6 7 8 9 0F1659A 0F1657A 0F1655A 0E5093A 0E7413A 0F1660A 0F1658A 0F1656A 0E5094A 0E7412A 0E5706 0E5048 0E5048A 0E5048B 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 0C3993 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F ROTOR REPLACEMENT PARTS 30 31 047248 070892

QTY.

1 1 1 1 1 1 1 1 1 1 1 REF REF REF 1 1 8 4 4 4 4 1 1 4 4 1 1 4 4 1 1 1 4 1 1

DESCRIPTION

ROTOR 390 15KW 1P DIRECT HSB (2.5L FORD) ROTOR 390 20KW 1P DIRECT HSB (2.5L FORD) ROTOR 390 25KW 1P DIRECT HSB (2.5L FORD) ROTOR 390 30KW 1P DIRECT HSB (3.0L FORD & 2.5L FORD) ROTOR 390 40KW 1P DIRECT HSB (3.9L CHRYSLER) STR 390 15AD HSB (382MM LONG)(2.5L FORD) STR 390 20AD HSB (382MM LONG)(2.5L FORD) STR 390 25AD HSB (382MM LONG)(2.5L FORD) STR 390 35AD1 HSB (382MM LONG)(3.0L FORD & 2.5L FORD) STR 390 40AD HSB (433MM LONG)(3.9L CHRYSLER) REAR BEARING CARRIER 390/DRCT FLEXPLATE 3.0L FORD FLEXPLATE 3.9L HSB FLEXPLATE 2.5L FORD FLYWHEEL ASSY 3.0L HSB LG GEAR REVCOR FAN 10.75 X 2 W/PRESS DIS WASHER LOCK M10 SCREW HHC M10-1.5 X 16 G8.8

STUD M14-2.0 X 490 G5 ZINC (3.0L FORD & 2.5L FORD) STUD M14-2.0 X 540 G5 ZINC (3.9L CHRYSLER) WASHER LOCK M14 NUT HEX M14-2.0 G8 YEL CHR ASSY BRUSH HOLDER 390/HSB WASHER SHAKEPROOF INT #8 SCREW HHTT M4-0.7 X 25 BP SCREW SHC M10-1.5 X 30 G12.9

WASHER FLAT .688 ID X 3.25 OD KEY SQ 3/8 X 1 STEEL SCREW HHC M16-2.0 X 45 G8.8

WASHER LOCK #8-M4 WASHER FLAT #8 ZINC CONDUIT FLEX 1-1/4" (30" LG - 3.0L FORD & 3.9L CHRYSLER) CONDUIT FLEX 1-1/4" (18" LG - 2.5L FORD) BALL BEARING-45 MM SLIP RING -MACHINED 51

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Muffler — Drawing No. 0F2930-C

1 7 6 3 1 9 20 11 17 20 7 6 5 4 5 4 12 24 20 11 1 3 15 6 1 8 15 14 16 9 8

ITEM PART NO.

QTY.

DESCRIPTION

10 11 12 1 2 3 4 5 6 7 8 9 52 0F2912 0F2869 0F2823 036434 036449 022129 022259 0E0170A 044149 0E8816 0F2925 0F2926 1 2 1 1 1 1 2 2 6 4 1 1 PIPE MUFFLER OUT PIPE EXHAUST 2.5L FORD MUFFLER 2.5L FORD BOLT U 5/16-18 X 2.09

SADDLE 2 INCH WASHER LOCK M8-5/16 NUT HEX 5/16-18 STEEL EXHAUST BLANKET 800MM GASKET EXHAUST RING EXHAUST FLANGE 2" PIPE STRAP MUFFLER BRACKET, MUFFLER 2 10 21 22 2 3

ITEM PART NO.

QTY.

DESCRIPTION

13 14 15 16 17 18 19 20 21 22 23 24 042568 022097 022473 049813 039253 045771 0A4010 022145 022131 085917 0D2611 052858 2 2 1 4 4 8 4 2 2 1 5 2 SCREW HHC M6-1.0 X 20 G8.8

WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC NUT HEX M6 X 1.0 G8 YEL CHR SCREW HHC M8-1.25 X 20 G8.8

NUT HEX M8-1.25 G8 YEL CHR SCREW HHC M8-1.25 X 60 G8.8 FT WASHER FLAT 5/16-M8 ZINC WASHER FLAT 3/8-M10 ZINC WASHER LOCK 3/8 SS SCREW HHC 3/8-16 X 1-3/4 SS NUT TOP LOCK FL M8-1.25

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Stepper Motor — Drawing No. 0E9979-C

6 7 10 9 17 TO "A" 11 10 CARBURETOR ARM (REF.) 5 4 3 2 "A" 12 7 6 1 ITEM (13) NEOPRENE COATING 15 14 SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN.

WIRE HARNESS 7 16 INTAKE MANIFOLD (REF.)

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO.

098290 098941A 0F0454 098942A 098225 043146 022097 0E7358 098783 037398 0E1326 0A7106 074031 029333A 022507 022473 064526 0E1694

QTY.

1 1 REF 1 2 3 5 REF 1 2 1 1 AR 1 2 2 1 1

DESCRIPTION

ASM MOTOR STEPPER HOUSING GOVERNOR CONNECTOR HARN GOV 2.5L FORD COVER CONNECTOR HOUSING SCREW PFHST #2 X 5/8 SCREW HHC M6-1.0 X 10 G8.8

WASHER LOCK M6-1/4 SCREW PPPH HI-LO #4-24 X 3/8 LEVER STEPPER MOTOR NUT LOCK HEX #10-32 NYL INS ASSY. CARBURETOR LINKAGE ROD BRACKET STEPPER MOTOR LIQUID NEOPRENE TIE WRAP 7.4"X.19" BLK UL SCREW HHC 1/4-20 X 1/2 G5 WASHER FLAT 1/4 ZINC SCREW TAP HWH #6-25 X 3/8 ZINC SPRING,ANTI LASH 53

6 1 9

Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Radiator — Drawing No. 0E9965-F

1 26 1 8 1 8 25 9 7 12 11 2 5 14 5 9 8 10 5 5 TO THERMO S TAT ADAPTER TO BA S E OF WATER INLET TUBE (ON BLOCK) 7 15 16 17 3 21 20 9 8 10 27 24 24 27 4 2 3 4 5 6 7 8 9 10 11 12 14

ITEM PART NO.

QTY.

DESCRIPTION

1 0E9769 0F0779 0E9769A 0E9837 0F0123 0F0118 099502 0C2454 052250 022097 022473 022127 046627 060035 0F0127 REF REF REF 1 1 1 4 REF.

2 8 12 8 1 4 1 SUPPORT RADIATOR 2.5L FORD SUPPORT RADIATOR 2.5L AL SUPPORT RADIATOR 2.5L FORD ALM RADIATOR 2.5L FORD VENTURI 16" FAN 2.5L FORD GUARD FAN 2.5L FORD CLAMP HOSE #24 B1.06-2.00

SCREW THF M6-1 X 16 N WA Z/JS TAPE FOAM 1 X 1(21" LG) WASHER LOCK M6-1/4 WASHER FLAT 1/4 ZINC NUT HEX 1/4-20 STEEL CAP RADIATOR SPACER .41 X .75 X .87 ST/ZNC HOSE, UPPER RADIATOR 174MM TAL 54

ITEM PART NO.

QTY.

DESCRIPTION

15 16 17 18 19 20 21 24 25 26 27 0E9833 035461 069860C 0A7275 031669 065852 0A2111 0C2454 022287 077992 050275 1 1 1 4 4 1 1 6 4 REF 2 HOSE, 2.5L FORD LOWER RADIATOR BARBED STR 1/4 NPT X 3/8 HOSE OIL DRAIN ASSY 21" FOAM 1.5 X 1 ADHESIVE BACKING (21.5" LG) BOLT CARR 1/4-20 X 1-3/4 JS500 SPRING CLIP HOLDER .37-.62

SCREW SWAGE 10-32 X 5/16 Z/YC SCREW TH-FRM M6-1 X 16 N WA Z/JS SCREW HHC 1/4-20 X 3/4 G5 NUT HEX LOCK M6-1.0 SS NY INS DECAL WARNING-FAN

Section 9 — Installation Diagram Liquid-cooled 15, 20 and 25 kW Generators Installation Diagram — Drawing No. 0F1022-A

55

Section 10 – Warranty Liquid-cooled 15, 20 and 25 kW Generators

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.

* cation or improper maintenance of your engine. In California, new utility, and lawn and garden equipment engines must be designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modifi Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, dur ing such 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 Dealer.

PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:

As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory supplied

Owner’s Manual.

For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.

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

You are responsible for presenting your engine to a Generac Authorized Warranty Service Dealer as soon as a prob lem occurs.

The warranty repairs should be completed 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 Dealer.

To locate the Generac Authorized Warranty Service Dealer 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 California law. See also the “Generac Power Systems, Inc., Two Year Limited Warranty” 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 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 Warranty describe important rights and obligations with respect to your new engine.

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

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the fol lowing address:

ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 WHITEWATER, WI 53190

Part 1

56

Section 10 – Warranty Liquid-cooled 15, 20 and 25 kW Generators

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall con tinue for 24 consecutive months thereafter.

(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or equipment and to each subsequent purchaser/owner that each of its engines is ...

(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority, and (2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a war ranted emissions-related part to fail to be identical in all material respects to the part as described in the engine man ufacturer’s application for certification.

(c) The ECS Warranty only pertains to emissions-related parts on your 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 warranted 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 Warranty shall be warranted for the remainder of the ECS Warranty Period.

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 (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 emissions-related part.

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

(5) When the engine is inspected by a Generac Authorized Warranty Service Dealer, the owner shall not be held responsi ble 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 warranty of any emission-related part covered by the ECS Warranty.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-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 shall not reduce Generac ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.

Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or “grey market” part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System: 1.2) LPG/Natural Gas carburetion assembly and its internal components.

a) Fuel controller (if so equipped) b) Mixer and its gaskets (if so equipped) c) Carburetor and its gaskets (if so equipped) d) Primary gas regulator (if so equipped) e) LP liquid vaporizer (if so equipped) 3) Ignition System including: a) Spark plug b) Ignition module 4) Catalytic Muffler Assembly (if so equipped) including: a) Muffler gasket b) Exhaust manifold 5) Crankcase Breather Assembly including: a) Breather connection tube 2) Air Induction System including: a) Intake pipe/manifold b) Air cleaner * Generac engine types covered by this warranty statement include the following: 1) Prepackaged Standby Generator 2) Auxiliary Power Unit (APU) Generator 3) Standby Generator

Part 2

57

Section 10 – Warranty Liquid-cooled 15, 20 and 25 kW Generators GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR QUIETSOURCE™ "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"

For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Quietsource generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or an Authorized Warranty Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac Quietsource prepackaged emergency automatic standby generators sold and rated for use in "Standby" applications.

WARRANTY SCHEDULE

YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and maintenance is required): Engine - All Components Alternator - All Components Transfer System - All Components All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat Rate Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Quietsource generators that utilize non-Generac replacement parts.

• Quietsource generators utilizing non-Generac automatic transfer switches.

• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by Generac Power Systems.

• Any Quietsource generators used as rental or trailer mounted applications.

• Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist.

• Costs of normal maintenance, adjustments, installation and start-up.

• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Damage related to rodent and/or insect infestation.

• Products that are modified or altered in a manner not authorized by Generac in writing.

• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).

• Failure due to misapplication.

• Telephone, cellular phone, facsimile, internet access or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.

• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.

• Rental equipment used while warranty repairs are being performed.

• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.) • Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

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. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.

This warranty gives you specific legal rights. You also have other rights from state to state.

Part No. 0F1007 P.O. BOX 297 • WHITEWATER, WI 53190 Revision F (07/25/05) Revision (2.05) Printed in U.S.A.

1 2 3 4 5 6 7 8 9 18 19 20 21 10 11 12 13 14 15 16 17 30 31 0F1659A 0F1657A 0F1655A 0E5093A 0E7413A 0F1660A 0F1658A 0F1656A 0E5094A 0E7412A 0E5706 0E5048 0E5048A 0E5048B 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 092980 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F 047248 070892 1 1 1 1 1 1 1 1 1 1 1 REF REF REF 1 1 8 4 4 4 4 4 1 1 4 4 1 1 1 4 4 1 1 ROTOR 390 15KW 1P DIRECT HSB (2.5L FORD) ROTOR 390 20KW 1P DIRECT HSB (2.5L FORD) ROTOR 390 25KW 1P DIRECT HSB (2.5L FORD) ROTOR 390 30KW 1P DIRECT HSB (3.0L FORD & 2.5L FORD) ROTOR 390 40KW 1P DIRECT HSB (3.9L CHRYSLER) STR 390 15AD HSB (382MM LONG)(2.5L FORD) STR 390 20AD HSB (382MM LONG)(2.5L FORD) STR 390 25AD HSB (382MM LONG)(2.5L FORD) STR 390 35AD1 HSB (382MM LONG)(3.0L FORD & 2.5L FORD) STR 390 40AD HSB (433MM LONG)(3.9L CHRYSLER) REAR BEARING CARRIER 390/DRCT FLEXPLATE 3.0L FORD FLEXPLATE 3.9L HSB FLEXPLATE 2.5L FORD FLYWHEEL ASSY 3.0L HSB LG GEAR REVCOR FAN 10.75 X 2 W/PRESS DIS WASHER LOCK M10 SCREW HHC M10-1.5 X 16 G8.8

STUD M14-2.0 X 490 G5 ZINC (3.0L FORD & 2.5L FORD) STUD M14-2.0 X 540 G5 ZINC (3.9L CHRYSLER) WASHER LOCK M14 NUT HEX M14-2.0 G8 YEL CHR ASSY BRUSH HOLDER 390/HSB WASHER SHAKEPROOF INT #8 SCREW PPHM M4-0.7 X 25 SCREW SHC M10-1.5 X 30 G12.9

WASHER FLAT .688 ID X 3.25 OD KEY SQ 3/8 X 1 STEEL SCREW HHC M16-2.0 X 45 G8.8

WASHER LOCK #8-M4 WASHER FLAT #8 ZINC CONDUIT FLEX 1-1/4" (30” LG - 3.0L FORD & 3.9L CHRYSLER) CONDUIT FLEX 1-1/4" (18” LG – 2.5L FORD) ROTOR REPLACEMENT PARTS 1 1 BALL BEARING-45 MM SLIP RING -MACHINED-

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 33 34 35 36 37 25 26 27 28 29 30 31 32 0F1705 0E8834 0E9911 049813 022097 026850 055414 022473 047411 052860 052251 052257 052252 052259 052891 0536210261 074906 077483 0F0796 025507 060619 046526 022131 021991 038805G 050331 050331A 038804J 045771 022129 027482 0F3976 0E9748A 0F0795 0C2454 065852 045764 1 1 1 1 4 2 1 4 4 4 4 4 4 4 4 1 1 REF 3 3 1 1 1 1 1 REF REF 1 REF REF 1 1 1 3 33 1 1 SUPPORT BATTERY TRAY HOLD DOWN BATTERY ASSEMBLY BATTERY TRAY NUT HEX M6 X 1.0 G8 YEL CHR WASHER LOCK M6-1/4 WASHER SHAKEPROOF EXT 1/4 STL LUG SLDLSS #2-#8 X 17/64 CU WASHER FLAT 1/4-M6 ZINC SCREW HHC M6-1.0 X 16 G8.8

NUT FLANGED HEX M12-1.75

DAMPENER VIBRATION 40 BLUE SPACER .49 X .62 X 1.87 PWDR/ZNC DAMPENER VIBRATION WASHER FLAT M12 SCREW HHC M12-1.75 X 80 G8.8

ASSY WIRE #0 12.00" SCREW HHTT M6-1.0 X 20 BP BATT 12VDC 75-AH 26 (NOT SHOWN) BRACKET CONTROL PANEL SUPPORT WASHER SHAKEPROOF EXT 7/16 STL SCREW SHC M10-1.50 X 40 G12.9

WASHER LOCK M10 WASHER FLAT 3/8-M10 ZINC EARTH STRAP CABLE BATT BLK #1 X 41.50

BATTERY POST COVER (BLACK) BATTERY POST COVER (RED) CABLE BATT RED #1 X 40.50

NUT HEX M8-1.25 G8 YEL CHR WASHER LOCK M8-5/16 WASHER SHAKEPROOF EXT 5/16 STL BOOT, CONTACTOR CABLES ASSY MTG BASE 2.5L AL ENCL SUPPORT CONTROL PANEL 2.5L

SCREW THF M6-1 X 16 N WA Z/JS SPRING CLIP HOLDER .37-.62

SCREW HHTT M4-0.7 X 8 BP

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 41 42 43 44 45 33 34 35 36 37 38 39 40 0F0790 0F0789 0F0791 0E9704 067680 0E6875A 0C3910 048468 0D5070A 057073 040213 0C2265 029673 0F0793 0E7890 0D5541* 0D5544** 0F1264 0F1263 0F1262 0E7403A 0E7403C 0E2514 020911 023897 022152 051716 082573 0E4494 0C4167 0C2699 0C2212 047411 022097 022473 0E7358 064733 0F0798A 0E6881 048352 0C1127 0C1229 0F2632 0F2629 0E7193 0F6146 4 4 4 4 2 1 REF 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 18 1 1 1 1 1 1 1 2 1 1 1 2 4 2 2 1 1 REF.

4 1 TOP, CONTROL PANEL BACK & BOTTOM, CONTROL PANEL PANEL, FRONT 2.5L CONTROL PNL ASSY PCB HSB CONTROLLER 2.5L

ASSY VOLTAGE REGULATOR 60HZ RELAY, 12VDC C FORM W/DIODE XFMR 240/16V 1VA&56VA CIRCT BRK 8 X 1 ETA 46-500-P ASSY PCB 2A 12V UL BATT CHRGR JUNCTION BLOCK 3/8-16 PCB SUPPORT SNAP-IN 1/4" SCREW PHTT M4-0.7 X 12 ZYC DIO BRIDGE 25A 600V BRACKET, CB SIEMENS BQ BRKT CB MTG BACK CB 0070A 2P 240V S BQ2 LL CB 0100A 2P 240V S BQ2 LL ADPTR,LH SIDE WICKMAN 178.6192

ADPTR,RH SIDE WICKMAN 178.6191

HOLDER, FUSE WICKMANN 178.6150

FUSE ATO TYPE 5 AMP (TAN) FUSE, ATO TYPE 15 AMP (BLUE) FITTING CONDUIT STR 1-1/2" SCREW PPHM M5-0.8 X 30 ZINC WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX M5-0.8 G8 YEL CHR SWITCH ROC DPST 125V SPD SWITCH ROC DPDT ON-OFF-ON BLOCK TERM 20A 14 X 6 X 1100V SCREW PHTT #6-32 X 3/8 ZYC SCREW PHTT M4-0.7 X 16 ZYC SCREW HHC M6-1.0 X 16 G8.8

WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW PPPH HI-LO #4-24 X 3/8 RES MTG BRACKET HARNESS, C-PNL 2.5L QS 15&20KW (NOT SHOWN) SOCKET, RELAY RES 5R 5% 25W DECAL AVR COVER DECAL WARNING ELECTRICAL SHOCK DECAL TERMINAL BLOCK DECAL CONTROL HSB DECAL, WARNINGS HSB HANG TAG 2 WIRE START (NOT SHOWN) * 15KW ** 20KW

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 0F0783 0F0781 0F0780 0C2454 0F0779 0E0072AB 0E0072AC 0E0072AD 0E5912 0F0787 089961 0A2115 0E0072AE 0F0165A 0F0165 022097 022473 0E7570 0E7571 070015 0E7662 0F0164A 0F0164 0D2023 078115 0F2179 0F0788 0E7829B 0D3037A 0C7781 0F0786 0E0072Q 0D3037 0E0072Y 0E0072AF 0E0072AA 0F0782 026850 0912970064 0912970063 049813 0F0784 0F0785 0E8665 0E8837 0A3359 0E8404 1 1 1 1 1 4 2 2 10 1 1 1 1 1 1 1 1 1 34 1 1 1 1 2 1 2 4 1 1 1 13 13 2 4 4 4 1 1 3 8 1 1 2 1 2 1 2 DUCT INTAKE MID AL 2.5L

DUCT DISCHARGE RH AL 2.5L

DUCT DISCHARGE LH AL 2.5L

SCREW TH-FRM M6-1 X 16 N WA Z/JS SUPPORT RADIATOR 2.5L AL AI INSULATION SIDE REAR CORNER POST RH AI INSULATION INTAKE DUCT TOP PANEL AI INSULATION LH SIDE REAR CORNER POST PANEL (BOTTOM) DOOR SIDE HSB AL SUPPORT RH SIDE AL 2.5L

FOAM STRIP 3/4" WIDE X 3/16" THK (40” LG) WASHER NYLON .257

AI NSULATION LH SIDE REAR CORNER POST PANEL (TOP) HINGE TYPE B W/STUDS, SOCKET HINGE TYPE B W/STUDS, PIN WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC GAS SPRING BALL STUD GAS SPRING MOUNT NUT HEX 5/16-18 LOCK SCREW WING M6-1.00 X 25 HINGE TYPE A W/STUDS, SOCKET HINGE TYPE A W/STUDS, PIN GASKET CLIP-ON SELF GRIPPING (84” LG) WASHER SELF LOCKING DOME KIT SAE FOAM 2.5L QUIET SOURCE ROOF 2.5L FORD AL AI DOOR PANEL LATCH 1/4 TURN NONLOCKING PAWL DOOR HSB SUPPORT LH SIDE AL 2.5L

AI INSULATION RAD SUPPORT PANEL LATCH QUARTER TURN LOCKING AI INSULATION SIDE BRACE PANEL RH AI INSULATION SIDE BRACE PANEL LH AI INSULATION ROOF PANEL DUCT DISCHARGE MID AL 2.5L

WASHER SHAKEPROOF EXT 1/4 STL ASSY WIRE 14AWG 7.5 #0 GRN/YEL ASSY WIRE 14AWG 7.5 #0 GRN/YEL NUT HEX M6 X 1.0 G8 YEL CHR CORNER POST REAR LH SIDE AL CORNER POST REAR RH SIDE AL BRACKET STIFFENER LH FRONT DOOR BATTERY COMPARTMENT SCREW BHSC M6-1.0 X 16 SS BRACKET STIFFENER RH FRONT * ALL ITEMS NOTATED WITH “AI” ARE COMPONENTS OF 0F2179

1 2 3 4 5 6 7 8 * 9 10 11 12 13 14 15 16 * 33* 34* 35* 36* 37* 38* 39* 40 41 42 17 18 19 20 21 * 22 * 23 24 25 26 27 28 29 30* 31* 32* 0E8456 075580 0E9967 039253 022145 022129 045771 0F1570 0A6344 0F3994 0E1056 0F0397 0A5547 048031C 0D1509 0E0591 059402 037561 0E1028A 059401 091526 049226 026307 062522 022127 022259 050279 0A6125 0C2454 0E1104 0E0668 0E0590A 0C5133 0E0665 0E1108 033138 022152 0E0645 034339 059193D 057823 0F0382 1 1 1 4 2 6 2 1 1 REF.

1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 4 4 1 1 1 2 1 2 3 1 1 1 BRACKET FUEL REGULATOR FLANGE FUEL INLET ASSY FUEL REG 2.5L FRD N/G-L/P SCREW HHC M8-1.25 X 20 G8.8

WASHER FLAT 5/16 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 YEL CHR BODY CARBURETOR ASSEMBLY BARBED EL 90 1/8 NPT X 3/8 PCV VALVE 2.5L FORD FUEL HOSE ASSM. NAT. GAS/L.P.V.

HOSE CRANKCASE BREATHER COVER AIR CLEANER CLAMP HOSE BAND 1/4 DECAL INLET PRESSURE ADAPTER CARB. TO AIR CLNR FILTER ELEMENT NUT WING 1/4-20 NYLK CARBURETOR ASSY. 2.5L FORD CARBURETOR GASKET SCREW PPHM M5-0.8 X 12 ZNC WASHER LOCK M5 ELBOW 90D STREET 3/4 STUD TH 1/4-20 X 3 G2 ZNC FULL NUT HEX 1/4-20 STEEL NUT HEX 5/16-18 STEEL DECAL FUEL INLET NG STUD 5/16-18 X 1.25 F THR SCREW TH-FRM M6-1 X 16 N WA Z/JS GASKET, AIR CLEANER ADAPTER O-RING 2-028 1.38 X 1.50 X .06

VENTURI 20MM 0-RING 29.82 X 2.62

SCREW THROTTLE PIN STOP THROTTLE ARM REWORK SCREW HHM #10-32 X 5/8 WASHER LOCK #10 LEVER,THROTTLE STOP BARBED EL 90 3/8 NPT X 5/8 HOSE 5/8 ID X 20.5" LG CLAMP HOSE #10 .56 - 1.06

HOSE 3/8" 90 DEG 2.5L PVC * INCLUDED IN ITEM 19 (CARBURETOR ASSY )

12 13 14 15 9 10 11 1 2 3 4 5 6 7 8 0E9909 0E9739 049814 0F0001 0D3488B 0A8584 0E2507 0A6751 035579 026925 0E9611 0E9611A 0E9681 039253 097962 022145 REF 1 8 1 1 1 1 1 1 1 1 1 1 4 4 8 ENGINE 2.5L FORD PULLEY, 2.5L FORD WATER PUMP SCREW HHC M10-1.5 X 25 G8.8

CLUTCH, COOLING FAN 2.5L FORD SERPENTINE BELT – 40.85” LENGTH SWITCH,OIL PRESSURE,10PSI,2POL PROBE, COOLANT LEVEL 3/8NPTF SW-TMP 245DEG 3/8NPT BUSHING REDUCER 1/4 TO 1/8 PLUG STD PIPE 3/8 STEEL SQ HD MANIFOLD, INTAKE (MACHINED) (STEPPER MOTOR) MANIFOLD INTAKE MACH BOSCH32 (BOSCH GOV.) (NOT SHOWN) GASKET, 2.5L FORD INTAKE MAN.

SCREW HHC M8-1.25 X 20 G8.8

SCREW SHC M6-1.0 X 25 G12.9 ZP WASHER FLAT 5/16-M8 ZINC 16 17 18 19 20 21 22 23 24 25 26 59 60 61* 62 63 64 65 66 67 68 69 70 71 72 73 74** 75 76 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 022097 022129 043107 022131 046526 052625 0E9708 0E9738 0E9929 0F0230 0E9834 0E9834A 0D5417 0E5048B 0E9655 057192 060619 0E8940 0E9680 0E9609 0E9930 049821 0E9747 047411 022473 045772 064416 0F0252 0E9868 0F0035 026082 0E9928 0F0383 035473 0E9737 0F0393 045757 069860C 048031J 043790 077456 052677 049813 0E9738A 0F1132 0F1133 059355 076749 029032 0F1433 084929 083896 085296 045771 048031C 077043A 042568 039253 025507 056739 0F6749 0F9483 11 18 10 13 23 2 2 1 1 1 1 1 6 1 1 4 2 1 1 1 1 3 1 4 8 2 2 1 1 1 1 1 1 2 1 1 2 1 REF 1 1 1 1 1 1 1 8 1 1 1 3 3 3 1 REF 1 1 1 2 1 1 1 WASHER LOCK M6-1/4 WASHER LOCK M8-5/16 SCREW HHC M8-1.25 X 25 G8.8

WASHER FLAT 3/8-M10 ZINC WASHER LOCK M10 SCREW SHC M10-1.5 X 35 G12.9

ENGINE FOOT, 2.5L FORD DIPSTICK, 2.5L FORD BRACKET, DIPSTICK TUBE FAN 16" COOLING HARNESS, 2.5L FORD ENGINE (NOT SHOWN) HARNESS,2.5L FORD (BOSCH GOV.) (NOT SHOWN) SCREW HHC M10-1.0 X 25 G10.9

FLEXPLATE 2.5L FORD ADAPT CASTING MACH 2.5L FORD SCREW SHC M10-1.5 X 30 G12.9

SCREW SHC M10-1.50 X 40 G12.9

SPACER FLEXPLATE HSB GASKET, 2.5L FORD EXHAUST MAN.

MANIFOLD, EXHAUST ( MACHINED) HEAT SHIELD, EXHAUST MANIFOLD SCREW SHC M8-1.25 X 30 G12.9

STARTER, 12 VOLT SCREW HHC M6-1.0 X 16 G8.8

WASHER FLAT 1/4-M6 ZINC NUT HEX M10-1.5 G8 YEL CHR SCREW HHC M10-1.5 X 45 G8.8

SPRING BUSHING ALTERNATOR, D.C

BRKT,D.C. ALTERNATOR(MACHINED) SCREW HHC 3/8-16 X 2-1/4 G5 TENSIONER, D.C. ALTERNATOR HOSE,2.5L FORD COOLANT BY-PASS CLAMP HOSE #12 .50-1.25

LOWER HOSE ADAPTER,2.5L FORD O-RING 1-3/16 X 1-7/16 X 1/8 SCREW HHC M6-1.0 X 25 G8.8

HOSE OIL DRAIN ASSY 21" HOSE CLAMP BAND 5/8" BARBED EL 90 3/8 NPT X 3/8 ADAPTER M12-1.75 3/8NPT WASHER NYLON .50 X .87 X .06

NUT HEX M6 X 1.0 G8 YEL CHR DIPSTICK TUBE, 2.5L FORD COVER, R/H SIDE ENGINE ADAPTOR COVER, L/H SIDE ENGINE ADAPTOR SCREW SHC M10-1.50 X 50 G12.9

TANK COOLANT RECOVERY HOSE 9/32 ID (39”LG) BRACKET,2.5L FORD WATER BOTTLE WASHER FLAT 1/4 SS WASHER LOCK 1/4-M6 SS SCREW HHC 1/4-20 X 1/2 SS NUT HEX M8-1.25 G8 YEL CHR CLAMP HOSE BAND 1/4 CONDUIT FLEX .38"ID (6”LG) SCREW HHC M6-1.0 X 20 G8.8

SCREW HHC M8-1.25 X 20 G8.8

WASHER SHAKEPROOF EXT 7/16 STL RELAY SOLENOID 12VDC PNL MNT ADAPTER 3/8 TO 3/8 BRASS ASSY PCB WATERLEVEL SNSR INTFC * NOTE: TORQUE TO 44 FT/LBS.

** NOT SHOWN

33 34 35 37 38 39 40 41 42 43 44 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 0F0790 0F0789 0F0791 0E9704 067680 0E6875A 0C3910 054450 0D5070A 057073 040213 0C2265 029673 0F0793 0E7890 0A2077 0F1264 0F1263 0F1262 0E7403A 0E7403C 0E2514 020911 023897 022152 051716 082573 0E4494 0C4167 0C2699 0C2212 047411 022097 022473 0E7358 0F0798 0E6881 0C1127 0C1229 0F2632 0F2629 0E7193 0F6146 4 4 4 1 REF 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 16 1 1 1 1 1 1 2 1 1 1 2 4 2 2 1 1 REF.

4 1 4 TOP, CONTROL PANEL BACK & BOTTOM, CONTROL PANEL PANEL, FRONT 2.5L CONTROL PNL ASSY PCB HSB CONTROLLER 2.5L

ASSY VOLTAGE REGULATOR 60HZ RELAY, 12VDC C FORM W/DIODE XFMR 240/16V 1VA&56VA CIRCT BRK 5.5 X 1 ETA 46-500-P ASSY PCB 2A 12V UL BATT CHRGR JUNCTION BLOCK 3/8-16 PCB SUPPORT SNAP-IN 1/4" SCREW PHTT M4-0.7 X 12 ZYC DIO BRIDGE 25A 600V BRACKET, CB SIEMENS BQ BRKT CB MTG BACK CB 0125A 2P 240V S BQ2 LL ADPTR,LH SIDE WICKMAN 178.6192

ADPTR,RH SIDE WICKMAN 178.6191

HOLDER, FUSE WICKMANN 178.6150

FUSE ATO TYPE 5 AMP (TAN) FUSE, ATO TYPE 15 AMP (BLUE) FITTING CONDUIT STR 1-1/2" SCREW PPHM M5-0.8 X 30 ZINC WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX M5-0.8 G8 YEL CHR SWITCH ROC DPST 125V SPD SWITCH ROC DPDT ON-OFF-ON BLOCK TERM 20A 14 X 6 X 1100V SCREW PHTT #6-32 X 3/8 ZYC SCREW PHTT M4-0.7 X 16 ZYC SCREW HHC M6-1.0 X 16 G8.8

WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW PPPH HI-LO #4-24 X 3/8 HARNESS CTRL PNL 2.5L FORD AL (NOT SHOWN) SOCKET, RELAY DECAL AVR COVER DECAL WARNING ELECTRICAL SHOCK DECAL TERMINAL BLOCK DECAL CONTROL HSB DECAL, WARNINGS HSB HANG TAG 2 WIRE START (NOT SHOWN)

1 19 20 21 24 25 26 27 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 0E9769 0F0779 0E9769A 0E9837 0F0123 0F0118 099502 0C2454 052250 022097 022473 022127 046627 060035 0F0127 0E9833 035461 069860C 0A7275 031669 065852 0A2111 0C2454 022287 077992 050275 1 1 4 4 1 1 6 4 REF 2 REF REF REF 1 1 1 4 REF.

2 8 12 8 1 4 1 1 SUPPORT RADIATOR 2.5L FORD SUPPORT RADIATOR 2.5L AL SUPPORT RADIATOR 2.5L FORD ALM RADIATOR 2.5L FORD VENTURI 16" FAN 2.5L FORD GUARD FAN 2.5L FORD CLAMP HOSE #24 B1.06-2.00

SCREW THF M6-1 X 16 N WA Z/JS TAPE FOAM 1 X 1(21” LG) WASHER LOCK M6-1/4 WASHER FLAT 1/4 ZINC NUT HEX 1/4-20 STEEL CAP RADIATOR SPACER .41 X .75 X .87 ST/ZNC HOSE, UPPER RADIATOR 174MM TAL HOSE, 2.5L FORD LOWER RADIATOR BARBED STR 1/4 NPT X 3/8 HOSE OIL DRAIN ASSY 21" FOAM 1.5 X 1 ADHESIVE BACKING (21.5” LG) BOLT CARR 1/4-20 X 1-3/4 JS500 SPRING CLIP HOLDER .37-.62

SCREW SWAGE 10-32 X 5/16 Z/YC SCREW TH-FRM M6-1 X 16 N WA Z/JS SCREW HHC 1/4-20 X 3/4 G5 NUT HEX LOCK M6-1.0 SS NY INS DECAL WARNING-FAN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 098290 098941A 0F0454 098942A 098225 043146 022097 0E7358 098783 037398 0E1326 0A7106 074031 029333A 022507 022473 064526 0E1694 1 1 REF 1 2 3 5 REF 1 2 1 1 AR 1 2 5 1 1 ASM MOTOR STEPPER HOUSING GOVERNOR CONNECTOR HARN GOV 2.5L FORD COVER CONNECTOR HOUSING SCREW PFHST #2 X 5/8 SCREW HHC M6-1.0 X 10 G8.8

WASHER LOCK M6-1/4 SCREW PPPH HI-LO #4-24 X 3/8 LEVER STEPPER MOTOR NUT LOCK HEX #10-32 NYL INS ASSY. CARBURETOR LINKAGE ROD BRACKET STEPPER MOTOR LIQUID NEOPRENE TIE WRAP 7.4"X.19" BLK UL SCREW HHC 1/4-20 X 1/2 G5 WASHER FLAT 1/4 ZINC SCREW TAP HWH #6-25 X 3/8 ZINC SPRING,ANTI LASH

17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0F2912 0F2869 0F2823 036434 036449 022129 022259 0E0170A 044149 0E8816 0F2925 0F2926 042568 022097 022473 049813 039253 045771 0A4010 022145 022131 085917 0D2611 052858 2 2 1 5 2 2 2 1 1 1 1 2 2 6 4 1 1 1 2 1 4 4 8 4 PIPE MUFFLER OUT PIPE EXHAUST 2.5L FORD MUFFLER 2.5L FORD BOLT U 5/16-18 X 2.09

SADDLE 2 INCH WASHER LOCK M8-5/16 NUT HEX 5/16-18 STEEL EXHAUST BLANKET 800MM GASKET EXHAUST RING EXHAUST FLANGE 2" PIPE STRAP MUFFLER BRACKET, MUFFLER SCREW HHC M6-1.0 X 20 G8.8

WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC NUT HEX M6 X 1.0 G8 YEL CHR SCREW HHC M8-1.25 X 20 G8.8

NUT HEX M8-1.25 G8 YEL CHR SCREW HHC M8-1.25 X 60 G8.8 FT WASHER FLAT 5/16-M8 ZINC WASHER FLAT 3/8-M10 ZINC WASHER LOCK 3/8 SS SCREW HHC 3/8-16 X 1-3/4 SS NUT TOP LOCK FL M8-1.25

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