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Serial Number
STANDBY GENERATOR
OWNER'S MANUAL
QT
2.4L
45kW
Model: 005261-0
A new standard of reliability
—
CAUTION
—
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
. 0G0201 t No Par
This manual should remain with the unit.
v. 0 02/06 Cover043 Re
SECTION PAGE
SAFETY RULES ................................................
1-1
INTRODUCTION .....................................................1-3
Read this Manual Thoroughly ...................................1-3
Operation and Maintenance ......................................1-3
How to Obtain Service ..............................................1-3
IDENTIFICATION RECORD .....................................2-1
EQUIPMENT DESCRIPTION ...................................3-1
Equipment Description ................................................3-1
Engine Oil Recommendations ......................................3-1
Coolant Recommendations...........................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
High Coolant Temperature Switch ............................4-1
Low Coolant Level Sensor .........................................4-1
Low Oil Pressure Switch ...........................................4-1
RPM Sensor Loss Shutdown .....................................4-1
FUEL SYSTEMS .....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP Fuel System .........................................................5-1
SPECIFICATIONS ...................................................6-1
Engine.......................................................................6-1
Cold Weather Kit .......................................................6-2
Reconfiguring the Fuel System ..................................6-2
GENERAL INFORMATION .......................................7-1
Generator AC Lead Connections ..................................7-1
Alternator Power Winding Connections ........................7-1
INSTALLATION .......................................................8-1
Installation ...................................................................8-1
Preparation Before Start-up .........................................8-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Standby Generator Sets
Table of Contents
OPERATION ...........................................................9-1
Generator Control and Operation ................................9-1
Operating Unit with Manual Transfer Switch ...............9-1
Engine Start-up and Transfer ...................................9-1
Retransfer and Shutdown .........................................9-1
Operating Unit with Automatic Transfer Switch ...........9-1
MAINTENANCE .....................................................10-1
Maintenance Performed by Authorized
Service Facilities .....................................................10-1
Every Three Months ...............................................10-1
Once Every Six Months ...........................................10-1
First 100 Operating Hours ......................................10-1
Every 500 Operating Hours ....................................10-1
Every 800 Operating Hours ....................................10-1
Exhaust Manifold Procedure ......................................10-1
Intake Manifold Procedure .........................................10-1
Cylinder Head Procedure ...........................................10-1
Cooling System ..........................................................10-2
Overload Protection for Engine DC
Electrical System ....................................................10-2
Checking Fluid Levels ................................................10-2
Check Engine Oil ....................................................10-2
Maintenance Owner/Operator Can Perform ................10-3
Check Engine Oil Level ...........................................10-3
Inspect Cooling System ...........................................10-3
Check Engine Coolant Level....................................10-3
Perform Visual Inspection .......................................10-3
Inspect Exhaust System ..........................................10-3
Check Fan Belt ........................................................10-3
Inspect Engine Governor ........................................10-3
Changing Engine Oil ...............................................10-3
Changing the Engine Air Cleaner ............................10-3
Miscellaneous Maintenance ........................................10-4
Cleaning the Generator ...........................................10-4
Initial Inspection for QT Genset Start-up .....................8-1
Start-up Checklist ........................................................8-2
Preparation for Start-up............................................8-2
SERVICE SCHEDULE ...........................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide ...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
WARRANTY
0 09/05 Content004 Rev.
Stationary Emergency Generator
Important Safety Instructions
INTRODUCTION
Thank you for purchasing this model of the Stationary
Emergency Generator set product line.
Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing procedures.
Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed 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 personal 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 compliance 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 information that, if not followed, could endanger personal safety and/or property of others.
This symbol points out potential explosion hazard.
1-1
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 recommends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by an Authorized
Service Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.
Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum. See an Authorized Service
Dealer for service aids and accessories.
Operating instructions presented in this manual assume that the generator electric system has been installed by an Authorized Service Dealer or other competent, qualified contractor. Installation of this equipment is not a “do-it-yourself” project.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, simply contact an Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs.
When contacting an Authorized Service Dealer or the factory about parts and service, always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit.
AUTHORIZED SERVICE DEALER LOCATION
To locate the nearest AUTHORIZED
SERVICE DEALER, please call this number:
1-800-333-1322
or locate us on the web at:
www.generac.com
v. B 10/08 Safety 001 Re
Stationary Emergency Generator
Important Safety Instructions
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all
operators, potential operators, and service and repair technicians for this equipment.
WARNING:
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
WARNING:
This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit.
The generator 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 fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all inclusive. If a procedure, work method or operating technique is used that the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the generator unsafe.
DANGER
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 maintain this equipment.
Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.
Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.
GENERAL HAZARDS
• For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by 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 regulations.
• 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 serviced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations.
• The engine exhaust fumes contain carbon 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.
This should be considered prior to installing the generator. The unit should be positioned to direct exhaust gasses safely away from any building where people, animals, etc., will not be harmed.
Any exhaust stacks that ship loose with the unit must be installed properly per the manufacturer's instruction, and in strict compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air is critical in any room or building housing the generator to prevent buildup of explosive gases and to ensure correct generator operation.
Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator.
• Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous.
• When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.
• Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts.
v. B 10/08 Safety 001 Re
1-2
Stationary Emergency Generator
Important Safety Instructions
• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.
• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.
ELECTRICAL HAZARDS
• All Stationary Emergency Generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the generator.
Avoid contact with bare wires, terminals, connections, etc., on the generator as well as the transfer switch, if applicable. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while 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 platform. Work on the equipment only while standing on such insulative mats.
• The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator or by static electricity. Never disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and cord sets must be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.
• Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are positively turned off at their source.
Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating. Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy.
1-3
• Stationary Emergency Generators installed with an automatic transfer switch will crank and start automatically when normal (utility) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, disable the generator’s automatic start circuit (battery cables, etc.) before working on or around the unit. Then, place a “Do
Not Operate” tag on the generator control panel and on the transfer switch.
• In case of accident caused by electric shock, immediately shut down the source of electrical power.
If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.
FIRE HAZARDS
• Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department.
EXPLOSION HAZARDS
• Properly ventilate any room or building housing the generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
• These generators may operate using one of several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the unit’s fuel system frequently and correct any leaks immediately. Fuel supply lines must be properly installed, purged and leak tested according to applicable fuel-gas codes before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids such as natural gas and liquid propane
(LP) gas are extremely EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air; install leak detectors accordingly.
v. B 10/08 Safety 001 Re
Stationary Emergency Generator
General Information
IDENTIFICATION RECORD
DATA LABEL
Every generator set has a DATA LABEL that contains important information pertinent to the generator. The data label, which can be found attached to the generator’s lower connection box, lists the unit’s serial number and its rated voltage, amps, wattage capacity, phase, frequency, rpm, power factor, production date, etc.
NOTE:
For actual information related to this particular model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data label affixed to the unit.
Stationary Emergency Generator Model and
Serial Number
This number is the key to numerous engineering and manufacturing details pertaining to your unit. Always supply this number when requesting service, ordering parts or seeking information.
Data Label
GENERATOR SET DATA
MADE IN USA
MODEL
RATED KW
RATED VOLTAGE
POWER FACTOR
SERIAL
RATED KVA
HERTZ
RATED AMPS
ENGINE RPM PRODUCTION DATE
ALTERNATOR SUBTRANSIENT REACTANCE
PHASE
ALT RPM
ALTERNATOR TRANSIENT REACTANCE
CLASS ROTOR STATOR WINDING INSULATION AT 25 ° C AMBIENT
GENERAC POWER SYSTEMS, INC.
WAUKESHA, WI
C 01/09 Identy 002 Rev.
2-1
Stationary Emergency Generator
Equipment Description
EQUIPMENT DESCRIPTION
This equipment is a revolving field, alternating current Stationary Emergency Generator. It is powered by a gaseous fueled engine operating at 1800 rpm for
4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers. The unit comes complete with a sound attenuated enclosure, internally mounted muffler, control console, mainline circuit breaker, battery charger, and protective alarms as explained in the following paragraph.
All AC connections, including the power leads from the alternator, 120 volt battery charger input and control connections to the transfer switch are available in the main connection box.
The Stationary Emergency Generator incorporates the following alternator features:
• Rotor and Stator insulation is Class H rated as defined by NEMA MG1-32.6, NEMA MG1-1.66.
The generator is self ventilated and drip-proof constructed.
• The voltage waveform deviation, total harmonic content of the AC waveform and telephone influence factor have been evaluated and are acceptable according to NEMA MG1-32.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 5W-20 engine oil at the factory. Use a high-quality detergent oil classified “For
Service SJ or SH.” Detergent oils keep the engine cleaner and reduce carbon deposits. When changing the engine oil, be sure to use 5W-30 engine oil.
Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure.
NOTE:
For temperatures below 32° F, it is strongly recommended to use the optional Cold Weather Start Kit
(part number listed in the Specification Section).
The oil grade for temperatures below 32° F is 5W-
30 synthetic oil.
COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol base anti-freeze and deionized water. Cooling system capacity is listed in the specifications. Use only deionized water and only low silicate anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture.
Do not use any chromate base rust inhibitor with ethylene glycol base anti-freeze or chromium hydroxide (“green slime”) forms and will cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high silicate anti-freeze boosters or additives will also cause overheating. The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment.
DANGER
Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result.
Ethylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the radiator, recovery bottle or any container. Wash hands thoroughly after handling. Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them.
D 10/08 Equip001 Rev.
3-1
Stationary Emergency Generator
Engine Protective Devices
ENGINE PROTECTIVE DEVICES
The Stationary Emergency Generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low, the coolant temperature is too high, the coolant level is too low, or the engine is running too fast.
NOTE:
Engine protective switches and sensors are mentioned here for the reader’s convenience. Also refer to the applicable control panel manual for additional automatic engine shutdown information.
HIGH COOLANT TEMPERATURE SWITCH
The switch will close if the temperature should exceed approximately 140° C (284° F), initiating an engine shutdown. The generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level.
LOW COOLANT LEVEL SENSOR
To prevent overheating, the engine has a low coolant level sensor. If the level of engine coolant drops below the level of the low coolant level sensor, the engine automatically shuts down.
LOW OIL PRESSURE SWITCH
This switch has normally closed contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure drop below the 8 psi range, switch contacts close, and the engine shuts down. The unit should not be restarted until oil is added, and the AUTO/OFF/MANUAL switch must be turned to OFF and then back to AUTO.
OVERCRANK SHUTDOWN
After a prespecified duration of cranking, this function ends the cranking if the engine has failed to start. The overcrank LED will turn ON. Turn OFF the
AUTO/OFF/MANUAL switch, then turn switch back to
AUTO to reset the generator control board.
NOTE:
If the fault is not corrected, the overcrank feature will continue to activate.
Approximate Crank Cycle Times
• 15 seconds ON
• 7 seconds OFF
• 7 seconds ON
• 7 seconds OFF
• Repeat for 45 seconds
Approximately 90 seconds total.
OVERSPEED SHUTDOWN
A speed circuit controls engine cranking, start-up, operation and shutdown. Engine speed signals are delivered to the circuit board whenever the unit is running. Should the engine overspeed above a safe, preset value, the circuit board initiates an automatic engine shutdown. Contact the nearest Authorized
Dealer if this failure occurs.
RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine shutdown will occur.
DC FUSES
Fuse F1 (15 amp) is located inside of the control panel. It protects the panel wiring and components from damaging overload. Always remove this fuse before commencing work on the generator.
The unit will not start or crank if the fuse is blown.
Fuse F2 (25 amp) is located in the engine wire harness adjacent to the DC alternator. It is used to prevent circuit failure due to DC alternator falure. If this fuse is blown, battery charging will not occur while the engine is running. Replace these fuses with the same size, type, and rating. (See the exploded views and parts lists at the end of this manual for replacement part number.)
B 09/08 EngProt001 Rev.
4-1
Stationary Emergency Generator
Fuel Systems
FUEL SYSTEM
FUEL REQUIREMENTS
The Stationary Emergency Generator may be equipped with one of the following fuel systems:
• Natural gas fuel system
• Propane vapor (PV) fuel system
The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the unit.
Recommended fuels should have a Btu content of at least 1,000 Btu's per cubic foot for natural gas; or at least 2,520 Btu's per cubic foot for LP gas. Ask the fuel supplier for the Btu content of the fuel.
Required fuel pressure for natural gas is 5 inches to 14 inches water column (0.18 to 0.5 psi); and for liquid propane, 5 inches to 14 inches of water column (0.18 to 0.5 psi).
NOTE:
Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below five inches water column for natural gas or 5 inches water column for propane vapor for all load ranges.
NOTE:
It is the responsibility of the installer to make sure that only the correct recommended fuel is supplied to the generator fuel system. Thereafter, the owner/operator must make certain that only the proper fuel is supplied.
NATURAL GAS FUEL SYSTEM
Natural gas is supplied in its vapor state. In most cases, the gas distribution company provides piping from the main gas distribution line to the standby generator site. The following information applies to natural gas fuel systems.
• Gas pressure in a building is usually regulated by national, state and local codes.
• To reduce gas pressure to a safe level before the gas enters a building, a primary regulator is needed. The natural gas supplier may or may not supply such a regulator.
• It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator.
• Gas pressure at the inlet to the fuel shutoff solenoid should not exceed approximately 14 inches water column (0.5 psi). Optimum pressure at the fuel shutoff solenoid is 11 inches water column
(0.4 psi).
5-1
PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
This type of system utilizes the vapors formed above the liquid fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state. The vapor withdrawal system is generally best suited for smaller engines that require less fuel. The installer should be aware of the following:
• When ambient temperatures are low and engine fuel consumption is high, the vapor withdrawal system may not function efficiently.
• Ambient temperatures around the supply tank must be high enough to sustain adequate vaporization, or the system will not deliver the needed fuel volume.
• In addition to the cooling effects of ambient air, the vaporization process itself provides an additional cooling effect.
LP LIQUID FUEL SYSTEM
LP is supplied as a liquid in pressure tanks. It is usually made up of propane, butane, or a mixture of the two gases. Propane tends to vaporize readily even at temperatures as low as -20° F (-29° C). However, butane reverts to its liquid state when temperatures drop below 32° F (0° C).
LP in a liquid withdrawal system must be converted to its gaseous state before it is introduced into the engine carburetor. A vaporizer-converter is generally used to accomplish this. In such a converter, heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state.
B 09/08 FuelSys001 Rev.
Standby Generator Sets
Specifications
SPECIFICATIONS
GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ................................................................... Class H
Stator Insulation .................................................................. Class H
Total Harmonic Distortion ..........................................................<5%
Telephone Interference Factor (TIF) ..........................................< 50
Alternator Output Leads 3-phase ........................................... 4-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) ............................................45kW*
*
NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural gas.
Excitation System ....................................................................Direct
Generator Output Voltage/kW - 60 Hz kW Amp CB Size
120/240V, 1-phase, 1.0 pf 45 188 200
120/208V, 3-phase, 0.8 pf
277/480V, 3-phase, 0.8 pf
45 156 175
45 68 80
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208, 3-phase ............................................ 80 KVA
480V, 3-phase .................................................................. 100 KVA
ENGINE
Make ................................................................................... Generac
Model ..................................................................................... In Line
Cylinders and Arrangement ............................................................ 4
Displacement ....................................................................... 2.4 Liter
Bore ...................................................................................... 3.41 in.
Stroke ................................................................................... 3.94 in.
Compression Ratio ...............................................................8.5-to-1
Air Intake System ...............................................Naturally Aspirated
Valve Seats ....................................................................... Hardened
Lifter Type .......................................................................... Hydraulic
Engine Parameters
Rated Synchronous RPM ..............................................60 Hz, 3600
HP at rated kW ..................................................................60 Hz, 71
Exhaust System
Exhaust Flow at Rated Output 60 Hz .................................. 429 cfm
Exhaust Temperature at Rated Output ................................ 1150° F
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz ................................................. 144 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation ......................................................± 0.25%
Engine Lubrication System
Type of Oil Pump ...................................................................... Gear
Oil Filter ............................................... Full Flow Spin-on, Cartridge
Crankcase Oil Capacity ....................................................4 U.S. qts.
6-1
COOLING SYSTEM
Type ...................................................Pressurized Closed Recovery
Water Pump .................................................................... Belt Driven
Fan Speed .........................................................................2150 rpm
Fan Diameter .....................................................................22 inches
Fan Mode ................................................................................ Puller
Air Flow (inlet air including alternator and
combustion air) ...........................................................4500 ft 3 /min.
Coolant Capacity ........................................................ (3.0 U.S. gal.)
Heat Rejection to Coolant ..........................................173,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature ................................50° C (140° F)
FUEL SYSTEM
Type of Fuel ......................................... Natural Gas, Propane Vapor
Carburetor ...................................................................... Down Draft
Secondary Fuel Regulator .................................................Standard
Fuel Shut-off Solenoid ........................................................Standard
Operating Fuel Pressure ...................... 5 in. - 14 in. Water Column
Fuel Consumption - ft 3 /hr (Natural Gas/LPV)
Exercise 25% 50% 75% 100%
Cycle Load Load Load Load
102/40.4 194/77.1 373/148 520/206.3 720/286
ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 30 Amp
Static Battery Charger ............................................................2 Amp
Recommended Battery ...................................... Group 26, 525CCA
System Voltage .....................................................................12 Volts
Voltage Regulator
Type .................................................................................. Electronic
Sensing ........................................................................ Single-phase
Regulation ................................................................................± 1%
Features ................................................. V/F Adjustable, Adjustable
Voltage and Gain LED Indicators
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C ..................................................... 25
1.65% for every 10° above °F .................................................... 77
Altitude Deration
1% for every 100 m above m ................................................... 183
3% for every 1000 ft. above ft. ................................................. 600
Controller .................................................R-200
B 05/06 GenSpec020 Rev.
Standby Generator Sets
Specifications
Figure 1 — Interconnections
CONTROL PANEL
GENERATOR
CONNECTION
BOX
N1
N2
23
194
183
178
120 Volt +
Neutral
Grd
Battery
Charger
Input
CIRCUIT
BREAKER
GROUND
TO
ALTERNATOR
NEUTRAL
Transfer Switch
4- # 14 GA
WIRES TO
GENERATOR
CONNECTION
BOX
Gen
N1
N2
23
194
186
178
Utility In
NEUTRAL
Load
Out
TO GENERATOR
CONNECTION BOX
To Generator Control Panel
FRAME RAIL
Ground Level
Concrete Slab
STUB-UP AREA
See Install Dwg for
Dimensions
CIRCUIT BREAKER SIZE
KW VOLTS / AMPS LUG SIZE
45 240 1 Ø 200 #6 to 300 mcm
45 208 3 Ø 175 #6 to 300 mcm
45 480 3 Ø 80 #6 to 300 mcm
COLD WEATHER KIT
For cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes:
• Battery Warmer
• 4” Junction Box with hardware
• 6 qt. pack 5W-30 synthetic oil (engine)
10. Reverse the procedure to convert back to natural gas.
11. The Dip switch inside the control panel must be in the LP or NG position when switching to different fuels.
Figure 6.2 — Reconfigure the Fuel System
RECONFIGURING THE FUEL SYSTEM
NOTE:
All models are configured for natural gas or LP vapor from the factory.
To reconfigure the fuel system from NG to LP, follow these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet port (Port 1) of the demand regulator (Figure
6.2).
3. Remove the brass hose fitting from the outlet port
(Port 1) of the demand regulator.
4. Remove the brass hose fitting with solenoid from
Port 2.
5. Install brass hose fitting into Port 2.
6. Install the brass hose fitting with solenoid into
Port 1.
7. Connect carburetor gas hose to brass fitting.
8. Tighten all clamps and plugs.
B 05/06
9. Make sure fuel supply is of the proper pressure and type for configuration.
GenSpec020 Rev.
6-2
NOTE:
Port 1 is for NG only and Port 2 is for LP vapor only. No provision for dual fuel has been made.
DANGER
Serious injury or damage may occur if not configured properly. Please consult an Authorized
Service Dealer with any questions.
Stationary Emergency Generator
General Information
ALTERNATOR AC LEAD CONNECTIONS
See “Voltage Codes”. This Stationary Emergency
Generator may be rated at any one of three voltages, either single-phase or three-phase. The electrical wires in the unit’s AC connection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. If there are any questions regarding lead connection, refer to the wiring diagrams at the back of this manual.
Voltage codes apply to the type of stator assembly installed on a particular generator.
FOUR-LEAD, SINGLE-PHASE STATOR
Four-lead alternators (see Figure 7.1) are designed to supply electrical loads with voltage code “A” (240V,
1-phase, 60 Hz). Electrical power is produced in the stator power windings. These windings were connected at the factory to the main circuit breaker as shown in Figure 7.1.
The rated voltage between each circuit breaker terminal is 240V. The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V.
Figure 7.1 — Four-lead, Single-phase Stator
ALTERNATOR POWER WINDING
CONNECTIONS
3-PHASE ALTERNATORS
The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory to the main circuit breaker with a “Y” configuration as shown in
Figures 7.2 and 7.3.
The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is either 480V or 208V depending on the model.
The rated voltage between each circuit breaker terminal and the neutral point 00 is either 277V or 120V depending on the model.
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 277/480V (6 Lead)
S1 E1
INTERNAL
CONNECTIONS
L-L
S6 S4
NEUTRAL
S5
E3 S3
S2 E2
L-N
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 120/208V (6 Lead)
E1
S1 S1
7-1
S3
E3
S3
S4
S6
S4
S5
00 (NEUTRAL)
L-L
S6 S5
S2
L-N
S2
E2 v. A 10/08 ACConn001 Re
Stationary Emergency Generator
Installation
INSTALLATION
Refer to the separate “Installation Guide QT Product
Line” supplied with the unit.
PREPARATION BEFORE START-UP
The instructions in this section assume that the
Stationary Emergency Generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor. Be sure to read the “Safety Rules”, as well as all other safety information in this manual, before attempting to operate this (and related) equipment.
Before starting the generator for the first time, the installer must complete the following procedures. For follow-up maintenance information and/or service intervals, please refer to the “Maintenance” section and the “Service Schedule”.
TRANSFER SWITCH
If this generator is used to supply power to any electrical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (For additional information, see the applicable transfer switch manual for this unit.) The transfer switch, as well as the generator and other electrical components, must be properly located and mounted in strict compliance with applicable codes, standards and regulations.
FUEL SYSTEM
Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and (b) is properly purged and leak tested according to code. No fuel leakage is permitted. See
“Specifications” for more information.
GENERATOR SET LUBRICATION
Check the engine crankcase oil level before operating and add oil to the proper level – the dipstick “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 “break-in” oil. This oil should be changed after 30 hours of operation.
Check the oil level in the generator gearbox (if so equipped) prior to initial use and at the intervals indicated by the “Service Schedule.” The recommended oil is SAE 90 gear lubricant.
Also, if the engine is equipped with a mechanical governor, make sure the governor is properly lubricated with clean engine oil.
8-1
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.
ENGINE COOLANT
Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See “Specifications” and “Coolant” sections.
BELT TENSION
Check-the engine-fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of approximately 22 pounds (10 kg), applied midway between pulleys, deflects the belt about 3/8- to 5/8inch (10 to 16 mm).
ELECTRICAL SYSTEM
Make sure the generator is properly connected to an approved earth ground.
Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use.
NOTE:
Battery charger must be connected to 120 VAC, 15 amp circuit to operate.
Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear of any moving generator set components.
INITIAL INSPECTION FOR QT GENSET
STARTUP
Inspect for the following.
• Freight Damage.
• Manuals present.
• Fluid Levels (Oil, coolant, battery, Gear Drive).
• Correct fuel piping.
• Correct muffler installation for external application.
• Adequate air flow, clearances and ventilation per installation drawings and applicable codes.
• Correct AC and DC wire size, connections and grounding. Control and communication wiring to/ from the transfer switch must be run in a separate conduit from the AC power leads.
E 11/08 Install001 Rev.
Stationary Emergency Generator
Installation
• Battery charger connection to 120 VAC.
• Communication wires connected between transfer switch and generator (HTS only).
• Unit secured to pad.
START-UP CHECKLIST
Before working on the Stationary Emergency
Generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The 120VAC supply to the battery charger is switched OFF.
PREPARATION FOR START-UP
• Ensure that the 120VAC circuit breaker to the battery charger is open.
• Remove the fuse from the the control panel. For the H-100 and R-series: Open the front door of the control box and remove the 15 Amp ATO fuse in the lower left-hand corner of the control box.
• Connect the battery cables to the battery. Attach negative battery cable last.
• Close the 120VAC circuit breaker to the battery charger.
• Measure the voltage at the battery before and after the charger is turned on.
• Verify all AC electrical connections are tight at the circuit breaker and transfer switch.
• Visually inspect entire area looking for loose paper, plastic wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or damage.
• Check all electrical plugs throughout the generator. Ensure each plug is seated correctly and fully inserted into its receptacle.
• Verify the AUTO/OFF/MANUAL switch is in OFF position.
• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel lines).
• Open the generator main line circuit breaker.
• Connect a manometer to the gas line and record the static pressure. It must be as listed in the
Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the MAN-
UAL position. The engine should now crank and start.
• Check voltage at the generator terminals.
• For 3-phase units, check phase rotation at the transfer switch terminals. The generator phase rotation must match the utility phase rotation.
• Check for coolant, fuel, oil, and exhaust leaks.
• Close the generators main line circuit breaker.
• Turn the generator set off.
• Connect the UTILITY supply to the transfer switch.
• Set the AUTO/OFF/MANUAL switch to AUTO.
• Disconnect utility power before the transfer switch.
Engine should start, transfer to load.
Run at least 15 minutes on generator power.
Make certain all 3-phase loads are functioning correctly (correct phase rotation).
• Reconnect Utility power
Transfer switch will transfer back to Utility and engine will shut down within the given time parameters set up for the specific transfer switch and controller.
• Install all covers, access plates and door panels.
• Put the Owners Manual in a safe and accessible place.
• Make certain the AUTO/OFF/MANUAL switch is in the AUTO position.
START-UP INSPECTION
When a start-up is performed by an Authorized
Service Dealer, a standard three-part form titled
“Start-up Inspection for Standby Power Systems”
(part no. 067377), should be completed by the installation technician or engineer. See page 1-3 for information on locating the nearest Authorized Service
Dealer. The installer should complete the form and disseminate copies as follows:
• White copy: Mail to Generac Warranty Department,
P.O. Box 340, 211 Murphy Dr., Eagle, WI 53119-
2062.
• Pink Copy: For service file of installing dealer.
• Yellow Copy: For the customer’s records.
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8-2
Stationary Emergency Generator
Operation
STATIONARY EMERGENCY GENERATOR
CONTROL AND OPERATION
Refer to the appropriate control panel operator’s manual for this unit.
OPERATING UNIT WITH MANUAL
TRANSFER SWITCH
If the Stationary Emergency Generator was installed in conjunction with a transfer switch capable of manual operation only, the following procedure applies.
A manually operated transfer switch is one that will not provide automatic start-up and does not include an intelligence circuit.
Do not crank the engine continuously for longer than 30 seconds, or the heat may damage the starter motor.
• Let engine stabilize and warm up.
• Check all applicable instrument and gauge readings. When certain that all readings are correct, move the transfer switch manual handle to the
STANDBY position, i.e., load circuits supplied by the generator.
• Set the generator’s main line circuit breaker to its
ON (or CLOSED) position.
• Load circuits are now powered by the generator.
ENGINE START-UP AND TRANSFER
For additional information, refer to the applicable control panel manual for this unit, as well as any literature pertaining to the specific transfer switch.
DANGER
The Maintenance Disconnect Switch and the
AUTO/OFF/MANUAL switches (if so equipped) must be set properly, or the generator will crank and start as soon as the utility power to the transfer switch is turned off. Refer to applicable control panel and transfer switch manuals for more information.
Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to
UTILITY.
Do not attempt manual operation until all power supplies to the transfer switch have been positively turned off, or extremely dangerous - possibly lethal - electrical shock will result.
Transfer switch enclosure doors should be kept closed and locked. Only authorized personnel should be allowed access to the transfer switch interior. Extremely high and dangerous voltages are present in the transfer switch.
In order to transfer load from the utility source to the generator, follow these directions:
• Turn OFF or disconnect the utility power circuit to the transfer switch, using the means provided
(such as the utility source main line circuit breaker).
• Set the transfer handle to its UTILITY (NORMAL) position with load circuits connected to the utility power supply.
• Set the generator’s main line circuit breaker to its
OFF (or OPEN) position.
• Start the generator.
9-1
RETRANSFER AND SHUTDOWN
For additional information, refer to the applicable control panel manual for this unit, as well as any literature pertaining to the specific transfer switch.
To transfer the load back to the utility power source and shut down the generator, follow these directions:
• Set the generator’s main line circuit breaker to its
OFF (or OPEN) position.
• Manually move the transfer switch handle to its
UTILITY (NORMAL) position, i.e., load circuits connected to the utility.
• Turn ON the utility power supply to the transfer switch, using the means provided (such as the utility power source main line circuit breaker).
• Let the generator run at no-load for a few minutes to stabilize internal temperatures.
• Shut down the generator.
OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH
If the Stationary Emergency Generator has been installed with an automatic transfer switch, such as an RTS, HTS, or GTS-type transfer switch, the engine may be started and stopped automatically or manually.
NOTE:
Refer to the applicable manual for your transfer switch and to “Transfer Switch Start Signal
Connections”. In addition, please note the dangers under “Engine Start-up and Transfer.”
A 09/08 Oper001 Rev.
Standby Generator Sets
Maintenance
MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE FACILITIES
Before working on the generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The 15A fuse has been removed from the control box.
• The 120VAC supply to the battery charger is switched OFF.
EVERY THREE MONTHS
2. Inspect and test fuel system.
5. Check engine ignition system.
ONCE EVERY SIX MONTHS
1. Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature).
ONCE ANNUALLY
1. Test engine governor; adjust or repair, if needed.
COOLING SYSTEM
Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow.
Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See the installation diagram.)
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.
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.
FIRST 30 OPERATING HOURS
1. Change engine "break-in" oil and filter.
FIRST 100 OPERATING HOURS
1. Change engine oil and oil filter. After initial change, service engine oil and filter at 100 operating hours or six months, whichever comes first.
3. Retorque intake and exhaust manifold.
EVERY 500 OPERATING HOURS
If a circuit breaker opens or a fuse element melts, find the cause of the overload before resetting the circuit breaker or replacing the fuse.
CHECKING FLUID LEVELS
CHECK ENGINE OIL
Check engine crankcase oil level (Figure 10.1) at least every 20 hours of operation, or prior to use.
• Remove oil dipstick and wipe dry with a clean, lintfree 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 Recommendations” for recommended oils.
3. Check engine DC alternator.
EVERY 800 OPERATING HOURS
2. Retorque intake and exhaust manifold.
0 02/06 Maint010 Rev.
10-1
Standby Generator Sets
Maintenance
Figure 10.1 - Oil Dipstick and Oil Fill Cap
Oil
Dipstick
Oil Fill Cap
EXERCISE SYSTEM
Start the generator engine at least once every seven days and let it run at least 20 minutes. See “Weekly
Exercise Cycle”.
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.
CHECK ENGINE COOLANT LEVEL
See “Checking Fluid Levels”.
BATTERY FLUID
Check battery electrolyte fluid based on the
Maintenance Schedule. Fluid should cover separators in all battery cells. If fluid level is low, add distilled water to cover tops of separators. DO NOT USE
TAP WATER IN BATTERY.
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 fasteners. Look for fuel, oil or coolant leaks.
0 02/06
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 recovery system for leaks.
MAINTENANCE OWNER/
OPERATOR CAN PERFORM
CHECK ENGINE OIL LEVEL
Refer to “Checking Fluid Levels”.
CHECK BATTERY
• See “Checking Fluid Levels”.
• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as necessary.
Maint010 Rev.
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.
10-2
CHECK FAN BELT
• Inspect fan belts every three months. Replace any damaged, deteriorated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 of an inch. Adjust belt tension as required.
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 qualified service technicians should adjust the governed speed.
Standby Generator Sets
Maintenance
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 running. This means warm up the engine, shut it down and drain immediately as follows:
1. Remove OIL DRAIN HOSE from its retaining clip.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container.
3. When all oil has drained, install and tighten OIL
DRAIN HOSE CAP, and re-install into its retaining clip.
4. Turn OIL FILTER (Figure 10.2) counterclockwise and remove. Properly dispose of old filter.
Figure 10.2 – Oil Filter
Figure 10.3 – Engine Air Cleaner
Air Cleaner
Oil
Filter
(Doors Removed for Clarity)
SPARK PLUGS
Reset the spark plug gap or replace the spark plugs as necessary (Figure 10.4).
1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean.
2. Remove the spark plugs and check the condition.
Replace the spark plugs if worn or if reuse is questionable. See the “Service Schedule,” Section
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 electrode (Figure 10.4).
Figure 10.4 – Setting the Spark Plug Gap
SET PLUG GAP AT 1.07 - 1.17 mm
(0.042 - 0.046 inch)
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.
CHANGING THE ENGINE AIR CLEANER
COOLANT CHANGE
To replace the engine air cleaner, remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover
(Figure 10.3).
See the “Service Schedule,” for air cleaner maintenance.
10-3
Every year, have an Authorized Service Facility drain, flush and refill the cooling system. See “Specifications” for cooling system recommendations.
0 02/06 Maint010 Rev.
Standby Generator Sets
Maintenance
0 02/06
MISCELLANEOUS MAINTENANCE
CLEANING THE GENERATOR
Keep the generator as clean and as dry as possible.
Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance.
Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dry, low pressure air to remove any accumulations of dirt. The generator is housed inside an all-weather enclosure, clean the enclosure with a soft, damp cloth or sponge and water.
Once each year have the generator cleaned and inspected by an Authorized Service Dealer. That dealer will use dry, low pressure air to clean internal windings. Parts inside the control console should be cleaned and inspected at this time as well.
Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low, the generator may require drying.
BATTERY
All lead-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 battery 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.
Maint010 Rev.
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 battery 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 corrosive sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid is spilled, flush the affected area immediately with clear water.
Do not use any jumper cables or booster battery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging.
Be sure the AUTO/OFF/MANUAL switch is set to the OFF position, before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.
Be sure the 120VAC power supply to the battery is turned OFF, or sparking may occur at the battery posts as the cables are attached and cause an explosion.
BATTERY REPLACEMENT
When replacing batteries, use the same number and the type of battery that follows:
BCI Group No.
26
CCA
525 @ 0 deg. F
10-4
NOTE:
The BCI number should be located directly on the battery.
Stationary Emergency Generator
Service Schedule
SERVICE SCHEDULE
22 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR
The following is a recommended maintenance schedule for Gaseous Stationary Emergency Generator sets from 22kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe 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 potential problem areas.
This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
Disable the generator set from starting and/or connecting to the load by setting the control panel Auto/Off/
Manual switch to the “OFF” position.
• Remove the 15 amp control panel fuse.
• Turn off the battery charger.*
• Remove the negative battery cable.
* The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits.
Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required.
2 A wear-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.
Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by a Service Dealer.
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.
Performed semi-annually or following each 50 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by a Service Dealer.
4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.
Performed annually or following each 100 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by a Service Dealer.
5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required, and to identify any potential problem areas.
Performed annually or following each 250 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by a Service Dealer.
v. E 02/09 SrvSchd001 Re
11-1
Stationary Emergency Generator
Service Schedule
Maintenance Level 1 Level 2 Level 3 Level 4 Level 5
Tasks
RecomTask Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Datemonthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)
10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.
1. Disable the unit from operating per the first page warning.
Check the engine oil level. Adjust as necessary.
Check the engine coolant level.
Adjust as necessary.
4. coolant thermal protection level.
Correct as necessary.
5. gas delivery system for leaks and correct pressure on gas engine driven units. Tighten connections as necessary.
Check the air inlets and outlets for debris. Clean as necessary.
electrolyte level and specific gravity if accessible. Adjust as necessary.
Check the battery posts, cables, and charger for loose connections, corrosion, and proper operation.
Correct as necessary.
wiring for loose connections, corrosion, and damage. Correct as necessary.
v. E 02/09 SrvSchd001 Re
11-2
Stationary Emergency Generator
Service Schedule
Maintenance Level 1 Level 2 Level 3 Level 4 Level5
Tasks
RecomTask Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Datemonthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)
250 hrs.
10. Check the engine accessory drive belts and fan coupling device if equipped for correct tension, wear, weather cracking, and damage. Replace as necessary.
11. Check the engine valve clearance/ lash. Adjust as necessary.**
12. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary.
13. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary.
14. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal
10 hrs. 30 hrs. 50 hrs. 100 hrs. operating conditions.
Correct as necessary.
15. Replace the engine accessory drive belts.
16. Check gearbox oil level (if equipped).
17. Change gearbox oil (if equipped).
** Not required for engines equipped with hydraulic lifters. See the "Specification" section for lifter type.
v. E 02/09
11-3
SrvSchd001 Re
Stationary Emergency Generator
Service Schedule
Maintenance Level 1 Level 2 Level 3 Level 4 Level5
Tasks
RecomTask Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Datemonthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) annually/ Initials)
10 hrs. 30 hrs. 50 hrs. 100 hrs. 250 hrs.
18. 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.
19. Perform an engine oil analysis (send a sample to a lab for results).
Change the engine oil and filters if the analysis results indicate this is required.
20. Change the engine oil.
21. Replace the engine oil filter(s).
22. Replace engine spark plugs.
Clean and re-gap or replace as necessary.
23. Replace the engine air filter(s).
24. Perform a 5 minute no-load operational run of the unit looking for any post service problems.
25. Return the unit to standby setup for operation when required.
v. E 02/09 SrvSchd001 Re
11-4
Stationary Emergency Generator
Troubleshooting
TROUBLESHOOTING GUIDE
PROBLEM CAUSE
Engine won’t crank.
Engine cranks but won't start
Engine starts hard, runs rough.
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.
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14A from Engine Control circuit board.
4. Spark plugs defective.
5. Door on tank not closed.
1. Flame arrestor (air cleaner) plugged or damaged.
2. Plugged fuel line.
3. Defective spark plugs.
4. Fuel pressure incorrect.
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.
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.
5. Close door on tank.
1. Clean or replace as needed.
2. Unclog fuel line.
3. Clean, regap or replace plugs.
4. Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS.
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.
1. Check main line circuit breaker.
2. Check circuit breaker & fuses.
3. Transfer switch set to NORMAL position
4. Generator internal failure.
5. Thermal circuit breaker open.
3. Replace board.*
1. Reset to ON or CLOSED.
2. Reset and replace, if necessary.
3. Set to GENERATOR position.
4. *
5. Auto-reset - Wait 5 min. and attempt restart.
*Contact the nearest Authorized Dealer for assistance.
A 10/08 lsht001 Rev.
T rb
12-1
Stationary Emergency Generator
Notes
12
13
14
(2) 15
(2) 16
17
18
19
20
21
23
24
(1) 26
(1) 9
10
11
4
5
6
7
8
1
2
3
(3) 39
(4) 40
(4) 41
(4) 42
(4) 43
(4) 44
(4) 45
(4) 46
47
1)
A
C
27
28
29
30
31
32
33
34
35
36
37
2)
A
G
H
J
K
L
C
D
E
F
G
D
E
F
0F3824
0A9457
057073
0D5466
0A7822
022237
022241
049226
0C2266
0C2454
022473
022097
0D4698
0F3137
0F3188
0F3189
023484N
0F6366B
0F6366A
043180
022264
0C3990
057701
022155
0C2428
0F4464
025433
024469
067210A
0D6029
081008
077043J
051713
0F6156
029289
047411
0G0770
0H0348
036943
023897
022152
022158
0C2454
055934D
0F6145
0F3328
0D5552
0D5553
0D5554
0D5556
0D9693
0F0492
048927
023897
022152
022158
0C2454
029289
0F1733
0F3138
0D5572
0D5573
0D5574
0D5575
0D5576
0F0199
081320
022473
022097
1
1
1
2
2
2
1
1
1
PAN CB CONN BOX
STAND RH CONTROL
STAND LH CONTROL
BUSHING SNAP SB-2.5-31
XFMR DUAL 120V/16V (F OR 120/240V & 277/480V UNITS)
XFMR DUAL 104V/16V (F OR 120/208V UNITS)
WASHER FL AT M4
WASHER LO CK #8-M4
SCREW PHTT M4-0.7 X 10 ZYC
REF BLOCK TERM 20A 8 X 6 X 1100V
4 WASHER LO CK #6
4 SCREW PHTT #6- 32 X 1/2 ZYC
1
1
2
DECAL UT IL SENSE/CUST CONN
DECAL NEUTRAL
JUNCTION BLOCK 3/8-16
REF BUS BAR NEUTRAL BLOCK 390
REF LUG SLDLSS 600/250-1/0 X 1/4-28
2
2
6
WASHER LO CK 3/8
NUT HEX 3/8-16 STEEL
WASHER LO CK M5
6
8
SCREW PHTT M5-0.8 X 16 ZYC
SCREW THF M6-1 X 16 N WA Z/JS
8
4
WASHER FL AT 1/4-M6 ZINC
WASHER LO CK M6- 1/4
REF BLOCK TERM 20A 6 X 3 X 1100V
4
2
2
1
1
2
1
4
1
1
1
1
1
2
1
1
4
DECAL CUST CO NN 120V UTILITY
LUG SLDLSS #6- 14 X 13/64 CU
SCREW HHTT #10-32 X 3/8 CZ
DECAL GROUND LUG
SCREW HHTT M6-1.0 X 16 Z YC
GROMMET 1.25 X .25 X .75
CONDUIT FLEX 2.0" ID (36” LG)
WASHER FL AT M5
PLATE W IRE SNGL G ALV
TAPE ELEC 1/2 FO AM (AS REQ’D)
SCREW HHC M6-1.0 X 16 G8.8
HARNESS, TRANSFO RMER ADAPTER
ASSY ENCLOSURE PCB 4.2L IGN MD
SCREW PPHM #10/32 X 2
WASHER FL AT #10 ZINC
WASHER LO CK #10
NUT HEX #10-32 STEEL
1
1
SCREW THF M6-1 X 16 N WA Z/JS
CLAMP VINYL 1.06 X .406 Z
A/R SEAL W EATHER .45" DIA
UL CIRCUIT BREAKER (ED)
1
1
-
COVER ED CB SHO RT STND
CB 0050A 3P 480V S ED4 LL
CB 0060A 3P 480V S ED4 LL
1
4
4
4
-
-
-
1
4
4
-
-
-
CB 0070A 3P 480V S ED4 LL
CB 0090A 3P 480V S ED4 LL
CB 0125A 3P 480V S ED4 LL
INSULATOR CB S (ED-3P)
SCREW RHM #10-32 X 4- 1/2
WASHER FL AT #10 ZINC
9
1
4
4
WASHER LO CK #10
NUT HEX #10-32 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
TAPE ELEC 1/2 FO AM (AS REQ’D)
1
UL CIRCUIT BREAKER (F D)
1
DECAL CUSTOMER CONNECT INSIDE
COVER CB CONN BO X
1
-
CB 0150A 3P 600V S FD6 LL
CB 0175A 3P 600V S FD6 LL
CB 0200A 3P 600V S FD6 LL
CB 0225A 3P 600V S FD6 LL
CB 0250A 3P 600V S FD6 LL
INSULATOR CB FD FRAME 30MIL
SCREW SHC 1/4-20 X 4.5 G8.8 NZ
WASHER FL AT 1/4-M6 ZINC
WASHER LO CK M6- 1/4
F
G
H
4)
A
C
J
K
L
D
E
F
G
H
L
3)
A
C
D
E
H
J
K
J
K
0C2454
029289
0F1733
0F8135
0E7283
0E7284
0E3664
074908
0F8140
036261
0C2454
022127
0C2454
029289
0F1733
0F3329
0D5577
0F2353
022770
022473
022097
022127
029289
0F1733
4
9
1
NUT HEX 1/4-20 STEEL
SCREW THF M6- 1 X 16 N W A Z/JS
TAPE ELEC 1/2 FOAM (AS REQ’D)
1 DECAL CUSTOMER CONNECT INSIDE
UL CIRCUIT BREAKER (JD+L D)
1 COVER JD/L D CB SHRT STAND
1
2
4
CB 0300A 3P 600V S JD6 LL
INSULATOR CIRCUIT BR. JD/LD
SCREW RHM 1/4- 20 X 3
4
4
4
W ASHER FLAT 1/4-M6 ZINC
W ASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
1
-
-
1
2
9
1
SCREW THF M6- 1 X 16 N W A Z/JS
TAPE ELEC 1/2 FOAM (AS REQ’D)
1 DECAL CUSTOMER CONNECT INSIDE
UL CIRCUIT BREAKER (QN)
COVER QN FRM CB
CB 0150A 2P 240V S QN2 LL
CB 0175A 2P S QN2 LL 240V
BASE, QN CIRCUIT BREAKER
SCREW HHTT M5-0.8 X 10 BP
1
4
11
COVER QN CB DISH
RIVET POP .125 X .275 SS
SCREW THF M6- 1X16 N WA Z/JS
1
1
TAPE ELEC 1/2 FOAM (AS REQ’D)
DECAL CUSTOMER CONNECT INSIDE
(1) ITEM INCL UDED W IT H HARNESS
(2) ITEM INCL UDED W IT H 0D5464B
(3) ITEM USED W IT H EARLY MO DEL 208V UNITS ONLY
(4) ITEMS USED ON 4.2L MO DELS O NL Y.
H
J
K
(2) L
D
E
F
G
(2) V
(1) W
X
7)
A
C
N
P
(2) R
(2) S
(2) T
(2) U
(2) F
(2) G
(2) H
(2) J
K
L
(2) M
(2) W
(2) X
Y
(2) M
N
P
(1) S
T
U
V
D
E
A
B
C
Q
6)
L
M
N
P
H
J
K
D
E
F
G
5)
A
C
0F8843
W/CB
0G3259
0F4187
0F4166$
0F1733
042419
023897
022152
022158
0C2454
029289
052647
053640
038150
022264
022471
029289
0F1733
022129
0F8432
0F8432A
0C2454
0F8451
049897
022145
045771
046526
W/CB
0A7822
W/CB
023334
022097
022473
W/CB
W/CB
0G3259
0F1733
0F4185
058306
0F4165$
0F4143
0F4148
0F4149
0F4151
0G5247$
0G5250
0G4478
0F4186
0F4186AGS0R
036261
0F8137
0E7994
0F8136
036261
022473
022097
022127
0F8139
0C2454
022237
048527
029289
022770
2
2
1
2
2
1
9
UL CIRCUIT BREAKER (QJ-2P)
1
-
COVER QJ 2P FRM CB
CB 0225A 240V 2P S QJ22
1
4
2
2
COVER QJ 2P CB DISH
RIVET POP .125 X .275 SS
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
INSUL CB 2P QJ
SCREW THF M6-1 X 16 N WA Z/JS
WASHER LOCK 3/8
SCREW SHC 3/8-16 X 3/4 G8.8 NZ
TAPE ELEC 1/2 FOAM (AS REQ’D)
SCREW RHM 1/4-20 X 3
1 DECAL CUSTOMER CONNECT INSIDE
UL CIRCUIT BREAKER (225AF) (2P & 3P)
1
3
COVER CB C2-C4 (225AF)
SCREW SHC M8-1.25 X 25 G12.9
REF CIRCUIT BREAKERS 200A FRAME (3P)
REF CB 0040A 3P 480V 225AF (3P)
REF CB 0125A 3P 480V G 225AF
REF CB 0150A 3P 480V G 225AF
REF CB 0200A 3P 480V G 225AF
REF CB 200A FRAME G 240V (2P)
REF CB 175A 2 POLE 240V 225AF (2P)
REF CB 200A 2 POLE 240V 225AF (2P)
1 COVER CB DISH 225AF (3P)
4
COVER CB DISH 225AF (2P)
RIVET POP .125 X .275 SS
2/4 SCREW RHM #8-32 X 3-1/4
2/4 WASHER FLAT #8 ZINC
2/4 WASHER LOCK #8-M4
2/4 NUT HEX #8-32 STEEL
2 TAPE ELEC 1/2 FOAM
1 DECAL CUSTOMER CONNECT INSIDE
6/9 WASHER LOCK M8-5/16
1
1
INSULATOR CB 225AF (3P)
INSULATOR CB 225AF (2P)
11 SCREW THF M6-1 X 16 N WA Z/JS
2/3 LUG SLDLSS 300 MCM-6 AL/CU
4/6 SCREW SHC M8-1.25 X 20 G8
4/6 WASHER FLAT 5/16-M8 ZINC
2/3 NUT HEX M8-1.25 G8 CLEAR ZINC
2/3 BUS BAR 200A LUG ADAPTOR
2 TERMINAL COVER CB
1 DECAL TERMINAL SHOCK HZD BI
UL CIRCUIT BREAKER (400AF)
1 COVER CB C2-C4 400AF
REF CIRCUIT BREAKERS 400A FRAME
1
4
4
4
DECAL CUSTOMER CONNECT INSIDE
SCREW RHM 10-32 X 4
WASHER FLAT #10 ZINC
WASHER LOCK #10
4
9
NUT HEX #10-32 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
1 TAPE ELEC 1/2 FOAM
2/3 SCREW SHC M10-1.5 X 25 G12.9
2/3 WASHER LOCK M10
3 BUS BAR CB ADAPTER 225-400 A
3 LUG SLDLSS 600/250-1/0 X 1/4-28
2
6
6
6
TERM COVER CB
SCREW HHC 1/4-28 X 1/2 G5
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
2/3 SCREW SHC M10-1.5 X 25 G12.9
2/3 WASHER LOCK M10
1 DECAL TERMINAL SHOCK HZD BI
N
H
J
K
L
M
E
F
G
C
D
9)
A
F
G
H
B
C
D
E
8)
A
0A2077
040532
0C3990
0E7890
0E6002
022859
0G0008
023897
022152
022158
0F1733
029289
0C2454
0D5466
039287
022145
022129
045771
045335
083896
0A7822
0G1968
0G1970
NEUTRAL BLOCK 390 / 200-400A
2 BUS BAR NEUTRAL BLOCK 390
1
1
1
1
SCREW HHC M8-1.25 X 45 G8.8 FT
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
2
2
SCREW HHC 1/4-28 X 3/4 G5
WASHER LOCK 1/4-M6 SS
1 LUG SLDLSS 600/250-1/0 X 1/4-28
UL CIRCUIT BREAKER (BQ)
1
-
6
1
1
-
1
-
2
COVER BQ CIR BREAKER CPL 3P
COVER BQ CIR BREAKER CPL 2P
CB 0125A 2P 240V S BQ2 LL
CB 0100A 3P 240V S BQ3 LL
SCREW PHTT M4-0.7 X 10 ZYC
BRKT CB MTG BACK
MTG TRACK BQ SIEMENS CB 3P
SCREW RHM #10-32 X 3/4
BRKT BQ CB STANDOFF
6
6
6
1
1
WASHER FLAT #10 ZINC
WASHER LOCK #10
NUT HEX #10-32 STEEL
DECAL CUSTOMER CONNECT INSIDE
TAPE ELEC 1/2 FOAM
11 SCREW THF M6-1 X 16 N WA Z/JS
(1) HARDWARE FOR MTG. CB TERMINAL COVERS IS
SUPPLIED WITH CIRCUIT BREAKERS.
(2) QTY. REQ’D FOR “2POLE / 3POLE” BREAKER
17
18
19
20
21
22
11
12
13
14
15
16
6
7
8
9
10
3
4
5
23 *
24 *
25
26
2
1
0G6567
0H0201
0H1299
0H1300
0H1301
0C9708
SEE ENGINE EV
SEE ENGINE EV
0F5767B
0E5706
0F7874
0G0587
038150
023454
077043E
04576100BU
052646
043123
051779
0A2601
072879
0F8408
046526
0C3992
022264
047248
070892
0G0588
077043A
0G0059
0G0183
0G0184
0G1932
0G2098
0G2099
0G2100
0G3736
0G3737
0G3738
0G6104
0G6563
0G6565
0G6566
0F9677
0G0056
0G0959
0G1155
0G1931
0G2101
0G3734
0G6562
0G6564
0F9664
0G0057
0G0058
4
4
4
1
1
4
4
4
4
1
1
4
REF
REF
REF
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
ROTOR-2390-45KD1 CPL
ROTOR-2390-35KD1 CPL
ROTOR-2390-45KD1 CPL (G2)
ROTOR-2390-35KD1 CPL (G2)
ROTOR 25KW 3PH DIRECT 390 1800
ROTOR 25KW 1PH DIRECT 390 1800
RTR-2390-60KD2 CPL
RTR 390 35AD1 CPL
RTR 390 35KD1 CPL
STATOR-390 45K 2P 1PH DIRECT
STATOR-2390-35AD1 CPL
STATOR-2390-35KD1 CPL
STATOR-2390-35GD1 CPL
STATOR-2309-45KW 2P 3PH 208V
STATOR-2309-45-KD1 CPL
ASSY STR 390 25GD3 CPL
ASSY STR 390 25AD1 CPL
ASSY STR 390 25KD3 CPL
ASSY STR 390 25JD3 CPL
ASSY STR 2390 60AD2 CPL
ASSY STR 390 60KW 2P 3PH 208V
ASSY STR 390 60KW 2P 3PH 480V
STR-2390--45JD1 CPL
STR 390 35AD1 CPL
STR 390 35GD1 CPL
STR 390 35KD1 CPL
STR 390 35JD1 CPL
STR-2390--60JD2 CPL
ASSY STR 390 36AD1 CPL
ASSY STR 390 36JD1 CPL
ASSY STR 390 36 GD1 CPL
INSTR HYPOT TEST (NOT SHOWN)
ENGINE ADAPTER
FLEXPLATE
ASSY FLYWHEEL CPL W/40MM FAN B
REAR BEARING CARRIER 390/DRCT
ASSY BRUSH HOLDER 390/HSB
GUARD REAR BEARING CARRIER
WASHER FLAT #8 ZINC
KEY WOODRUFF #E
CONDUIT FLEX 1.0" ID (35” LG)
STUD M14-2.0 570 G5 ZINC
WASHER FLAT M14
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
SCREW HHC M16-2.0 X 45 G8.8
SPACER .69 X 2.75 X .37 ST/ZNC
SCREW HHC M10-1.50 X 16 G10.9
WASHER LOCK M10
SCREW HHTT M4-0.7 X 16 BP
WASHER LOCK #8-M4
1
1
1
1
BALL BEARING-45 MM
SLIP RING MACHINED
GUARD REAR BEARING CARRIER
CONDUIT FLEX .38" ID (60”)
* ROTOR REPLACEMENT PARTS
4
5
7
8
9
10
11
036261
043181
0F8710B
0F1262
0F1263
0F1264
0F1725C
COMPONENTS INCLUDED IN 0F9696E
1 0F1823A 1
2 0F3078 1
6
4
1
4
1
1
1
COVER
3 0F2606 1
12 067680 1
CONTINUOUS
RIVET POP .125 X .275 SS
SCREW PHM M3-0.5 X 10MM
6 052777 7 FLAT
ASSY PCB CPL2 CTRLR 3600 RPM
HOLDER, FUSE WICKMANN 178.6150
ADPTR RH SIDE WICKMAN 178.6191
ADPTR LH SIDE WICKMAN 178.6192
ASSY PCB 2AMP 12V UL BATT CHGR
13
14
15
16
0E6875A
055911
0F5459
0E3161
1
1
2
1
VOLTAGE
RELAY 12VDC C FORM W/DIODE
BLOCK TERM 20A 12 X 6 X 1100V
DECAL CPL CONTROL PANEL FUSES
ASSY PCB BOSCH GOV DRIVER
17 0F5090 1
18 0F5462 1
19
20
0A5062J
029673
4
1
21 048467 1
22 0F1958 1
CPL
SPACER 9.5H 3.2 ID
DIO BRIDGE 25A 600V
CIRCT BRK 7 X 1 ETA 46-500-P
23 082573 1
24 0E4494 1
CLAMP
SWITCH RKR DPST 125V SPD
SWITCH ON-OFF-ON
DECAL
26 0F6305 3
28 0F5886 3
SEAL
27 0F6305A 1 COVER
SCREW HHPM M5-0.8 X 12
29 051713 12
30 049226 12
35
36
37
38
31
32
33
34
0F5752F
0F5884
0F5896
0C2265
0C3990
091526
051716
079224
9
2
2
4
2
4
1
2
LOCK
RES WW 15R 5% 25W QK CONN
SCREW PHTT M3.5-0.6 X 10
SCREW PHTT M3.5-0.6 X 16
SCREW PHTT M4-0.7 X 12 ZYC
SCREW PHTT M4-0.7 X 10 ZYC
SCREW PPHM M5-0.8 X 12 ZNC
NUT HEX M5-0.8 G8 CLEAR ZINC
39 075476 2
SCREW PPHM M5-0.8 X 30 SS
SCREW PPHM M4-0.7 X 16
40 043180 2
41 022264 2 LOCK
NUT HEX M4-0.7 G8 YEL CHR 42
43 043182 7
44
45
46
47
051715
051714
0F3192
0E7403C
0F9785
056739
022287
2
1
1
7
1
LOCK
NUT HEX M3-0.5 G8 YEL CHR
COMPONENTS INSTALLED PER THIS DRAWING
1
2
SUPPORT ANGLE PCB
FUSE ATO TYPE 15 AMP (BLUE)
HARN 3600RPM R200 CONTROL PNL
A
B
RELAY SOLENOID 12VDC PNL MNT
SCREW HHC 1/4-20 X 3/4 G5
WASHER
D 022097 2
L
E 022127 2
F 0F6145 A/R
LOCK
NUT HEX 1/4-20 STEEL
G
H
0F2627A
091526
1
4
WEATHER
COVER CONTROL PANEL SIDE
SCREW PPHM M5-0.8 X 12 ZNC
J 049226 4
0G3545 1
WASHER
K 051713 4 FLAT
DANGER HIGH VOLTAGE (SPANISH)
30
21
22
23
24
25
26
27
29
15
16
17
18
19
20
9
10
11
12
6
7
8
13
14
1
2
3
4
5
0F9596A
052212
049813
022261
0F9597A
045764
062963
022302
022131
065852
0F9597
022129
026204
022145
045771
0F9596
0F9517
052860
052251
052257
052252
052259
052891
0536210410
042909
047411
055414
022447
022097
022473
WELDMENT FRAME 2.4L C2
NUT FLANGED HEX M12-1.75
DAMPENER VIBRATION 40 BLUE
SPACER .49 X .62 X 1.87 PWDR/ZNC
DAMPENER VIBRATION
WASHER FLAT M12
SCREW HHC M12-1.75 X 80 G8.8
ASSY WIRE 14.00"
SCREW HHC M8-1.25 X 30 G8.8
SCREW HHC M6-1.0 X 16 G8.8
LUG SLDLSS #2-#8 X 17/64 CU
WASHER SHAKEPROOF INT 1/4
WASHER LOCK M6-1/4
WASHER FLAT M6-1/4 ZINC
NUT HEX M6 -1.0 G8 YEL CHR
WASHER SHAKEPROOF INT 3/8
SUPPORT LH ENGINE 2.4L
SCREW HHTT M4-0.7 X 8 BP
SCREW HHC M10-1.25 X 30 G8.8
WASHER LOCK 7/16
WASHER FLAT 3/8-M10 ZINC
SPRING CLIP HOLDER .37-.62
SUPPORT RH ENGINE 2.4L
WASHER LOCK M8-5/16
WASHER SHAKEPROOF INT 5/16
WASHER FLAT 5/16-M8 ZINC
NUT HEX M8-1.25 G8 CLEAR ZINC
SPACER ENGINE MOUNT (2.4L G1)
SPACER LH ENGINE MOUNT (2.4L G2)
SCREW HHC M10-1.25 X 25 C8.8
1
1
1
1
1
1
1
5
1
1
1
4
5
1
1
1
1
1
1
1
5
5
1
1
2
1
4
5
5
5
14
15
16
17
9
10
11
12
7
8
5
6
3
4
1
2
0F3408B
0F3411
025507
052212
046526
022131
050331A
050331
038805Y
03880400AE
045771
022129
0F3976
0C2454
022145
077483
1
1
REF
REF
1
4
REF
REF
1
1
REF
REF
REF
REF
REF
REF
BATTERY TRAY C1 CPL
STRAP BATTERY RETAINMENT
WASHER SHAKEPROOF EXT 7/16 STL
SCREW HHC M10-1.25 X 25 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
BATTERY POST COVER RED +
BATTERY POST COVER BLACK -
CABLE BATTERY BLACK #1 X 18.00
CABLE BATT RED #1 X 18.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
BOOT CONTACTOR CABLES
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FLAT 5/16-M8 ZINC
BATTERY 12VDC 75-AH 26
9
10
11
5
6
7
8
1
2
3
4
0G0158
022131
0F9585
046525
052212
0E9868A
0F3216B
0G0115
0A86220296
0D3488Q
0F9501
1
3
1
3
1 (REF)
1 (REF)
1 (REF)
1 (REF)
(REF)
1 (REF)
1 (REF)
ENGINE 2.4L G1
WASHER FLAT 3/8-M10 ZINC
EXHAUST ADAPTER 2.4L MACH
NUT HEX M10-1.25 G8 YEL CHR
SCREW HHC M10-1.25 X 25 G8.8
ALTERNATOR DC W/OUT PULLEY
PULLEY 117 OD DC ALTERNATOR
BRACKET TENSIONER
CARTRIDGE OIL FILTER
BELT SERPENTINE 44.13"
ADAPTER 2.4L CRANKSHAFT MACH
68
69
70
71
64
65
66
67
60
61
62
63
56
57
58
59
13
14
15
17
18
19
20
21
026925
0A6751
0G0638
0F9793
0F9420
0F3903F
042574
0A8584
1 (REF) PLUG STD PIPE 3/8 STEEL SQ HD
1 (REF) SWITCH HI-TEMP 245D X 3/8 NPT
1 (REF) SPACER ALTERNATOR 2.4L G1
16 0E9747 1
1 (REF)
1
1
1 (REF)
12
BRACKET DC ALTERNATOR
ADAPTER ENGINE 2.4L MACHINE
FLEX PLATE 2 POLE 2.4 G1
1 (REF) ADAPTOR 1/8 NPTF TO 1/8 BSPT
SWITCH OIL PRESSURE 10 PSI 2 POL
22 0C7649 1 HOSE
HOSE DRAIN ASSY 28"
046526
049808
049821
022145
022129
042907
0G0344
0G0343
0G0180
0F9723
040976
0G0149
039414
022237
0D2244M
025507
046526
0F3217
051736
0F9836
051730
0G0145
077996
035472
0G0141
0F9792
062963
022131
0D3973
068485
098544
0G0143
069860E
0G0136
022400
063076
0G1738
057823
0F9486
045772
022241
043790
057765
052830
022129
022145
057772
0G0114
52
53
54
55
48
49
50
51
44
45
46
47
40
41
42
43
35
36
37
39
31
32
33
34
27
28
29
30
23
24
25
26
1
1 (REF) SPACER ALTERNATOR 2.4L G1
1 (REF) SCREW HHC 3/8-16 X 3 G5
6 WASHER FLAT .531 ID X 1.062 OD
1 (REF) CAP ANTIFREEZE RUBBER 9.5DIA
1 (REF) CLAMP HOSE #10 .56-1.06
1 ADAPTER FLEX PLATE PILOT 2.4L
1 (REF) NUT HEX M10-1.5 G8 YEL CHR
1 (REF) NUT HEX 3/8-16 STEEL
1
1
2
3
BARBED EL 90 3/8 NPT X 3/8
ADAPTER M14-1.50 X 3/8 NPT
SCREW HHC M10-1.25 X 45 G8.8
WASHER LOCK M8-5/16
1 (REF) WASHER FLAT 5/16-M8 ZINC
1
6
3
1 (REF) SPACER DC ALTERNATOR PULLEY
1 (REF)
1
3
WASHER NYLON .565
SCREW HHC M12-1.25 X 15 G10.9
WASHER LOCK M10
SCREW HHC M10-1.5 X 80 G8.8
1 (REF) GASKET- THROTTLE BODY
1 (REF) INTAKE ADAPTER MACHINED
4 (REF) SCREW SHC M8-1.25 X 20 G12.9
1 (REF) SCREW SHC M14-1.5 X 35 G10.9
4 (REF) SCREW HHC M8-1.25 X 35 G8.8
1(REF)
1
5
HARN ENG 2.4L R-200 G1 (NOT SHOWN)
1 (REF) SCREW HHC M8-1.25 X 60 G8.8
1 (REF) CAP VACUUM 5/32"
1 (REF) CAP ANTIFREEZE RUBBER
1 (REF) CLAMP HOSE #6 .43-.78
1 (REF) O-RING 5/8" ID X 7/8" OD BUNA-N
1 (REF) PLUG WATER PUMP
SCREW HHC M10-1.25 X 30 G8.8
11 (REF) WASHER FLAT 3/8-M10 ZINC
4 (REF) PLUG EXPANSION 16MM TWINREG
1 (REF) SCREW HHC M12-1.25 X 20 G8.8
1 (REF) SCREW HHC M10-1.25 X 16 G10.9
1 (REF) HEAT SHIELD 2.4L G1
7 (REF) WASHER LOCK M10
1 (REF) WASHER FLAT M12
3 SCREW SHC M8-1.25 X 30 G12.9
3 (REF) WASHER FLAT 5/16-M8 ZINC
4 (REF) WASHER LOCK M8-5/16
4 (REF) SCREW HHC M8-1.25 X 16 G8.8
1 (REF) GASKET INTAKE COVER G1
1 (REF) COVER INTAKE G1
WASHER LOCK 3/8
ASSY MAGPICKUP(3/8-24 MALE)
WASHER SHAKEPROOF EXT 7/16 STL
9
10
7
8
5
6
3
4
1
2
0F9529
0F2608
0F5263
046526
059981
022222
0F5050
042568
0F2573
0F4011
1
8
4
2
1
1
1
5
1
1
WELDMENT RADIATOR SUPPORT 2.4L
RADIATOR 598 X 568 X 49 CPL RH
V-BELT 31/64" X 57-3/8"
WASHER LOCK M10
SCREW HHC M10-1.5 X 30 G10.9
SCREW HHC 5/16-24 X 1-1/2 G5
SHIELD RADIATOR C5
SCREW HHC M6-1.0 X 20 G8.8
PULLEY FAN V-GROOVE 9"
FAN COOL 22" DIA 10 BLADE LH
048031C
031971
0F4496
042911
0F2872
022304
022195
022196
0F8651
045772
0F9867
0F2461
022145
022129
039414
082774
0F2572
0F5689
0F2862
0F2560
022131
0E2507
035685
0F2561
0C8145
052250
0C7043
043790
022473
0C8146
022097
076749
0F9982
0F9781
049813
052644
0C8566
0C2454
090283
080713
045764
065852
069811
069860C
0C7649
39
40
41
42
35
36
37
38
31
32
33
34
27
28
29
30
23
24
25
26
19
20
21
22
15
16
17
18
11
12
13
14
47
48
49
50
43
44
45
46
51
52
53 *
54
55
1
10
1
1
1
1
9
1
1
1
1
2
1
1
1
1
16
2
16
1
8
2
12
1
4
1
7
1
1
1
1
1
1
1
8
2
8
1
1
1
1
1
REF.
1
1
ARM TENSIONER
SCREW SHC SHLDR LKG M8X16LG
SPRING TENSION CPL
PULLEY V-BELT 4" FLANGED
WASHER FLAT 3/8-M10 ZINC
PROBE COOLANT LEVEL 3/8NPTF
CLAMP HOSE #28 1.32-2.25
HUB FLEX PLATE
WASHER FLEX (THIN)
TAPE FOAM 1 X 1 (26.75” LG)
DISK FLEX
BARBED EL 90 3/8 NPT X 3/8
WASHER FLAT 1/4-M6 ZINC
SCREW HHC 5/16-24 X 1.124
WASHER LOCK M6-1/4
TANK COOLANT RECOVERY
CLAMP HOSE BAND 1/4
BEARING #6205 2NSE C3 E SRI2 S
PULLEY 4.5" DIA MACHINED
SCREW HHC M10-1.5 X 30 G8.8
SCREW HHC 1/2-13 X 2" G8
WASHER FLAT 1/2 ZINC
WASHER LOCK 1/2
NUT HEX 1/2-13 STEEL
SCREW HHFC M8-1.25 X 20 W/M6
NUT HEX M10-1.5 G8 YEL CHR
SHAFT FAN DRIVE
RETAINER BEARING
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 35 G8.8
KEY WOODRUFF 4 X 19D
HOSE LOWER RADIATOR
HOSE UPPER RADIATOR 2.4L G1
NUT HEX M6 X 1.0 G8 YEL CHR
SPACER .5 X 1.5 X .25 STL/ZINC
SCREW HHFC M6-1.0 X 20 G8.8
SCREW THF M6-1 X 16 N WA Z/JS
CAP RADIATOR 13 PSI
BRACKET COOLANT TANK
SCREW HHTT M4-0.7 X 8 BP
SPRING CLIP HOLDER .37-.62
CAP HEX 1/4 NPT BRASS
HOSE OIL DRAIN ASSY 21"
CLAMP HOSE .38-.87
* ITEM 53 IS INCLUDED WITH ITEM 64.
BEARING PRESS NOTE:
APPLY LOCTITE 620 BEARING RETAINMENT
COMPOUND TO BEARING SURFACE ON ITEM 37
PRIOR TO PRESSING ITEM 28 ONTO ITEM 37.
ALSO APPLY LOCTITE 620 BEARING RETAINMENT
COMPOUND TO THE OUTSIDE OF 28 PRIOR TO
INSTALLING ITEM 28 INTO ITEM 38.
0E6586
0E0519A
0C8127
049815
022127
062974
0G0190
037561
(1) 6
7
8
1
2
3
4
5
1
1
1
4
1
1
1
1
GASKET BOSCH 32 & 40
ADAPTER CARBURETOR W/PVC CONN
ELEMENT AIR CLEANER
SCREW HHC M5-0.8 X 16 G8.8
NUT HEX 1/4-20 STEEL
STUD TH 1/4-20 X 4-1/2 G2 ZNC
PLATE, AIR CLEANER TOP 2.4L
NUT WING 1/4-20 NYLK
(1) APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON
ONE END OF I/N 6 (STUD) THAT SCREWS INTO I/N 2 (CARB ADAPTER).
21
22
27
28
29
30
23
24
25
26
31
32
33
34
35
9
10
11
12
13
14
15
16
17 *
7
8
5
6
3
4
1
2
18
19
20
050279
050280
0F9723
0E6586
0E4394
0E4395
040105
057753B
0E6382B
0E6382C
0F7790E
0E7121
040976
022097
051751
035685
026915
075580
0F6390B
039253
022145
022129
045771
0G0180
0E8286
026812
0F8379
0F3869
057823
059057
044118
0D1509
0F6155
047290
030340
042574
028414
040173
0F2119
1
1
1 (REF)
1
1
1
1
1
1
1
1
1
4 (REF)
4
4
2
1
2
2
1
2
2
2
1 (REF)
1
2
1
1 (REF)
1
1
4
1
1
1
1
1 (REF)
1 (REF)
2
1
NIPPLE CLOSE 3/4 X 1.375
FLANGE FUEL INLET
REGULATOR ASSY 2.4L
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 CLEAR ZINC
GASKET- THROTTLE BODY
STREET EL 45D 1/2 NPT BRASS
ELBOW 90D 3/4 NPT
NIPPLE PIPE 3/4 NPT X 7
SWITCH, PRESSURE GAS 5" RISE (INCLUDED WITH I/N 3)
CLAMP HOSE #10 .56 - 1.06
HOSE 3/4 ID SAE-30R2 (30.0” LG)
BARBED STR 1/2NPT X 5/8
DECAL INLET PRESSURE
DECAL FUEL INLET NG (NATURAL GAS APPLICATION)
DECAL FUEL INLET LPG (LP VAPOR APPLICATION)
INTAKE ADAPTER MACHINED
GASKET BOSCH 32
ACTUATOR BOSCH 40 GOVERNOR (45KW)
ACTUATOR BOSCH 32 GOVERNOR (35KW)
HOSE COOL 2IN ID 20R4 (45KW)
HOSE 1.5 ID X 2 LG 20R4 (35KW)
VENTURI HOLDER W/40MM ACTUATOR (45KW)
VENTURI HOLDER W/32MM ACTUATOR (35KW)
VENTURI THROTTLE 26MM
O-RING 47.625 ID X 2.38 WIDTH
SCREW SHC M8-1.25 X 20 G12.9
WASHER LOCK M6-1/4
SCREW HHC M6-1.0 X 50 G8.8
CLAMP HOSE #28 1.32-2.25
HARNESS, CPL FUEL JUMPER
HOSE 3/8 ID SINGLE BRAID (10.0”LG)
HOSE 1/4 ID SAE 30R7 (22”LG)
ADAPTOR 1/8NPTF TO 1/8BSPT
BARBED STR 1/8NPT X 1/4
CLAMP HOSE #5.5 .62-.62
O-RING 45.63 ID X 2.62 WIDTH
NOTES:
1.
REGULATOR (I/N 3) AS SHOWN IN ILLUSTRATION IS SET UP FOR
NATURAL GAS APPLICATION.
2.
TO CONFIGURE REGULATOR FOR LP VAPOR, SWITCH HOSE BARB,
HOSE CLAMP (I/N 13) AND HOSE (I/N 14) FROM “OUT-1” TO “OUT-2”.
REPLACE PIPE PLUG FROM “OUT-2” TO “OUT-1”. USE PIPE SEALANT
ON HOSE BARB AND PIPE PLUG. MAKE SURE TO KEEP PORTS FREE
FROM DEBRIS DURING RECONFIGURATION PROCESS.
3*. FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL INLET DECAL P/N
050280 FOR NG FUEL INLET DECAL P/N 050279 (ITEM17).
4 . WHEN SWITCHING FUEL TYPES, THE PROPER DIP SWITCH SITTINGS
MUST BE MADE TO THE CONTROL PANEL. SEE OWNERS MANUAL, FUEL
SECTION FOR MORE DETAILS.
21
22
23
24
25
26
27
28
15
16
17
18
19
20
6
7
8
9
10 *
11
12
13
14
1
2
3
4
5
35
36
37
38
39
40
29
30
31
32
33
34
0G0045 (XX)
0C2454
0F5849 (XX)
087233
0E3257
0F5852 (XX)
0F9833 (XX)
0F5851 (XX)
049813
077992
0F9835 (XX)
0F2786
0F2785
0F3364
0F4880
0F5049
0C2634A
022473
022097
022127
0F3072
078115
0F4051
0F4051A
0F5048D
0E5968
0F3760K
0F3760E
0F4051C
0F3890B
0F4051B
0F3890
0F3890A
0F3760L
042568
0912970094
022447
0G0266
0F8869D
078115A
1
2
2
16
42
2
1
2
3
1
1
2
2
1
2
21
1
2
2
2
1
1
1
1
54
2
2
4
REAR WRAP C2 CPL
SCREW THF M6-1 X 16 N WA Z/JS
DOOR C2
RIVET POP .1875 X .450 SS
SCREW TH-FRM M6 W/CAP SHKPRF W
DISCHARGE DUCT LH & RH SIDE C2
FRONT CORNERS C2
DISCHARGE CENTER DUCT C2
NUT HEX M6 X 1.0 G8 YEL CHR
NUT HEX LOCK M6-1.0 SS NY INS
ROOF C2
SLITTER C4
SPLITTER LOWER C4
SPLITTER STINGER C2
SUPPORT SPLITTER LH C2
TAB PULL
ASSEMBLY COVER ACCESS
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
INSULATION RETAINMENT HANGER
WASHER SELF LOCKING DOME #4-40
INSULATION DOOR C2
INSULATION ROOF TOP
VISE-ACTION LATCH SLOTTED CIR
GASKET EXTRUDED TRIM (440.64” LG)
INSULATION SPLITTER
INSULATION SPLITTER
4
3
1
1
8
2
INSULATION DUCT
RETAINER INSULATION (820)
INSULATION DUCT SIDES
RETAINER INSULATION (450)
RETAINER INSULATION (740)
INSULATION LOWER SPLITTER
1
1
6
2
2
2
SCREW HHC M6-1.0 X 20 G8.8
ASSY WIRE 14 AWG 34.8" GRN/YEL
WASHER SHAKEPROOF INT 1/4
INSULATION W/ REFL. HT. SHIELD
KEY VISE-ACTION LATCH SLOT CIR
WASHER SELF LOCKING DOME #8-32
OPTIONAL COMPARTMENT MATERIALS:
ALL P/N’S WITH AN (XX) SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION.
USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER:
PART NO. MATERIAL COLOR
0XXXXXSN STEEL TAN
0XXXXXAN ALUMINUM TAN
0XXXXXSG STEEL GRAY
0XXXXXAG ALUMINUM GRAY
* ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO
THE BASE FRAME MUST BE SECURED USING ITEM 2 & 5 THREAD FORMING
FASTENER AND ITEM 39 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD
FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN
ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE SECURED IN THE SAME
MANNER.
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
21
22
23
17
18
19
20
0F9794
0G0113
0F9937
0F2830
0F2962
080762
0E0170A
0C2454
0F9736
0G0007
044149
085917
0D2611
0E8816
049721
022097
022473
036797
022259
070006
088775
022241
085917
2
2
2
1
1
2
1
1
1
4
1
2
1
1
1
1
2
4
4
2
2
2
1
MUFFLER 7" X 9" X 18-1/2" 2" IN/OUT
EXHAUST ELBOW 2 1/4 OD 2 1/2OD
BRACKET MUFFLER
MUFFLER BRACKET STIFFENER
MUFFLER STRAP
BOLT U 3/8-16 X 2.62
EXHAUST BLANKET 988MM (C2)
SCREW THF M6-1 X 16 N WA Z/JS
PIPE EXHAUST 2.4L G1
DIFFUSER EXHAUST WELDMENT
GASKET EXHAUST RING
WASHER LOCK 3/8 SS
SCREW HHC 3/8-16 X 1-3/4 SS
EXHAUST FLANGE 2" PIPE
SCREW HHC M6-1.0 X 35 G8.8 BLK
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
BOLT U 5/16-18 X 2.25
NUT HEX 5/16-18 STEEL
WASHER LOCK M8 SS
WASHER FLAT 3/8 SS
NUT HEX 3/8-16 STEEL
WASHER LOCK 3/8 SS
4.)
A
B
C
1.)
A
B
2.)
A
B
3.)
A
B
C2 UNITS
0F9832
0F9832GGS0R
0C2454
C3 UNITS
0F9832B
0F9832KGS0R
0C2454
C4 UNITS
0F9832A
0C2454
C5 UNITS
0F9832C
0F9832D
0F9832EGS0R
0F9832HGS0R
0F9832JGS0R
0F9832FGS0R
0C2464
1
1
1
1
1
1
3
1
3
1
1
3
1
1
4
SHIELD CONN BOX C2
SHIELD CONTROL STAND C2
SCREW THF M6-1 X 16 N WA Z/JS
SHIELD CONTROL STAND C3
SHIELD CONTROL STAND C3
SCREW THF M6-1 X 16 N WA Z/JS
SHIELD CONTROL STAND C4
SCREW THF M6-1 X 16 N WA Z/JS
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SHIELD CONTROL STAND C5
SCREW THF M6-1 X 16 N WA Z/JS
Stationary Emergency Generator
Warranty
GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR
HOME STANDBY/LIGHT COMMERCIAL STATIONARY EMERGENCY PRODUCT BELOW 50kW
For a period of two (2) years from the date of sale, Generac Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/ Certified Generac Power Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Generators used in "Stationary Emergency" applications, as Generac Power Systems, Inc. has defined Stationary
Emergency, provided said generator has been properly installed and inspected on-site by appropriate personnel. Scheduled maintenance, as outlined by the generator owner's manual, is highly recommended. This should be performed by an Authorized/Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been performed on the unit throughout the warranty period.
WARRANTY SCHEDULE
YEARS ONE and TWO — Limited comprehensive coverage on mileage, labor, and parts listed.
• - ALL COMPONENTS
*Start-up and/or On-line Registration, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.
Guidelines: branch thereof.
Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.
ownership of original structure.
• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
• Use of Non-Generac replacement part(s) will void the warranty in its entirety.
applicable).
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1. Any unit built/manufactured prior to January 1, 2005.
2. Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).
3. Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition.
normally exist.
6. Failures caused by any act of God and other force majeure events beyond the manufactures control.
7. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
8. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.
defective part(s).
10. Failure due to misapplication, misrepresentation, or bi-fuel conversion.
11. Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.
12. Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).
13. Overtime, holiday, or emergency labor.
14. Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.
15. Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct cause of the problem.
16. Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/ owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner specific legal rights. Purchaser/owner also may have other rights that vary from state to state.
Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187
Ph: (262) 544-4811 • Fax: (262) 544-4851
1-888-GENERAC (1-888-436-3722)
Bulletin 0171360SVE / Rev. C 12.08 / Printed in U.S.A.
Printed in U.S.A.
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