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Elite 005212-0 User's Manual

1. MAN AUTO INPUT 7 1815A FOR 3 PHASE SEE DWG OF6839 JUTILITY FROM T SW UTILITY FROM T SW TRANSFER RELAY COIL TRANSFER RELAY COIL REMOTE START REMOTE START x REVISION 2 51 COMMERCIAL PROD LINE DATE 05 23 05 DRAWING 0F7104 WIRING DIAGRAM GROUP G D P Us EMEN ANE NNI OM dE CER CUN EK M MU 1 x AFS AIR FUEL SDLENDID ALT D C CHARGE ALTERNATOR BATTERY CS CRANK SENSOR CB J FS FUEL SOLENOID FS2 AUX FUEL SOLENOID DEG 12V 1 GND GROUND INP RET L2 805 HCT HIGH CDDLANT TEMP SWITCH DEG GND 3 O JI CONNECTOR 1 UN PCB COOLANT SENSORS 4 85 FP LOW FUEL PRESSURE SWITCH DEG 0 5 LOW DIL PRESSURE SWITCH DEG 5v 6 OXYGEN SENSOR DISTRIBUTOR 12V 7 STARTED CONTACTOR AFS DUT 8 808 STARTER MOTOR CRANK SENSOR IN 9 79 STEPPER MOTOR CRANK SENSE 10 0 WLS COOLANT LEVEL SWITCH LFP IN 11 601 vIRE SPLICE DEG FDBK 12 DX 413 804 COIL 14 8458 COIL 15 25 DISTRIBUTOR RET 16 DISTR INPUT 17 DEG 18 DEG ENABLE 19 LOW DIL PRESS 2
2. 4 EXPLODED VIEW NATURAL GAS FUEL OR LPV DRAWING 0F7440 APPLICABLE TO 251 FORD ITEM PART QTY DESCRIPTION 1 0 8456 1 BRACKET FUEL REGULATOR 2 075580 1 FLANGE FUEL INLET 3 OF6364 1 FUEL REG 2 5L FORD REWORK 4 4 SCREWHHC 1 25 20G88 5 022145 2 WASHER FLAT 5 16 ZINC 6 022129 6 WASHER LOCK 5 16 7 045771 2 HEXIVE L25 G8 YEL 8 0F1570 1 BODY CARBURETOR ASSEIVBLY 9 44 1 BARBEDEL 9018 X38 10 F3994 REF PCVVALVE 25L FORD 026582 1 NIPPLE PIPE 3 4 4 LGBI 12 020897 1 HOSE CRANKCASE 13 5 7 1 COVER AIR CLEANER 14 0C7649 1 CLANP HOSE 38 87 15 001509 1 DECAL PRESSURE 16 0 0501 1 ADAPTER CARB TOAR CLNR 17 0594002 1 FILTER ELEIVENT 18 087561 1 WING 1 4 20NYLK 19 0 10288 1 CARBURETOR ASSY 2 51 FORD 20 050401 1 CARBURETOR GASKET 21 091526 4 SCREWPPHMIMB 0 8 X 12ZNC 20 019226 4 WASHER LOCK 23 026915 2 NIPPLE CLOSE 34 1 375 24 062522 1 STUDTH 1 4 20X3 G2 ZNC FULL 25 022127 1 HEX 1 4 20STEEL 26 2 HEX 516 18 STEEL 27 1 DECAL FUEL INLET NG 1 DECAL FUEL INLET LPG 28 046125 2 STUD y16 18X L25 F THR 29 0254 3 SCREWTH FRMIM6 1X 16 2 S 30 0 1104 1 GASKET AIR CLEANER ADAPTER 31 0 0668 1 52 081 38 1 50 06 32 1 VENTURI 20MM 33 0C5133 1 ORING 29 82 X 2 62 0 0665 1 SCREWTHROTILE PIN STOP 35 CETI08A 1 THROTTLE ARMREWORK 25L FORD 36
3. FPP00283 CYLINDER HEAD PROCEDURE Position head gasket on the block Figure 10 2 Position cylinder head to cylinder block 3 Install 10 cylinder head bolts in numerical sequence Tighten to 70 N m 52 Ib ft in sequence Retighten to 70 N m 52 lb ft in sequence Then turn all head bolts an additional 90 100 degrees in sequence 90 80 0 5001 MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance Figure 10 2 Cylinder Head Installation CYLINDER HEAD GASKET CYLINDER HEAD FPP00024 COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See the installation diagram warninc amp The exhaust system parts from this product get extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via a 15 amp fuse These overcurrent prote
4. SENSU IN pco LOS LOW OIL PRESSURE SWITCH CRANK SENSE 110 0 SC STARTER CONTACTOR INP 111 601 SM STARTER MOTOR DEG FDBK 12 STM STEPPER UX INP 113 804 WLS COOLANT LEVEL SWITCH COIL 14 158 LT TT COIL 2 15 25 DISTRIBUTOR RET 16 DISTR INPUT 17 DEG ig DEG ENABLE 19 LOW GIL PRESS 120 86 CRANK SHIELD T21 SHLD COIL lt 2122 COIL B 23 25B sa r3 7 15R 15 9 58 14 105 M 86 EMISSION L 85 0 OPTIONAL HCT CONTROL 5 WLS 1 85 5 gt C 56 B 1 0 LFP 601 i I Ic pe c LU C Jd SCHEMATIC DIAGRAM REVISION 2 5L COMM PROD LINE PAGE 2 OF 2 DATE 08 04 05 DRAWING 0F7420 EXPLODED VIEW INSTALL DWG 1 5L 20KW AND 2 5L 25KW DRAWING 0F7555 GROUP G APP
5. 10 4 Cleaning Generator 10 4 Battery 10 4 Battery Maintenance eret rettet eret hee 10 4 Battery ete iret tenete 10 5 SERVICE SCHEDULE 11 1 TROUBLESHOOTING 12 1 Troubleshooting Guide sees 12 1 NOTES EXPLODED VIEWS amp PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS WARRANTY 90 60 0 700902 Standby Generator Sets SAFETY RULES Important Safety Instructions N SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas Safety should be stressed to all operators potential operators and service and repair technicians for this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of 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 fai
6. 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 10 3 DIG A N Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incor rect frequency and or voltage Only qualified service technicians should adjust the governed speed CHANGING ENGINE OIL Refer to maintenance performed by authorized ser vice facilities for engine oil and filter change frequen cies 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 OI
7. eet e tr nein dae 4 1 RPM Sensor Loss Shutdown 4 1 DC FUSE Em 4 1 FUEL SYSTEMS 5 1 Puel Requirements aaa Q a anaq 5 1 Natural Gas Fuel System 5 1 Propane Vapor Withdrawal Fuel System 5 1 LP Fuel 5 1 SPECIFICATIONS 6 1 GENET inrer texere RON ta RE ORE 6 1 Pea IS PET 6 1 Cooling cie 6 1 Fidel System oue 6 1 Electrical System aon 6 1 Cold Weather Riti uu e tope estate ays 6 2 Reconfiguring the Fuel 6 2 GENERAL 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 ee beoe 7 1 8 1 8 1 Preparation Before Start up eoe naqa 8 1 Transter EEEE 8 1 8 1 Generator Set
8. These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety infor mation that if not followed could endanger personal safety and or property of others A This symbol points out potential explosion hazard Important Safety Instructions This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency 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 consid
9. 6 2 GENERAL INFORMATION GENERATOR AC LEAD CONNECTIONS See Voltage Codes This generator may be rated at any one of three voltages either single phase or three phase The electrical wires in the units AC con nection lower panel should be installed according to the number of leads and the voltage phase required for the application If there are any questions regard ing lead connection refer to the wiring diagrams at the back of this manual Voltage codes apply to the type of stator assembly installed on a particular generator FOUR LEAD SINGLE PHASE STATOR Four lead generators see Figure 7 1 are designed to supply electrical loads with voltage code 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 00 is 120V Figure 7 1 Four lead Single phase Stator m tm oen E M p E3 120 I VOLTS 33 10 240 33 120 i VOLTS 11 L I H Y Y CIRCUIT BREAKER Standby Generator Sets General Information GENERAL INFORMATION ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS The generator is desig
10. used to accomplish this In such a converter heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state 90 80 0 100545114 SPECIFICATIONS GENERATOR WO vice Synchronous Rotor Insulation aii pite ete Class H Stator Insulation soa ttr nes Class H Total Harmonic Distortion 3 5 Telephone Interference Factor 50 Alternator Output Leads 3 phase 4 wire P Sanga us M Sealed Ball suwanqa Sua panapas Flexible Disc Load Capacity Standby 25kW 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 Syste Minaa ee EE RC Direct Generator Output Voltage kW 60 Hz kW CBSize 120 240V 1 phase 1 0 pf 25 104 125 120 208V 3 phase 0 8 pf 25 85 100 Generator Locked Rotor KVA Available Voltage Dip of 3596 Single phase or 208 3 38 KVA ENGINE EE In Line Cylinders and
11. 083138 1 SCREWHHM 410 32 X 5 8 37 022152 1 WASHER LOCK 10 38 0 0645 1 LEVER THROTTLE STOP 084339 1 BARBEDEL 9038 X58 40 059194 1 HOSE 5 8 IDLPG amp NG 24 LG 41 057223 2 CLAMP HOSE 10 56 1 06 42 0 0882 1 HOSE 3 8 90 DEG 2 4 43 089617 1 BARBED STR 1 4NPT X 1 4MALE 44 030840 1 HOSE 1 4 30R7 24 LG 45 040173 2 CLAMP HOSE 3555 62 62 46 6155 1 HARNESS FUEL J UMPER SINGLE REG 4 026812 2 ELBOW9O0D 3 4 INCLUDEDINITEM 19 CARBURETOR ASSY NOTES 1 REGULATOR AS SHOWNINILLUSTRATIONIS SET UP FOR NATURAL GAS APPLICATION 2 TOCONHGURE REGULATOR FOR LP VAPOR SWITCH HOSE BARB HOSE CLAMP N41 AND HOSE 40 FROM OUT 1 TO OUT 2 REPLACE PIPE PLUG FROM OUT 2 TO OUT 1 USE PIPE SEALANT ON HOSE BARB AND PIPE PLUG SURE TO KEEP PORTS FREE FROM DEBRIS DURING RECONFIGURATION PROCESS FORLPVAPOR APPLICATIONSUBSTITUE LPG FUEL INLET DECAL P N 050280 FOR NG FUEL INLET DECAL P N 050279 27 4 5 FUEL TYPES THE PROPER DIP SWITCH SITTINGS MUST BE MADE TO THE CONTROL PANEL SEE OV NERS MANUAL FUEL SECTION FOR MORE DETAILS DATE 6 15 05 GROUP E PAGE 2 OF 2 GROUP F INSULATION AND RETAINERS LOCATED ON THE NEAR SIDE O S INSULATION AND RETAINERS LOCATED ON THE FAR SIDE TYPICAL MOUNTING OF ACOUSTIC INSULATION ENCLOSURE C1 CPL DRAWING gt m
12. A Q 0 7356 PAGE 1 OF 2 DATE 6 13 05 EXPLODED VIEW ENCLOSURE C1 CPL DRAWING 0F7356 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 1 ROOF C1CPL 2 OF 7004 1 CORNER POST LHSIDE C1CPL 3 OF 7008 1 DOOR REAR C1 CPL 4 OF 7005 1 CORNER POST RH SIDE C1CPL 5 OF 7007 2 DOOR LH amp RHSIDE C1 CPL 6 OF 7006 1 DUCT FRONT DISCHARGE C1CPL 7 0C2634A 1 ASSEMBLY COVER ACCESS 8 0912970001 1 ASSY AVG 13 8 GRN YEL 9 0012970000 2 ASSY WRE 14AWG 33 5 GRNYEL 10 E5968 1 GASKET EXTRUDED TRIM 356 LG E3257 6 SCREWHMHIF 1 0 16 12 077992 18 6 1 055 INS 13 025049 3 TABPULL 14 qF5048 3 LATCHMSE ACTION 5 16 HEXSKT 15 022473 1 WASHER FLAT 14M5 ZINC 16 02209 1 WASHER LOCK 1 4 17 02127 1 HEX 1 4 20STEEL 18 25 2 SCREWTHF 5 1 16 2 5 19 078115 20 WASHER SELF LOCKING DOIVE 20 2 RETAINER INSULATION 820 21 qr3800 4 RETAINER INSULATION 450 2 0 7365 2 INSULATIONSIDE DOOR 23 073658 1 INSULATION REAR DOOR C1 CPL 2 F7365A 1 INSULATION ROOF C1 DATE 6 13 05 OPTIONAL MATERIALS ALL P NS WTHAN 00 SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER 000005 5 ALUMNUM STEEL ALUMINUMENCLOSURE NOTE ALL ENC
13. AN Ethylene glycol base antifreeze is poisonous Do not use mouth to siphon coolant from the radiator recovery bottle or any container Wash hands thoroughly after handling Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them 90 80 LOOdinb3 GENERAL INFORMATION ENGINE PROTECTIVE DEVICES The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant tempera ture oil pressure or rpm For that reason the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low the coolant temperature is too high the coolant level is too low or the engine is running too fast NOTE Engine protective switches and sensors are men tioned here for the reader s convenience Also refer to the applicable control panel manual for additional automatic engine shutdown informa tion HIGH COOLANT TEMPERATURE SWITCH This switches contacts close if the temperature should exceed approximately 140 C 284 F initiating engine shutdown The generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level LOW COOLANT LEVEL SENSOR Should the engine coolant level drop below th
14. Lubrication 8 1 Prior to Initial 8 1 Engine Coolant iiec eter pd 8 1 Belt Tensi n 8 1 Electrical Sy Stemi uya sa Qusa 8 1 Initial Inspection for QT Genset Start up 8 1 Startup Checklist oe ERE 8 2 Preparation for Start up bete roten tds 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 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 10 1 Every 800 Operating HOurs 10 1 Exhau
15. 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 Insert the fuse into the control panel Move the AUTO OFF MANUAL switch to the MAN UAL position The engine should now crank and start SO LL V 100188 Check voltage at generator terminals For 3 phase units check phase rotation at the transfer switch terminals The generator phase rotation must match the utility phase rotation Check for coolant fuel oil and exhaust leaks Close the generators main line circuit breaker Turn the generator set off Connect the UTILITY supply to the transfer switch Set the AUTO OFF MANUAL switch to AUTO Disconnect utility power before the transfer switch Engine should start transfer to l
16. filter at 150 operat ing hours or six months whichever comes first 2 Retorque cylinder head 3 Retorque intake and exhaust manifold EVERY 500 OPERATING HOURS l 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 710 1 EXHAUST MANIFOLD PROCEDURE If necessary clean gasket surfaces on exhaust manifold and cylinder head 2 Install exhaust manifold and exhaust manifold gasket 3 Install fasteners NOTE Exhaust manifold fasteners must be tightened in two stages 4 Tighten fasteners to 20 30 N m 15 22 lb ft dur ing the first stage 5 Retighten fasteners to 60 80 N m 44 59 lb ft during the second stage NIONE MANIFOLD PROCEDURE Clean and inspect the mounting surfaces of the intake manifold and the cylinder head Both sur faces must be clean and flat Figure 10 1 2 Clean and lightly oil the manifold bolt stud threads 3 Install a new lower intake manifold gasket 4 Position the lower intake manifold to the cylinder head 5 Install retaining bolts studs finger tight 6 Tighten all bolts studs to specifications in the tightening sequence shown First pass 7 10 N m 5 7 lb ft Final pass 26 38 N m 19 28 lb ft Figure 10 1 Intake Manifold Installation FASTENER TORQUE SEQUENCE
17. only by an Authorized Service Dealer 3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed semi annually this requires approximately 1 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer 4 A mid level inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed annually this requires approximately 4 0 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer 11 1 50 01 9 OODU9SAIS Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp done Comp to be done Comp Required Comp to be Date 3 months Date Semi Date to be done Date monthly Initials Break in Initials annually Initials Annually Initials 10 Hrs 30 Hrs Disable the unit from operating per the first page warning Check the engine oil level Adjust as necess
18. to site load and exercise it for at least 1 hour looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 14 Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 the engine filter s filter s 18 Replace the engine fuel filter s on diesel engine driven units and re prime the fuel system 19 Check the engine spark plugs on gas engine driven units Clean and re gap or replace as necessary 20 Perform a 5 minute no load operational run of the unit looking for any post service problems 21 Return the unit to standby setup for operation when required 100 Hrs 11 3 40 01 200025415 TROUBLESHOOTING Standby Generator Sets 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 fuse blown Out of fuel Fuel solenoid FS is defective Open
19. used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not normally exist Failures caused by any external cause or act of God such as but not limited to collision fire theft freezing vandalism riot or wars lightning earthquake windstorm hail volcanic eruption water or flood tornado hurricane terrorist acts or nuclear holocaust Products that are modified or altered in a manner not authorized by Generac Power Systems in writing Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation or sizing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s 10 Failure due to misapplication misrepresentation or bi fuel conversion 11 Telephone facsimile cell phone satellite internet or any other communication expenses 12 Rental equipment used while warranty repairs are being performed i e rental generators cranes etc 13 Overtime holiday or emergency labor 14 Planes ferries railroad busses helicopters snowmobiles snow cats off road vehicle or any other mode of transportation deemed abnormal 15 Any and all expenses incurred investigating performance complaints unless defective Generac materials and or workmanship were the direct cause of the problem 16 Start
20. 0 86 CRANK SHIELD G1 sHLDI COIL C 22 COIL gt 423258 49 AFS 808 OPTIONAL EMISSION CONTROL 0 o 0 GND 601 14 0 56 56 Er 601 56 93 56 9 0 s 1 05 85 5 170 114 cC PC TCU PI pc c E LM Jd WIRING DIAGRAM REVISION 2 5L COMMERCIAL PROD LINE DATE 05 23 05 PAGE 2 OF2 DRAWING 0F7104 GROUP G Dd EE c MT ea C NUT a M N QE EON ABRE M MM Ra 1 NTRUL AVR AUTOMATIC VOLTAGE REGULATOR BCH BATTERY CHARGER BR1 BRIDGE RECTIFIER CIRCUIT BREAKER EXCITATION F1 FUSE BAT 154 TYPE Je CONNECTOR 2 UN PCB USEDT 1 J3 CUNNECTUR UN PCB NOT USED R4 FIELD BOOST RESISTOR BLACK W1 RL1 RELAY 1 START RELAY RED We RELAY CENGINE RUN WHITE W3 5 1 AUTO OFF MANUAL SWITCH GREEN W4 SWe SET EXERCISER SWITCH TR1 TRANSFORMER 1 6 240 16 VAC 2 N PCB J2 ANALOG INP RET 1 15 START RELAY 564 15 FUEL RUN RELAY 3 14 SW2 2 WIRE STARTCD 4 183 MOMENT L 5 155 15 910 15 5 1 0 15 l2 WIRE STARTC2 7 6 178 239 r 194 MAN AUTO INPU
21. 0KW 90 GIL FILL CAP emer oom ermer woe Qu M 3547 NEA s REFERENCE OWNERS MANUAL FOR PERIODIC REPLACEMENT PART LISTINGS REMOVE COVER FOR ACCESS TO RADIATOR FILL CAP y BATTERY 12 VOLT 24F 625 COLD CRANKING AMPS 6 8241 13 5 53 DIA MOUNTING 100 394 1603 631171 HOLE 4 PLACES LOCATED ON BOTTOM OF GENERATOR VIEW MOUNTING FRAME VISE ACTION LATCH ONE PER DOOR DNE DOOR PER SIDE OF GENERATOR 1803 70 98 CONTROL PANEL R100 TYPE BATTERY CHARGER IS ENCLOSED WITHIN 736 28 98 AIR INLET LOUVERS 928 36 547 DOOR TYP EXHAUST MUFFLERS ENCLOSED WITHIN SEE NOTE 6 FRONT COVER SEE NOTE 4 35 67 CIRCUIT BREAKER SEE NDTE 3 1 27 TYP 837 32 957 SIDE 2 5L 636 25 047 CRIGHTHAND SIDE 1 5L FUEL LINE CONNECTION 3 4 NPT FEMALE COUPLING LIFTING PROVISION 4 PLACES SEE NOTE 5 AND REAR VIEW CENTER OF GRAVITY DIMENSIONS FIELD CUT HOLE FOR DUTSIDE CONDUIT LEFT SIDE VIEW CONNECTION ONLY SEE 4A REVISION DATE 9 8 05 PAGE 2 2 Standby Generator Sets Warranty GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR HOME STANDBY LIGHT COMMERCIAL PRODUCT 45kW AND BELOW For a period of two 2 years from the date of sale or start up by Authorized Certified Generac Power Systems Dealer or branch thereof Generac Power Systems Inc will at its o
22. 4 Dip ge or aoi ao oe n GEO or dm 2 5 Liter BOlG sss zu 3 78 jl 3 4 Compression Ratios iua ccc cerrar ciet 9 4 to 1 Air Intake System Naturally Aspirated Replaceable Lifter Type Overhead Cam Rocker Arm Hydraulic Lifter Engine Parameters Rated Synchronous 60 Hz 1800 HP at rated 60 Hz 40 Exhaust System Exhaust Flow at Rated Output 60 7 227 Exhaust Temperature at Rated 1000 F Combustion Air Requirements Natural Gas Flow at rated power 60 67 5 Do Electronic Frequency Regulation Isochronous Steady State 0 2596 Engine Lubrication System Type of Oll Gear OIL FIllGI Full Flow Spin on Cartridge Crankcase Oil Capacity 4 U S qts E Standby Generator Sets pe INFORMATION Specifications INFORMATION COOLING SYSTEM TYDE Pressurized Closed Recovery Water PUM te etre ri eterne t
23. 5 1 CABLE BATTERY BLK 4 X 30 00 10 0888040 1 CABLE BATTERY RED 28 00 015771 REF HEX MB L25G8 YEL CHR WASHER LOCK 5 16 B 07482 WASHER SHAKEPROOF EXT 5 16 STL 0F3976 3 BOOT CONTACTOR CABLES 15 0 2454 4 SCREWTHF 1 16 ZJ S 16 WASHER FLAT 5 16 MB ZINC 17 077483 BATTERY 12 0 75H26 18 0742600131 1 ASSY WRE 16 RED 16 REVISION G 6517 D DATE 9 23 05 GROUP C PAGE 2 OF 2 867140 ONIM VANGA JO 50 80 6 ALYA 19 C SLYVd NOININOO 3NION3 2 1669 0 OL AINO SLINN H3dd31S EXPLODED VIEW ENGINE COMMON PARTS 2 51 DRAWING 0F7423 APPLICABLE TO 251 FORD ITEM E9900 0 9739 NEUE EEE ERE 8 REVISION G 6531 C DATE 9 28 05 PART DESCRIPTION ENGINE 25L FORD PULLEY 25L PUMP SCREWHHC 15 25 G88 SERPENTINE BELT 40 85 LENGTH SWITCHOIL PRESSURE 10 5 2POL ASSY WATER LEVEL SENSOR C E PL 245 DEG 38 NPT BUSHING REDUCER 1 4TO 1 8 PLUG STDPIPE 38STEEL SQ MANFOLDINTAKE MACHINED STEPPER MOTOR GASKET 25L FORD INTAKE MAN WASHER SHAKEPROOF EXT 7 16 STL CONDUIT FLEX 38 ID 6 LG WASHER FLAT 5 16 ZINC SSGAURALAVHASSRYRALHNABSRAKAHRAHASYBYRHRUNAB
24. BBNRORUNNBECROE 0 9708 0 9738 09029 BARR RWW WORE REE BREN BEN BEB BEE NNO BR WEE BEN BBB ORB EENNDG BBY GROUP D DESCRIPTION WASHER LOCK 1 4 WASHER LOCK 5 16 SCREWHHC 1 25 25 088 WASHER FLAT 38 ZINC WASHER LOCK MIO SCREWSHC 1 5 350129 ENGINE FOOT 2 5L FORD DIPSTICK 2 5 FORD BRACKET DIPSTICK TUBE SCREWHHC M amp LOX20G88 HARNESS ENGINE 25L R 100 CPL NOT SHOWN SCREWHHC 1 0 25 6109 FLEX PLATE 2 POLE 25L FORD CASTING MACH 25L FORD SCREWSHC 1 5 306129 SCREWSHC 1 50 400129 SPACER FLEXPLATE GASKET 25L FORD EXHAUST MAN MANIFOLD EXHAUST MACHINED HEAT SHELD EXHAUST MANIFOLD SCREWSHC IVB 1 25 300129 STARTER 12 SCREWHHC 1 0 16G88 WASHER FLAT 1 4 M6 ZINC HEXMIO L5 G8 YEL CHR SCREWHHC 1 5 45 088 SPRING BUSHING ALTERNATOR DC BRKT DC ALTERNATOR MACHINED SCREWHKC 3 8 16 2 1 4G5 TENSIONER DC ALTERNATOR HOSE 2 5L FORD COOLANT BY PASS CLAMP HOSE 12 50 125 LOWER HOSE ADAPTER 2 5 FORD ORING 1316 1716 18 SCREWHHC M amp LOX25G88 HOSE DRAIN ASSY 21 HOSE CLAMP BAND 58 BARBEDEL 9038 X 38 ADAPTER MI2 175 38 NPT WASHER NYLON 50X 87 X 06 NUT LOG8 YEL CHR DIPSTICK TUBE 25L FORD COVER R HSIDE ENGINE ADAPTOR COVER L HSIDE ENGINE ADAPTOR SCREWSHC 10 1 50 506129 SCREWHHC 1 4 20 1255 WASHER LOCK 1 4 655 WASHER FLAT 1455 WASHER SHAKEPROOF EXT 5 16 STL
25. D EXPLODED VIEW MOUNTING BASE 2 5L FORD DRAWING 0F7416 APPLICABLE TO ITEM PART REVISION G 6148 A DATE 8 10 05 QTY 8 DESCRIPTION 108 CHR WASHER LOCK 1 4 WASHER SHAKEPROOF EXT 1 4STL LUG SLDLSS 2 8 17 64CU WASHER FLAT 14M5 ZINC SCREWHHC M6 10X 16G88 NUTFLANGEDHEXMD2 175 DAVPENERMBRATIONAOBLUE SPACER 49X 62X 1 87 PADR ZNC DAIVPENER VIBRATION WASHER FLAT SCREWHHC 2 1 75 80 88 ASSY WIRE 4012 00 SCREWHHIT 1 0 WASHER SHAKEPROOF EXT 7 16STL MIG BASE 25L 1 WASHER LOCK MIO SCREWHHC MIO 15X 25 G88 WASHER FLAT 38 MIO ZINC GROUP C PAGE 2 OF 2 STARTER O QO 24 a O 2 lt pom ee 5 lt N o X CN 15 STARTER SOLENOID EXPLODED VIEW BATTERY C1 CPL REVISION G 6517 D 0F7422 DRAWING PAGE 1 OF2 9 23 05 DATE EXPLODED VIEW BATTERY C1 CPL DRAWING 0F7422 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0 34088 1 BATTERY TRAY 2 0341 1 STRAP BATTERY RETAINVENT 3 025507 REF WASHER SHAKEPROOF EXT 7 16 STL 4 52647 REF SCREWSHC 1015 25 12 9 5 046526 REF WASHERLOCK MIO 6 02131 WASHER FLAT 3 8 MIO ZINC 7 1 BATT POST COVER RED 8 060831 BATT POST COVER BLK 9 08880
26. Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extin guisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris These generator sets may operate using one of several types of fuels fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulat ing the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks immediately Fuel supply lines 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 detectors accordingly Stand
27. L FILTER Figure 10 3 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 caution A 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 part number 059402 simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 10 3 See the Service Schedule for air cleaner mainte nance 90 80 0 5001 MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance 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 r
28. LICABLE TO WEIGHT DATA 1 5L 20 289KG 1774 516 2 51 25KW 389KG 1043101 WDDDEN SHIPPING SKIDS INCREASE OVERALL WEIGHT T B D NOTES 12 MINIMUM RECOMMENDED CONCRETE PAD SIZE 1346 53 0 WIDE X 2413 95 042 LUNG REFERENCE INSTALLATION GUIDE P N OF 5298 FOR CONCRETE PAD REINFORCEMENT AND PAD DEPTH GUIDELINES 2 GENERATOR MUST BE LOCATED A MINIMUM DISTANCE OF S FEET FROM A WALL OR FENCE ALLOW 5 FOOT MINIMUM PERIMETER OF OPEN SPACE AROUND THE ENTIRE GENERATOR REFERENCE INSTALLATION GUIDE P N OF 5298 FOR OUTDOOR ROOF MOUNTED APPLICATIONS 32 CIRCUIT BREAKER INFORMATION SEE SPECIFICATION SHEET WITHIN OWNERS MANUAL 4 INSIDE STUB UP AREA FOR AC LOAD LEAD CONDUIT CONNECTION NEUTRAL CONNECTION BATTERY CHARGER 120 VOLT AC 5 MAX CONNECTION AND ACCESS TO TRANSFER SWITCH CONTROL WIRES REMOVE FRONT COVER FOR ACCESS 4 FIELD CUT HOLE IS ONLY REQUIRED FOR MOUNTING OF GENERATOR DN EXISTING PAD 52 REFERENCE OWNERS MANUAL FOR LIFTING WARNINGS 6 REMOVE LIFT OFF ENCLOSURE TO ACCESS EXHAUST MUFFLER EXHAUST AND AIR DISCHARGE LOUVERS FRONT AND SIDES 13 5 53 DIA MOUNTING HOLE 42 PLACES 12 7 1 2 DIA MASONRY ANCHOR BOLTS RECOMMENDED CONCRETE MOUNTING PAD SEE NOTE 1 FRONT VIEW REVISION DATE 9 8 05 PAGE 1 OF 2 EXPLODED VIEW INSTALL DWG 1 5L 20KW AND 2 5L 25KW DRAWING 0F7555 GROUP G APPLICABLE TO SERVICE ITEM ACCESSIBILITY CHART CENTER OF GRAVITY 870 34257 151 2
29. LOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 18 amp 11 THREAD FORMING FASTENER AND ITEM 12 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 SAIVE MANNER GROUP F PAGE 2 OF 2 GROUP F EXPLODED VIEW EXHAUST SYSTEM 2 5L C1 DRAWING u REVISION G 6457 A 0F7385 PAGE 1 OF2 9 15 05 DATE EXPLODED VIEW EXHAUST SYSTEM 2 5L C1 DRAWING 0F7385 GROUP F APPLICABLE TO ITEM PART QTY DESCRIPTION MUFFLER C1 MUFFLER SADDLE PIPE EXHAUST OUTLET PIPE EXHINLET MFLR SIDE 2 5L SCREW HMHIF M6 L0 X16 PIPE EXHINLET MANIFLDSIDE 2 5 BOLT 95 16 18 2 1 4 BOLT U 516 18 2 09 SADDLE 2 INCH WASHER LOCK 5 16 NUT HEX 516 18 STEEL SCREWHHC 1 0 30088 GASKET EXHAUST RING EXHAUST BLANKET 988VM FLANGE EXHAUST 2 PIPE WASHER FLAT 3 8 M10 ZINC WASHER LOCK 3855 SCREWHHC 3 8 16 13455 MUFFLER STRAP HEXM6 X LOGS YEL CHR WASHER FLAT 1 446 ZINC WASHER LOCK 6 1 4 REVISION G 6457 A DATE 9 15 05 PAGE 2 OF 2 GROUP G EDNIBHESPANEESPEGEND RV 2 1 AVR AUTOMATIC VOLTAGE REGULATOR BATTERY CHARGER CUSTOMER CONNECTION DIODE lt FIELD BOOST CIRCUIT B
30. NUT HEX MB L25 GB CLEAR ZINC EARTHSTRAP WASHER LOCK 5 16 SCREWSHC 1 5 256129 FILTER 25L FORDOIL NOTE TORQUE 44 FT LBS PAGE 2 OF 2 GROUP D ENGINE TRES CDNTRDL PANEL THE ITEMS INSIDE THE DASHED RECTANGLE WTS REPLACE WATER LEVEL SENSOR PART NUMBER WLS 0 0561 A B x Pd TYPICAL ped s e ra PANEL CONNECTION 2 1 0 P N OF9483 9 3 WIRING DIAGRAM NEW COOLANT LEVEL SENSOR MECHANICAL DIAGRAM NEW COOLANT LEVEL SENSUR INSTALATILUN TH A P N 0E2307 P N 0F6749 SEALANT MUST BE APPLIED TO THREAD PRIOR TO INSTALATION WHERE APPLICABLE P N 9483 EXISTING COOLANT LEVEL SENSOR LOCATION DN UNIT EXISTING COOLANT LEVEL SENSOR WIRE HARNESS CONNECTOR EXPLODED VIEW REVISION ERRATA SHEET FOR 0 0561 DATE 12 7 05 PAGE 1 OF 2 DRAWING 0F9502 GROUP D PAGE EXPLODED VIEW REVISION ERRATA SHEET FOR 0E0561 DATE 12 7 05 PAGE 2 OF 2 DRAWING 0F9502 077 40 ONIMVUG S0 S1 9 ALVA Ad1 1913 9 3NION3 OL fy 47 NOLLWWHOSNI uolvinoau HOS 8 Z L LL Wn OL Lv 3AO8V 5 NI NMOHS NOILO3UIG NI ONILNIOd MOHHV Q3TIV LSNI LSNW GION31OS INVLYOdWI SSANYVH 3NION3 NOISU3ANOO HOdVA 1 61 8820130 ASSV
31. QTY DESCRIPTION 1 0F7489 1 ROTOR 30KW DIRECT 3904 1800 0F7490 1 ROTOR 25 DIRECT 390 1800 2 7458 1 STR 390 30AD1 HSB TECUM 027459 1 ASSY STR 390 25 GDL CPL 3 0 9708 INSTR HYPOT TEST NOT SHOWN 4 SEE ENGINE EV REF ENGINE ADAPTER 5 SEE ENGINE EV REF FLEXPLATE 6 9073648 1 ASSY FLYWHEEL CPL W25VMFANB 7 0E5706 1 REAR BEARING CARRIER 390DRCT 8 0F7874 1 ASSY BRUSH HOLDER 390HSB 070892 1 SLIP RING MACHNED 10 017248 1 BALL BEARING 45 MM 023454 1 KEY WOODRUFF 12 0 7045 1 CONDUIT FLEX 10 ID 20 LG 13 045761008 4 STUD MI4 2 0X 490 G5 ZINC 052646 4 WASHER FLAT 15 043123 4 WASHER LOCK MIA 16 051779 4 NUT HEXMIA 20G8 YEL CHR 17 04601 1 SCREWHHC 6 20 45 88 18 04260 1 WASHER FLAT 688D X 3 2500 19 08 008 4 SCREWHHC MIO L50X 16 109 20 016526 4 WASHERLOCK 2 4 SCREWHHIT 7 25 2 4 WASHER LOCK 8 M1 23 088150 4 WASHER FLAT 8 24 0700438 1 CONDUIT FLEX 50 ID 16 LG ROTOR REPLACEMENT PARTS REVISION G 6376 C DATE 9 6 05 PAGE 2 OF 2 11 WE 7 lt t 9 N u luz a o oqs 9 w N TO THERMOSTAT ADAPTER MOUNTING FRAME REF REVISION G 6474 C DATE 9 21 05 EXPLODED VIEW COOLING SYSTEM 2 5L C1 DRAWING 0F7363 PAGE 1 OF 2 EXPLODED VIEW COOLING SYSTEM 2 5L C1 DRAWING 0F7363 APPLICABLE TO ITEM PART QT
32. RAL INFORMATION PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid fuel in the supply tank Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state The vapor withdrawal system is generally best suited for smaller engines that require less fuel The installer should be aware of the following The natural gas and LP gas systems are similar However the natural gas system delivers gas at a pressure of approximately five inches water col umn to the carburetor When ambient temperatures are low and engine fuel consumption is high the vapor withdrawal system may not function efficiently Ambient temperatures around the supply tank must be high enough to sustain adequate vaporiza tion or the system will not deliver the needed fuel volume In addition to the cooling effects of ambient air the vaporization process itself provides an additional cooling effect LP FUEL SYSTEM LP is supplied as a liquid in pressure tanks It is usually made up of propane butane or a mixture of the two gases Propane tends to vaporize readily even at temperatures as low as 20 F 29 C However butane reverts to its liquid state when temperatures drop below 32 F 0 C LP in a liquid withdrawal system must be converted to its gaseous state before it is introduced into the engine carburetor A vaporizer converter is generally
33. REAKER EXCITATION ALTERNATOR ND FUSE BAT POWER 15 TYPE BRUSH ASSEMBLY GENERATOR CONNECTOR 2 ICT INTERCONNECT TERMINAL BLOCK CONNECTOR 3 PCB MCB MAINLINE CIRCUIT BREAKER FIELD BOOST RESISTOR 15 OHM NEUTRAL BLOCK RELAY 1 START RELAY UCT UTILITY CONNECT TERMINAL BLOCK RELAY 2 ENGINE RUND AUTD DFF MANUAL SWITCH SWe SET EXERCISER SWITCH NOTE TR WIRES ARE E OTHERWISE NOTED AS SHOWN SIZ CAWG 15 1 Helis 13 I4 15 a 15 5 02 120 VAC IESE UTILITY PCB J3 NOT USED 1 RAK 3 W1 4 We mEn 5 w3 R4 6 W4 _ ANALOG INP RET J START RELAY T 2 S6A C J J LLL LLL 1 e FUELX RUN RELAY T 14A 4 2 WIRE STARTOD 4 183 MOMENT OPEN 5 9 15 2 WIRE 5 02 6 178 16 SENSED 8 224 NI AVR 162 ALARM RELAY 9 i XFER RELAY 710 23 14 MAN INPUT 411 239 TBI 195 16 SENSE 412 225 d d ex ANALOG INP 113 44 GND B 1418 0 0 6 1 SaS 1 4 959 i MEI 4 v z 253 197 SEA 3993 EPS deus Se ee 15 RSS LIS 15 614 15 Pie NON N SINGLE PHASE STATOR SHOWN
34. Serial Number QT 2 5L Model 005212 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 226740 Hed 90 60 0 8101910 SAFETY RULES 1 1 INTRODUCTION 1 3 Read this Manual 1 3 Operation and Maintenance 1 3 How to Obtain Service uo err teta ee RR ve dp e 1 3 IDENTIFICATION 2 1 2 1 EQUIPMENT DESCRIPTION 3 1 Equipment Description 3 1 Engine Oil Recommendations 3 1 Coolant 3 1 ENGINE PROTECTIVE DEVICES 4 1 High Coolant Temperature Switch 4 1 Low Coolant Level 4 1 Low Oil Pressure Switch reete eere edens 4 1 Overcrank Shutdown eee reete 4 1 Overspeed Shutdown
35. T 7 15 16 SENSECD 78 224 n ALARM RELAY 9 XFER RELAY 710 23 1 MAN INPUT 111 239 ai 16 SENSECO 119 225 ANALOG INP 13 GND B 114 0 C 14 1 14 N 15 E O T 15A e ICT 2 UTILITY FROM T SW 56A ICT 3 TRANSFER COIL RELAY 94 ICT 4 TRANSFER COIL RELAY NB 56 83 5 START Y T 15 78 6 START _ lt lt gt 15 CUSTOMER CONNECTION amp ALTERNATOR LEGEND BRUSH ASSEMBLY GENERATOR CB1 MAINLINE CIRCUIT BREAKER 240V TO TRANSFER SWITCH ICT INTERCONNECT TERMINAL BLOCK NB NEUTRAL BLOCK UCT UTILITY CONNECT TERMINAL BLOCK NOTE 1 WIRING SHOWN FOR 1 BA AND STATOR IS TYPICAL FOR SINGLE PHASE FOR 3 PHASE SEE DWG OF 6839 se SSeS SS Seo SS aS SSS SS SS ee SSS SSS SS a eS MP Saas J SCHEMATIC DIAGRAM REVISION 2 5L COMM PROD LINE PAGE 1 OF 2 DATE 08 04 05 DRAWING 0 7420 GROUP G ENGINE WIRING LEGEND 3 AFS AIR FUEL SOLENOID ALT D C CHARGE ALTERNATOR MURUS BAT 12VDC BATTERY COIL PACK DX CS CRANK SENSOR FS FUEL SOLENOID COOLANT SENSORS 4 85 FS2 AUX FUEL SOLENOID DEG S Too HIGH COOLANT TEMP SWITCH DEG 5V 6 1 CONNECTOR 1 PCB DISTRIBUTUR VAR Am LFP LOW FUEL PRESSURE SWITCH
36. Wire 14 from Engine Control circuit board Spark plugs defective Door on tank not closed Flame arrestor air cleaner plugged or damaged Plugged fuel line Defective spark plugs Fuel pressure incorrect Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch Defective AUTO OFF MANUAL switch Open disconnected wire 415A between AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open ww CORRECTION 1 2 Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replace fuse Replenish fuel Replace solenoid 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 l
37. X 3 8 16 STEEL 20 02223 1 WASHER LOCK 3 8 a 057329 1 LUG SLDLSS 350 6 X 13 32 AL CU 2 057073 1 J UNCTION BLOCK 38 16 23 023484 1 BUSHING SNAP SB 200026 24 0E3257 15 1 0 16 25 0 7890 BRKT CB BACK 2P 0 6002 MTG TRACK SIEMENS 3P 26 2P 240 5 BQ2 LL 151 2POLE 005544 062812 00804 240 5 LL 1 51 3 POLE 042077 0125A 2P 240 5 BQ2 LL 2 5L 2POLE REF CB 01004 240 5 2 5L 3 POLE 27 2 REF SCREWHHC M5 0 8X 20G88 NOT SHOWN 28 023897 WASHER FLAT 10 ZINC NOT SHOWN 29 REF WASHER LOCK NOT SHOWN 30 REF NUT HEXIV5 08 GB CLEAR ZINC NOT SHOWN 3l 1 LUGSLDLSS 76 14X 1364 CU 051716 025433 32 QA1354A REF REGULATOR DC ALT 33 042568 SCREWHHC 1 0 20 8 8 022473 WASHER FLAT 1 4 ZINC 35 02097 WASHER LOCK 1 4 36 049813 REF NUT HEX LOGS YEL CHR 0 7191 057598 37 REF BRACKET PANEL SUPPORT 1 5 38 1 CABLE TIE MOUNT BLACK 39 0F1733 1 DECAL CUSTOIVER CONNECT INSIDE USEDON 1 5 ONLY REVISION G 6772 E DATE 11 2 05 PAGE 2 OF 2 167430 ONIA V3IG I 0 9 6 ALYA NOLLV LLIOX3 HOLVNSALTV 140 O 9LE9 D IHOLDIOO1 aV OL V dodo EXPLODED VIEW ALTERNATOR DIRECT EXCITATION DRAWING 0F7491 GROUP A APPLICABLE TO ITEM PART
38. Y DESCRIPTION 1 0F7074 1 SUPPORT RADIATOR LH SIDE 2 0F7076 1 VENTURI 16 DIA FAN 3 OND 1 SUPPORT RADIATOR RH SIDE 4 0E9837A 1 RADIATOR 2 5L CPL 5 2 1 FANCOOL 16 8 BLADE 6 0F7130 1 SPACER FAN2 5L C1 7 0 9833 1 HOSE 2 5L FORDLOMWER RADIATOR 8 000502 4 CLAMP HOSE 24 1 06 200 9 069860 1 HOSE DRAINASSY 21 10 085461 1 BARBEDSTR I ANPT X 38 F027 1 HOSE UPPER RADIATOR IZ4VMTAL 016627 1 RADIATOR 13 052250 2 TAPE FOAM1X1 20 LG 14 022173 4 WASHER FLAT 14M6 ZINC 15 02209 12 WASHER LOCK 16 0 8566 8 SCREWHHFC 6 1 0 20 588 17 049813 4 HEX 1 08 YEL CHR 18 2454 24 SCREWTHF M amp 1X 16 2 S 19 030976 8 SCREWSHC 1 25 20 129 2 4 WASHER FLAT 5 1608 ZINC 21 022129 4 WASHER LOCK 5 16 22 0C7629 1 CLAMP HOSE 38 87 23 076749 1 TANK COOLANT RECOVERY 24 1 BRACKET 25L FORD WATER BOTTLE 25 0380B1C 2 HOSE BAND 1 4 26 029082 1 HOSE 9 32 ID 40 LG 27 019814 REF SCREWHHC 1 5 25 G88 28 016526 REF WASHER LOCK MIO 29 02131 REF WASHER FLAT 3 8 M10 ZINC 30 0 7307 1 GUARD FAN RH 1 31 0F7308 1 GUARD FANLHC1 CPL 029107 1 GROMMET 7 8 316 X58 REVISION G 6474 C DATE 9 21 05 GROUP C PAGE 2 OF 2 50 01 78 8719 9 IO I HDVd 9430 DNIA VIG 0404192 4574 ONILNNOW 1 OL x lt 5 _ 2 d 1O I
39. ain 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 ft 600 Controller R 100 2109905090 Standby Generator Sets E INFORMATION Specifications INFORMATION Figure 1 Interconnections 000000 Utility In Transfer Switch CONTROL PANEL NEUTRAL o TO ALTERNATOR NEUTRAL N 5 GENERATOR 4 14 Load BOX BREAKER WIRES TO 178 BOX GROUND TO GENERATOR gm To Generator Control Panel FRAME RAIL CIRCUIT BREAKER SIZE KW VOLTS AMPS LUGSIZE 25 24010 125 4 to 1 0 Ground Level STUB UP AREA Concrete Slab See Install Dwg for Dimensions COLD WEATHER KIT 10 Reverse the procedure to convert back to natural gas For cold climates optional cold weather kit part number 0F6148 is recommended The kit includ
40. ary Check the engine coolant level Adjust as necessary Check the engine coolant thermal protection level Correct as necessary Check the natural gas delivery system on gas engine driven units Tighten connections as necessary Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiring for loose connections corrosion and damage Correct as necessary 10 Check the engine accessory drive belts for wear weather cracking and damage Replace as necessary 11 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 12 Test the engine and transfer switch safety devices Correct and or adjust as necessary e N gt a 20049546 11 2 Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp be done Comp Comp Required Comp to be done Date 3 months Date i Date be done Date monthly Initials Break in Initials Initials Annually Initials 10 Hrs 13 Initiate an automatic start and transfer of the unit
41. by Generator Sets INTRODUCTION Thank you for purchasing this model of the standby generator set product line Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest Authorized Service Dealer for start ing operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert person nel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows A After this heading read instructions that if not strictly complied with will result in personal injury or property damage warninc 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
42. ches to 14 inches of water column 0 18 to 0 5 psi NOTE Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below five inches water column for natural gas or 5 inches water column for propane vapor for all load ranges NOTE It is the responsibility of the installer to make sure that only the correct recommended fuel is sup plied to the generator fuel system Thereafter the owner operator must make certain that only the proper fuel is supplied NATURAL GAS FUEL SYSTEM Natural gas is supplied in its vapor state In most cases the gas distribution company provides piping from the main gas distribution line to the standby generator site The following information applies to natural gas fuel systems Gas pressure in a building is usually regulated by national state and local codes To reduce gas pressure to a safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff sole noid should not exceed approximately 14 inches water column 0 5 psi Optimum pressure at the fuel shutoff solenoid is 11 inches water column 0 4 psi Standby Generator Sets Fuel Systems GENE
43. ction devices will open if the circuit is overloaded caution A 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 90 80 0 CHECKING FLUID LEVELS CHECK ENGINE OIL Check engine crankcase oil level Figure 10 3 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Engine Oil Recommen dations for recommended oils Figure 10 3 Oil Dipstick and Oil Fill Cap T Engine Fill Cap gt Cleaner TENN BATTERY FLUID Check battery electrolyte fluid based on the Maintenance Schedule Fluid should cover separa tors in all battery cells If fluid level is low add dis tilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications e Add recommended coolant mixture as necessary e 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 fille
44. d storage batteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury 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 a
45. ded to be used in conjunction with the genset If a Non Generac Power Systems Inc Transfer Switch is substituted for use and directly causes damage to the genset no warranty coverage shall apply All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty Policies and Procedures Flat Rate Manual Units that have been resold are not covered under the Generac Power Systems Warranty as this Warranty is not transferable Unit enclosure is only covered against rust or corrosion the first year of the warranty provision Use of Non Generac replacement part s will void the warranty in its entirety Engine coolant 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 applications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted or Rental Unit definition and warranty Units
46. e level of the high coolant temperature switch it is possible for the engine to overheat without automatic shut down To prevent such overheating the engine has a low coolant level sensor If the level of engine coolant drops below the level of the low coolant level sensor the engine automatically shuts down LOW OIL PRESSURE SWITCH This switch has normally closed contacts that are held open by engine oil pressure during cranking and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO Standby Generator Sets Engine Protective Devices GENERAL INFORMATION OVERCRANK SHUTDOWN After a prespecified duration of cranking this func tion ends the cranking if the engine has failed to start The overcrank LED will turn ON Turn OFF the AUTO OFF MANUAL switch then turn switch back to AUTO to reset the generator control board NOTE If the fault is not corrected the overcrank feature will continue to activate Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds 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 whenev
47. eak Add coolant Replace Switch 1 Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Auto reset Wait 5 min and attempt restart Contact the nearest Authorized Dealer for assistance 12 1 90 80 0 100149191 5 Standby Generator Sets Notes NOTES 296 40 ONIMVUG ALVA SLUVd 145 NOILOANNOO TH OO IXH 8 7 LL E EXPLODED VIEW CONNECTION BOX SPL PARTS DRAWING 0F7352 APPLICABLE TO GROUP A ITEM PART QTY DESCRIPTION 1 027135 1 2 027022 1 SUPPORT CONTROL PANEL SIDE 3 027021 1 SUPPORT CONTROL PANEL SIDE LH 4 0r7260 1 COVER CIRCUIT BREAKER 2P 0F7136 1 COVER CIRCUIT BREAKER 3P 5 OF6156 1 PLATE WIRE SNGL GALV 6 0054464 1 DECAL CUST CONN 120V UTILITY 7 024698 BLOCK TERM20A 6X 3X 1100 8 02382 1 DECAL UTIL SENSE CUST 9 057701 REF BLOCK TERM20A 8X 6X 1100 10 OF6146 1 HANG TAG 2 START NOT SHOWN R 081008 1 GROMMET 125 X 25X 75 B 0C2267 2 SCREWHHIT M508X 12 2 WASHER LOCK 5 051713 2 WASHER FLAT V5 16 0 2212 SCREWPHIT M07 X 16ZYC 17 WASHER LOCK 8 4 18 OF6366A 1 XFMR DUAL 104V 16V 1 PHASE OF 63668 1 XFMR DUAL 120 16 PHASE 19 02241 1 NUT HE
48. ecommended 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 MISCELLANEOUS MAINTENANCE CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer That dealer will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well 90 80 0 10 4 Finally have insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying BATTERY lead aci
49. eet Belt Driven M 2090 rpm Fan ari dm to ppt rere dee o 16 inches Molla l l an ai Pusher Air Flow inlet air including alternator and combustion air sse 1438 ft8 min Coolant Capacily ruere 8 0 U S gal Heat Rejection to Coolant 95 000 Btu h Maximum Operating Air Temp on Radiator 60 C 150 Maximum Ambient Temperature 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 Load Load Load Load 60 24 140 56 22087 300 119 380 151 ELECTRICAL SYSTEM Battery Charge Alternator 12V 30 Amp Static Battery Charger sse 2 Amp Recommended Group 26 525CCA System 12 Volts Voltage Regulator oe naa Electronic Single phase ae a 1 FealulGS temi hanes V F Adjustable Adjustable Voltage and G
50. er the unit is running Should the engine overspeed above a safe preset value the circuit board initiates an automatic engine shutdown Contact the nearest Authorized Dealer if this failure occurs RPM SENSOR LOSS SHUTDOWN If the speed signal to the control panel is lost engine shutdown will occur DC FUSE This fuse is located inside of the control panel It protects the panel wiring and components from damaging overload Always remove this fuse before commencing work on the generator The unit will not start or crank if the fuse is blown Replace the fuse with one of the same size type and rating See the exploded views and parts lists at the end of this manual for replacement part number 90 80 O AH 10010 46 3 GENERAL INFORMATION FUEL SYSTEM FUEL REQUIREMENTS The standby generator may be equipped with one of the following fuel systems Natural gas fuel system Propane vapor PV fuel system The Manual Drawing Listing that is affixed to the unit includes the Identification Code which may be used to identify the type of fuel system installed on the unit Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is 5 inches to 14 inches water column 0 18 to 0 5 psi and for liquid propane 5 in
51. erator for the first time the installer must complete the following procedures For follow up maintenance information service intervals please refer to the Maintenance section and the Service Schedule TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems For additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with applicable codes standards and regulations FUEL SYSTEM Make sure the fuel supply system to the genera tor a delivers the correct fuel at the correct pres sure b is properly purged leak tested according to code No fuel leakage is permitted See Specifications for more information GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULT mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications and Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with break in oil This oil should be changed after 30 ho
52. erator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts 90 80 0 100 jejes 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 Z ELECTRICAL HAZARDS All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the standby generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appropriate covers guards and barriers are in
53. ered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by an Authorized Service Dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact an Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting an Authorized Service Dealer or the factory about parts and service always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit AUTHORIZED SERVICE DEALER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 or locate us on the web at www generac com 90 80 100 GERE i Standby INFORMATION IDENTIFICATION RECORD DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the gene
54. es 11 The Dip switch inside the control panel must be in the LP or NG position when switching to differ Battery Warmer ent fuels 4 Junction Box with hardware 6 qt pack 5W 30 synthetic oil engine Figure 6 2 Reconfigure the Fuel System RECONFIGURING THE FUEL SYSTEM x n C PLUG Brass HOS LIES PLUG models are configured for natural gas or LP Pore vapor from the factory HOUSING PORTS To reconfigure the fuel system from NG to LP follow these steps 8 5 1 Turn main gas supply off 2 Remove the carburetor fuel hose from the outlet port Port 1 of the demand regulator Figure 5 6 2 3 Remove brass hose fitting from outlet port EIN Port 1 of the demand regulator NOTE 4 Remove pipe plug from Port 2 5 Install brass hose fitting into Port 2 Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made 6 Install pipe plug into Port 1 7 Connect carburetor gas hose to brass fitting IDANGER A 8 Tighten all clamps and plugs 9 Make sure fuel supply is of proper pressure AN Serious injury or damage may occur if not con and type for configuration figured properly Please consult an Authorized Service Dealer with any questions 2109905099
55. he engine before it has been properly serviced with the recom mended oil may result in an engine failure NOTE For temperatures below 32 it is strongly recom mended to use the optional Cold Weather Start Kit part number listed in the Specification Section The oil grade for temperatures below 32 F is 5W 30 synthetic oil Standby Generator Sets Equipment Description GENERAL INFORMATION COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is listed in the specifications Use only deion ized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the recommended coolant mixture When adding coolant always add the recommended 50 50 mixture caution 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 Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result
56. ial problem areas Performed monthlu this requires approximatelu 5 man hours per unit to complete This inspection mau be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the control panel AUTO OFF MANUAL switch to the OFF position Remove the 5 amp and 15 amp control panel fuses Turn off the battery charger turn OFF utility supply to ATS Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ONLY ONCE following the first three months or 30 run time hours of operation after purchase of the unit and requires approximately 2 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed
57. ing batteries fuses light bulbs engine fluids and overnight freight cost for replacement part s THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to purchaser owner GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF 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 Bulletin 0171360SVE Printed in U S A 7 05 Printed in U S A
58. ling to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If a pro cedure work method or operating technique is used that the manufacturer does not specifically recom mend ensure that it is safe for others Also make sure the procedure work method or operating tech nique utilized does not render the generator unsafe DIE 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 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 A 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 Insta
59. llation operation servicing and repair of this and related equipment must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electri cal and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operated and serviced in accordance with the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon monox ide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people animals etc will not be harmed This exhaust system must be installed properly in strict compliance with applicable codes and stan dards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical in any room or building hous ing the generator to prevent buildup of explosive gases and to ensure correct gen
60. n any loose wires to keep them clear of any moving generator set components INITIAL INSPECTION FOR QT GENSET STARTUP Inspect for the following Freight Damage Manuals present Fluid Levels Oil coolant battery Gear Drive Correct fuel piping Correct muffler installation for QT50 0770 QT100 QT150 Adequate air flow clearances and ventilation per installation drawings and applicable codes Correct AC and DC wire size connections and grounding Control and communication wiring to from the transfer switch must be run in a separate conduit from the AC power leads Battery charger connection to 120 VAC Communication wires connected between transfer switch and generator HTS only Unit secured to pad V 10088 INSTALLATION Standby Generator Sets Installation INSTALLATION START UP CHECKLIST A warninc Before working on the generator ensure the fol lowing The AUTO OFF MANUAL switch is in the OFF position The 120VAC supply to the battery charger is switched OFF PREPARATION FOR START UP Ensure that the 120VAC circuit breaker to the bat tery charger is open Remove the fuse from the the control panel For the H 100 and R 100 Open the front door of the control box and remove the 15 Amp ATO fuse in the lower left hand corner of the control box Connect the battery cables to the battery Attach negative battery cable last Close the 120VAC circuit breaker to the
61. n 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 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 PERIODIC REPLACEMENT PART Oil Filter Motorcraft FL 400 S supplied with engine 046627 059402 Spark Plug Motorcraft AWSF 52 C supplied with engine 077483 10 5 90 80 0 GOOIEN Standby Generator Sets MAINTENANCE MAINTENANCE Service Schedule SERVICE SCHEDULE The following is a recommended maintenance schedule for small standby and residential generator sets The established intervals in the schedule are the maximum recommended when the unit is used in an average service application They will need to be decreased performed more frequently if the unit is used a severe applica tion Use calendar time or accumulated run time from the previous maintenance interval to determine the next required maintenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten t
62. nd if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTER IES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer 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 Standby Generator Sets MAINTENANCE MAINTENANCE Maintenance Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster 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 ca
63. ndle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the standby generator s main line circuit break er to its OFF or OPEN position Start the generator Operation caution Do not crank the engine continuously for longer than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge read ings When certain that all readings are correct move the transfer switch manual handle to its STANDBY GENERATOR position i e load cir cuits supplied by the generator the standby generator s main line circuit break er to its ON or CLOSED position Load circuits are now powered by the standby generator RETRANSFER AND SHUTDOWN For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch To transfer the load back to the utility power source and shut down the generator follow these direc tions Set the standby generator s main line circuit break er to its OFF or OPEN position Manually move the transfer switch handle to its UTILITY NORMAL position i e load circuits connected to the utility Turn ON the utility power supply to the transfer switch using the means provided such as the util ity power source main line circuit breaker Let the generator run at
64. ned to supply 3 phase electri cal loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit breaker with a Y configuration as shown in Figures 7 2 and 7 3 The rated voltage between circuit breaker terminals 1 2 1 E2 E3 is either 480V or 208V depending on the model The rated voltage between each circuit breaker termi nal and the neutral point 00 is either 277V 120V depending on the model Figure 7 2 Stator Power Winding Connections 3 phase 277 480V 6 Lead S1 E1 1 INTERNAL CONNECTIONS L L 56 lt gt 84 NEUTRAL 2 1 53 S2 Tw Figure 7 3 Stator Power Winding Connections 3 phase 120 208V 6 Lead E1 S4 54 00 NEUTRAL S3 53 52 40 80 0 100 4099 INSTALLATION Standby Generator Sets C y Installation i INSTALLATION INSTALLATION Refer to the separate Installation Guide QT Product Line supplied with the unit PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed ser viced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules as well as all other safety information in this manual before attempting to operate this and related equipment Before starting the gen
65. no load for a few minutes to stabilize internal temperatures Shut down the generator OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If the generator has been installed with an automatic transfer switch such as an RTS HTS or GTS type transfer switch the engine may be started and stopped automatically or manually NOTE Refer to the applicable manual for your trans fer switch and to Transfer Switch Start Signal Connections In addition please note the dangers under Engine Start up and Transfer 90 80 1001990 MAINTENANCE Standby Generator Sets 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 Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY 1 Test engine governor adjust or repair if needed 2 Clean inspect generator 3 Flush cooling system FIRST 100 OPERATING HOURS 1 Change engine oil and oil filter After initial change service engine oil and
66. nsfer switch is one that will not provide automatic start up and does not include an intelligence circuit ENGINE START UP AND TRANSFER For additional information refer to the applicable control panel manual for this unit as well as any lit erature pertaining to the specific transfer switch DIG A The Maintenance Disconnect Switch and the AUTO OFF MANUAL switches if so equipped must be set properly or the generator will crank and start as soon as the utility power to the transfer switch is turned off Refer to applicable control panel and 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 doors should be kept closed and locked Only authorized personnel should be allowed access to the transfer switch interior Extremely high and dangerous voltages are present in the transfer switch In order to transfer load from the utility source to the generator follow these directions Turn OFF or disconnect the utility power circuit to the transfer switch using the means provided such as the utility source main line circuit break er Set the transfer ha
67. oad 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 of installing dealer Yellow Copy For the customer s records Standby Generator Sets OD GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator s manual for this unit OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the generator was installed in conjunction with a transfer switch capable of manual operation only the following procedure applies A manually operated tra
68. om the electric utility distribution system when the generator is operat ing Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy 90 80 0 100 5 Standby Generator Sets Important Safety Instructions SAFETY RULES Generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to person nel disable the generator s automatic start circuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and 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 causing injury FIRE HAZARDS
69. place before operating the gen erator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT If personnel must stand on metal or concrete while installing operating servicing adjusting or repair ing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static electricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maxi mum electrical current ampacity to which they will be subjected Before installing or 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 switch so as to isolate the generator electric system fr
70. ption repair or replace any part s which upon examination inspection and testing by Generac Power Systems or an Authorized Certified Generac Power Systems Dealer or branch thereof is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be examined by the nearest Authorized Certified Generac Power Systems Dealer or branch thereof This warranty applies only to Generac Power Systems Generators used in Standby applications as Generac Power Systems Inc has defined Standby provided said generator has been properly installed and inspected 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 e ALL COMPONENTS Start up and or On line Registration or Registration Card along with Proof of Purchase must be performed and or sent in Guidelines Any and all warranty repairs and or concerns must be performed and or addressed by an Authorized Certified Generac Power Systems Dealer or branch thereof A Generac Power Systems Inc Transfer Switch is highly recommen
71. r 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 10 2 MAINTENANCE Standby Generator Sets MAINTENANCE Maintenance 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 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 Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks security damage CHECK FAN BELT
72. rator The data label which can be found attached to the gen erator s lower connection box lists the unit s serial number and its rated voltage amps wattage capacity phase frequency rpm power factor etc rator Sets E General Information INFORMATION NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Generator Model and Serial Number This number is the key to numerous engineering and manufacturing details pertaining to your unit Always supply this number when requesting service order ing parts or seeking information Data Label GENERATOR SET DATA MADE IN USA MODEL SERIAL RATED KW RATED KVA PHASE RATED VOLTAGE RATED AMPS POWER FACTOR HERTZ ALT RPM ENGINE RPM PRODUCTION DATE ALTERNATOR SUBTRANSIENT REACTANCE ALTERNATOR TRANSIENT REACTANCE CLASS ROTOR STATOR WINDING INSULATION AT 25 C AMBIENT GENERAC POWER SYSTEMS INC WAUKESHA WI 90 21 V 200 GENERAL INFORMATION EQUIPMENT DESCRIPTION This equipment is a revolving field alternating cur rent generator set It is powered by a gaseous fueled engine operating at 1800 rpm for 4 pole direct drive units 3600 rpm for 2 pole direct drive
73. st Manifold Procedure 10 1 Intake Manifold Procedure aus eornm 10 1 Cylinder Head Procedure assqa sasa rot een 10 1 Cooling 10 2 Overload Protection for Engine DC Electrical Sy Stemi 10 2 Checking Fluid Levels 10 2 Check Engine Oil uuu asua asa 10 2 Battery Fluid oie w ua esos a sa PE SEES 10 2 Engine Coolant 10 2 Maintenance Owner Operator Can Perform 10 3 Check Engine Oil 1 20 11 1 10 3 10 3 Exercise 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 Fan Belt R 10 3 Inspect Engine Governor 10 3 Changing Engine Oil 10 3 Changing the Engine Air Cleaner 10 3 Spark Phigs 3 oro 10 4 Coolant Changes y k uu asha teer ep 10 4 Miscellaneous Maintenance
74. units and 2300 3000 rpm for quiet drive gear units See the Specifications section for exact numbers The unit comes complete with a sound attenuated enclosure internally mounted muffler control console main line circuit breaker battery charger and protective alarms as explained in the following paragraph All AC connections including the power leads from the alternator 120 volt battery charger input and control connections to the transfer switch are avail able in the main connection box The generator incorporates the following generator features Rotor and Stator insulation is Class H rated as defined by NEMA MG1 32 6 NEMA 1 1 66 The generator is self ventilated and drip proof con structed The voltage waveform deviation total harmonic content of the AC waveform and telephone influ ence factor have been evaluated and are acceptable according to NEMA MG1 32 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE SE Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Temperature Above 80 27 C SAE 30W or 15W 40 SAE 20W 20 or 15W 40 32 to 80 0 to 27 C Below 32 0 C See Note caution Ak Any attempt to crank or start t
75. urs of operation Check the oil level in the generator gearbox if so equipped prior to initial use and at the intervals indicated by the Service Schedule The recom mended oil is SAE 90 gear lubricant Also if the engine is equipped with a mechanical gov ernor make sure the governor is properly lubricated with clean engine oil PRIOR TO INITIAL START UP caution Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications and Coolant sections BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inch 10 to 16 mm ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground Make sure the generator battery is fully charged properly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrai

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