Home

Grandstream Networks 005261-0 User's Manual

1. d REVISION G 7805 B DATE 4 3 06 QTY 1 1 REF REF REF REF REF REF 1 1 REF REF 1 4 REF REF DESCRIPTION BATTERY TRAY C1CPL STRAP BATTERY RETAINVENT WASHER SHAKEPROOF EXT 71651 SCREWHHC MIO 125 X 25G88 WASHER LOCK MIO WASHER FLAT 3 amp MIO ZINC BATTERY POST COVER RED BATTERY POST COVER BLACK CABLE BATTERY BLACK 1800 CABLE BATT RED 1X 1800 NUT 125 GBYEL CHR WASHER LOCK 516 BOOT CONTACTOR CABLES SCREWTHF 1 16 2 5 WASHER 5 16 8 ZINC BATTERY 12V0C 75 25 GROUP C PAGE 2 OF 2 GROUP D EXPLODED VIEW ENGINE COMMON PARTS DRAWTNG 0F9805 AS SN Z 65 D RS D We EYAN 7 e Sa PAGE 1 OF 2 REVISION G 9514 D DATE 1 15 07 EXPLODED VIEW ENGINE COMMON PARTS DRAWING 0F9805 APPLICABLE TO ITEM PART QTY 1 060158 1 2 022131 3 3 029585 1 4 046525 3 5 052212 1 REF 6 9868 1 REF 7 14271152 1 REF 8 060115 9 10 0034880 1 REF 11 9501 1 REF REVISION G 9514 D DATE 1 15 07 DESCRIPTION ENGINE 24 G1 WASHER FLAT 3 8MIO ZINC EXHAUST ADAPTER 2 4L MACH NUT HEXMIO L25 G8 YEL CHR SCREWHHC MI0 125 X25 088 ALTERNATOR DC WOUT PULLEY PULLEY 117 ODDC ALTERNATOR BRACKET TENSIONER CARTRIDGE OIL FILTER BELT SERPENTINE 44 13 ADAPTER 2 4L CRANKSHAFT MACH ITEM
2. PART 026925 046751 050638 1 REF 1 REF 1 REF 1 1 REF 1 1 1 REF 1 REF 1 1 1 REF 1 REF 6 1 REF 1 REF 1 1 REF 1 REF 1 1 2 3 1 REF 1 6 3 1 REF 1 REF 1 REF 1 REF 1 REF 1 REF 1 REF 1 REF 1 REF 4 REF 1 REF 1 REF 1 REF 7 REF 1 REF 3 REF GROUP D DESCRIPTION PLUG STDPIPE 38STEEL SQHD SWITCHH TEMP 2450 X 38 NPT SPACER ALTERNATOR 241 G1 STARTER 12 VOLT BRACKET DC ALTERNATOR ADAPTER ENGINE 2 4L MACHINE FLEXPLATE 2 POLE 2461 ADAPTOR 1 8 NPTF TO 1 8 BSPT SWITCHOIL PRESSURE 10 PSI 2 POL HOSE 38 87 HOSE DRAIN ASSY 28 SPACER ALTERNATOR 241 SCREWHHC 3816X3G5 WASHER FLAT 531IDX 106200 CAP ANTIFREEZE RUBBER 95DIA CLAP HOSE 340 56 1 06 ADAPTER FLEX PLATE PILOT 2 4L NUT HEX MIO L5 G8 YEL CHR NUT HEX 38 16 STEEL BARBEDEL 9038 NPT X 38 ADAPTER 150 38 NPT SCREWHHC 1 25 X 45 G88 WASHER LOCK 516 WASHER FLAT 516 ZINC WASHER 565 SCREWHHC 2 1 25 15 109 WASHERLOCK MIO SPACER DC ALTERNATOR PULLEY SCREWHHC 15 80688 HARNENG 241 R 200G1 NOT SHOWN SCREWHHC 1 25 60G88 CAPVACUUMS22 CAP ANTIFREEZE RUBBER CLANP HOSE 6 43 78 O RING5 8 IDX7 8 OD BUNAN PLUG WATER PUIVP SCREWHHC 1 25 X 30G88 WASHER FLAT 3 8MIOZINC PLUG EXPANSION IGVMTWINREG SCREWHHC MI2 125 X20G88 SCREWHHC 1 25 16G109 HEATSHELD24L G1 WASHERLO
3. 8 1 e 8 1 Generator Set Lubrication 8 1 Prior to Initial 8 1 Engine Coolant iiec eter pd 8 1 Belt Tensi n 8 1 1 ere 8 1 Initial Inspection for QT Genset Start up 8 1 Startup Checklist 8 2 Preparation for Start up 8 2 Start up Inspection oe erp 8 2 TABLE Standby Generator Sets TABLE CONTENTS Table of Contents CONTENTS OPERATION 9 1 Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch 9 1 Engine Start up and Transfer 9 1 Retransfer and Shutdown 9 1 Operating Unit with Automatic Transfer Switch 9 1 10 1 Maintenance Performed by Authorized Service Facilities 10 1 Every Three Months gt ertet 10 1 Once Every Six Months enesis nnr 10 1 Once Antal ys 10 1 First 100 Operating 10 1 Every 500 Operating Hours
4. T JO 7 HDVd 90 1 01 8016 0 335 NOILOSNNOO M3IA 3015 1441 3dISiNO 403 AIH 103 07313 SNDISN3WIG 30 331N329 MITA NUN G 335 S32V d P RE NOISIAQYd 9 1 317 S 3A U1 219 m NIHLIA 3 079 3 TON SI N39BNVHO 31198 0024 13 4 2 501953439 30 341 5004 440 1417 434 2191 1199 ASIA 59 1511 LN3W32V 18334 3IDIS3d 203 IWANVYW SASNMO 39N33 332 1138 3 1HOI3 50014 4945 2009 13 1331 50 NIvad 4 1 14 4 1HOI3 350 1944 110 0 1HOI3 31113 110 1HOI3 2911 awo 110 WALI 5 13 1111 1553229 WILI 32IAN3S D 147061 1 5 082 HT 3015 SIHL 319007 ONTIdNOD 3198334 LAN 0 0 599 IVafnivN Lee 335 3339338 1102412 NIW 91 335 83AU2 1 043 LTSP z 9 1 335 NIHLIM G3SD 19N3 331330 LSAVHXS 8 1 6 22 9 1 0561 1092 492 LIA 21 31198
5. 120VAC s PAGE 1 DF 5 WIRING DIAGRAM REVISION H 0767 D R SERIES CPL ALTERNATOR DATE 07 23 07 PAGE 1 OF 6 DRAWING 0F6839 GROUP CELL LEX LC 71 2 THREE PHASE R SERIES CONTROL PANEL 6 120 208 LEGEND AR ALTERNATOR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER NEUTRAL BLHC 1 BLACK 4 RED x p x 1 6 4 S38 4 6 956 1 11 i 9 66 53 44 9769 s 52 DIRECT DRIVE 5 54 8 LCB NB 1 Ee GE RATOR DUTPU CUSTOMER CONNECTION E1 E3Sx208VAC E1 E3 Fl TO NB 120VAC TE
6. GE RATOR DUTPU CUSTOMER C ECTIUN E1 TO 240 E1 E3 Fl TO NB 120VAC TE THE 8th DIG F THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE j 120 240 PAGE 5 DF 5 Hed PCM E Cyr REC ECCE x ce p vt e M TEE 441 WIRING DIAGRAM REVISION H 0767 D R SERIES CPL ALTERNATOR DATE 07 23 07 PAGE 5 OF 6 DRAWING 0 6839 GROUP WIRING DIAGRAM R SERIES CPL ALTERNATOR DRAWING 0F6839 NALLY BLANK INIENI PAGE 6 OF 6 atl Se PAGE REVISION H 0767 D DATE 07 23 07 GROUP CONTROL PANEL LEGEND NOTE ALL WIRES ARE AVR AUTOMATIC VOLTAGE REGULATOR AWG UL LISTED UNLESS BCH BATTERY CHARGER OTHERWISE NOTED AS SHOWN BRI DIODE FIELD BOOST 512 CB2 CIRCUIT BREAKER 7A EXCITATION EMISSIONS CUSTOMER CONNECTIONS F1 FUSE BAT POWER 15A ATO TYPE 42 CONNECTOR 2 ON 120 R4 FIELD BOOST RESISTOR 15 OHM UTILITY SUPPLY RL1 RELAY 1 START RELAY RL2 RELAY 2 ENGINE RUN SCR CR BRIDGE MODULE W PCB 50 AUTO OFF MANUAL SW2 SET EXERCISER SWITCH TERMINAL BLOCK 1 TRANSFORMER 6VA UTIL 16 F1 13 T4 15 14 99 1
7. Generac EE E In Line Cylinders and 4 cn oio hire a oro noi dedo dn 2 4 Liter i 3 41 in SUQK asa 3 94 in Compression 8 540 1 Air Intake Naturally Aspirated Hardened ce et preda Hydraulic Engine Parameters Rated Synchronous 60 Hz 3600 HP atrated KW vin sa saq minae nana 60 Hz 71 Exhaust System Exhaust Flow at Rated Output 60 7 429 Exhaust Temperature at Rated 1150 F Combustion Air Requirements Natural Gas Flow at rated power 60 144 Governor Electronic Frequency Regulation Isochronous Steady State Regulation sss 0 2596 Engine Lubrication System Type Of Oll PUMP Gear Qil Filt a Full Flow Spin on Cartridge Crankcase Oil Capacily l a 4 0 5 qts Standby Generator Sets INFOR
8. NON ec 292 XXX e 3 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 elec trode 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 COOLANT CHANGE Every year have an Authorized Service Facility drain flush and refill the cooling system See Specifications for cooling system recommendations 90 00 0 0101 Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance MISCELLANEOUS MAINTENANCE CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean g
9. 10 1 Every 800 Operating Hours 10 1 Exhaust Manifold Procedure 10 1 Intake Manifold Procedure aus eornm 10 1 Cylinder Head Procedure assqa sasa rot een 10 1 Cooling 2 2 10 2 Overload Protection for Engine DC 1 10 2 Checking Fluid Levels 10 2 Check Engine Oll 10 2 Battery Fluid oie eee ua esos a sa PE yasa 10 2 Engine Coolant usu u 10 2 Maintenance Owner Operator Can Perform 10 3 Check Engine Oil Level esee 10 3 CHECK Battery 10 3 Exercise u vieta errans ree eee nore Vue 10 3 Inspect Cooling 10 3 Check Engine Coolant 10 3 Perform Visual 10 3 Inspect Exhaust 2 2 10 3 Check R 10 3 Inspect Engine Governor 10 3 Changing Engine Oil 10 3 Changing the Engine Air Cleaner 10 3 Spark PIGS 580143 10 4 Coolant Changes y k uu asha teer ep eens 10 4 Miscellaneous Maint
10. ANY 39133 LSAVHXS 553009 01 341 SD 1331 3AUW3S3 1317 3404 SS3NMD 32N333333 5 NV 3D1V33N39 30 5 11 303 93410938 SI 3 DH 103 01314 1553009 204 LNOYS 3ADUW3S S38IM 1 41 H31IMS ASASNVAL 01 55300 1103 0 XVW 9 672 081 AB3IIV8 NOILOANNOD 7TWaln3N NOILOANNOD LINGNOD 4931 4901 29 204 v3av 015 5 WOANYW 133HS NDIIVOIJIO3dS 335 NOILVWAOANT 2332398 1102419 S3JANLINJLS ASHLO S3ONVISIG WAWINIW 403 53003 190071 NV 31915 7943933 SV 71138 SV 504 0 915 04 NV ZE VddN 3d 8V2I ddy 1N323303 HLIM 30 440009 NI 311915 1 38 LSAW LINN 5 ANY 403 401943 30 SHL 30 53015 119 NO NDD 3305 11 SJNI130In9 vd 31339ND9 204 LINA HLIM G3I ddnS 30109 NDIIVTIVISNI 32N333433 OND C 8 882 X 3 IM S 3215 1353 9 v 2 SALON 41 86 LHOI3M 35933 SCIAS SNIddIHS 3 00 dl DAYO SE Ge VIVI LHOI3M 90 11 01 4 8016 0 NOISIAS3I 965090 DNIA V zd MAGY 9 SZ 7772 NL11SNI
11. E1 1 gt E1 E3 1 NB 277VAC THE 8th DIG F THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE K 227 480 PAGE 3 DF 5 2 e um E m ee Um uem m T cue uum t eL LS E 441 WIRING DIAGRAM REVISION H 0767 D R SERIES CPL ALTERNATOR DATE 07 23 07 PAGE 3 OF 6 DRAWING 0 6839 GROUP LLL 71 ES CONTROL PANEL 12 1 180 208 ERNA RNA DP CIRCU EUTRAL HAA NA 1 gt 1 4 RED AR 93 16049 9567 B1 SS S1 11 53 44 51 11 53 44 S7 S1 S8 S2 S9 5 AS ECT S4 55 56 29761 PAGE 4 DF 5 REVISION H 0767 D DATE 07 23 07 S10 S11 512 O O IO O
12. DESCRIPTION 4 NUT HEX 1 4 20 STEEL 9 SCREW THF 6 1 16 2 5 1 TAPE ELEC 1 2 FOAM AS REQ D 1 DECAL CUSTOMER CONNECT INSIDE UL CIRCUIT BREAKER JD _ D 1 COVER JD LD CB SHRT STAND CB 0300A 600V S JD6LL INSULATOR CIRCUIT BR JD LD SCREW RHM 1 4 20 3 WASHER FLAT 1 4 M6 ZINC WASHER LOCK M6 1 4 NUT HEX 1 4 20 STEEL SCREW THF M6 1X 16 2 5 TAPE ELEC 1 2 FOAM AS REQ D DECAL CUSTOMER CONNECT INSIDE PD UL CIRCUIT BREAKER QN 1 COVER QN FRMCB 0150A 2P 240V S 2 LL 0175A2P 5 QN2LL 240V 1 BASE QN CIRCUIT BREAKER 2 SCREW HHTT M5 0 8 X 10BP 1 COVER QN CB DISH 4 RIVET 125 X 275 11 SCREW THF 6 1 16 N WA 7 5 1 TAPE ELEC 1 2 FOAM AS REQ D DECAL CUSTOMER CONNECT INSIDE 1 ITEM INCLUDED WITH HARNESS 2 ITEM INCLUDED WITH 0D5464B 3 ITEM USEDWITH EARLY MODEL 208V UNITS ONLY 4 ITEMS USED ON 4 2L MODELS ONL Y PAGE 20F 4 166640 DNIA VYA t dO dDVd 80 21 11 ALYA 8SH X313 79 20 149 X 8LvV H N W Sav3l riv Sava LIV 9 EXPLODED VIEW CPL C2 amp C4 FLEX HSB DRAWING 0F3391D APPLICABLE TO ITEM PART 5 A 0F8137 0 7994 0F8136 E 036261 F 022473 G 022097 H 022127 J 0F8139 K 0 2454 L 022237 M 048527 N 029289 P 022770 01733 6 04185 B 058306 0F4165 0F4143 0F4148 0F4149 0 4151 065247 065250 064478
13. GENERATOR DUTPU CUSTOMER C ECTION E1 Fe 1 Sxe08VAC EI El OR NB 120 THE 8th DIG F THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 208 PAGE 4 OF 6 WIRING DIAGRAM R SERIES CPL ALTERNATOR DRAWING 4 0F6839 GROUP apa pi aco uui t a 71 5 THREE PHASE DELTA R SERIES CONTROL PANEL 7 WIRE 120 240 LEGEND AR ALTERNATUR ROTOR AS ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER NEUTRAL BLOC 1 BLACK 4 RED AR gt 1 amp 6 4 S38 e 4 6 956 51 1 amp 66 53 44 i 9769 85 2 56 53 4 e 00 LCB NB 1
14. Pi oil if equipped Not required for engines equipped with hydraulic lifters See the Specification section for lifter type 11 3 60 20 3 ed 100 95 45 Stationary Emergency Generator MAINTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom Task Required Task Required Task Task Required mended Comp to be done Comp to be done Comp Required Comp to be done to be done Date 3 months Date Semi Date to be done Date Bi monthly Initials Initials annually Initials Annually Initials annually 10 hrs 30 hrs 50 hrs 100 hrs 250 hrs Start and 18 19 20 21 22 23 24 25 exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary Perform an engine oil analysis send a sample to a lab for results Change the engine oil and filters if the analysis results indicate this is required engine oil T engine oil filter s Replace engine spark plugs Clean and re gap or replace as necessary Replace the engine air filter s Perform a 5 minute no load operational run of the unit looking for any post service problems Return the unit to standby setup for
15. M3IA dAl 6 89 OSZI 33S 4 1 LY 001 L 21 5 85 69 61 2 1 228 1 161 584 ALIAVAD 3WV3 3 ONILNOAOW JU 331N32 SDIV33N39 30 WOLLO NO 3194007 530914 v 3 DH 490 1114 01 ONILNNOW VIC GES GEI SS322V 404 49100 3ADW3S GROUP H E C3 UNITS C5 UNITS E z 5 C2 UNITS C4 CB CONNECTION BOX SHIELDING C2 C4 EXPLODED VIEW DRAWING REVISION H 0973 A 0G0258D PAGE 1 OF2 8 29 07 DATE EXPLODED VIEW C4 CB CONNECTION BOX SHIELDING C2 C4 DRAWING 0602580 APPLICABLE PART QTY DESCRIPTION 1 C2 UNITS A 0F9832 1 SHIELD CONN BOX C2 0F9832GGSOR 1 SHIELD CONTROL STAND C2 B 002454 4 SCREW THF M6 1 X 16 N WA Z JS 2 C3 UNITS A 0F9832B 1 SHIELD CONTROL STAND C3 0F9832KGSOR 1 SHIELD CONTROL STAND C3 B 002454 3 SCREW THF M6 1 X 16 N WA Z JS 3 C4 UNITS A 0F9832A 1 SHIELD CONTROL STAND C4 B 002454 3 SCREW THF M6 1 X 16 N WA Z JS 4 C5 UNITS A 0F9832C 1 SHIELD CONTROL STAND C5 0F9832D 1 SHIELD CONTROL STAND C5 0F9832EGSOR 1 SHIELD CONTROL STAND C5 0F9832HGSOR 1 SHIELD CONTROL STAND C5 0F9832JGSOR 1 SHIELD CONTROL STAND C5 B 0F9832FGSOR 1 SHIELD CONTROL STAND C5 002464 3 SCREW THF M6 1 X 16 N WA Z JS REVISION H 0973 A DATE 8 29 07 GROUP H PAGE 2 OF 2 Stationary Emergency Generator Warranty GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR HOME STANDBY LIGHT COMMERCIAL STATIONA
16. brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via a 15 amp fuse These overcurrent protection devices will open if the circuit is overloaded caution If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse CHECKING FLUID LEVELS CHECK ENGINE OIL Check engine crankcase oil level Figure 10 1 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Engine Oil Recommen dations for recommended oils 90 00 0 Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance Figure 10 1 Oil Dipstick and Oil Fill Cap Oil Fill Cap gt lt S d 4 Oi s COSE 7 Dipstick E A BATTERY FLUID Check battery electrolyte fluid based on the Maintenance Schedule Fluid should cov
17. 0 4186 0F4186AGSOR E 036261 2 053640 26 038150 2 H 022264 2 J 022411 K 029289 L 0F1733 2 022129 N 0F8432 0F8432A P 0C2454 2 0 8451 2s 049897 2T 022145 2 0 045771 2 V 0 843 WICB 063259 1 0 4187 0 4166 0 1733 042419 023897 G 022152 H 022158 J 0C2454 K 029289 2L 052647 2 046526 N WICB P 0A7822 08 WICB T 023334 U 022097 V 022473 2W WICB 2X WICB Y 063259 REVISION 3478 DATE 11 12 08 QTY DESCRIPTION UL CIRCUIT BREAKER QJ 2P 1 COVER QJ 2P FRM CB CB 0225A 240V 2P S QJ22 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 ZIJS 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 DECAL CUSTOMER CONNECT INSIDE UL CIRCUIT BREAKER 225 2 amp 3P 1 COVER CB C2 C4 225AF 3 SCREW SHC 8 1 25 X 25 G12 9 REF X CIRCUIT BREAKERS 200A FRAME REF 0040 480V 225AF REF 0125A 480V G 225AF REF 0150 480V 225AF REF 0200 480V 225AF REF 200A FRAME G 240V 2P REF CB 175A 2 POLE 240V 225AF 2P REF 200A 2 POLE 240V 225AF 2P 1 COVER CB DISH 225AF 3P COVER CB DISH 225AF 2P 4 RIVET POP 125 X 275 SS 24 SCREW 48 32 X 3 1 4 214 WASHER FLAT 8 ZINC 214 WASHER LOCK 8 M4 24
18. 049226 12 WASHERLOCK 31 575 1 RES WW ISR 5 52 CONN gt 055881 2 SCREWPHIT VB 5 06X 10 3 025896 2 SCREWPHIT VB 506X 16 3 0C2265 4 SCREWPHIT M40 7 X 12 ZYC 0 3990 2 SCREWPHITM4 t07 X 10ZYC 36 091526 4 SCREWPPHMIMB 0 8 X 12 ZNC 3 051716 9 NUT HEX M508 G8 CLEAR ZINC 38 072224 2 SCREWPPHMIMB 0 8 X30 SS 39 075476 2 5 7 X 16 40 013180 2 WASHERFLAT 41 2 WASHER LOCK SI MI 42 051715 2 NUT HEXM 07G8 YEL CHR 43 043182 7 WASHERLOCK NB 44 051714 7 NUT 5 G8 YEL CHR 5 OF3192 1 SUPPORT ANGLE PCB 4 E7408C 1 FUSE ATO 15 BLUE 47 029785 1 HARN 3600RPMR200 CONTROL PNL COMPONENTS INSTALLED PER THS DRAWING A 056739 1 RELAY SOLENOID MNT B 2 SCREWHHC 1 4 20 34G5 002473 4 WASHER FLAT 144 21 D 02209 2 WASHER LOCK 6 1 4 E 022127 2 NUT HEX 1 4 20STEEL F OF6145 AR SEAL WEATHER G OF2627A 1 COVER CONTROL PANEL SIDE H 091526 4 SCREW PPHMIMB 0 8 X 12 ZNC J 019226 4 WASHER LOCK K 051713 4 WASHER FLAT L 063545 1 DANGER HIGH VOLTAGE SPANISH REVISION G 8959 A DATE 9 28 06 GROUP B 2 OF 2 GROUP ENGINE 6 7 SUPPORT 5 8 2 25 gt 9 EXPLODED VIEW MOUNTING BASE 2 4L C2 24 REVISION H 2901 C DATE 8 18 08 DRAWING 0F9807 PAGE OF 2 EXPLODED VIEW MOUNTING BASE 2 4L C2 DRAWING 0F9807 APPLICABLE TO ITEM PART QTY D
19. 12 Volts Voltage Regulator Electronic SINGIN te Single phase aea 196 FealulGS temi hanes V F Adjustable Adjustable Voltage and Gain LED Indicators Power Adjustment for Ambient Conditions Temperature Deration 3 for every 10 C above 25 1 65 for every 10 above 77 Altitude Deration 1 for every 100 m above 183 3 for every 1000 ft above 600 Controller R 200 6 1 90 50 8 ed 0202908090 GENERAL INFORMATION Standby Generator Sets Specifications GENERAL INFORMATION Figure 1 Interconnections CONTROL PANEL TO ALTERNATOR NEUTRAL GENERATOR CONNECTION BOX CIRCUIT BREAKER o o o GROUND 120 Nowra FRAME RAIL Ground Level Concrete Slab STUB UP AREA 1 See Install Dwg for Dimensions COLD WEATHER KIT For cold climates optional cold weather kit part number 0 6148 is recommended The kit includes Battery Warmer 4 Junction Box with hardware 6 qt pack 5W 30 synthetic oil engine RECONFIG
20. AND COLOR OPTION USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER OXXXXXSN OXXXXXAN OXXXXXSG OXXXXXAG ALUMINUM ENCLOSURE NOTE ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 2 amp 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 GROUP F PAGE 2 OF 2 19640 ONIM VYA T AO 1 4 90 71 6 H LVG MASY Tr c 5 S3 1H30N V LV9L D NOISIATH 15 3dIS H H OL LNAWLYVdNOS OL EXPLODED VIEW MUFFLER EXHAUST 2 41 45KW C2 DRAWING 0F9812 GROUP F APPLICABLE TO ITEM PART QTY DESCRIPTION 1 029794 1 MUFFLER 7 X9 X 18 1 2 2 INOUT 2 050113 1 EXHAUST ELBOW2 1 4002 1200 3 0F9937 1 BRACKET MUFFLER 4 022830 1 MUFFLER BRACKET STIFFENER 5 022962 1 5 6 2 BOLT U 38 16 2 62 7 OEOT 0A 1 EXHAUST BLANKET 988 2 8 0C2454 4 SCREWTHF 1 16 ZJ S 9 0F9736 1 PIPE EXHAUST 24 G1 10 050007 1 DIFFUSER EXHAUST MELDIVENT 11 044149 1 GASKET EXHAUST RING 2 085017 2 WASHERLOCK 3855 1 002611 2 SCREWHHC 3 8 16 13455 08816 1 EXHAUST FLANGE 2 PIPE 15 019721 2 SCREWHHC M6 10X 35 8 BLK 16 022097 2 WASHER LOCK 1 4 17 022473 2 WASHER FLAT 14M6 ANC 18 086797 1 BOLT U5 16 18X2
21. ASSY STR 390 25AD1 CPL 0G2099 1 ASSY STR 390 25KD3 CPL 0G2100 1 ASSY STR 390 25JD3 CPL 063736 1 ASSY STR 2390 60AD2 0G3737 1 ASSY STR 390 60KW 2P 3PH 208V 063738 1 ASSY STR 390 60KW 2 480V 066104 1 STR 2390 45JD1 CPL 0G6563 1 STR 390 35AD1 CPL 0G6565 1 STR 390 35GD1 CPL 0G6566 1 STR 390 35KD1 CPL 0G6567 1 STR 390 35JD1 CPL 0H0201 1 STR 2390 60JD2 CPL 0H1299 1 ASSY STR 390 36AD1 CPL 0H1300 1 ASSY STR 390 36JD1 CPL 0H1301 1 ASSY STR 390 36 GD1 CPL 3 0C9708 REF INSTR HYPOT TEST NOT SHOWN 4 SEE ENGINE EV REF ENGINE ADAPTER 5 SEE ENGINE EV REF FLEXPLATE 6 0F5767B 1 ASSY FLYWHEEL CPL W 40MM FAN B 7 0 5706 1 REAR BEARING CARRIER 390 DRCT 8 0F7874 1 ASSY BRUSH HOLDER 390 HSB 9 0G0587 1 GUARD REAR BEARING CARRIER 10 038150 4 WASHER FLAT 8 ZINC 11 023454 1 KEY WOODRUFF 12 077043E 1 CONDUIT FLEX 1 0 ID 35 LG 13 04576100BU 4 STUD M14 2 0 570 G5 ZINC 14 052646 4 WASHER FLAT M14 15 043123 4 WASHER LOCK M14 16 051779 4 NUT HEX M14 2 0 G8 YEL CHR 17 0A2601 1 SCREW HHC M16 2 0 X 45 G8 8 18 072879 1 SPACER 69 X 2 75 X 37 ST ZNC 19 0 8408 4 SCREW 10 1 50 X 16 610 9 20 046526 4 WASHER LOCK M10 21 0 3992 4 SCREW M4 0 7 X 16 BP 22 022264 4 WASHER LOCK 8 M4 23 047248 1 BALL BEARING 45 MM 24 070892 1 SLIP RING MACHINED 25 0G0588 1 GUARD REAR BEARING CARRIER 26 077043A 1 CONDUIT FLEX 38 ID 60 REVISION H 3379 K DATE 10 23 08 ROTOR REPLACEMENT PARTS GROUP A PAGE 2 OF 2 0969630 ONIM
22. Annually annually Initials 50 hrs 100 hrs 250 hrs 10 hrs 30 hrs Stationary Emergency Generator MAINTENANCE MAINTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom Task Required Task Required Task Task Required Task mended Comp to be done Comp to be done Comp Required Comp to be done Comp to be done Date 3 months Date Semi Date to be done Date Bi Date monthly Initials Initials annually Initials Annually Initials annually Initials 10 hrs 30 hrs 50 hrs 100 hrs 250 hrs 10 Check the engine accessory drive belts and fan coupling device if equipped for correct tension wear weather cracking and damage Replace as necessary 11 Check the engine valve clearance 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 operating conditions Correct as necessary 15 Replace the engine accessory drive belts 16 Check gearbox oil level if equipped
23. Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result AN Ethylene glycol base antifreeze is poisonous Do not use mouth to siphon coolant from the radiator recovery bottle or any container Wash hands thoroughly after handling Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them 80 01 G ed 10091034 GENERAL INFORMATION ENGINE PROTECTIVE DEVICES The Stationary Emergency Generator may be required to operate for long periods of time without an opera tor 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 run ning too fast NOTE Engine protective switches and sensors are men tioned here for the reader s convenience Also refer to the applicable control panel manual for additional automatic engine shutdown informa tion HIGH COOLANT TEMPERATURE SWITCH 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
24. HEX 8 32 STEEL 2 TAPE ELEC 1 2 FOAM 1 DECAL CUSTOMER CONNECT INSIDE 6 9 WASHER LOCK 8 5 16 1 INSULATOR CB 225 3P 1 INSULATOR CB 225AF 2P 11 SCREW THF M6 1 X 16 N WA ZIJS 2 3 106510155 300 MCM 6 AL CU 46 SCREW SHC 8 1 25 X 20 G8 4 6 WASHER FLAT 5 16 M8 ZINC 2 3 NUT HEX 8 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 X CIRCUIT BREAKERS 400A FRAME DECAL CUSTOMER CONNECT INSIDE SCREW RHM 10 32 X 4 WASHER FLAT 10 ZINC WASHER LOCK 10 NUT HEX 10 32 STEEL SCREW THF M6 1 X 16 N WA ZIJS TAPE ELEC 1 2 FOAM SCREW SHC M10 1 5 X 25 G12 9 WASHER LOCK M10 BUS BAR CB ADAPTER 225 400 A LUG SLDLSS 600 250 1 0 X 1 4 28 TERM COVER CB SCREW 1 4 28 X 1 2 G5 WASHER LOCK M6 1 4 6 WASHER FLAT 1 4 M6 ZINC 23 SCREW SHC M10 1 5 X 25 612 9 2 13 WASHER LOCK M10 1 DECAL TERMINAL SHOCK HZD BI ITEM re rommoou co 2 005466 039287 022145 022129 045771 045335 083896 047822 061968 061970 032077 040532 0 3990 0 7890 0 6002 022859 060008 023897 022152 022158 0 1733 029289 002454 GROUP A QTY DESCRIPTION NEUTRAL BLOCK 390 200 400A 2 BUS BAR NEUTRAL BLOCK 390 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 SCREW HHC 1 4 28 X 3 4 G5 WASHER LOCK 1 4 M6 SS
25. SHLD 766 6 DEG DRIVER ELEC GOVERNOR DIST DISTRIBUTOR FS FUEL SOLENOID 52 AUX FUEL SOLENOID GOV ELEC GOVERNOR ACTUATOR HCT HIGH COOLANT TEMP SWITCH IGNITION COIL J1 CONNECTOR 1 LFP LOW FUEL PRESSURE SWITCH LOS LOW OIL PRESSURE SWITCH 1 MAGNETIC PICKUP 02 OXYGEN SENSOR SM STARTER MOTOR WLS COOLANT LEVEL SWITCH COIL 122 COIL 125 ux 0 79 r fT 1 808 15 Bi 79711 loptionaL EMISSION CONTROL L DSF Ea ana a gs ap E Z 4 SCHEMATIC DIAGRAM REVISION G 8208 A 2 4L 2 POLE DATE 05 24 06 FAS DRAWING 060118 965090 DNIA V zd IO I HDVd MAGY 9 SZ 7772 5 D M3IA 1 0 3 335 ONILNNOW 31340 00 Q30N3NWD233 510108 SMDOHONV ABINDSVNW VIG G D 533914 3 DH QNILNNOW 910 GES GEI 9 53415 1 044 3OBVHOSIT XIV ANY 15 11438
26. THE 8th DIG F THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 208 PAGE 2 OF 5 ye cc I hh ee 241 WIRING DIAGRAM REVISION H 0767 D R SERIES CPL ALTERNATOR DATE 07 23 07 PAGE 2 OF 6 DRAWING 0 6839 GROUP Ld DC LT 71 PTIDN 3 THREE PHASE R SERIES CONTROL PANEL 6 WIRE 277 480V LEGEND ALTERNATOR ROTOR 5 ALTERNATOR STATOR MLCB MAIN CIRCUIT BREAKER NEUTRAL BLOC 1 BLACK 4 RED AR gt 1 x 555 x e 4 m C SNP 9559 st5 1 S 6 S 516 44 S 769 52 DIRECT DRIVE 5 55 O O O L LCB NB O O O O GENERATOR CUSTOMER C
27. TO THE OUTSIDE OF 28 PRIOR TO INSTALLING ITEM28 INTO ITEM3 amp REVISION G 8927 A DATE 10 13 06 PAGE 2 OF 2 608630 ONIM VAGA C 1 4 10 81 01 ALYA CO H3NV3TO 1 4 9 EXPLODED VIEW AIR CLEANER C2 DRAWING 0F9809 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0 6586 1 GASKET BOSCH 32 8 40 2 0 0519 1 ADAPTER CARBURETOR W PVC CONN 3 0C8127 1 ELEMENT AIR CLEANER 4 049815 4 SCREW HHC M5 0 8 X 16 G8 8 5 022127 1 NUT HEX 1 4 20 STEEL 1 6 062974 1 STUD 1 4 20 X 4 1 2 G2 ZNC 7 060190 1 PLATE AIR CLEANER 2 41 8 037561 1 NUT WING 1 4 20 NYLK REVISION H 1248 A DATE 10 18 07 1 APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON ONE END OF 6 STUD THAT SCREWS INTO I N 2 CARB ADAPTER GROUP D PAGE 2 OF 2 35 GROUP E 2 13 3 it eta 2 A S9 ETO N 9 2 am 217 T N Hin 4 riu U SEE NOTE 1 2 amp 3 FOR REGULATOR INFORMATION CONNECT TO WIRE HARNESS REVISION G 7590 B DATE 3 7 06 0F9810 DRAWING PAGE 2 EXPLODED VIEW FUEL SYSTEM 24L C2 CPL DRAWING 0F9810 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 026915 2 NPPLE CLOSE 34X 1 375 2 075580 1 FLANGE FUEL INLET 3 0263908 1 REGULATOR ASSY 24 4 089253 2 SCREWHHC IVB 1 25 X 20688 5 022145 2 WASHER FLAT 5 16 MB
28. VACA JO 1 4 90 8 6 ALVA 009 002 4 V 6S68 D NOISIATY QHGO Id XH 4 0 Ze REM qa 3 22921872 EXPLODED VIEW 200 3600 RPM DRAWING 0F9696D APPLICABLE TO ITEM PART QTY DESCRIPTION COMPONENTS INCLUDED IN OF9696E 1 OF1823A 1 ENCL HSB CONTROL PANEL 2 0F3078 1 COVER CONTROL PANEL 3 OF2606 1 HINGE CONTINUOUS H PANEL 4 086261 6 RIVET POP 125 27555 5 043181 4 SCREWPHMIVB 05 10MM 6 052777 7 WASHER 7 0287108 1 ASSY PCB CPL2CTRLR 3600 RPM 8 021252 4 HOLDER FUSE WCKMANN 1786150 9 021263 1 ADPTR 5 1786191 10 021264 1 ADPTR LH SIDE WCKIVAN 1786192 11 02175 1 ASSY PCB 2 127 UL BATT CHGR 2 067680 1 ASSY VOLTAGE REGULATOR 60HZ 13 0 6875 2 RELAY 120 FORMWDIODE 55911 1 BLOCK TERM20A 12 X 6X 1100V 15 1 DECAL CPL CONTROL PANEL FUSES 16 0 3161 1 ASSY PCB BOSCH GOV DRIVER 17 0F5090 1 ASSY PCB SCR BRIDGE 18 055262 1 DECAL CPL 39L 1 19 5 4 SPACER 95H32ID 20 029673 1 DIO BRIDGE 25A 600 21 048467 1 CRCT BRK 7 X 1ETA46 500P 2 OF 1958 1 PLATE HARNESS 23 082573 1 SWITCHRKR DPST 125 SPD E4494 1 SWITCH RKR DPDT ON OFF ON 5 0 3215 1 DECAL CONTROL HSB 26 026305 3 SEAL COVER 3 18 12 7 382 7 1 SEAL COVER 3 18 12 7 283 28 025886 3 SCREWHHPMIVB 0 8 X 12 29 051713 12 WASHER FLAT 30
29. ZINC 6 022129 2 WASHER LOCK MB 5 16 7 045771 2 NUT HEX 1 25 GB CLEAR ZINC 8 050180 1 REF GASKET THROTTLE BODY 9 1 STREET EL 45D 1 2 NPT BRASS 10 026812 2 3 4 028379 1 NPPLE PIPE 341 7 12 023869 1 REF PRESSURE GAS 5 RISE INCLUDED WTHI N 3 13 057223 4 HOSE 0 56 1 06 14 059057 1 HOSE 3 4 ID SAE 30R2 30 0 LG 15 024118 1 BARBED STR 1 2NPT X 5 8 16 001509 1 DECAL INLET PRESSURE 17 1 DECAL FUEL NG NATURAL GAS APPLICATION 050280 1 DECAL FUEL INLET LPG LP VAPOR APPLICATION 18 0F9723 1 REF INTAKE ADAPTER MACHINED 19 E6586 1 GASKET BOSCH 32 2 E4304 1 ACTUATOR BOSCH 4OGOVERNOR 45 4 1 ACTUATOR BOSCH 32 GOVERNOR 21 040105 1 HOSE COOL ANID 2084 45KW 05775388 1 HOSE 15IDX2LG 2 OEG3EDB 1 VENTURI HOLDER W40MMACTUATOR KW 0 6382 1 VENTURI HOLDER W32MMACTUATOR 35KVJ 23 F7790E 1 VENTURI THROTTLE 26 24 7121 1 ORING 47 65 IDX 2 38 25 040976 4 REF 5 5 125 20 129 26 02209 4 WASHERLOCK 1 4 27 051751 4 SCREWHHC 1 0 50688 28 085685 2 CLAMP HOSE 28 132 225 29 6155 1 HARNESS CPL FUEL J UVPER 30 017290 1 HOSE 38IDSINGLE 10016 31 080840 1 HOSE 1 4 IDSAE 3087 221 gt 02574 1 REF ADAPTORI 8NPTF Y8BSPT 33 008414 1 REF BARBED STR 1 8 X 1 4 34 040173 2 CAMP HOSE 55 62 62 35 or2119 1 ORING 45 63 IDX 262 WDTH REVISION G 759
30. changing the engine oil be sure to use 5W 30 engine oil caution Any attempt to crank start the engine before it has been properly serviced with the recom mended oil may result in an engine failure NOTE For temperatures below 32 it is strongly recom mended to use the optional Cold Weather Start Kit part number listed in the Specification Section The oil grade for temperatures below 32 F is 5W 30 synthetic oil Stationary Emergency Generator Equipment Description GENERAL INFORMATION COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is listed in the specifications Use only deion ized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the recommended coolant mixture When adding coolant always add the recommended 50 50 mixture caution AN Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chro mium hydroxide green slime forms and will cause overheating Engines that have been oper ated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment DIG A
31. clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury 90 20 0 OLOUIEN BATTERY MAINTENANCE The battery should be inspected per Section 4 7 Scheduled Maintenance The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer DANI A A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charg ing The slightest spark can ignite the gas and cause an explosion Such an explosion can shat ter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smok ing open flame sparks or any spark producing tools or equipment near the battery Battery electrolyte fluid is an extremely
32. corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster battery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging warninc Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the 120VAC power supply to the battery is turned OFF or sparking may occur at the bat tery posts as the cables are attached and cause an explosion BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 26 525 Q 0 deg F NOTE The BCI number should be located directly on the battery Stationary Emergency Generator MAINTENANCE 5 MAINTENANCE 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 u
33. of installing dealer Yellow Copy For the customer s records Stationary Emergency Generator OD 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 man ual operation only the following procedure applies A manually operated transfer switch is one that will not provide automatic start up and does not include an intelligence circuit ENGINE START UP AND TRANSFER For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch DIG A AN The Maintenance Disconnect Switch and the AUTO OFF MANUAL switches if so equipped must be set properly or the generator will crank and start as soon as the utility power to the transfer switch is turned off Refer to applicable control panel and transfer switch manuals for more information Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to UTILITY Do not attempt manual operation until all power supplies to the transfer switch have been posi tively turned off or extremely dangerous pos sibly lethal electrical shock will result Transfer switch enclosure doo
34. operation when required 60 20 3 ed 100425415 11 4 MAINTENANCE Task Comp Date Initials TROUBLESHOOTING Stationary Emergency Generator Troubleshooting TROUBLESHOOTING GUIDE CAUSE PROBLEM Engine won t crank Engine cranks but won t start Engine starts hard runs rough Engine starts then shuts down AUTO OFF MANUAL Switch at OFF engine continues to run No AC output from generator 1 2 15 amp fuse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery 5 amp fuse blown Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Door on tank not closed Flame arrestor air cleaner plugged or damaged Plugged fuel line Defective spark plugs Fuel pressure incorrect Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch Defective AUTO OFF MANUAL switch Open disconnected wire 415A between AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal
35. 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 9 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 Stationary Emergency Generator Engine Protective Devices GENERAL INFORMATION 9 OVERCRANK SHUTDOWN After a prespecified duration of cranking this func tion ends the cranking if the engine has failed to start The overcrank LED will turn ON Turn OFF the AUTO OFF MANUAL switch then turn switch back to AUTO to reset the generator control board NOTE If the fault is not corrected the overcrank feature will continue to activate Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total OVERSPEED SHUTDOWN A speed circuit controls engine cranking start up operation and shutdown Engine speed signals are delivered to the circuit board whenever the unit is running Should
36. 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 1 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 har ness adjacent to the DC alternator It is used to pre vent 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 replace ment part number 80 60 8 100 GENERAL INFORMATION 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 na
37. 0 B DATE 3 7 06 NOTES 1 2 REGULATOR AS SHOANINILLUSTRATIONIS SET UP FOR NATURAL GAS APPLICATION TOCONHGURE REGULATOR FOR LP VAPOR SWTCHHOSE BARB HOSE CLAMP 13 AND HOSE 14 FROM OUI 1 OUT 2 REPLACE PIPE PLUG FROM OUT 2 TO OUT 1 USE PIPE SEALANT ONHOSE BARB AND PIPE PLUG MAKE SURE TO KEEP PORTS FREE FROMDEBRIS DURING RECONFIGURATION PROCESS FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL INLET DECAL P N 060280 FOR NG FUEL INLET DECAL P N 050279 ITEML7 WHEN SWITCHING FUEL TYPES THE PROPER DIP SWITCH SITTINGS MUST BE MADE TO THE CONTROL PANEL SEE OWNERS MANUAL FUEL SECTIONFOR DETAILS GROUP E PAGE 2 OF 2 GROUP INSULATION AND RETAINERS LOCATED ON THE NEAR SIDE LOCATED ON THE FAR SIDE TYPICAL MOUNTING OF ACOUSTIC 7 INSULATION AND RETAINERS INSULATION SEE DETAIL AND B FOR SPLITTER VARIATIONS EXPLODED VIEW ENCLOSURE C2 0 lt m WM a ED REVISION G 9222 C DATE 11 6 06 DRAWTNG 0F9811 PAGE 1 OF2 EXPLODED VIEW ENCLOSURE C2 DRAWTNG 0F9811 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0G0045 XX 2 0C2454 3 0F5849 XX 4 087233 5 0E3257 6 0F5852 XX 7 0F9833 XX 8 0F5851 XX 9 049813 10 077992 11 0 9835 12 0 2786 13 0 2785 4 0 3364 15 0 4880 16 0 5049 17 0 2634 18 022473
38. 19 022097 20 022127 21 0 3072 22 078115 23 0 4051 24 0 4051 25 0 50480 26 0 5968 27 0F3760K 28 0F3760E 29 0F4051C 30 0F3890B 31 0 4051 32 0 3890 33 0F3890A 34 0F3760L 35 042568 36 0912970094 37 022447 38 0G0266 39 0F8869D 40 078115A REVISION G 9222 C DATE 11 6 06 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 amp 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 INSULATION DUCT RETAINER INSULATION 820 INSULATION DUCT SIDES RETAINER INSULATION 450 RETAINER INSULATION 740 INSULATION LOWER SPLITTER 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 48 32 OPTIONAL COMPARTMENT MATERIALS ALL P N S WITH AN XX SUFFIX INDICATE A MULTIPLE MATERIAL
39. 25 19 022259 2 NUT HEX 5116 18 STEEL 20 070006 2 WASHER LOCK MBSS 088775 2 WASHERFLAT 38SS 2 022241 4 NUT 398 165 23 085917 4 WASHERLOCK 38 SS REVISION G 7647 A DATE 3 14 06 PAGE 2 OF 2 GROUP y PTION 1 SINGLE PHASE R SERIES CONTROL PANEL 240V LEGEND AR ALTERNATOR ROTOR AS ALTERNATUR STATUR MLCB MAIN CIRCUIT BREAK NEUTRAL BLOC 1 4 RED gt 1 amp e 4 r c 956 gt 1 11 11 6 44 44 9769 11 44 AS BS NB pM JENERATOR DUTPU CUSTDMER 1 m 240VAC E1 NB 120
40. 43 2 DISKFLEX 2 013790 1 BARBEDEL 9038 X38 23 022173 16 WASHER FLAT 1 4HV6 ZINC OC8146 2 5 Y1624X 1124 25 2297 16 WASHER LOCK M6 1 4 26 076749 1 TANK COOLANT RECOVERY 27 048081C 1 CLANP HOSE BAND 1 4 28 081971 1 BEARING 56205 58125 29 49 6 1 PULLEY 45 DIA MACHINED 30 042911 1 SCREWHHC MIO L5X 30688 31 0 2872 1 SCREWHHC 1 2 13 2 G8 32 2 WASHER FLAT 1 2ZINC 022195 1 WASHER LOCK 1 2 x 022196 1 NUT HEX 1 2 13 STEEL 8651 9 SCREWHHFC 1 25 X 20 5 36 015772 1 NUT HEXMIO L5G8 YEL CHR 3 029867 1 SHAFT 38 F2461 1 RETAINER BEARING 39 022145 1 WASHER FLAT 5 16 B ZINC 40 022129 10 WASHER LOCK 5 16 41 1 SCREWHHC 125 35688 42 082774 1 KEY WOODRUFF 4X 19D 2 1 HOSE LOWER RADIATOR 4 OF9781 1 HOSE UPPER RADIATOR 24 G1 45 049813 8 NUT LOGBYEL CHR 46 264 1 SPACER 5X 15X 25 STUZINC 4 0 8566 8 SCREWHHFC 1 0 20688 48 2454 2 SCREWTHF 16 ZJ 49 1 CAP RADIATOR 13 PSI 50 080713 1 BRACKET COOLANT TANK 51 045764 1 SCREWHHIT IM4 0 7 X 52 065852 1 SPRING CLIP HOLDER 37 62 53 069811 CAP HEX 1 4NPT BRASS x 069860 1 HOSE OIL DRAIN ASSY 21 55 7649 1 CLAMP HOSE 38 87 ITEM53IS INCLUDED WITH 4 BEARING PRESS NOTE APPLY LOCTITE 620 BEARING RETAINVENT COMPOUND TO BEARING SURFACE ONITEM37 PRIOR TO PRESSING ITEM28 ONTO ITEM 37 ALSO APPLY LOCTITE 620 BEARING RETAINVENT COMPOUND
41. 60 10 ed 200 GENERAL INFORMATION EQUIPMENT DESCRIPTION This equipment is a revolving field alternating cur rent 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 num bers The unit comes complete with a sound attenu ated 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 avail able 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 1 1 66 The generator is self ventilated and drip proof con structed The voltage waveform deviation total harmonic content of the AC waveform and telephone influ ence factor have been evaluated and are acceptable according to NEMA MG1 32 ENGINE OIL RECOMMENDATIONS The unit has been filled with 5W 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
42. 999 Une Wa 1 CB J 14 14 EC 49 AFS OUT 1 808 a 808 80842 808 START RELAY 2 56A7 1 225 FUEL RUN RELAY T 3 14A Ly 224 1 0 4 lt 0 2 WIRE START 1 4 185 d 5 15 ER 2 5 2 6 1178 MAN AUTO INPUT 7 1815A __ ____ 16VAC SENSE 1 18 224 ALARM RELAY 2 CB2 XFER RELAY 710 23 N2 am MAN INPUT 1 11 239 0 16 SENSE 2 112 225 E 2 IN P ji EMISSIONS AVR 4A 44 F s 2 N OPTIONAL EMISSIONS Au ONLY 5 2 0 56 601 601 56 11 34 SINGLE PHASE STATOR SHOWN FOR 3 5 SEE DWG OF6839 CENTER TERMINAL ork NOT USED UTILITY FROM T SW 0 UTILITY FROM T SW 60 TRANSFER RELAY COIL 9127 TRANSFER RELAY COIL 921 4 REMOTE START 5 0 REMOTE START 1 CONNECTIONS T 35 Sr L m S D 4 WIRING DIAGRAM REVISION G 8208 A 2 4L 2 POLE DATE 05 23 06 ISO DRAWING 0F9705 CUSTOMER SCONNECTION cea uve ova Qe TI Sg ee Vie P amp
43. ALTERNATOR LEGEND ENGINE WIRING LEGEND BA BRUSH ASSEMBLY GENERATOR AFS AIR FUEL SOLENOID ICT INTERCONNECT TERMINAL BLOCK ALT D C CHARGE ALTERNATOR MCB MAINLINE CIRCUIT BREAKER BAT 12VDC BATTERY STARTI NTACTOR UTILITY CONNECT TERMINAL BLOCK E EC COVERNOR CB J DE PS FUEL SOLENOID DEG 412V 118 14 8 71 52 AUX FUEL SOLENOID OX INP RET 2 805 2 GND GROUND DEG GND 0 5 GOV ELEC GOVERNOR ACTUATOR COOLANT TEMP 4 85 14 2 HCT HIGH COOLANT TEMP SWITCH GOV ov 15 767 5 IGNITION COIL GOV 45v 6 765 51 CONNECTOR 1 ON DISTRIBUTOR 12V 7 194 2 LOW FUEL PRESSURE SWITCH COOLANT LEVEL 8 573 eal LOS LOW OIL PRESSURE SWITCH CRANK SENSOR IN 9 79 MAGNETIC PICKUP CRANK SENSE RET H0 0 771 9 02 OXYGEN SENSOR INP 111 601 768 10 STARTER MOTOR 11 COOLANT LEVEL SWITCH GOV FDBK 112 766 OX INP 113 804 cde COIL 1418 9 COIL 1518 25 771 1 DISTRIBUTOR RET 116 5 767 2 DISTR INPUT 17 402 765 3 DEG PWM 18 769 DEG ENABLE 19 768 Ht tt tt LOW OIL PRESS 20 86 LH 766 6 CRANK SHIELD 21 SHLD COIL e 22 1 COIL B 23 H 49 808 AFS 0 808 402 194 194 402 OPTIONAL 25 EMISSION Ls CONT
44. AND RH CONTROL 3 0F3189 1 STAND LH CONTROL 4 023484 1 BUSHING SNAP 8 2 5 31 5 0 6366 1 XFMR DUAL 120V 16V F OR 120240 amp 277 480V UNITS 0 6366 1 DUAL 104V 16V F OR 120208 UNITS 6 043180 2 WASHERFLAT M4 7 022264 2 WASHER LOCK 8 4 8 003990 2 SCREW PHTT M4 0 7 102 1 9 057701 REF BLOCKTERM 2048 X6 X1100V 10 022155 4 WASHERLOCK 6 11 0C2428 4 SCREW 86 32 1 22 12 0F3824 1 DECAL UTIL SENSE CUST CONN 13 0A9457 1 DECAL NEUTRAL 4 057073 2 JUNCTION BLOCK 38 16 2 15 005466 REF BUS BAR NEUTRAL BLOCK 390 2 16 0 7822 REF LUG SLDLSS 600 250 1 0 X 1 4 28 17 022237 2 WASHERLOCK 3 8 18 022241 2 NUT HEX 3 8 16 STEEL 19 049226 6 WASHERLOCK M5 20 0C2266 6 SCREW PHTT M5 0 8 162 21 0 2454 8 SCREW THF M6 1 X 16N WA 25 23 022473 8 WASHERFLAT 1 4 M6 ZINC 24 022097 4 WASHERLOCK 6 1 4 1 26 0D4698 REF BLOCK TERM 20A 6 X3 X1100V 27 0 4464 1 DECAL CUST 120V UTILITY 28 025433 1 LUG SLDLSS 6 14 X 13 64 CU 29 024469 1 SCREW HHTT 10 32 X 3 8 CZ 30 067210A 1 DECAL GROUND LUG 31 0D6029 4 SCREW 6 1 0 X 162 YC 32 081008 1 GROMMET 1 25 25 X 75 33 077043 1 CONDUIT FLEX 2 0 ID 36 LG 051713 2 WASHERFLAT M5 35 0 6156 1 PLATE WIRE SNGL GALV 36 029289 1 TAPE ELEC 1 2 FOAM AS REQ D 37 047411 4 SCREW HHC M6 1 0 X 16 68 8 3 39 060770 1 HARNESS TRANSFO RMER ADAPTER 4 40 0H0348 1 ASSY ENCLOSURE PCB 42L IGN MD 4 41 036943 2 SCREW PPHM 10 32 X2 4 42 023897 4 WASHER FLAT 10 ZIN
45. B 56 ICT 5 REMOTE START Y Ts 6 START Dr 5 cem em moms xL 154 1 WIRING SHOWN FOR CB1 NB BA AND STATOR IS TYPICAL FOR SINGLE 3 PHASE SEE DWG 0 6839 REVISION G 8208 A DATE 05 24 06 FUEL RUN RELAY 3 144 CUSTOMER CONNECTION amp ALTERNATOR LEGEND BA BRUSH ASSEMBLY GENERATOR CB1 MAINLINE CIRCUIT BREAKER 240V OUTPUT TO TRANSFER SWITCH ICT INTERCONNECT TERMINAL BLOCK NB NEUTRAL BLOCK PHASE FOR UCT UTILITY CONNECT TERMINAL BLOCK SCR F1 FUSE BAT POWER 15A ATO TYPE 4 SCHEMATIC DIAGRAM 2 4L 2 POLE DRAWING 0G0118 PAGE 1 OF2 GROUP G ENGINE WIRING LEGEND 2 AFS AIR FUEL SOLENOID CB J ALT D C CHARGE ALTERNATOR BAT 12VDC BATTERY DEG 12V7 1 14 STARTER CONTACTOR OX INP RET 2 805 DEG GND 3 0 COOLANT TEMP 4 85 GOV OV 5 767 Gov 5 6 765 DISTRIBUTOR 12V 7 194 COOLANT LEVEL 8 573 CRANK SENSOR IN 9 79 CRANK SENSE RET 10 0 LFP 11 601 GOV FDBK 112 766 OX INP 113 804 COIL 14 9A COIL A 15 25 DISTRIBUTOR RET 116 5 DISTR INPUT 17 402 DEG 18 769 DEG ENABLE 19 768 LOW OIL PRESS 120 86 CRANK SHIELD 21
46. C 4 43 022152 2 WASHERLOCK 10 4 44 022158 2 NUT HEX 10 32 STEEL 4 45 0C2454 1 SCREW THF M6 1 X 16N WA 25 4 46 0559340 1 CLAMP VINYL 1 06 X 406 Z 4 0F6145 AR 45 1 UL CIRCUIT BREAKER ED A 0F3328 1 COVERED CB SHORT STND 005552 1 0050 480V S ED4 LL 0D5553 0060 3P 480V S ED4 LL 005554 CB0070A 3P 480V 5 ED4 LL 005556 0090 480V ED4 LL 0D9693 CB0125A 480V S ED4 LL D 0 0492 1 INSULATOR CB 5 ED 3P E 048927 4 SCREW 0 32 4 12 F 023897 4 WASHER FLAT 10 ZINC G 022152 4 WASHERLOCK 10 H 022158 4 NUT HEX 10 32 STEEL J 0C2454 9 SCREW THF M6 1 X 16N WA 25 K 029289 1 TAPE ELEC 1 2 FOAM AS REQ D L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE 2 UL CIRCUIT BREAKER F D A 0F3138 1 COVERCB CONNBOX 005572 1 CB0150A 600V S FD6LL 0D5573 0175 600V S FD6LL 005574 0200 600V S FD6LL 005575 0225 600V S FD6LL 005576 0250 3P 600V S FD6LL D 0F0199 1 INSULATOR CB FD FRAME 30ML E 081320 4 SCREW SHC 1 4 20 X 4 5 68 8 NZ F 022473 4 WASHERFLAT 1 4 M6 ZINC 022007 4 WASHFRI 14 REVISION H 3478 X DATE 11 12 08 gt ore 022127 0 2454 029289 0 1733 0 3329 005577 0 2353 022770 022473 022097 022127 0 2454 029289 0 1733 0 8135 0 7283 0 7284 0E3664 074908 0 8140 036261 0 2454 029289 0 1733 GROUP QTY
47. CK MIO WASHER FLAT MI2 SCREWSHC 125 30G129 WASHER FLAT 5 16 MB ZINC WASHER LOCK 516 SCREWHHC 1 25 16 G88 GASKET INTAKE COVER G1 COVERINTAKE G1 GASKET THROTTLE BODY INTAKE ADAPTER MACHNED SCREWSHC 125 206129 SCREWSHC 15 35G109 SCREWHHC MB 1 25 35 88 WASHERLOCK 38 ASSY MAGPICKUP 38 24 MALE WASHER SHAKEPROOF EXT 7 16 STL PAGE 2 OF 2 GROUP D THERMOSTAT HOUSING TO CRANKSHAFT TO 777777 777777777777 REFER TO BEARING PRESS NOTE 0 9806 C2 COOLING SYTEM 8 DRIVE EXPLODED VIEW DRAWING PAGE 1 OF2 REVISION G 8927 A DATE 10 13 06 EXPLODED VIEW C2 COOLING SYTEM amp FAN DRIVE DRAWING 0F9806 APPLICABLE TO GROUP D ITEM PART QTY DESCRIPTION DESCRIPTION 1 029529 1 WELDIVENT RADIATOR SUPPORT 24L n 1 ARMTENSIONER 2 0222608 1 RADIATOR 598 X 568 49 CPL 12 1 SCREWSHC 5 LKG VEXIGLG 3 025263 1 V BELT 31 64 57 38 13 1 SPRING TENSION CPL 4 046526 5 WASHER LOCK MIO 1 PULLEY V BELT 4 FLANGED 5 059981 4 SCREWHHC 15 30 109 15 7 WASHER FLAT 3 8 ZINC 6 2 5 5 16 24 X 1 1 2 G5 16 1 PROBE COOLANT LEVEL 7 1 SHELDRADIATOR C5 17 4 CLAMP HOSE 28 1 32 2 25 8 012568 8 SCREWHHC 1 0 20688 18 QF2561 1 HUB FLEX PLATE 9 0F2573 1 PULLEY FAN V GROOVE 9 19 Oc8l 5 8 WASHER FLEX THIN 10 0 4011 1 FANCOOL 22 DIA 10 BLADE LH 20 052250 2 FOAM1X 1 26 75 LG 21 0 70
48. E3 1 1 120 I 10115 33 OUTS 120 VOLTS 11 L I H Y Y CIRCUIT BREAKER Stationary Emergency Generator General Information GENERAL INFORMATION ALTERNATOR POWER WINDING CONNECTIONS 5 5 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 1 2 1 and E2 E3 is either 480V or 208V depending on the model The rated voltage between each circuit breaker termi nal and the neutral point OO is either 277V or 120V depending on the model Figure 7 2 Stator Power Winding Connections 3 phase 277 480V 6 Lead 1 E1 1 INTERNAL CONNECTIONS L L NEUTRAL Y S3 82 E2 L N Figure 7 3 Stator Power Winding Connections 3 phase 120 208V 6 Lead E1 54 54 00 NEUTRAL 53 53 52 80 0 1004 099 INSTALLATION Stationary Emergency Generator J Installation i INSTALLATION INSTALLATION Refer to the separate Installation Guide QT Product Line supplied with the unit PREPARATION BEFORE START UP The instructions in this section assume that the Sta
49. ESCRIPTION 1 0F9517 1 WELDMENT FRAME 2 4L C2 2 052860 4 NUT FLANGED HEX M12 1 75 3 052251 5 DAMPENER VIBRATION 40 BLUE 4 052257 5 SPACER 49 X 62 X 1 87 PWDR ZNC 5 052252 5 DAMPENER VIBRATION 6 052259 5 WASHER FLAT M12 7 052891 5 SCREW M12 1 75 X 80 68 8 8 0536210410 1 ASSY WIRE 14 00 9 042909 1 SCREW 8 1 25 X 30 68 8 10 047411 1 SCREW HHC M6 1 0 X 16 G8 8 11 055414 1 LUG SLDLSS 2 8 X 17 64 CU 12 022447 1 WASHER SHAKEPROOF INT 1 4 13 022097 1 WASHER LOCK M6 1 4 14 022473 2 WASHER FLAT M6 1 4 ZINC 15 049813 1 NUT HEX M6 1 0 G8 YEL CHR 16 022261 1 WASHER SHAKEPROOF INT 3 8 17 0F9597A 1 SUPPORT LH ENGINE 2 4L 18 045764 1 SCREW HHTT M4 0 7 X 8 BP 19 062963 4 SCREW HHC M10 1 25 X 30 G8 8 20 022302 5 WASHER LOCK 7 16 21 022131 5 WASHER FLAT 3 8 M10 ZINC 22 065852 1 SPRING CLIP HOLDER 37 62 23 0F9597 1 SUPPORT RH ENGINE 2 4L 24 022129 1 WASHER LOCK M8 5 16 25 026204 1 WASHER INT 5 16 26 022145 1 WASHER FLAT 5 16 M8 ZINC 27 045771 1 NUT HEX 8 1 25 G8 CLEAR ZINC 29 0F9596 1 SPACER ENGINE MOUNT 2 4L G1 0F9596A 1 SPACER LH ENGINE MOUNT 2 4L G2 30 052212 1 SCREW HHC M10 1 25 X 25 C8 8 REVISION H 2901 C DATE 8 18 08 GROUP C PAGE 2 OF 2 618640 5 ONIM VIG C JO HDVd 90 r ALVA 140 17 AH3LLV8 lt 08 0 GION31OS YALYVLS OL d 1O ID EXPLODED VIEW BATTERY 24L CPL DRAWING 0F9813 APPLICABLE TO PART
50. Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY 1 Test engine governor adjust or repair if needed 2 Clean inspect generator 3 Flush cooling system FIRST 30 OPERATING HOURS 1 Change engine break in oil and filter FIRST 100 OPERATING HOURS 1 Change engine oil and oil filter After initial change service engine oil and filter at 100 operat ing hours or six months whichever comes first 2 Retorque cylinder head 3 Retorque intake and exhaust manifold EVERY 500 OPERATING HOURS 1 Service air cleaner 2 Check starter 3 Check engine DC alternator EVERY 800 OPERATING HOURS 1 Retorque cylinder head 2 Retorque intake and exhaust manifold 3 Check engine compression 4 Check valve clearance 5 5 Air intake and outlet openings the generator com partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See the installation diagram warninc The exhaust system parts from this product get extremely hot and remains hot after shutdown High grass weeds
51. LUG SLDLSS 600 250 1 0 X 1 4 28 UL CIRCUIT BREAKER 1 COVER BQ CIR BREAKER CPL 3P COVER BQ CIR BREAKER CPL 2P CB 0125A 2P 240V S BQ2LL 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 10 32 X 3 4 BRKT BQ CB STANDOFF WASHER FLAT 10 ZINC WASHER LOCK 10 NUT 10 32 STEEL DECAL CUSTOMER CONNECT INSIDE TAPE ELEC 1 2 FOAM SCREW THF M6 1 X 16 N WA Z JS a 1 HARDWARE FOR MTG CB TERMINAL COVERS IS SUPPLIED WITH CIRCUIT BREAKERS 2 QTY REQ D FOR 2POLE 3POLE BREAKER PAGE 4 OF 4 608640 DNIM VAA NOILV LIOX3 199410 YOLVNYSLTV 149 AHIA QHGO IdXH V C dO 19094 80 20701 EXPLODED VIEW CPL ALTERNATOR DIRECT EXCITATION DRAWING 0F9803 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F9677 1 ROTOR 2390 45KD1 CPL 0G0056 1 ROTOR 2390 35KD1 CPL 0G0959 1 ROTOR 2390 45KD1 CPL G2 0G1155 1 ROTOR 2390 35KD1 CPL G2 0G1931 1 ROTOR 25KW 3PH DIRECT 390 1800 062101 1 25KW 1PH DIRECT 390 1800 063734 1 RTR 2390 60KD2 CPL 0G6562 1 RTR 390 35AD1 CPL 0G6564 1 RTR 390 35KD1 CPL 2 0 9664 1 STATOR 390 45K 2P DIRECT 0G0057 1 STATOR 2390 35AD1 CPL 060058 1 STATOR 2390 35KD1 CPL 0G0059 1 STATOR 2390 35GD1 CPL 0G0183 1 STATOR 2309 45KW 2P 3PH 208V 060184 1 STATOR 2309 45 KD1 CPL 0G1932 1 ASSY STR 390 25GD3 CPL 0G2098 1
52. MATION Specifications INFORMATION COOLING SYSTEM Pressurized Closed Recovery Water Pump Belt Driven Fan 2150 rpm Fan PETIT 22 inches Mol Puller Air Flow inlet air including alternator and combustion air senes 4500 ft3 min Coolant Capacily 8 0 U S gal Heat Rejection to 173 000 Btu h Maximum Operating Air Temp on Radiator 609 C 1509 Maximum Ambient 50 C 140 FUEL SYSTEM Type of Fuel Natural Gas Propane Vapor Down Draft Secondary Fuel Regulator Standard Fuel Shut off Solenoid sss Standard Operating Fuel Pressure 5 in 14 in Water Column Fuel Consumption ft3 hr Natural Gas LPV Exercise 2596 5096 7596 100 Cycle Load Load Load Load 102404 194 771 373 148 520 206 3 720 286 ELECTRICAL SYSTEM Battery Charge Alternator 12V 30 Amp Static Battery 2 Amp Recommended Battery Group 26 525CCA System Voltage sees
53. ROL 9 DIST A a O 11 B cCT Ye M z zt ee St Z J WIRING DIAGRAM REVISION G 8208 A 2 4L 2 POLE DATE 05 23 06 PAE RRE DRAWING 0F9705 Qi GROUP G NTROL PAN N AVR AUTOMATIC VOLTAGE REGULATOR BCH BATTERY CHARGER BR1 BRIDGE RECTIFIER CB2 CIRCUIT BREAKER EXCITATION 42 CONNECTOR 2 ON MOV VARISTOR 680V 1 2 820 OHM RES R3 470 OHM RES R4 FIELD BOOST RESISTOR RLI RELAY 1 START RELAY RL2 RELAY 2 ENGINE RUN SCR SCR BRIDGE SW AUTO OFF MANUAL SWITCH SW2 SET EXERCISER SWITCH TRI TRANSFORMER 6VA UTIL 16 VAC 225 _ J2 15A AFS OUT 4 1 808 START RELAY 2 56A 15 SW2 5 1 2 WIRE START 1 4 183 MOMENT OPEN 5 15E 2 WIRE START 2 T 6 178 MAN AUTO INPUT 7 15A 16VAC SENSE 1 I 8 224 ALARM RELAY 9 XFER RELAY 710 23 MAN INPUT 711 239 16VAC SENSE 2 112 225 EMISSIONS ENABLE 13 0 GND B 114 0 CONNECT FOR OPTIONAL EMISSIONS ONLY 14 fa UCT 1 L1 UCT 2 N UCT 3 GND 14 Os 11 244 15 5 44 11 2 4 N1 _ ICT 1 UTILITY FROM T SW 0 15 2 ICT 2 UTILITY FROM T SW 22 56 ICT 3 TRANSFER RELAY 33 ICT 4 TRANSFER COIL RELAY N
54. RT 2 PURT 1 PURT 2 NG FUEL SYSTEM LP FUEL SYSTEM NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made DIG A Serious injury or damage may occur if not con figured properly Please consult an Authorized Service Dealer with any questions 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 60 Hz Electrical power is produced in the stator power windings These windings were con nected at the factory to the main circuit breaker as shown in Figure 7 1 The rated voltage between each circuit breaker ter minal is 240V The rated voltage between each circuit breaker terminal and the neutral point OO is 120V Figure 7 1 Four lead Single phase Stator m eom c 44
55. RY 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 examina tion 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 Any and all warranty repairs and or concerns must be perform
56. Serial Number QT 2 4L Model 005261 0 STANDBY GENERATOR OWNER S MANUAL A new standard of reliability GUARDIAN by Generac Power Systems Inc CAUTION A ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit 102090 Hed 90 00 0 6 0 9 00 SECTION PAGE SAFETY RULES 1 1 INTRODUCTION 1 3 Read this Manual 1 3 Operation and Maintenance 1 3 How to Obtain Service uo err teta 1 3 IDENTIFICATION RECORD 2 1 seen qu 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 reete eere edens 4 1 Overcrank Shutdown eee r
57. URING 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 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 Tighten all clamps and plugs 9 Make sure fuel supply is of the proper pressure and type for configuration 90 50 009905090 Utility In Transfer Switch NEUTRAL 4 14 GA WIRES TO 5 GENERATOR CONNECTION 2s a mn TO GENERATOR CONNECTION BOX To Generator Control Panel 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 differ ent fuels Figure 6 2 Reconfigure the Fuel System FUEL HOSE FUEL REGULATOR REGULATOR FUEL HOSE FUEL HOSE BRASS BRASS HOSE FITTING REDUCER REDUCER HOSE FITTING JET JET 2 PORT 1 Q PU
58. ator to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts Before performing any maintenance on gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS 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 connec tions etc on the generator as well as the transfer switch if applicable Ens
59. 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 i
60. e a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks security damage CHECK BELT Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 of an inch Adjust belt tension as required INSPECT ENGINE GOVERNOR Visually inspect electronic governor DIG A Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incor rect frequency and or voltage Only qualified service technicians should adjust the governed speed Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance CHANGING ENGINE OIL Refer to maintenance performed by au
61. e 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 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 Acomprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required and to identify any potential problem areas Performed annually or following each 250 hours of operation of the unit This inspection c
62. e them carefully Their definitions are as follows DG A After this heading read instructions that if not strictly complied with will result in serious person al injury including death or property damage amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety infor mation that if not followed could endanger personal safety and or property of others A This symbol points out potential explosion hazard Important Safety Instructions This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual a
63. ed and or addressed by an Authorized Certified Generac Power Systems Dealer or branch thereof A Generac Power Systems Inc Transfer Switch is highly recommended to be used in conjunction with the genset If a Non Generac Power Systems Inc Transfer Switch is substituted for use and directly causes damage to the genset no warranty coverage shall apply All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty Policies and Procedures Flat Rate Manual Units that have been resold are not covered under the Generac Power Systems Warranty as this Warranty is not transferable except with change of 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 Engine coolant heaters block heaters heater controls and circulating pumps are only covered during the first year of the warranty provision If applicable THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Any unit built manufactured prior to January 1 2005 Costs of normal maintenance i e tune ups associated part s adjustments loose leaking clamps installation and start up Any failure caused by contaminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze Units sold rated or used for Prime Power Trailer Mounted or Rental Unit ap
64. eete 4 1 Overspeed Shutdown eet nein dae 4 1 RPM Sensor Loss Shutdown 4 1 DC FUSE Em 4 1 FUEL SYSTEMS 5 1 Puel Requirements aaa Q 5 1 Natural Gas Fuel System 5 1 Propane Vapor Withdrawal Fuel System 5 1 LP Fuel SySUSIY 5 1 SPECIFICATIONS 6 1 6 1 6 1 Cooling 6 1 Fidel System 6 1 Electrical System e conte tee 6 1 Cold Weather tope estate 6 2 Reconfiguring the Fuel 6 2 GENERAL INFORMATION 7 1 Generator AC Lead Connections 7 1 Four lead Single phase Stator 7 1 Alternator Power Winding Connections 7 1 S phase Alternators 2 sas 7 1 INSTALLATION 8 1 1 06 16 aww sa 8 1 Preparation Before Start up eoe 8 1 Transter Switch
65. enance 10 4 Cleaning the Generator 10 4 Battery de MD 10 4 Battery Maintenance eret eret hee 10 4 Battery ete iret tenete 10 5 SERVICE SCHEDULE 11 1 TROUBLESHOOTING 12 1 Troubleshooting Guide 12 1 NOTES EXPLODED VIEWS amp PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS WARRANTY 90 60 0 t001u9luoo Stationary Emergency Generator INTRODUCTION Thank you for purchasing this model of he 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 con tact the nearest Authorized Service Dealer for start ing operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert person nel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly Observ
66. enerator 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 bat tery fluid is spilled flush the affected area with
67. er separa tors in all battery cells If fluid level is low add dis tilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications Add recommended coolant mixture as necessary Periodically remove radiator pressure cap only when engine has cooled down to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radiator filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact an Authorized Service Dealer Inspect cooling system and coolant recov ery 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 cor rosion or damage Clean tighten or replace as necessary 90 20 0 OLOUIEN 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 PERFORM VISUAL INSPECTION Complet
68. failure Thermal circuit breaker open CORRECTION 1 2 Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replace fuse Replenish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Close door on tank Clean or replace as needed Unclog fuel line Clean regap or replace plugs Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch 1 Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Setto GENERATOR position Auto reset Wait 5 min and attempt restart Contact the nearest Authorized Dealer for assistance 12 1 80 01 V ed 001451921 Ba Stationary Emergency Generator Notes NOTES 916830 DNIM VACA y dO 1 dOVd ALVA 8SH X314 rO 20 140 X 8LVCH Q3GO Id X3 LL N eos SSANYVH V 4 EXPLODED VIEW CPL C2 amp C4 FLEX HSB DRAWING 0F3391D APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F3137 1 PAN CB CONN BOX 2 0F3188 1 ST
69. fore 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 80 60 8 ed L00S gjon4 SPECIFICATIONS GENERATOR WO vice Synchronous Rotor Insulation iei tte etes Class H Stator Insulation soa dott etre nes Class H Total Harmonic Distortion e lt 5 Telephone Interference Factor 50 Alternator Output Leads 3 phase 4 wire P Saga H Sealed Ball suwanqa Sua panapas Flexible Disc Load Capacity Standby Rating 45kW NOTE Generator rating and performance in accordance with 1508528 5 55514 SAE J1349 1503046 and DIN 6271 Standards KW rating is based on LPG fuel and may derate with natural gas Excitation a eir c Direct Generator Output Voltage kW 60 Hz kW Am CBSize 120 240V 1 phase 1 0 pf 45 188 200 120 208V 3 phase 0 8 pf 45 156 175 277 480V 3 phase 0 8 pf 45 68 80 Generator Locked Rotor KVA Available Voltage Dip of 3596 Single phase or 208 80 KVA 480 33 100
70. itch so as to isolate the generator electric system from the electric utility distribution system when the generator is operat ing Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Stationary Emergency Generator Important Safety Instructions Stationary Emergency Generators installed with an automatic transfer switch will crank and start automatically when normal utility source volt age is removed or is below an acceptable preset level To prevent such automatic start up and pos sible 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 imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a dry rope or board to free the vic tim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causi
71. l 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 recom mended oil is SAE 90 gear lubricant Also if the engine is equipped with a mechanical gov ernor make sure the governor is properly lubricated with clean engine oil 9 PRIOR TO INITIAL START UP caution Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure 9 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 abo
72. n U S A
73. n 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 80 01 8 100 ayes Stationary Emergency Generator SAFETY RULES A Important Safety Instructions 7 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 install ing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reli ably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The ma
74. nd thoroughly understand all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency 9 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 9 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 Whe
75. nerator follow these direc tions 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 util ity power source main line circuit breaker Let the generator run at no load for a few minutes to stabilize internal temperatures Shut down the generator OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If the 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 trans fer switch and to Transfer Switch Start Signal Connections In addition please note the dangers under Engine Start up and Transfer 80 60 V 1001940 Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES warninc Before working on the generator ensure the fol lowing The AUTO OFF MANUAL switch is in the OFF position The 15A fuse has been removed from the con trol box The 120VAC supply to the battery charger is switched OFF EVERY THREE MONTHS Check battery condition Inspect and test fuel system Check transfer switch
76. ng injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extin guisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris These generators may operate using one of sev eral types of fuels All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulat ing the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks immediately Fuel supply lines must be prop erly installed purged and leak tested according to applicable fuel gas codes before placing this equip ment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detecto
77. nufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If a pro cedure work method or operating technique is used that the manufacturer does not specifically recom mend ensure that it is safe for others Also make sure the procedure work method or operating tech nique utilized does not render the generator unsafe DG A AN Despite the safe design of this generator operating this equipment imprudently neglect ing its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to install operate or main tain this equipment A 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 80 0 8 100 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 tech nician who is familiar with applicable codes stan dards and regulations The operator also must comply with all such codes standards and regula tions Installation operation servicing and repai
78. o the battery charger is switched OFF PREPARATION FOR START UP Ensure that the 120VAC circuit breaker to the bat tery charger is open Remove the fuse from the the control panel For the H 100 and R 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 dam age Check all electrical plugs throughout the genera tor Ensure each plug is seated correctly and fully inserted into its receptacle Verify the AUTO OFF MANUAL switch is in OFF position Open the valve to the engine fuel line 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 80 LL 3 ed 100188 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 unit
79. o the fuel shutoff sole noid should not exceed approximately 14 inches water column 0 5 psi Optimum pressure at the fuel shutoff solenoid is 11 inches water column 0 4 psi Stationary Emergency Generator Fuel Systems GENERAL INFORMATION 9 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 vaporiza tion or the system will not deliver the needed fuel volume In addition to the cooling effects of ambient air the vaporization process itself provides an additional cooling effect LP 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 be
80. ontains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by a Service Dealer 11 1 60 20 3 ed 100 95 15 MAINTENANCE MAINTENANCE Stationary Emergency Generator Service Schedule Maintenance Tasks 1 Disable the unit from operating per the first page warning 2 Check the engine oil level Adjust as necessary 3 Check the engine coolant level Adjust as necessary 4 Check the engine coolant thermal protection level Correct as necessary 5 Check the natural gas delivery system for leaks and correct pressure on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level and specific gravity if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiring for loose connections corrosion and damage Correct as necessary 60 20 3 ed 00 25415 Level 1 Level 2 Level 3 Level 4 Level 5 Recom Task Required Task Required Task Task Required Task mended Comp to be done Comp be done Comp Required Comp lto be done Comp to be done Date months Date Semi Date to be done Date Bi Date monthly Initials Break in Initials annually Initials
81. plications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted or Rental Unit definition Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not normally exist Failures caused by any act of God and other force majeure events beyond the manufactures control Products that are modified or altered in a manner not authorized by Generac Power Systems in writing Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation or sizing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s 10 Failure due to misapplication misrepresentation or bi fuel conversion 11 Telephone facsimile cell phone satellite internet or any other communication expenses 12 Rental equipment used while warranty repairs are being performed i e rental generators cranes etc 13 Overtime holiday or emergency labor 14 Planes ferries railroad busses helicopters snowmobiles snow cats off road vehicle or any other mode of transportation deemed abnormal 15 Any and all expenses incurred investigating performance complaints unless defective Generac materials and or workmanship were the
82. r of this and related equipment must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electri cal and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operated and serviced in accordance with the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon mon oxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided This should be considered prior to installing the generator The unit should be positioned to direct exhaust gasses safely away from any building where people animals etc will not be harmed Any exhaust stacks that ship loose with the unit must be installed properly per the manufacturer s instruction and in strict compliance with appli cable codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical in any room or building hous ing the gener
83. rs accordingly 80 01 8 100 Mayes GENERAL INFORMATION IDENTIFICATION RECORD 9 DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator The data label which can be found attached to the gen erator s lower connection box lists the units serial number and its rated voltage amps wattage capac ity phase frequency rpm power factor production date etc Stationary Emergency Generator General Information GENERAL INFORMATION NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit 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 order ing parts or seeking information Data Label GENERATOR SET DATA MODEL SERIAL RATED KW RATED KVA PHASE RATED VOLTAGE RATED AMPS POWER FACTOR HERTZ ALT RPM ENGINE RPM PRODUCTION DATE ALTERNATOR SUBTRANSIENT REACTANCE ALTERNATOR TRANSIENT REACTANCE CLASS ROTOR STATOR WINDING INSULATION AT 25 C AMBIENT GENERAC POWER SYSTEMS INC MADE IN USA
84. rs should be kept closed and locked Only authorized personnel should be allowed access to the transfer switch interior Extremely high and dangerous voltages are present in the transfer switch In order to transfer load from the utility source to the generator follow these directions Turn OFF or disconnect the utility power circuit to the transfer switch using the means provided such as the utility source main line circuit break er Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the generator s main line circuit breaker to its OFF or OPEN position Start the generator Operation caution Do not crank the engine continuously for longer than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge read ings When certain that all readings are correct move the transfer switch manual handle to 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 RETRANSFER AND SHUTDOWN For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch To transfer the load back to the utility power source and shut down the ge
85. s check phase rotation at the transfer switch terminals The generator phase rotation must match the utility phase rotation Check for coolant fuel oil and exhaust leaks Close the generators main line circuit breaker Turn the generator set off Connect the UTILITY supply to the transfer switch Set the AUTO OFF MANUAL switch to AUTO Disconnect utility power before the transfer switch Engine should start transfer to load Run at least 15 minutes on generator power Make certain all 3 phase loads are functioning correctly correct phase rotation Reconnect Utility power Transfer switch will transfer back to Utility and engine will shut down within the given time parameters set up for the specific transfer switch and controller Install all covers access plates and door panels Put the Owners Manual in a safe and accessible place Make certain the AUTO OFF MANUAL switch is in the AUTO position START UP INSPECTION When a startup is performed by an Authorized Service Dealer a standard three part form titled Start up Inspection for Standby Power Systems part no 067377 should be completed by the instal lation technician or engineer See page 1 3 for infor mation on locating the nearest Authorized Service Dealer The installer should complete the form and disseminate copies as follows White copy Mail to Generac Warranty Department PO Box 340 211 Murphy Dr Eagle WI 53119 2062 Pink Copy For service file
86. sed 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 caution 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 caution 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 opera tion when required 2 wear in service inspection of the generator set to insur
87. thorized service facilities for engine oil and filter change frequencies Drain the oil while the engine is still warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil completely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and re install into its retaining clip 4 Turn OIL FILTER Figure 10 2 counterclockwise and remove Properly dispose of old filter 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 AN After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 7 Start engine and check for oil leaks CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner 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 mainte nance Figure 10 3 Engine Air Cleaner Air Cleaner
88. tionary Emergency Generator has been properly installed serviced tested adjusted and otherwise prepared for use by a competent qualified installa tion 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 equip ment 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 9 TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems For additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other 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 genera tor a delivers the correct fuel at the correct pres sure and b is properly purged and leak tested according to code No fuel leakage is permitted See Specifications for more information GENERATOR SET LUBRICATION Check the engine crankcase oil leve
89. tural 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 sup plied to the generator fuel system Thereafter the owner operator must make certain that only the proper fuel is supplied 9 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 t
90. ure all appropriate cov ers guards and barriers are in place before operat ing 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 repair ing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground This grounding will help prevent danger ous 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 maxi mum electrical current ampacity to which they will be subjected Before installing or servicing this and related equipment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in hazardous and pos sibly fatal electrical shock Connecting this unit to an electrical system nor mally supplied by an electric utility shall be by means of a transfer sw
91. ut 3 8 to 5 8 inch 10 to 16 mm ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground Make sure the generator battery is fully charged properly installed and interconnected and ready for use NOTE Battery charger must be connected to 120 VAC 15 amp circuit to operate Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components INITIAL INSPECTION FOR 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 applica tion 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 80 11 3 ed 10088 INSTALLATION INSTALLATION C Jm Stationary Emergency Generator C Jm Installation Battery charger connection to 120 VAC Communication wires connected between transfer switch and generator HTS only Unit secured to pad START UP CHECKLIST warninc Before working on the Stationary Emergency Generator ensure the following The AUTO OFF MANUAL switch is in the OFF position The 120VAC supply t

Grandstream Networks 005261-0 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents