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Generac 25/30kW Portable Generator User Manual

1. x 14 ORANGE _ LvP 2 N1 N1 1 49 BLUE Lvp 3 UTILITY FROM TRANSFER SWITCH 6 2 2 DBI A DB2 1 E EE 0 FUSED 120 11 7 14 49 SOURCE FOR ur BATTERY CHARGER i 8 NEU NEU 14 14 2 E BE gt 8 HS X B 12 c 22 5 TRANSFER RELAY 194 194 EVR 1 Mov a c 13 2 x TRANSFER RELAY 001 25 25 183 LVP 6 R1 START 178 5 lt Y x 11 9 g sa 1 5 5 44 44 9 9 SB 6 x EM 1 BLACK 1 LvP 1 4 RED 4 9 q 4 5 11 16 10 2 mesa 7 4 14181 11 1 6 6 g
2. 15 4181 _ splice 2 1 QD 1 178 LVR 5 245 252 CENTER TERMINAL 4 817 BWR 2 NOT USED 5 818 BWR 3 6 15 He SPLICE 2 7 15 181 5 2 0 0 CND 8 SPLICE 1 9 0 SPLICE 1 10 0 MP1 2 14 4 14 EC 2 11 5 14 DCVR 5 12 820 BWR 1 1 LEP 14 42 8 13 K SA HVR 5 14 LVR 2 14 K 185 LVR 6 15 16 K SHLD MP1 1 17 819 BWR 4 601 J2 14 18 767 2 0 GND 19 765 GOV 3 20 766 GOV 6 21 68 WTS 2 22 0 SPLICE 1 23 79 1 3 LOCATED BACK OF CUSTOMER CONNECTION BOX 24 SB HVR 6 Sc V Ne 3 LOL 13 a o m 16 16 sy 27 28 K o 29 K i 30 15 1 31 573 WLS A m CND z 32 573 WLS B 33 K 86 LOS NC 34 K 804 EC 6 35 K 805 EC 5 42 12345 1 770 GOV 4 2 808 EC 4 qoom 3 568 FS2 4 25 16 1 14 4 5 258 16 2 13 SPLICE 5
3. REVISION H 7738 C DATE 10 29 10 PAGE 4 OF 4 EC CONNECTOR BWR CONNECTOR PIN TO FUNCTION PIN FUNCTION 1 0 GND NOTE 1 1 820 12 5V POWER FOR BASIC REMOTE 2 14 12 8 3 2 817 Ji 4 DISPLAY SYSTEM READY 3 12 23 5 3 818 3 5 DISPLAY ALARM 4 808 12 2 AIR FUEL RATIO SOLENOID DRIVER 4 819 W 17 REMOTE DISPLAY MAINTENANCE 5 805 31 55 OXYGEN SENSOR RETURN 5 0 GND NOTE 1 6 804 OXYGEN SENSOR 4 ENGINE CONTROL MODULE CONNECTIONS J1 J2 PIN WIRE TO FUNCTION PIN TO FUNCTION 1 178 CUST CON REMOTE START RETURN 1 770 GOV 4 THROTTLE DRIVE 4 817 BWR 2 REMOTE DISPLAY SYSTEM READY 2 808 EC 4 AIR FUEL RATIO SOLENOID DRIVER 5 818 BWR 3 __ REMOTE DISPLAY ALARM 5 568 FS2 STARTING FUEL SOLENOID CONTROL 8 15 Fi NOTE 4 4 25A GNITION COIL DRIVE 1 AND 4 7 15 Fi NOTE 4 5 25B 2 DRIVE 2 3 a 0 GND NOTE 1 8 14 1 5 2 NOTE 9 0 GND NOTE 1 9 771 GOV 1 THROTTLE DRIVE 1010 1 2 FLYWHEEL SENSOR 10 402 CAM 2 HALL FFFECT CAMSHAFT SEN
4. D cma mU OP vc FE payaa 71 OPTION 3 THREE PHASE CPL CONTROL PANEL 6 WIRE 277 480 S15 S15 S16 S16 TB DIRECT lt AR S15 516 g 1 BLACK 1 RED 2 BRUSHLESS 1 BLACK 4 RED NOTE USED WITH G4 6L amp S16 S16 G6 8L UNITS 515 515 ONLY 51 51 52 52 53 53 pm 2 DIRECT DRIVE y AS NB E2 I LEGEND GENERATOR OUTPUT CUSTOMER CONNECTIONS duca e a E ROTOR E2 TO 3 4BOVAC OR 400VAC ax E 02027 TO E3 E1 E2 OR TO NB 277VAC OR 231VAC MER NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES EUIS OUTPUT VOLTAGE NB NEUTRAL BLOCK K 277 480VAC 60HZ pee 231 400VAC 50HZ OPTION 4 THREE PHASE DELTA CONTROL PANEL 7 WIRE 120 240 51 51 55 55 DIRECT TB1 JEH 0250 53 BLACK 1 1 4 4 RED 4 4 D 2 2 BRUSHLESS 1 BLACK m 6 He 8 1 8 4 RED m NOTE USED WITH G4 6L amp 51 51 G6 8
5. J 10 0 16 4 5 1 fo pup Tees J1 30 15H 1 42 10 402 1 1 LOS J1 33 m J1 fo 21 68 cu ws rS x J1 31 573A 32 573 H S EC 8 I 2 dE 4 808 His EC 3 15A 1 0 EC 2 14 5 805 6 804 OPTIONAL IPTE E PAGESE OE REVISION H 7738 C 4222 G1 6L G11 NEXUS 100
6. Co EC GND 0 0 OS D SPLICE 4 14 lt 14 05 SPLICE 5 15A 15 AFS 2 J2 2 808 808 5 1 1 35 805 805 05 804 804 05 a 0 lt lt 22 9 771 i GOV J1 18 767 2 19 765 5 42 1 770 N C 5 20 766 j MR D REDE RR RE RE 1 WIRING DIAGRAM REVISION H 7738 C G1 6L 11 NEXUS DATE 10 29 10 PAGE 3 OF 4 DRAWING 0H6685 GROUP G crm 4 4 23 8 79 3 J 10 0 16 4 5 1 fo pup Tees J1 30 15H 1 42 10 402 1 1 LOS J1 33 m J1 fo 21 68 cu ws rS x J1 31 573A 32 573 H S EC 8 I 2 dE 4 808 His EC 3 15A 1 0
7. 4 OF 4 2 22 o um o m m m ee y exec to pu Rie emm 21 REVISION H 9868 D DATE 10 18 11 PAGE 4 OF 4 WIRING DIAGRAM CPL ALTERNATOR DRAWING 0H6342 GROUP G L1 L2 13 00 0 2 gt ss o g 2 Bz 2 at VS f z NS 9 e 2 hd hd hd hd 5 N 1 gt O ALON 2 O m E lt lt 2 9 zh 2 zd E 85 If VS Wr ALTERNATOR MAIN WIRES L1 d 00 A d L3 f 2 qmi i 25 lt 9 zr 00 80 ALTERNATOR CONNECTIONS FOR 19 UNITS ALTERNATOR CONNECTION BOX GENERATOR SET 4 a 08 x 08 lt 22 0 59 23 ZN 52 o N 72 a V lt ul n 98 vO 207 100 5 HSL 5 HS TU 0 I B n 64 P E 5 zi n ILON 0 5 291 8
8. nin CIENCIA i 71 OPTION 1 SINGLE PHASE CPL CONTROL PANEL 11 11 44 44 DIRECT AR BA uE 59 44 1 BLACK 1 4 4 4 4 I 2 1 BRUSHLESS 1 BLACK _ ieg s 4 RED NOTE USED WITH G4 6L amp 11 11 G6 8L UNITS 44 44 ONLY p DIRECT DRIVE GEAR BOX 5 AS DRIVE 5 MLCB NB El E2 GENERATOR OUTPUT CUSTOMER CONNECTIONS AR ALTERNATOR ROTOR 21 240 220 AS ALTERNATOR STATOR E1 TO NB BRUSH ASSEMBLY ESTO NBI 120VAC OR 110vAC EF EXCITER FIELD NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES MLCB MAIN LINE CIRCUIT BREAKER OUTPUT VOLTAGE NB NEUTRAL BLOCK xis TERMINAL BLOCK A 120 240VAC 60HZ a M 110 220VAC 50HZ OPTION 2 THREE PHASE CONTROL PANEL 120 208V 51 51 55 55 DIRECT 5 5 TB1 JEH 0250 53 1 BLACK 1 1 4 8 4 RED 4 4 Jang 2 2 BRUSHLESS BAD m 5 8 5 1 8 4 NOTE USED WITH G4 6L amp 57 57 66 81 UNITS 51 51 ONLY 58 58 52 52 59 SQ 55 55 2 DIRECT DRIVE 55 ES
9. Check Engine Oil Changing Engine 0il Cooling Intake Outlet Inspect Cooling System GOOlAIN Coolant Change ironiari nnan Overload Protection for Engine DC Electrical System 10 2 Exercise System a 10 2 Perform Visual Inspection 10 2 Inspect Exhaust System m Check Fam Belt repetentes Inspect Engine Changing the Engine Air Filter m SES Battery Maintenance Battery Replacement Battery FILII crece i ee Cleaning the Stationary Emergency Generator 10 3 SERVICE 5 1 11 1 TROUBLESHOOTING 12 1 Troubleshooting Guide 12 1 EMISSIONS WARRANTY 13 1 NOTES EXPLODED VIEWS amp PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS 01 90 ed Safety Instructions SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas Safety should
10. 062110 2 1 01 50 ed 00 Equipment Description EQUIPMENT DESCRIPTION This equipment is a revolving field alternating current Stationary Emergency Generator It is powered by a gaseous fueled engine operating at 1800 rpm for 4 pole direct drive units 3600 rpm for 2 pole direct drive units and 2300 3000 rpm for quiet drive gear units See the Specifications section for exact numbers The unit comes complete with a sound attenuated enclosure internally mounted muffler control console mainline circuit breaker bat tery charger and protective alarms as explained in the following paragraph All AC connections including the power leads from the alterna tor 120 volt battery charger input and control connections to the transfer switch are available in the main connection box The Stationary Emergency Generator incorporates the following alternator features Rotor and Stator insulation is Class F rated as defined by NEMA MG1 32 6 NEMA MG1 1 66 The generator is self ventilated and drip proof constructed The voltage waveform deviation total harmonic content of the AC waveform and telephone influence factor have been evalu ated 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 cle
11. f 2 qmi i 25 lt 9 zr 00 80 ALTERNATOR CONNECTIONS FOR 19 UNITS ALTERNATOR CONNECTION BOX GENERATOR SET 4 a 08 x 08 lt 22 0 59 23 ZN 52 o N 72 a V lt ul n 98 vO 207 100 5 HSL 5 HS TU 0 I B n 64 P E 5 zi n ILON 0 5 291 8 2 992 59 OLL n S94 5 ue In 292 oZ o e ILL lt SCHEMATIC DIAGRAM G1 6L 611 NEXUS DRAWING 0H6684 REVISION H 7738 C DATE 10 29 10 PAGE 1 OF 4 GROUP G 5522 5455 AS d o 20223 a 1 A T 1 o 1 12 0 E2 39 ONLY ONLY PAS 2 l
12. SERVICE SCHEDULE Weekly W Monthly M Inspect Change Clean Yearly Y ss Ir W x d w De SOS vY w Engine Coolant nes amp Comectons Emo Mw x EO v j x x x T Sp v x gt j Battery Remove Corrosion Ensure Dryness X C X amp Tighten eminas m x T x Check Charge State x J J check Ekctrovielevel Mw x x J General Condition Vibration Noise Leakage Temperature Generator System Complete Tune up and System Inspection To be completed by an Authorized Service Dealer Footnotes the oil level monthly or every 12 hours during continuous operation Change oil and oil filter after the first 30 hours of operation and then every 100 hours or annually thereafter whichever occurs first Change sooner when operating under heavy load or in a dusty or dirty environment or in high ambient temperatures Replace as necessary 11 1 01 90 8 Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won t crank 1 Control panel 7 5 amp fuse blown 1 Replace fuse 2 Loose or corroded or defective 2 Tighten clean or replace battery cables battery cables as nece
13. 2 992 59 OLL n S94 5 ue In 292 oZ o e ILL lt SCHEMATIC DIAGRAM G1 6L 611 NEXUS DRAWING 0H6684 REVISION H 7738 C DATE 10 29 10 PAGE 1 OF 4 GROUP G 5522 5455 AS d o 20223 a 1 A T 1 o 1 12 0 E2 39 ONLY ONLY PAS 2 l o lt M M o 00 2 GND gt 0 NOTE 3 14 25 5 Y 5 5 t J2 4 29 N2 ow2 lt H 081 gt Eb NXN F gt 9 5 NEU VOoA NEU lt 9 J2 1 t 4 L 225 J2 4 082 23 925 lt 194 194 2 2 1 2 178 178 183 183 ALTERNATOR CONNECTION BOX S gt 2 209 0209 lt GENERATO
14. 4 BRUSHLESS 1 BLACK m ig 1 RED NOTE USED ss WITH G6 8L 53 53 UNITS ONLY S9 S9 58 58 52 52 51 51 57 57 54 2 55 5 Pell 56 DRIVE S10 AS MLCB NB 511 512 1 2 L J LEGEND GENERATOR OUTPUT CUSTOMER CONNECTIONS AR ALTERNATOR ROTOR TO E2 AS ALTERNATOR STATOR E2 TO 3 208VAC BA BRUSH ASSEMBLY E1 TO E3 EF EXCITER FIELD E1 E2 OR TO NB 120VAC MLCB MAIN LINE CIRCUIT BREAKER NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES NB NEUTRAL BLOCK OUTPUT VOLTAGE TERMINAL BLOCK G 120 208VAC 60HZ OPTION 6 THREE PHASE CPL CONTROL PANEL GEARBOX REVERSE ROTATION 515 515 516 516 DIRECT 1 lt 515 515 TRLTSIE 516 6 516 1 BLACK 1 0240 1 4 RED 4 09509 4 2 peor 2 ENS BRUSHLESS s ee 4 RED NOTE USED WITH G6 8L S3 S3 UNITS ONLY 52 52 51 51 2 GEARBOX 512 DRIVE S6
15. GROUP E DESCRIPTION NUT WING 1 4 20 NYLK COVER AIR CLEANER STUD TH 1 4 20 X 3 G2 ZNC FULL NUT HEX 1 4 20 STEEL FILTER ELEMENT SCREW PPHM M5 0 8 X 12 ZNC WASHER LOCK M5 ADAPTER CARBURETOR W PVC CONN CLAMP HOSE BAND 63 GASKET BOSCH 32 amp 40 FUEL REG REWORK 1 6L VENTURI THROTTLE 21MM O RING 47 625 ID X 2 38 WIDTH MIXER ACTUATOR 32MM MACHINED STREET EL 45D 1 2 NPT BRASS BARBED STR 1 2 NPT X 3 4 CLAMP HOSE 10 56 1 06 CLAMP HOSE 28 1 32 2 25 HOSE 1 5 ID X 2 LG 20R4 ACTUATOR BOSCH 32 GOVERNOR WASHER LOCK M8 5 16 BARBED EL 90 1 8 NPT X 3 8 CLAMP HOSE BAND 1 0 HOSE BARB REDUCR TEE 3 4 3 8 HOSE 3 8 ID SINGLE BRAID 11 5 LG HOSE 3 8 ID SINGLE BRAID 12 LG PCV VALVE 2 5L FORD HOSE BREATHER 1 6L CLAMP HOSE BAND 88 HOSE 3 4 ID LPG amp NG 16 LG NUT HEX 8 1 25 G8 YEL CHR SCREW HHC M6 1 0 X 45 C8 8 FTH WASHER LOCK M6 1 4 SCREW 8 1 25 X 20 G8 8 ASSY REG INLET NPT FITTINGS ELBOW 90D 3 4 NPT NIPPLE PIPE 3 4NPTX4 5 BLK IRN NIPPLE PIPE 3 4NPT X 2 FLANGE FUEL INLET DECAL INLET PRESSURE DECAL FUEL INLET WASHER FLAT 5 16 ZINC NIPPLE CLOSE 3 4 X 1 375 GASKET BOSCH 32 1 INCLUDED IN ITEM 35 ASSY REG INLET NPT FITTINGS REVISION H 9610 B DATE 9 9 11 Page 2 of 2 INSULATION AND WASHERS LOCATED ON THE NEAR SIDE INSULATION AND DOME WASHERS LOCATED ON THE FAR SIDE TYPICAL MOUNTING OF ROOF ACOUSTIC INSULATION
16. 1 0 LVR 1 0 105 0 WTS 1 0 BWR 5 0 2 4 cm Pe MU e Lx ee a WIRING DIAGRAM REVISION H 7738 C G1 6L G11 NEXUS DATE 10 29 10 PAGE 2 OF 4 DRAWING 0H6685 GROUP G LESE HM uec di kz Z 1 COMPONENTS LOCATED ON ENGINE HVR LVR 1 k J1 25 1 k 0 GND 2 2 41 26 28 14 SPLICE 4 3 n 42 20 5 4 NEU 2 21 4 5 Sa J1 13 5 178 1 6 SB J1 24 6 183 7 7 23 42 12 8 8 194 2 13 9 25 4 cg K 6 L81 J2 16 11 4 J2 18 12 amp 1 81 12 19 BWR 1 K 820 01 12 2 817 1 4 818 J1 5 4 K 819 J1 17 5 0 GND 6 E HVR 9 2 16 5 0 42 17 162116 J2 5 18 16 258 16 154 16 5 42 23 15 5 AZE s J2 4 16 16 25
17. 5 54 MLCB NB mo lu 55 E2 516 515 GENERATOR OUTPUT CUSTOMER CONNECTIONS E2 2 Es E2 TO NB 277VAC NOTE THE DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE WIRING DIAGRAM REVISION H 9868 D CPL ALTERNATOR DATE 10 18 11 PAGE 3 OF 4 DRAWING 0H6342 OPTION 7 THREE PHASE SERIES DELTA CPL CONTROL PANEL GEARBOX REVERSE ROTATION SA SA 18 lt AR BA 1 BLACK 1 ss BRUSHLESS 1 BLACK s ieg iim NOTE USED 55 N3 N3 2 2 2 51 54 57 GEARBOX PS O 2 56 DRIVE d 59 5 MLCB NB lt 5 58 O O IO O 2 a 1 EGE GENERATOR OUTPUT CUSTOMER CONNECTIONS AR ALTERNATOR ROTOR E2 AS ALTERNATOR STATOR E2 TO Es 240VAC BRUSH ASSEMBLY FCN OR EDEN OR 120VAC MAN UNE CIRCUIT BREAKER NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES NB NEUTRAL BLOCK OUTPUT VOLTAGE TERMINAL BLOCK J 120 240VAC 6082
18. Exploded View ENCLOSURE C1 CPL Drawing No 003534 Revision H 9857 H Date 11 14 11 Page 1 of 2 EXPLODED VIEW EV ENCLOSURE CPL DRAWING 0G3534 ITEM PART 2 1 0G33370ALOR 2 2 0J14640AL0R 1 3 077992 2 4 0J14630ALOR 6 0 4487 7 022127 8 022097 9 022473 110 0C2454 11 OF5048D 12 0F5049 13 0 88690 14 089961 15 078115 16 0H7518 17 0H7518A 1 19 0E3257 20 0912970090 21 0H7518B 23 0 8566 24 0H0412 25 022097 3 26 0H7529 27 0H1208A 0H1208B 2 28 0G33350ALOR 1 29 0 1658 2 2 2 GROUP F DESCRIPTION ROOF 1 6L C1 REAR INTAKE WRAP C1 NUT HEX LOCK M6 1 0 SS NY INS DOOR LEFT RIGHT SIDE C1 ASSY ACCESS COVER NUT HEX 1 4 20 STEEL WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW THF M6 1 X 16 WA 2 8 VISE ACTION LATCH SLOTTED CIR TAB PULL KEY VISE ACTION LATCH SLOT CIR FOAM STRIP 3 4 WIDE X 3 16 THK 294 LG WASHER SELF LOCKING DOME INSULATION SIDE DOOR C1 INSULATION ROOF C1 SCREW HWHTF M6 1 0 X 16 ASSY WIRE 14AWG GRN YEL 32 25716 INSULATION REAR C1 SCREW HHFC M6 1 0 X 20 G8 8 NUT SPRINGCLIP M6 1 0 WASHER LOCK M6 1 4 FOIL ALUMINUM WITH ADHESIVE RF COVER PLATE PLASTIC BISQUE RF COVER PLATE PLASTIC GREY FRONT DISCHARGE WRAP 1 6L C1 WASHER LOCK SPECIAL 1 4 1 ENCLOSURE NOTE ALL PANELS THAT FASTEN TO THE ROOF MUST BE SECURED USING 10 THREAD FORMING FASTENER AND LO
19. NOLLVTTVISNI 2796C9 H NOISIATH 9 335 AND CUN dd nu LINGNOD 1 102 01314 379W34 LdN S83 1330W 1S0WHX3 NOILOSNNOD ANIT 13114 LIZ 0 084 SNHISN3WIQ 30 31N39 JION 335 530914 b DNIL3I1 MATA 3015 1H5I3 6 6 91 Lb L2 d E 335 41384344 1119412 33S 93 00 LINDA 4000 L 20 90v 691 0851 53015 ANY 1 043 86 80 962 ANY 15 G3SD 19N3 SI 3DaMVH2J 1198 S 1031 00 2 29 01943 30 3015 ano 440 1417 9000 434 2191 1109 ASIA AMJIA 656 61 269 29 21 335 v3av 15 ONILNOOW 01943 30 30 4011084 NO 1319901 590914 gt 3 DH ONILNAOW VIC CES 59 11811 LN3W32V dA 203 WANVW 32N33 3333l 1 691 T G9I 114 SdWV 0703 1HOTa NAHL 1138 NV4 92 deb 3108 338 SH31440W 1 LWA 21 31198 1HDIM NAHL SOfYId 80 4 3 71114 1HDIS 13 4 12 JIV
20. SCHEMATIC DIAGRAM G1 6L 611 NEXUS DRAWING 0H6684 1 LEGEND NOTE ALL WIRES 18 AWG AFS AIR FUEL SOLENOID HVR HIGH VOLTAGE RECEPTACLE 12 PIN 300V UL LISTED UNLESS ALT DC CHARGE ALTERNATOR ENGINE CONTROL MODULE 35 CONNECTOR SHOWN OTHERWISE AS ALTERNATOR STATOR J2 ENGINE CONTROL MODULE 23 PIN CONNECTOR BA BRUSH ASSEMBLY LFP LOW FUEL PRESSURE SWITCH AWG SIZE BATTERY 105 LOW OIL PRESSURE SWITCH 12 BWR BASIC WIRELESS RECEPTACLE LVP LOW VOLTAGE PLUG 8 BULKHEAD CAM CAMSHAFT SENSOR LVR LOW VOLTAGE RECEPTACLE 8 CAR COMMON ALARM RELAY MLCB MAIN LINE CIRCUIT BREAKER SPLICE CB CIRCUIT BREAKER MOV METAL OXIDE VARISTOR NUMBER CP COIL PACK MP1 MAGNETIC PICKUP DB DIODE BRIDGE NB NEUTRAL BLOCK DCVR DC VOLTAGE REGULATOR 05 EMISSIONS CONNECTOR R1 RESISTOR WIRE F1 FUSE INLINE 25A ATO SC STARTER CONTACTOR SPLICE FS_ FUEL SOLENOID SM STARTER MOTOR GND GROUND CONNECTION TERMINAL BLOCK CAGE CLAMP GOV ELECTRONIC GOVERNOR ACTUATOR WLS COOLANT LEVEL SENDER NOTE ALL WIRES ON THIS HIGH VOLTAGE PLUG 12 PIN BULKHEAD WTS COOLANT TEMPERATURE SENDER ARE 600V RATED COMPONENTS LOCATED IN CUSTOMER CONNECTION BOX
21. o lt M M o 00 2 GND gt 0 NOTE 3 14 25 5 Y 5 5 t J2 4 29 N2 ow2 lt H 081 gt Eb NXN F gt 9 5 NEU VOoA NEU lt 9 J2 1 t 4 L 225 J2 4 082 23 925 lt 194 194 2 2 1 2 178 178 183 183 ALTERNATOR CONNECTION BOX S gt 2 209 0209 lt GENERATOR SET 210 _0 210 250 FOR FIELD WIRING TO CUSTOMER CONNECTIONS TERMINAL BLOCKS m 4 WIRE SIZE 12 AWG ul E a o 9 9 gt 2 14 19 15 12345 48 48 48 F 15 13 25 12VDC 49 49 0 0 0 2 4 EN cc DTE cc S NA 4 SCHEMATIC DIAGRAM REVISION H 7738 C G1 6L G11 NEXUS DATE 10 29 10 PAGE 2 OF 4 DRAWING 0H6684 GROUP G
22. 01 01 01 01 01 A OL 01 N 7 2427 V df1O DD EXPLODED VIEW CONNECTION BOX CPL DRAWING 0H7234 GROUP A APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0 6795 1 BACK SIDES C1 CPL 2 0H6796 1 CONBOX TOP C1 CPL 4 3 0H67330STOR 1 BRACKET GIMBAL CONTROL PNL RAW 4 0H7115 2 KNOB M6 1 0 CONTROL PANEL 5 022097 2 WASHER LOCK M6 1 4 6 022473 4 WASHER FLAT 1 4 M6 ZINC 3 7 SEE CHART 1 CIRCUIT BREAKER 8 052777 3 WASHER FLAT M3 9 043182 3 WASHER LOCK M3 10 051714 3 NUT HEX M3 0 5 G8 CLEAR ZINC 4011 0H81040ASOR 1 COVER DPE BREAKER NEXUS 12 045764 2 SCREW M4 0 7 X 8 ZP 13 022264 3 WASHER LOCK 8 M4 14 0A9457 1 DECAL NEUTRAL 15 REF 1 ASSY CTRL PROGRAMMED 16 002454 18 SCREW HWHT 6 1 X 16 N WA Z JS 2 17 0A1354A 1 REGULATOR DC ALT 18 0D3700 6 NUT FLANGE M6 1 0 NYLOK 4 19 OH88380STOR 1 SHIELD HIGH LOW C1 RAW 20 056739 1 RELAY SOLENOID 12VDC MNT 21 OF 5458 12 SCREW HHSP 10 X 3 8 HI LOW 22 042568 2 SCREW HHC M6 1 0 X 20 C8 8 23 051716 2 NUT HEX M5 0 8 G8 CLEAR ZINC 24 049226 2 WASHER LOCK M5 25 051713 2 WASHER FLAT M5 26 0D7177V 2 DIODE BRIDGE 1P 35A 1000V 27 0 5752 1 RES WW 158 5 25W CONN 28 0H6267 1 COVER VOLTAGE SHIELD 29 056326 1 TRIM VINYL BLACK 1 8GP 3 LG 30 0G3524 1 COVER BELL HOUSING CONBOX 1 31 0D7393T REF TERM BLOCK 3P UL 12 20AWG 1 32 0D7393U REF TERM BLO
23. 3 phase Alternators Delta Configuration CONTROL PANELIL J Q Control Panel 1 Using the Auto Off Manual Switch Activate the Display Interface Menus Activation Chart Setting the Exercise Timer LOW Speed EXGrCISB cot t e ene teh User Adjustable Settings Fuel GOMVERSION s iicet teer re eee 2 C UR Automatic Transfer Operation Sequence of Automatic Operation Crank Cycles and Overcrank Auto Start Manual Alarm and Warning 5 5 Low Oil Pressure Shutdown Alarm High Coolant Temperature Shutdown Alarm 8 4 Overcrank Shutdown Alarm Overspeed Shutdown Alarm RPM Sensor Failure Shutdown Alarm Under frequency Shutdown Low Battery Low Battery Warning Low Coolant Level Alarm Missing Cam Pulse Alarm Missing Crank Pulse Alarm Low Fuel Pressure Warning
24. Governor Sensor Fault Alarm Wiring Error Undervoltage Alarm Overvoltage Alarm Internal Failure Shutdown Alarm Canbus lgnitiori Alarm 2 uu es Maintenance Warning Alarm Common Alarm Maintenance Alerts Menu SYStOM ccccccccccsssesesssssssessessssesssssesessessesessesseseesesserseseersees OPERATION mec Stationary Emergency Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch Engine Start up and Transfer Retransfer and Operating Unit with Automatic Transfer Switch General Check Engine Oil Changing Engine 0il Cooling Intake Outlet Inspect Cooling System GOOlAIN Coolant Change ironiari
25. 25 Adjustments DPOB jius una wayua Selectable 6 1 Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Cartridge Crankcase Oil 4 U S qts COOLING SYSTEM 2 222 E Closed Belt Driven Fan Speed rator eterna 2484 Fari 17 7 inches Fan MOE Pusher Air Flow inlet air including alternator and combustion air 1800 ft min Coolant 2 0 U S gal Heat Rejection to Coolant 25 35kW 112 000 135 000 Btu h Maximum Operating Air Temp on Radiator 60 C 150 F Maximum Ambient Temperature 50 C 140 F FUEL SYSTEM Type Of EUG soi Natural Gas Propane Vapor Dar DUEGIOL c s cs ds Down Draft Secondary Fuel Standard Fuel Shut Off Standard Operating Fuel Pressure 5 in 14 in Water Column Fuel Consumption ft hr Natural Gas LPV Exercise 2596 50 75 100 Load Load Load Load 25kW 60 24 120 48 220 87 310 123 390 155 30kW 60 24 145 58 260 103 370 147 470 187 ELECTRICAL
26. 25 SP1 5 4 5 5 2 5 15 AGE 3 OF 4 LP SCHEMATIC DIAGRAM G1 6L 611 NEXUS DRAWING 0H6684 REVISION H 7738 C DATE 10 29 10 PAGE 3 OF 4 GROUP G 54 a LL LK EE EM 7 5 1 WIRE 0 UNLESS 2 WIRE 13 3 WIRE 14 IS CRAN 4 WIRE 15 S CHASSIS GROUND BATTERY NOTED OTHERWISE IS UNFUSED 12VDC BATTERY IS FUSED 12VDC WHEN GENERATOR KING OR RUNNING IS FUSED 12VDC FOR GENERAL USE 5 WIRE 15A IS FUSED 12VDC FOR THE IGNITION L SOLENOID OPTION AND FOR THE COILS REVISION H 7738 C DATE 10 29 10 PAGE 4 OF 4 EC CONNECTOR BWR CONNECTOR PIN TO FUNCTION PIN FUNCTION 1 0 GND NOTE 1 1 820 12 5V POWER FOR BASIC REMOTE 2 14 12 8 3 2 817 Ji 4 DISPLAY SYSTEM READY 3 12 23 5 3 818 3 5 DISPLAY ALARM 4 808 12 2 AIR FUEL RATIO SOLENOID DRIVER 4 819 W 17 REMOTE DISPLAY MAINTENANCE 5 805 31 55
27. OL lt 53229 ISOH AOLVICVS 403 S3ADOS 1HDIN NIVe TIO LHD1a 831114 110 1H9I3 32115 TID ALIAVAD 30 831N329 ama 490 1114 TID rM 552009 321 435 1 0861 LYVHD 11 558392 WALI 3OIAS3S 61 9822 D GROUP G nin CIENCIA i 71 OPTION 1 SINGLE PHASE CPL CONTROL PANEL 11 11 44 44 DIRECT AR BA uE 59 44 1 BLACK 1 4 4 4 4 I 2 1 BRUSHLESS 1 BLACK _ ieg s 4 RED NOTE USED WITH G4 6L amp 11 11 G6 8L UNITS 44 44 ONLY p DIRECT DRIVE GEAR BOX 5 AS DRIVE 5 MLCB NB El E2 GENERATOR OUTPUT CUSTOMER CONNECTIONS AR ALTERNATOR ROTOR 21 240 220 AS ALTERNATOR STATOR E1 TO
28. 25KW 2P 2006 25KW 063451 1 ASSY 30KW 2 10 2006 2 0G0820A 1 HOUSING BLOWER LG PILOT 3 064452 1 BLOWER HOUSING SCREEN 4 020746 4 SCREW 5 0 8 X 8 ZINC 5 049226 4 WASHER LOCK M5 6 051713 4 WASHER FLAT M5 7 022129 4 WASHER LOCK M8 5 16 8 064825 1 ASSY STR 104 18AD1 EFF 18KW 064826 1 ASSY STR 104 18601 EFF 18KW 062926 1 STR 102 20 0AD1 CPL 2006 20KW 063682 1 STR 102 20 0GD1 CPL 2006 20KW 065584 1 STR 102 20 0JD1 CPL 2006 20KW 063685 1 STR 102 20 0KD1 CPL 2006 20KW 062826 1 ASSY STR 102 25AD1 2006 25KW 063683 1 STR 102 25 0GD1 CPL 2006 25KW 066573 1 STR 102 25 0 JD1 CPL 2006 25KW 063686 1 STR 102 25 0KD1 CPL 2006 25KW 063684 1 STR 102 30 0GD2 CPL 30KW 0G3687 1 STR 102 30 0KD2 CPL 30KW 0G5909 1 ASSY STR 102 30AD2 10 30KW 0G6103 1 STR 102 30 0JD2 9 0A5382A 1 BEARING CARRIER REAR LG PILOT 10 075591 1 ASSY HOLDER BRUSH 11 051787 4 SCREW 4 0 7 X 16 68 8 12 0A5601A 1 COVER REAR BEARING 13 068827 4 STUD 8 1 25 475 LONG 0G8827A 4 STUD 8 1 25 418 LONG 14 0A9375 4 SCREW RHM 10 24 X 2 15 022152 4 WASHER LOCK 10 16 064196 1 FLYWHEEL amp RINGGEAR ASSY 1 6L 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0J6102 4 SCREW HHFC M10 1 5 X 16 C10 9 19 0G0965B 1 PLATE FLEX 1 6L R12 7 20 053607 1 SCREW HHC M12 1 75 X 35 G8 8 21 051769 1 WASHER LOCK M12 22 023365 4 WASHER SHAKEPROOF INT 8 1 23 0 3353 6 SCREW 10 1 0 X 20 G10 9 24 072578 1 SPACER SHAFT 25 063
29. EC 2 14 5 805 6 804 OPTIONAL IPTE E PAGESE OE REVISION H 7738 C 4222 G1 6L G11 NEXUS 100 Owner s Manual Stationary Emergency Generator f a E cl C Cul c CL CIA gt CL CI CI Em C e CL C ez CL 225 25223 Cu CL LIA CL Y else 2 SS ele 2 22 0 A CAUTION 1 BL NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS 25 30kW M ode Is ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST ifi FUMES OUTDOOR INSTALLATION ONLY EPA Certified This manual should remain with the unit ON Hed 0 70 V ed 16148009 Table of Contents SECTION PAGE INTRODUCTION 1 1 Read this Manual Thoroughly 1 1 Operation and 1 1 How to Obtain Service 1 1
30. ONILNNOW 31332ND2 SNIddIHS 1HOI3A 9194 1HDI3A 9 00 51118 5 VIG G D 21 530414 3 DH DNILNODW GES SS3ARLDT 137 NIV dil414nW 15 553009 1411 3ADW3S 9 1317 404 WANVYW SS3NMD 39N33343 DNIISIX3 NV 019435 30 403 13411934 AINO SI AIH 103 01314 Vv 7553009 403 1 3ADW3SN I3dd3I0093 DS 412 103 0 HOLIMS 345 1 NV S3MIM TOALNOD HOLIMS B3JSNV Hl 01 553339 NOILOANNOD XVW 672 021 a3398VHO 119 4 1103 00 TWaLf3N NOILOANNOD LINGNOD 4931 0907 99 303 dn anis 3015 1 WANVW NIHLIM 133HS 119014103 5 335 NOILVYWAOANT 3293238 1119419 53401121418 3 10 S3ONVISIG WAWINIW 403 55400 19001 NV 319615 1943433 SV 1138 SV SISVINVIS OZ VddN NV ZE VddN 3184921 ddy HLIM 0 440009 NI 0311916 38 LSAW LINN NV 403 01943 3 0 3Hl 83415 119 NO WODO 1 31314 4 5 MOTIVY SJNII301I05 313382NDO 203 LINA HLIM 031199405 30119 NOILVVIVISNI 339N3234329 OND 5 7 2 681 X JAIM 0 Tv 1901 3715 31332NDO9 G3IN3WNWNDO38 WNWINIW I D df1OID SIIN 911890 DNIAA VICI Z JO 7 30Vd 0L 0 ALYA 199 15
31. 5 0 8 X 10 F 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS G 0J78230ASOR 1 SHIELD CB HANDLE CONBOX H 029289 1 TAPE ELEC 1 2 FOAM J 036261 4 RIVET POP 125 X 2 REVISION J 1182 J Page 7 of 8 DATE 12 16 11 EXPLODED VIEW CONNECTION BOX CPL DRAWING 0H7234 GROUP A APPLICABLE TO THIS PAGE LEFT INTENTIONALLY BLANK REVISION J 1182 J Page 8 of 8 DATE 12 16 11 82790 4 ONIM VAGA C JO I HOVd 01 81 02 ALVA 19 WALSAS 279v09 H NOISIAHH AHIA QHGO IdXH 42018 NO 3an H31VM 3578 OL OL EXPLODED VIEW COOLING SYSTEM 1 6L C1 DRAWING 003428 APPLICABLE PART GROUP C QTY DESCRIPTION 1 063418 2 063421 3 063419 4 0 9837 5 063553 6 0 257 7 064080 8 099502 9 064070 10 064072 11 064071 12 046627 13 052250 14 022473 15 022097 16 0 8566 17 045771 18 0 2454 19 042568 20 063573 21 063574 23 063420 24 080713 25 076749 26 048031 27 029032 28 064451 29 055934 30 0F9504 31 060568 32 063433 33 0 2507 0H1827 34 042628 35 029333 1 36 042907 37 027482 38 022129 39 039253 2 40 0H1851 REVISION H 6046 C DATE 2 18 10 RADIATOR SUPPORT LH SIDE 1 6L VENTURI 1 6L RADIATOR SUPPORT RH SIDE 1 6L RADIATOR 1 6L CHY FAN COOL 450MM DIA 7 BLADE SCREW HWHTF 6 1 0 X 16 HOSE LOW
32. 6 161_ 10 E M 44 16 6 75 1 HVP 12 2 23 1 PHASE ALTERNATOR STATOR HVP LVP SHOWN FOR L L 3 SEE 1 N1 TB2 1X 1 TB1 3X MLCB NB GND DRAWING 0H6342 2 TB2 2X 2 K 14 pe n 2 3 3 K 49 DBI IO O O 4 K NEU 2 4 4 5 K TB1 1X 5 178 183 4 m 6 K SB TB1 2X 6 183 T83 3X 7 7 23 TB3 2X 8 K 194 TB3 1x Ao Bo N GND 16 9 2 TB1 5X CUSTOMER CONNECTIONS 10 6 6 _ rB1 6x 11 4 El SPLICE 11 12 1 SPLICE 10 FOR FIELD WIRING CUSTOMER CONNECTIONS TERMINAL BLOCKS MAXIMUM WIRE SIZE 12 AWG 1 4 T p pu C gs et EC WIRING DIAGRAM REVISION H 7738 C G1 6L 11 NEXUS DATE 10 29 10 PAGE 1 OF 4 DRAWING 0H6685 GROUP G werde al EE At Upon FI yt cc s iu 1 COMPONENTS LOCATED ON ENGINE 56B 42 35
33. COOLING SYSTEM 2 222 E Closed Belt Driven Fan Speed rator eterna 2484 Fari 17 7 inches Fan MOE Pusher Air Flow inlet air including alternator and combustion air 1800 ft min Coolant 2 0 U S gal Heat Rejection to Coolant 25 35kW 112 000 135 000 Btu h Maximum Operating Air Temp on Radiator 60 C 150 F Maximum Ambient Temperature 50 C 140 F FUEL SYSTEM Type Of EUG soi Natural Gas Propane Vapor Dar DUEGIOL c s cs ds Down Draft Secondary Fuel Standard Fuel Shut Off Standard Operating Fuel Pressure 5 in 14 in Water Column Fuel Consumption ft hr Natural Gas LPV Exercise 2596 50 75 100 Load Load Load Load 25kW 60 24 120 48 220 87 310 123 390 155 30kW 60 24 145 58 260 103 370 147 470 187 ELECTRICAL SYSTEM Battery Charge 12V 15 Amp Static Battery Charger 2 0 or 2 5 Amp Recommended Group 26 525CCA System Voltage ess
34. Low Battery Low Battery Warning Low Coolant Level Alarm Missing Cam Pulse Alarm Missing Crank Pulse Alarm Low Fuel Pressure Warning Governor Sensor Fault Alarm Wiring Error Undervoltage Alarm Overvoltage Alarm Internal Failure Shutdown Alarm Canbus lgnitiori Alarm 2 uu es Maintenance Warning Alarm Common Alarm Maintenance Alerts Menu SYStOM ccccccccccsssesesssssssessessssesssssesessessesessesseseesesserseseersees OPERATION mec Stationary Emergency Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch Engine Start up and Transfer Retransfer and Operating Unit with Automatic Transfer Switch General
35. amp 30KW DRAWING 064008 APPLICABLE TO GROUP A ITEM PART QTY DESCRIPTION 1 064827 1 ASSY RTR 104 KD1 HI EFF 18KW 062927 1 RTR 102 20 0AD1 CPL 2006 20KW 062827 1 ASSY RTR 25KW 2P 2006 25 KW 063451 1 ASSY RTR 30KW 2P 10 2006 2 0G0820A 1 HOUSING BLOWERL GPILOT 3 064452 1 BLOWER HOUSING S CREEN 4 020746 4 SCREW M5 0 8 X 8 ZINC 5 049226 4 WASHERLOCKM5 6 051713 4 WASHER FLAT 5 7 022129 4 WASHER LOCK M8 5 16 8 0G4825 1 ASSY STR 104 18AD1 HI EFF 18KW 0G4826 1 ASSY STR 104 18601 HI EFF 18KW 062926 1 STR 102 20 0AD1 CPL 2006 20KW 063 682 1 5 102 20 0601 CPL 2006 20KW 065584 1 STR 102 20 0J D1 CPL 2006 20KW 063685 1 STR 102 20 0KD1 CPL 2006 20KW 062826 1 ASSY STR 102 25401 2006 25KW 063683 1 5 102 25 0601 CPL 2006 25KW 006 573 1 STR 102 25 0 JD1 CPL 2006 25 063 686 1 STR 102 25 0KD1 CPL 2006 25KW 063 684 1 STR 102 30 0GD2 CPL 30KW 0G3 687 1 STR 102 30 0KD2 CPL 30KW 065909 1 ASSY STR 102 30 2 10 30KW 0G6 103 1 STR 102 30 0J D2 9 0A5382A 1 BEARING CARRIER REARL GPILOT 10 075591 1 ASSY HOLDER BRUSH 11 051787 4 SCREW HHC M4 0 7 X 16 G8 8 12 0A5601A 1 COVER REAR BEARING 13 068 827 4 STUD M8 1 25 475 LONG 0G8827A 4 STUD M8 1 25 418 LONG 14 0A9375 4 SCREW 10 24 X 2 15 022152 4 WASHERLOCK 10 16 064196 1 FLYWHEEL 4 RINGGE ASSY 1 61 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 051756 4 SCREW HHC 10 1 5 X 20 C8 8 19 0G0965B 1 PLATE FLEX 1 6L R12 7 2
36. 3 n 42 20 5 4 NEU 2 21 4 5 Sa J1 13 5 178 1 6 SB J1 24 6 183 7 7 23 42 12 8 8 194 2 13 9 25 4 cg K 6 L81 J2 16 11 4 J2 18 12 amp 1 81 12 19 BWR 1 K 820 01 12 2 817 1 4 818 J1 5 4 K 819 J1 17 5 0 GND 6 E HVR 9 2 16 5 0 42 17 162116 J2 5 18 16 258 16 154 16 5 42 23 15 5 AZE s J2 4 16 16 25 Co EC GND 0 0 OS D SPLICE 4 14 lt 14 05 SPLICE 5 15A 15 AFS 2 J2 2 808 808 5 1 1 35 805 805 05 804 804 05 a 0 lt lt 22 9 771 i GOV J1 18 767 2 19 765 5 42 1 770 N C 5 20 766 j MR D REDE RR RE RE 1 WIRING DIAGRAM REVISION H 7738 C G1 6L 11 NEXUS DATE 10 29 10 PAGE 3 OF 4 DRAWING 0H6685 GROUP G crm 4 4 23 8 79 3
37. DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type battery hydrometer A DANGER Storage batteries give off explosive hydrogen sAgas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smok ing open flame sparks or any spark producing tools or equipment near the battery 10 3 Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging AWARNING 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 A Be sure the 120VAC power supply to the battery Ais turned
38. LONG 15 022097 1 WASHER LOCK M6 1 4 16 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 17 022473 6 WASHER FLAT 1 4 M6 ZINC REVISION A DATE 9 12 06 GROUP F PAGE 2 OF 2 945902 ONIA 4 01 06 6 ALVA 199 12 SNIMVSHG NOILVTIVLSNI MAIA wwimw 69011 0821 221 1 waninnw __ 166111 10821 281 16281 262 144158 Mx0e 79 1 162111 OTS 0821 221 nnw C 61811 166 t0821 21 16661 929 13315 81 79 1 M3IA XVAN 15813 EEN S811 53 L3SN39 1 191431904 T 3IUN 335 1552 1 9NIddIHS Ni orsa M 3NTONA ONILNNOW 31332ND2 SNIddIHS 1HOI3A 9194 1HDI3A 9 00 51118 5 VIG G D 21 530414 3 DH DNILNODW GES SS3ARLDT 137 NIV dil414nW 15 553009 1411 3ADW3S 9 1317 404 WANVYW SS3NMD 39N33343 DNIISIX3 NV 019435 30 403 13411934 AINO SI AIH 103 01314 Vv 7553009 403 1 3ADW3SN I3dd3I0093 DS 412 103 0 HOLIMS 345 1 NV S3MIM TOALNOD HOLIMS B3JSNV Hl 01 553339 NOILOANNOD XVW 672 021 a3398VHO 119 4 1103 00 TWaLf3N NOILOANNOD LI
39. NIPPLE PIPE 3 4NPTX4 5 BLK IRN NIPPLE PIPE 3 4NPT X 2 FLANGE FUEL INLET DECAL INLET PRESSURE DECAL FUEL INLET WASHER FLAT 5 16 ZINC NIPPLE CLOSE 3 4 X 1 375 GASKET BOSCH 32 1 INCLUDED IN ITEM 35 ASSY REG INLET NPT FITTINGS REGULATOR NOTES REGULATOR 11 AS SHOWN IN ILLUSTRATION IS SET UP FOR NATURAL GAS APPLICATION TO CONFIGURE REGULATOR FOR LP VAPOR REFER TO THE RECONFIGURING THE FUEL SYSTEM SECTION OF THIS MANUAL REVISION A DATE 1 21 10 Page 2 of 2 INSULATION AND DOME WASHERS LOCATED ON THE NEAR SIDE INSULATION AND DOME WASHERS LOCATED ON THE FAR SIDE TYPICAL MOUNTING ROOF ACOUSTIC INSULATION Exploded View EV ENCLOSURE C1 CPL Drawing 063534 Page 1 of 2 Revision J 1720 K Date 3 23 12 EXPLODED VIEW ENCLOSURE CPL DRAWING 063534 PART 2 1 0G33370ALOR 2 2 0J14640AL0R 1 3 077992 2 4 0J14630ALOR 6 0 4487 7 022127 8 022097 9 022473 110 0C2454 11 0 50480 12 0F5049B 13 0 88690 14 089961 15 078115 16 0H7518 17 0H7518A 1 19 0E3257 20 0912970090 21 0H7518B 23 0 8566 24 0H0412 25 022097 3 26 0H7529 27 0H1208A 0H1208B 2 28 0G33350ALOR 1 29 0 1658 2 2 GROUP F DESCRIPTION ROOF 1 6L C1 REAR INTAKE WRAP C1 NUT HEX LOCK M6 1 0 SS NY INS DOOR LEFT RIGHT SIDE C1 ASSY ACCESS COV
40. SAFETY RULES ceri rdiet GENERAL Identification Record een Data Label EQUIPMENT DESCRIPTION Equipment DeScfIplOri L Engine Oil Recommendations Coolant Recommendations ENGINE PROTECTIVE DEVICES Engine Protective Devices sss High Coolant Temperature Sender Low Coolant Level 0 Low Oil Pressure Switch Overcrank Shutdown Overspeed Shutdown ess RPM Sensor Loss Shutdown Fuel Requirements Natural Gas Fuel System Propane Vapor Withdrawal Fuel System Liquid Fuel SPECIFICATIONS uu uu uiaiia auqa sssssqauasass Stationary Emergency ENQING us Cooling 5 Fuel System Weather and Maintenance Kits Reconfiguring the Fuel System Fuel System Control Panel GENERAL INFORMATION Alternato
41. Transfer to standby power will not occur unless there is a utility failure ACTIVATE THE GENERATOR When battery power is applied to the generator during the instal lation process the controller will turn ON and the LCD screen will illuminate However the generator still needs to be activated before it will automatically run in the event of a power outage Activating the generator is a simple one time process that is guided by the controller screen prompts Once the product is activated the controller screen will not prompt you again even if you discon nect the generator battery To obtain the activation code record the generator serial number and log onto www activategen com or call 1 888 9ACTIVATE and follow the steps to retrieve the activation code After obtaining your activation code please complete the following steps at the generator s control panel in the Activation Chart on the following page NOTE The generator will only run in manual until the passcode has been entered 8 1 Upon power up this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block If utility voltage is detected the controller will display a warning message and lock out the generator preventing damage to the controller Power to the controller must
42. 10 064072 11 064071 12 046627 13 052250 14 022473 15 022097 16 0 8566 17 045771 18 0 2454 19 042568 20 063573 21 063574 23 063420 24 080713 25 076749 26 048031 27 029032 28 064451 29 055934 30 0F9504 31 060568 32 063433 33 0 2507 0H1827 34 042628 35 029333 1 36 042907 37 027482 38 022129 39 039253 2 40 0H1851 REVISION H 6046 C DATE 2 18 10 RADIATOR SUPPORT LH SIDE 1 6L VENTURI 1 6L RADIATOR SUPPORT RH SIDE 1 6L RADIATOR 1 6L CHY FAN COOL 450MM DIA 7 BLADE SCREW HWHTF 6 1 0 X 16 HOSE LOWER RADIATOR 1 6L CLAMP HOSE 24 B1 06 2 00 HOSE REAR COOLANT 1 6L TUBE ENGINE COOLANT 1 6L HOSE UPPER RADIATOR 1 6L CAP RADIATOR TAPE FOAM 1 X 1 24 LG WASHER FLAT 1 4 M6 ZINC WASHER LOCK 6 1 4 SCREW 6 1 0 20 68 8 NUT HEX 8 1 25 G8 CLEAR ZINC SCREW THF M6 1 X 12 WA Z JS SCREW HHC 6 1 0 X 20 68 8 GUARD FAN LH C1 GUARD FAN RH C1 RADIATOR BLOCK OFF BRACKET COOLANT TANK TANK COOLANT RECOVERY CLAMP HOSE BAND 1 4 HOSE 9 32 ID 43 LG BRACKET STEPPER MOTOR COOLANT CLAMP VINYL 1 31 2812 GROMMET 5 8 X 1 1 8 X 5 16 ASSY FAN BEARING SUPPORT BRACKET FAN ALT ADAPTER 1 6L PROBE COOLANT LEVEL 3 8NPTF PROBE COOLANT LEVEL 3 8 18NPTF USE WITH I N 40 P N 0H1851 PULLEY FAN 95 DIA TIE WRAP UL 7 4 X 19 BLK NOT SHOWN SCREW 8 1 25 X 16 68 8 WASHER SHAKEPROOF EXT 5 16 STL WASHER LOCK 8 5 16 SCREW HHC M8 1 25 X 20 G8 8 ASSY LCL SENSOR
43. 2yr 250 Control Panel 39NVN3INIVIN 19839 3395 31 11 3S1943X3 154110 5 14510 510410 9 40 109195 0 nueui Em au dn yoeq duinf 253 NIVIN AYOLSIH INA31SAS 3 STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator s manual for this unit OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the Stationary Emergency Generator was installed in conjunction with a transfer switch capable of manual operation only the fol lowing 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 literature pertaining to the specific transfer switch A DANGER The Maintenance Disconnect Switch and the AUTO OFF MANUAL switches if so equipped must be set properly or the generator will crank and start as soon as the utility power to the transfer switch is turned off Refer to appli cable control panel and transfer sw
44. 42 8 13 K SA HVR 5 14 LVR 2 14 K 185 LVR 6 15 16 K SHLD MP1 1 17 819 BWR 4 601 J2 14 18 767 2 0 GND 19 765 GOV 3 20 766 GOV 6 21 68 WTS 2 22 0 SPLICE 1 23 79 1 3 LOCATED BACK OF CUSTOMER CONNECTION BOX 24 SB HVR 6 Sc V Ne 3 LOL 13 a o m 16 16 sy 27 28 K o 29 K i 30 15 1 31 573 WLS A m CND z 32 573 WLS B 33 K 86 LOS NC 34 K 804 EC 6 35 K 805 EC 5 42 12345 1 770 GOV 4 2 808 EC 4 qoom 3 568 FS2 4 25 16 1 14 4 5 258 16 2 13 SPLICE 5 6 0 GND 7 ase es 14 SPLICE 4 TTE 9 771 GOV 1 10 402 CAM 2 48 11 K 209 CAR 12 25 LVR 7 13 K 194 LVR 8 ooo 14 K 601 15 210 16 K 6 10 17 162 CB 1 SM 18 K 4 T L HVR 1 al 19 1 12 A 5 16 5 20 HVR 3 DCVR 4 13 21 K NEU HVR 4 06 E 22 K 56 SC 1 6 H21 15 2 3 23 K 15A SPLICE 5 7 15 15 52 15 25 1 sc HOl_ 13 GOGO WIRE LOCATIONS 1 MAY CHANGE 99920 9 N GROUND BAR ON GROUND B GND
45. 55 56 5 510 MLCB NB 4511 512 ner ues 57 512 EXIST ONLY ON A 12 WIRE ALTERNATOR GENERATOR OUTPUT CUSTOMER CONNECTIONS E1 TO E2 E2 TO 25 208VAC TO Et E2 OR TO NB 120VAC NOTE THE DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 208VAC 60HZ 1 OF 4 ap 2 r p E 23 WIRING DIAGRAM REVISION H 9868 D CPL ALTERNATOR DATE 10 18 11 PAGE 1 OF 4 DRAWING 0H6342 GROUP G D cma mU OP vc FE payaa 71 OPTION 3 THREE PHASE CPL CONTROL PANEL 6 WIRE 277 480 S15 S15 S16 S16 TB DIRECT lt AR S15 516 g 1 BLACK 1 RED 2 BRUSHLESS 1 BLACK 4 RED NOTE USED WITH G4 6L amp S16 S16 G6 8L UNITS 515 515 ONLY 51 51 52 52 53 53 pm 2 DIRECT
46. 6 0 GND 7 ase es 14 SPLICE 4 TTE 9 771 GOV 1 10 402 CAM 2 48 11 K 209 CAR 12 25 LVR 7 13 K 194 LVR 8 ooo 14 K 601 15 210 16 K 6 10 17 162 CB 1 SM 18 K 4 T L HVR 1 al 19 1 12 A 5 16 5 20 HVR 3 DCVR 4 13 21 K NEU HVR 4 06 E 22 K 56 SC 1 6 H21 15 2 3 23 K 15A SPLICE 5 7 15 15 52 15 25 1 sc HOl_ 13 GOGO WIRE LOCATIONS 1 MAY CHANGE 99920 9 N GROUND BAR ON GROUND B GND 1 0 LVR 1 0 105 0 WTS 1 0 BWR 5 0 2 4 cm Pe MU e Lx ee a WIRING DIAGRAM REVISION H 7738 C G1 6L G11 NEXUS DATE 10 29 10 PAGE 2 OF 4 DRAWING 0H6685 GROUP G LESE HM uec di kz Z 1 COMPONENTS LOCATED ON ENGINE HVR LVR 1 k J1 25 1 k 0 GND 2 2 41 26 28 14 SPLICE 4
47. DBI A DB2 1 E EE 0 FUSED 120 11 7 14 49 SOURCE FOR ur BATTERY CHARGER i 8 NEU NEU 14 14 2 E BE gt 8 HS X B 12 c 22 5 TRANSFER RELAY 194 194 EVR 1 Mov a c 13 2 x TRANSFER RELAY 001 25 25 183 LVP 6 R1 START 178 5 lt Y x 11 9 g sa 1 5 5 44 44 9 9 SB 6 x EM 1 BLACK 1 LvP 1 4 RED 4 9 q 4 5 11 16 10 2 mesa 7 4 14181 11 1 6 6 g 6 161_ 10 E M 44 16 6 75 1 HVP 12 2 23 1 PHASE ALTERNATOR STATOR HVP LVP SHOWN FOR L L 3 SEE 1 N1 TB2 1X 1 TB1 3X MLCB NB GND DRAWING 0H6342 2 TB2 2X 2 K 14 pe n 2 3 3 K 49 DBI IO O O 4 K NEU 2 4 4 5 K TB1 1X 5 178 183 4 m 6 K SB TB1 2X 6 183 T83 3X 7 7 23 TB3 2X 8 K 194 TB3 1x Ao Bo N GND 16 9 2 TB1 5X CUSTOMER CONNECTIONS 10 6 6 _ rB1 6x 11 4 El SPLICE 11 12 1 SPLICE 10 FOR FIELD
48. DRIVE y AS NB E2 I LEGEND GENERATOR OUTPUT CUSTOMER CONNECTIONS duca e a E ROTOR E2 TO 3 4BOVAC OR 400VAC ax E 02027 TO E3 E1 E2 OR TO NB 277VAC OR 231VAC MER NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES EUIS OUTPUT VOLTAGE NB NEUTRAL BLOCK K 277 480VAC 60HZ pee 231 400VAC 50HZ OPTION 4 THREE PHASE DELTA CONTROL PANEL 7 WIRE 120 240 51 51 55 55 DIRECT TB1 JEH 0250 53 BLACK 1 1 4 4 RED 4 4 D 2 2 BRUSHLESS 1 BLACK m 6 He 8 1 8 4 RED m NOTE USED WITH G4 6L amp 51 51 G6 8L UNITS 55 55 ONLY 52 52 56 56 55 55 54 54 99 DIRECT DRIVE 25 Rol AS 4 MLCB NB El E2 GENERATOR OUTPUT CUSTOMER CONNECTIONS E1 TO E2 2 3 240VAC OR TO 120VAC NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE J 120 240VAC 60HZ L PAGE 2 OF 4 WIRING DIAGRAM REVISION H 9868 D CPL ALTERNATOR DATE 10 18 11 PAGE 2 OF 4 DRAWING 0H6342 GROUP G m XUI mM C TIENE Mu MC EE IM aa 71 OPTION 5 THREE PHASE CPL CONTROL PANEL GEARBOX REVERSE ROTATION SA SA SB SB TB DIRECT lt AR BA
49. NB BRUSH ASSEMBLY ESTO NBI 120VAC OR 110vAC EF EXCITER FIELD NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES MLCB MAIN LINE CIRCUIT BREAKER OUTPUT VOLTAGE NB NEUTRAL BLOCK xis TERMINAL BLOCK A 120 240VAC 60HZ a M 110 220VAC 50HZ OPTION 2 THREE PHASE CONTROL PANEL 120 208V 51 51 55 55 DIRECT 5 5 TB1 JEH 0250 53 1 BLACK 1 1 4 8 4 RED 4 4 Jang 2 2 BRUSHLESS BAD m 5 8 5 1 8 4 NOTE USED WITH G4 6L amp 57 57 66 81 UNITS 51 51 ONLY 58 58 52 52 59 SQ 55 55 2 DIRECT DRIVE 55 ES 55 56 5 510 MLCB NB 4511 512 ner ues 57 512 EXIST ONLY ON A 12 WIRE ALTERNATOR GENERATOR OUTPUT CUSTOMER CONNECTIONS E1 TO E2 E2 TO 25 208VAC TO Et E2 OR TO NB 120VAC NOTE THE DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 208VAC 60HZ 1 OF 4 ap 2 r p E 23 WIRING DIAGRAM REVISION H 9868 D CPL ALTERNATOR DATE 10 18 11 PAGE 1 OF 4 DRAWING 0H6342 GROUP G
50. NUT HEX 3 8 16 STEEL 40 025433 1 LUG SLDLSS 6 14 X 13 64 CU 41 023762 1 WASHER LOCK EXT 10 STL 42 0H7292 1 DECAL CUSTOMER CONTROL CONNECT 43 0H7293 1 DECAL CONBOX TB1 CONNECTIONS 44 029289 1 TAPE ELEC 1 2 FOAM 62 LG 45 0J0489 1 DECAL CUSTOMER POWER CONNECT 46 0A2115 2 WASHER NYLON 257 47 0F6146 1 HANG TAG 2 WIRE START NOT SHOWN 48 0H6692 1 HARN CONBOX NEXUS NOT SHOWN 49 0D7178T REF FUSE ATO TYPE 7 5AMP BROWN 50 067210A 1 DECAL GROUND LUG 51 0J6701 1 GASKET WIRE ENTRY COVER 52 0H8006 1 DECAL CAUTION ELEC SHOCK SM UL CIRCUIT BREAKER 225AF A 0G5249 REF CB 150A 2 POLE 240V 225AF B 0H6846 1 COVER CB G 225AF C1 CONBOX 0F8432A 1 INSULATOR CB 2P 225AF D 0G5734 1 SPRT CIRCUIT BREAKER G 225AF E 038150 2 WASHER FLAT 8 ZINC F 022264 2 WASHER LOCK 8 4 G 022471 2 NUT HEX 8 32 STEEL H 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS J 053640 2 SCREW RHM 8 32 X 3 1 4 K 0 8843 2 BUS BAR 2004 LUG ADAPTOR L 049897 4 SCREW SHC 8 1 25 X 20 G8 REVISION J 1182 J Page 4 of 8 DATE 12 16 11 EXPLODED VIEW CONNECTION BOX CPL DRAWING 0H7234 GROUP A APPLICABLE TO ITEM DESCRIPTION M 022129 6 WASHER LOCK M8 5 16 N 022145 4 WASHER 5 16 8 ZINC 045771 2 NUT HEX M8 1 25 G8 CLEAR ZINC R 058306 2 SCREW SHC 8 1 25 X 25 C12 9 S 0 8451 2 LUG SLDLSS 300 MCM 6 AL CU T 0G3259 1 DECAL TERMINAL SHOCK HZD BI U 0J78230AS0R 1 SHIELD CB HANDLE CONBOX V 029289 1 TAPE ELEC 1 2 FOAM 036261 4 RIVET POP 125 X 27
51. OFF or sparking may occur at the bat tery posts as the cables are attached and cause an explosion BATTERY REPLACEMENT NOTE Unit DOES NOT include battery When supplying or replacing the battery the recommended num ber and type of battery is listed in the Specifications Section NOTE The BCI number should be located directly on the battery BATTERY FLUID Check battery electrolyte fluid based on the Service Schedule Fluid should cover separators in all battery cells If fluid level is low add distilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY CLEANING THE STATIONARY EMERGENCY GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by a Service Dealer That dealer will use dry low pressure air to clean internal windings Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the genera tor may require drying 01 90 v
52. Parts Include the Following if so equipped 1 Fuel Metering System 3 Ignition System Including 1 1 Gasoline Carburetor Assembly And Internal A Spark Plug B Ignition Module Components A Fuel Filter B Carburetor C Fuel C Ignition Coil D Spark Plug Wires Pump 4 Exhaust System 1 2 Carburetion Assembly And Its Components A Catalyst Assembly B Exhaust Manifold A Fuel Controller B Carburetor And Its Gaskets C C Muffler D Exhaust Pipe E Muffler Gasket Mixer And It Gaskets D Primary Gas Regulator E Crankcase Breather Assembly Including Liquid Vaporizer A Breather Connection Tube B Pcv Valve 1 3 Fuel Regulator 6 Oxygen Sensor 2 Air Induction System Including Diagnostic Emission Control System A Intake Pipe Manifold B Air Cleaner 13 1 1 60 1OOQuiMWusui3 United States Environmental Protection Agency Compliance Requirements Stationary Emergency Spark Ignited Generators Purchaser s Owner s Recordkeeping Responsibilities The United States Environmental Protection Agency EPA and Generac Power Systems Inc Generac are pleased to explain your record keeping requirements for compliance with Subpart JJJJ Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60 As the engine purchaser owner who operates and maintains their certified emergency stationary engine and emission control system according to
53. WIRING CUSTOMER CONNECTIONS TERMINAL BLOCKS MAXIMUM WIRE SIZE 12 AWG 1 4 T p pu C gs et EC WIRING DIAGRAM REVISION H 7738 C G1 6L 11 NEXUS DATE 10 29 10 PAGE 1 OF 4 DRAWING 0H6685 GROUP G werde al EE At Upon FI yt cc s iu 1 COMPONENTS LOCATED ON ENGINE 56B 42 35 15 4181 _ splice 2 1 QD 1 178 LVR 5 245 252 CENTER TERMINAL 4 817 BWR 2 NOT USED 5 818 BWR 3 6 15 He SPLICE 2 7 15 181 5 2 0 0 CND 8 SPLICE 1 9 0 SPLICE 1 10 0 MP1 2 14 4 14 EC 2 11 5 14 DCVR 5 12 820 BWR 1 1 LEP 14
54. X 3 4 G8 8 NZ H 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS J 066715 4 SCREW RHM 8 32 X 4 1 2 K 022097 3 WASHER LOCK M6 1 4 L 0D5621 3 WASHER STEP 1 20DX9 32ID BRASS M 0J78230ASOR 1 SHIELD CB HANDLE CONBOX N 029289 1 TAPE ELEC 1 2 FOAM P 036261 4 RIVET POP 125 X 275 SS R 0K4772 1 DECAL SERVICE DISCONNECT UL CIRCUIT BREAKER QN2 2P A 0E7283 REF CB 0150A 2P 240V S QN2 LL B 0 6845 1 COVER S 2 C1 CONBOX 0E3664 1 BASE QN CIRCUIT BREAKER D 0G4112 1 BREAKER SUPPORT BRACKET 30KW E 074908 2 SCREW HHTT M5 0 8 X 10 BP F 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS REVISION J 6101 L Page 7 of 8 DATE 8 12 13 EXPLODED VIEW CONNECTION BOX CPL DRAWING 0H7234 GROUP A APPLICABLE TO ITEM DESCRIPTION G 0J78230AS0R 1 SHIELD CB HANDLE CONBOX H 029289 1 TAPE ELEC 1 2 FOAM J 036261 4 RIVET POP 125 X 2 K 0K4772 1 DECAL SERVICE DISCONNECT REVISION J 6101 L Page 8 of 8 DATE 8 12 13 82790 4 ONIM VAGA C JO I HOVd 01 81 02 ALVA 19 WALSAS 279v09 H NOISIAHH AHIA QHGO IdXH 42018 NO 3an H31VM 3578 OL OL EXPLODED VIEW COOLING SYSTEM 1 6L C1 DRAWING 003428 APPLICABLE PART GROUP C QTY DESCRIPTION 1 063418 2 063421 3 063419 4 0 9837 5 063553 6 0 257 7 064080 8 099502 9 064070
55. be stressed to all operators potential operators and service and repair technicians for this equipment INTRODUCTION Thank you for purchasing this model of the stationary emergency generator product line Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the nearest Service Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incor rectly or carelessly Observe them carefully Their definitions are as follows A DANGER INDICATES A HAZARDOUS SITUATION OR ACTION WHICH IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY A WARNING Indicates a hazardous situation or action which if not avoided could result in death or serious injury A CAUTION Indicates a hazardous situation or action which if not avoided could result in minor or moderate injury NOTE Notes contain additional information important to a procedure and will be found within the
56. greater than or equal to 130 HP the warranty period is three years from the date of the engine being placed into service Purchaser s Owner s Warranty Responsibilities As the engine purchaser owner you are responsible for the following 1 The engine must be installed and configured in accordance to the Generac s installation specifications 2 The completion of all maintenance requirements listed in your Owner s Manual 3 Any engine setting adjustment must be done in accordance and consistent with the instructions in the Owner s Manual 4 Any emission con trol system or component must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize emissions at all times Generac may deny any or all Emission Control System Warranty coverage or responsibility of the engine or an emission control system or component on your engine thereof if it has failed due to abuse neglect unapproved modification or improper maintenance or the use of counterfeit and or gray market parts not made supplied or approved by Generac Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service dealer 1 800 333 1322 for the dealer nearest you The purchaser owner shall be responsible for any expenses or other charges incurred for service calls and or transportation of the product to from the inspection or repair facilities The purchaser owner s
57. nnan Overload Protection for Engine DC Electrical System 10 2 Exercise System a 10 2 Perform Visual Inspection 10 2 Inspect Exhaust System m Check Fam Belt repetentes Inspect Engine Changing the Engine Air Filter m SES Battery Maintenance Battery Replacement Battery FILII crece i ee Cleaning the Stationary Emergency Generator 10 3 SERVICE 5 1 11 1 TROUBLESHOOTING 12 1 Troubleshooting Guide 12 1 EMISSIONS WARRANTY 13 1 NOTES EXPLODED VIEWS amp PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS 01 90 ed Safety Instructions SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas Safety should be stressed to all operators potential operators and service and repair technicians for this equipment INTRODUCTION Thank you for purchasing this model of the stationary emergency generator product line Every effort was expended to make sure that the information and ins
58. of maintenance conducted 3 Recordkeeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel solely dur ing emergency operations provided the engine is not certified to operate on propane 4 Meet all compliance notifications submitted to the purchaser owner and maintain all supporting documentation 5 Recordkeeping of hours of operation including what classified the operation as emergency and how many hours are spent for non emergency operation For emergency engines greater than or equal to 130 HP record keeping of hours of operation begins January 1 2011 For emergency engines less than 130 HP recordkeeping of hours of operation begins January 1 2009 Engines are equipped with non resettable hour meters to facilitate recordkeeping Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping reporting requirements Your permit to construct and or operate the engine may be contingent upon compliance with those requirements Check with your local Air Quality Management or Air Pollution Control District for specific requirements Emergency stationary internal combustion engines ICE may be operated for the purpose of maintenance checks and readiness testing provided that the tests are recommended by Federal State or local government Generac or the insurance company associated with the en gine Maintenance check
59. or steam could result Ethylene glycol base antifreeze is poisonous Do not use mouth to siphon coolant from the radiator recovery bottle or any container Wash hands thoroughly after handling Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them 1 Engine Protective Devices ENGINE PROTECTIVE DEVICES The Stationary Emergency Generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature oil pressure or rpm For that reason the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low the coolant temperature is too high the coolant level is too low or the engine is running too fast NOTE Engine protective switches and sensors are mentioned here for the reader s convenience Also refer to the applicable control panel manual for additional automatic engine shutdown infor mation HIGH COOLANT TEMPERATURE SENDER An analog coolant temperture sender located in the engine s cooling system will cause an engine shutdown if the temperature should exceed approximately 125 C 257 F The generator will automatically restart once the temperature has returned to a safe operating level LOW COOLANT LEVEL SENSOR To pre
60. that exit the engine harness loom directly behind the Nexus Control Panel and are labeled numbers 209 and 210 MAINTENANCE ALERTS Maintenance alerts will be provided for these conditions SERVICE SCHEDULE SERVICE SCHEDULE B Change Inspect spark plugs alert 2yr 250 Control Panel 39NVN3INIVIN 19839 3395 31 11 3S1943X3 154110 5 14510 510410 9 40 109195 0 nueui Em au dn yoeq duinf 253 NIVIN AYOLSIH INA31SAS 3 STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator s manual for this unit OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the Stationary Emergency Generator was installed in conjunction with a transfer switch capable of manual operation only the fol lowing 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 literature pertaining to the specific transfer sw
61. to convert both the Regulator and Control Panel will result in decreased performance and an increase in emissions and is a violation of EPA regula tions 6 2 General Information ALTERNATOR AC LEAD CONNECTIONS The electrical wires in the units AC connection lower panel should be installed according to the number of leads and the voltage phase required for the application The voltage and phase are described on the generator data label The number of lead wires can be identified using the Specifications section and the power output rating on the generator data label For example if the generator produces 130kW 277 480 Volt 3 phase power the generator has 12 alternator output leads Figure 7 3 describes the stator power winding connection for the generator FOUR LEAD SINGLE PHASE STATOR Four lead alternators see Figure 7 1 are designed to supply elec trical loads with voltage code 240V 1 phase 60 Hz Electrical power is produced in the stator power windings These windings were connected at the factory to the main circuit breaker as shown in Figure 7 1 The rated voltage between each circuit breaker terminal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator c 120 VOLTS 33 10015 120 10118 Y 1 CIRCUIT BREAKER ALTERNATOR PO
62. to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block If utility voltage is detected the controller will display a warning message and lock out the generator preventing damage to the controller Power to the controller must be removed to clear this warning Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass NOTE DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT WIRES IS NOT WARRANTABLE This test will be performed each time the controller is powered up Next the user must enter the minimum settings to operate These settings are current date and time and exercise day and time The maintenance intervals will be initialized i e started the first time the clock is set If the clock is never set at power up the mainte nance intervals will be reset every time power is applied If a subsequent power loss loss of battery power occurs the Installation assistant will operate upon power restoration The self test routine will be run and then the customer will be required to re enter the time and date as this is not retained during a power loss The unit will not require re activation DISPLAY INTERFACE MENUS The LCD display is organized as detailed below The Home page this page is the default page which will be displayed if no keys are pressed for 30 seconds This page norm
63. 0 053607 1 SCREW HHC M12 1 75 X 35 G8 8 21 051769 1 WASHER LOCK M12 22 023365 4 WASHER 5 ROOF INT 8 1 23 0F3353 6 SCREW HHC 10 1 0 X 20 G10 9 24 072578 1 SPACER ROTOR SHAFT 25 063787 10 WASHER 411D 94 OD 12 THK 26 0A88 30 4 WASHER FLAT 34 ID X 75 OD 27 077043E 1 FLEX CONDUIT 1 BLACK NOT SHOWN 28 062070 1 PLATE SPACER 14 1 6L BE USED WITH ENGINE PLATE P N 060834 0G2070A 1 PLATE SPACER 16 1 6L TO BE USED WITH ENGINE PLATE P N 0G0834A 29 045771 4 NUT HEX M8 1 25 G8 CLEAR ZINC 1 APPLY LOCTITE 242 BEFORE THREADING SCREW INTO CRANKSHAFT REVISION H 7966 M DATE 12 16 10 PAGE 2 OF 2 994 YEZLHO 9 Jo 9 1 1019 149 12 NOILOANNOD pepojdx3 96 14 gt e RS 08 SV gt 86 Rs E 66 01 se wor T LL aso 2408 L MALZIMAZZ m V Fee 4104 FC Wal 1300W 43 V338 34012 Y C1H0 810 eyeg 149 19 NOILOANNOD T L0L9 f OL S 01 V Y C1H0 810 eyeg 149 19 NOILOANNOD T LOL9 f
64. 0 9 SCREW HHC 8 1 25 X 35 G8 8 WASHER LOCK M8 5 16 WASHER FLAT 5 16 M8 ZINC TIE WRAP UL 7 4 X 19 BLK SCREW 8 1 25 X 40 G8 8 NUT HEX 8 1 25 G8 CLEAR ZINC SCREW HHC 1 4 20 X 1 2 G5 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW HHTT M6 1 0 X 12 ZINC WASHER FLAT M10 HEAVY DUTY TEMPERATURE SENDER DELPHI BSHG RDCR HEX 1 4 TO 1 8 HARN LOW OIL PRESS SWITCH ASSY ADAPTER DRAIN OIL HOSE OIL DRAIN ASSY 21 CAP HEX 1 4 NPT BRASS STRUT LH 1 6L ENG ADAPT PLATE NIPPLE PIPE 3 8 NPT X 1 1 2 PIPE TEE 3 8 NPT SCREW HWHTF M6 1 0 X 16 WASHER FLAT 34 ID X 75 OD HARN ENG G1 6L G11 NEXUS NOT SHOWN OIL FILTER 1 6L CONDUIT FLEX 25 ID 6 LG STRUT RH 1 6L ENG ADAPT PLATE BARBED STR 3 8 NPT X 3 8 CLAMP HOSE 38 87 HOSE COOLANT 3 8 ID 20R3 11 LG BRACKET FAN ALT ADAPTER 1 6L SCREW M10 1 5 X 35 08 8 DECAL EMISSION CTRL INFO 1 6L BRACKET STEPPER MOTOR COOLANT ANCHOR HARNESS Page 2 of 2 EXISTING HOSE FROM CRANKCASE IMPORTANT SOLENOID MUST BE INSTALLED WITH FLOW ARROW POINTING IN DIRECTION SHOWN IN ILLUSTRATION BELOW SEE REGULATOR NOTES FOR INFORMATION Exploded View FUELSYS NG LPV 1 6L CPL Drawing No 0H6671 Revision A Page 1 of 2 Date 0H6671 EXPLODED VIEW FUELSYS NG LPV 1 6L CPL DRAWING 0H6671 APPLICABLE TO ITEM PART 1 037561 2 0 5547 3 062522 4 022127 5 059402 6 091526 7 049226 8 0 0519 9 048031 10 0 6586 11 0G1397E 1
65. 090 3P 600V E FG LL B 0H7294 1 CB COVER E CC FG 3P C1 CONBOX 0 4698 1 INSULATOR 3P E CC FG D 0H4656 REF CIRCUIT BREAKER SUPPORT CC 0H5604 REF CIRCUIT BREAKER SUPPORT FG E 038150 4 WASHER FLAT 8 ZINC F 022264 4 WASHER LOCK 8 4 G 022471 4 NUT HEX 8 32 STEEL H 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS J 053640 4 SCREW RHM 8 32 X 3 1 4 CC 0H5721 4 SCREW PPHM 8 32 X 1 3 4 ZINC FG K 091526 3 SCREW PPHM M5 0 8 X 12 ZNC L 023897 6 WASHER FLAT 10 ZINC M 049226 3 WASHER LOCK M5 N 051716 3 NUT HEX M5 0 8 G8 CLEAR ZINC P 0J78230ASOR 1 SHIELD CB HANDLE CONBOX Q 029289 1 TAPE ELEC 1 2 FOAM R 036261 4 RIVET POP 125 X 275 SS REVISION J 1182 J Page 6 of 8 DATE 12 16 11 EXPLODED VIEW CONNECTION BOX CPL DRAWING 0H7234 GROUP A APPLICABLE TO ITEM PART QTY DESCRIPTION UL CIRCUIT BREAKER BQ 2P A 0D5543 REF 0090 2 240V 5 802 LL 0D5544 REF CB 0100A 2P 240V S BQ2 LL 0A2077 REF CB 0125A 2P 240V S BQ2 LL B 0 6842 1 COVER S 802 C1 0 7890 1 BRKT MTG BACK 0G4497 1 CIRCUIT BREAKER SUPPORT BQ E 052619 2 SCREW HHC M5 0 8 X 20 G8 8 F 023897 4 WASHER FLAT 10 ZINC G 049226 2 WASHER LOCK M5 H 002454 10 SCREW HWHT 6 1 X 16 N WA Z JS J 051716 2 NUT HEX M5 0 8 G8 CLEAR ZINC K 0G9708 2 SCREW PHTT M4 0 7 X 8 ZP L 022264 2 WASHER LOCK 8 M4 M 0J78230ASOR 1 SHIELD CB HANDLE CONBOX N 029289 1 TAPE ELEC 1 2 FOAM P 036261 4 RIVET POP 125 X 275 SS UL CIRCUIT BREAKER BQ 3P A 06
66. 1 1 01 90 8 Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won t crank 1 Control panel 7 5 amp fuse blown 1 Replace fuse 2 Loose or corroded or defective 2 Tighten clean or replace battery cables battery cables as necessary 3 Defective starter contactor 3 Replace contactor 4 Defective starter motor 4 Replace starter motor 5 Dead or Defective Battery 5 Remove change or replace battery Engine cranks but won t start 1 Out of fuel 1 Replenish fuel turn on fuel valve 2 Fuel solenoid FS is defective 2 Replace solenoid 3 Spark plugs defective 3 Clean regap or replace plugs Engine starts hard runs rough 1 Air cleaner plugged or damaged 1 Clean or replace as needed 2 Defective spark plugs 2 Clean regap or replace plugs 3 Fuel pressure incorrect 3 Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS 4 Insufficient fuel supply 4 Confirm fuel pressure to regualtor is as recommended in SPECIFICATIONS 5 Fuel system set to wrong fuel type 5 Reconfigure the fuel system See RECONFIGURING THE FUEL SYSTEM in manual Check oil and add oil as needed Engine is overheated Check cooling system for leaks Defective Low Oil Pressure Switch Replace switch Engine starts then shuts down 1 1 2 2 3 3 4 Defective Coolant Temperature Switch 4 Replace switch 5 5 6 6 7 7 Engine oil level is low Defective
67. 2 0F7790 13 0E7121 14 0G4573C 15 0E8286 16 047527 17 057823 18 035685 19 057753B 20 0E4395 21 022129 22 0A6344 23 048031L 24 0G1985 25 047290 26 047290 27 0F3994 28 0G3178 29 048031P 30 059057 31 045771 32 051767 33 022097 34 039253 35 069348 1 36 026812 1 37 076691 1 38 026490 1 39 075580 40 001509 41 075436 42 022145 143 026915 44 0 6586 GROUP E DESCRIPTION NUT WING 1 4 20 NYLK COVER AIR CLEANER STUD TH 1 4 20 X 3 G2 ZNC FULL NUT HEX 1 4 20 STEEL FILTER ELEMENT SCREW PPHM M5 0 8 X 12 ZNC WASHER LOCK M5 ADAPTER CARBURETOR W PVC CONN CLAMP HOSE BAND 63 GASKET BOSCH 32 amp 40 FUEL REG REWORK 1 6L VENTURI THROTTLE 21MM O RING 47 625 ID X 2 38 WIDTH MIXER ACTUATOR 32MM MACHINED STREET EL 45D 1 2 NPT BRASS BARBED STR 1 2 NPT X 3 4 CLAMP HOSE 10 56 1 06 CLAMP HOSE 28 1 32 2 25 HOSE 1 5 ID X 2 LG 20R4 ACTUATOR BOSCH 32 GOVERNOR WASHER LOCK M8 5 16 BARBED EL 90 1 8 NPT X 3 8 CLAMP HOSE BAND 1 0 HOSE BARB REDUCR TEE 3 4 3 8 HOSE 3 8 ID SINGLE BRAID 11 5 LG HOSE 3 8 ID SINGLE BRAID 12 LG PCV VALVE 2 5L FORD HOSE BREATHER 1 6L CLAMP HOSE BAND 88 HOSE 3 4 ID SAE 30R2 16 LG NUT HEX 8 1 25 G8 YEL CHR SCREW HHC M6 1 0 X 45 C8 8 FTH WASHER LOCK M6 1 4 SCREW HHC 8 1 25 X 20 G8 8 ASSY REG INLET NPT FITTINGS ELBOW 90D 3 4 NPT
68. 23 12 Page 2 of 2 468690 4 DNIA VIG C JO I HOVd 90 1 6 197 WALSAS LSNVHX4 NOISIATY AHIA QHGO Id XH dowd EXPLODED VIEW EXHAUST SYSTEM 1 6L DRAWING 063535 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F7366 1 MUFFLER C1 2 0F7647 1 MUFFLER SADDLE 3 0 8095 1 PIPE EXHAUST OUTLET 4 0G3576 1 EXHAUST PIPE LOWER 1 6L 5 0E3257 4 SCREW HWHTF M6 1 0 X 16 6 0F7644 2 MUFFLER STRAP 7 0 6119 1 BOLT U 5 16 18 X 2 1 4 8 036434 3 BOLT U 5 16 18 X 2 09 9 036449 3 SADDLE 2 INCH 10 022129 6 WASHER LOCK M8 5 16 11 022259 6 NUT HEX 5 16 18 STEEL 12 038750 1 SCREW 6 1 0 X 30 68 8 13 063575 1 EXHAUST PIPE UPPER 1 6L SS 14 0F3794A 1 EXHAUST BLANKET 500 LONG 15 022097 1 WASHER LOCK M6 1 4 16 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 17 022473 6 WASHER FLAT 1 4 M6 ZINC REVISION A DATE 9 12 06 GROUP F PAGE 2 OF 2 945902 ONIA 4 01 06 6 ALVA 199 12 SNIMVSHG NOILVTIVLSNI MAIA wwimw 69011 0821 221 1 waninnw __ 166111 10821 281 16281 262 144158 Mx0e 79 1 162111 OTS 0821 221 nnw C 61811 166 t0821 21 16661 929 13315 81 79 1 M3IA XVAN 15813 EEN S811 53 L3SN39 1 191431904 T 3IUN 335 1552 1 9NIddIHS Ni orsa M 3NTONA
69. 2812 REF CB 0080A 3P 240V S BQ3 LL 053691 REF CIRCT BRK 90 X 3 ITE BQ3 B090 040532 REF CB 0100A 3P 240V S BQ3 LL B 0 6843 1 COVER S C1 CONBOX 0 6002 1 TRACK SIEMENS 3P D 0G4497 1 CIRCUIT BREAKER SUPPORT BQ E 052619 3 SCREW HHC M5 0 8 X 20 G8 8 F 023897 6 WASHER FLAT 10 ZINC G 049226 3 WASHER LOCK M5 H 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS J 051716 3 NUT HEX M5 0 8 G8 CLEAR ZINC K 0G9708 2 SCREW PHTT M4 0 7 X 8 ZP L 022264 2 WASHER LOCK 8 M4 M 0J78230ASOR 1 SHIELD CB HANDLE CONBOX N 029289 1 TAPE ELEC 1 2 FOAM P 036261 4 RIVET POP 125 X 275 SS UL CIRCUIT BREAKER ED 3P A 0D5552 REF 0050A 480V S LL 0D5556 REF 0090A 480V S LL 0D5557 REF CB 0100A 480V S ED4 LL 0D9693 REF CB 0125A 480V S LL B 0H6844 1 COVER CB 5 ED3 C1 CONBOX 0G4498 1 CIRCUIT BREAKER SUPPORT ED D 038150 4 WASHER FLAT 8 ZINC E 022264 4 WASHER LOCK 8 4 F 022471 4 NUT HEX 8 32 STEEL G 0A8278 3 SCREW SHC 1 4 28 X 3 4 G8 8 NZ H 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS J 066715 4 SCREW RHM 8 32 X 4 1 2 K 022097 3 WASHER LOCK M6 1 4 L 0D5621 3 WASHER STEP 1 20DX9 32ID BRASS M 0J78230ASOR 1 SHIELD CB HANDLE CONBOX N 029289 1 TAPE ELEC 1 2 FOAM P 036261 4 RIVET POP 125 X 275 SS UL CIRCUIT BREAKER QN2 2P A 0E7283 REF CB 0150A 2P 240V S QN2 LL B 0 6845 1 COVER 5 QN2 C1 CONBOX 0E3664 1 BASE QN CIRCUIT BREAKER D 0G4112 1 BREAKER SUPPORT BRACKET 30KW E 074908 2 SCREW HHTT
70. 3 16 0G3900 17 0D2244M 18 036710 19 0C5479 20 059980 21 046526 22 022131 23 0G3922 24 0G0464 25 0G0465 26 052858 27 051735 28 0G3920 29 0A7387 30 039414 31 022129 32 022145 33 029333A 34 057821 35 045771 36 022507 37 022097 38 022473 39 090388 40 0A5768 41 0E0502 42 035579 43 0H7435 44 0C1852 46 069860C 47 069811 48 0G38580ST03 49 025065 50 027738A 51 0E3257 52 0A8830 53 OH6690 54 0G02070100 55 077043H 56 0G38620ST03 57 055596 58 0C7649 59 0H2250 61 0G3433 62 049541 63 0G7311 64 0G4451 65 0 4001 REVISION H 8414 C DATE 3 1 11 QTY REF REF n EL ODORE in GROUP D DESCRIPTION ENGINE 1 6L G11 CERT ENGINE PLATE 1 6L 6MM TO BE USED WITH PLATE SPACER P N 0G2070A HOUSING BLOWER LG PILOT STARTER MOTOR 12V ENGINE MOUNTING FOOT STAMPING EXHAUST MANIFOLD 1 6L MACHINED INTAKE MANIFOLD MACHINED 1 6L SHIELD 1 6L EXHAUST HEAT DC ALTERNATOR ADAPTER MACHINED PULLEY CRANKSHAFT MACHINED WASHER PULLEY BRACKET TENSIONER DC ALT SPACER ALTERNATOR DC ALTERNATR HAN KOK V BELT 3 8 X 30 6 CAP 1 5 HOLE SHALLOW ASSY MAGPICKUP 3 8 24 MALE PIN SPRING 1 4 X 3 4 SCREW HHC M12 1 5 X 40 G10 9 SCREW HHC M10 1 5 X 25 G10 9 WASHER LOCK M10 WASHER FLAT 3 8 M10 ZINC NUT HEX M10 1 5 CLASS 10 ZINC GASKET INTAKE MANIFOLD 1 6L GASKET EXHAUST MANIFOLD 1 6L NUT TOP LOCK FL M8 1 25 SCREW HHC M10 1 5 X 70 G8 8 SCREW HHC M10 1 5 X 110 G10 9 SCREW HHC M10 1 5 X 40 G1
71. 3 SI 3DaMVH2J 1198 S 1031 00 2 29 01943 30 3015 ano 440 1417 9000 434 2191 1109 ASIA AMJIA 656 61 269 29 21 335 v3av 15 ONILNOOW 01943 30 30 4011084 NO 1319901 590914 gt 3 DH ONILNAOW VIC CES 59 11811 LN3W32V dA 203 WANVW 32N33 3333l 1 691 T G9I 114 SdWV 0703 1HOTa NAHL 1138 NV4 92 deb 3108 338 SH31440W 1 LWA 21 31198 1HDIM NAHL SOfYId 80 4 3 71114 1HDIS 13 4 12 JIV OL lt 53229 ISOH AOLVICVS 403 S3ADOS 1HDIN NIVe TIO LHD1a 831114 110 1H9I3 32115 TID ALIAVAD 30 831N329 ama 490 1114 TID rM 552009 321 435 1 0861 LYVHD 11 558392 WALI 3OIAS3S 61 9822 D GROUP G
72. 3259 0J78230ASOR 029289 036261 0K4772 QTY pa RAR 1 ITEMS INCLUDED WITH HARNESS P N 0 6692 2 ITEMS USED ON 1 6L MODELS ONLY 3 SEE C1 DPE BREAKER SELECTION TABLE 4 GROUP A DESCRIPTION WASHER LOCK M8 5 16 WASHER FLAT 5 16 8 ZINC NUT HEX M8 1 25 G8 CLEAR ZINC SCREW SHC 8 1 25 X 25 C12 9 LUG SLDLSS 300 MCM 6 AL CU DECAL TERMINAL SHOCK HZD BI SHIELD CB HANDLE CONBOX TAPE ELEC 1 2 FOAM RIVET POP 125 X 275 SS DECAL SERVICE DISCONNECT SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS NO COLOR MANUFACTURING FOR CORRECT MATERIAL AND COLOR REFER 5400 BOM e CUSTOMER WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER FIRST 6 DIGITS ONLY IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR FOR REFERENCE SEE GUIDELINE 0H7169 REVISION J 6101 L DATE 8 12 13 Page 5 of 8 EXPLODED VIEW CONNECTION BOX CPL DRAWING 0H7234 GROUP A APPLICABLE TO ITEM DESCRIPTION UL CIRCUIT BREAKER CC 2P A 0H4745 REF CB 0100A 2P 240V E CC LL 0H4746 REF CB 0125A 2P 240V E CC LL 0H4747 REF CB 0150A 2P 240V E CC LL B 0H6847 1 COVER CB E CC 2P C1 CONBOX 051716 2 NUT HEX 5 0 8 G8 CLEAR ZINC D 0H4656 1 CIRCUIT BREAKER SUPPORT CC E 038150 2 WASHER FLAT 8 ZINC F 022264 2 WASHER LOCK 8 4 G 022471 2 NUT HEX 8 32 STEEL H 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS J 053640 2 SCREW RHM 8 32 X 3 1 4 K 091526 2 SCREW PPHM M5 0 8 X 12 ZNC
73. 5 7 022129 8 045771 9 071956 10 051730 11 021991 13 026850 14 0G3461 15 055414 16 047411 17 022097 18 022473 19 025507 REVISION H 5975 B DATE 2 5 10 QTY BPRQONNNAA GROUP C DESCRIPTION MOUNTING BASE 1 6L 2007 C1 WASHER SHAKEPROOF EXT 5 16 STL DAMPENER VIBRATION VIB ISO 70 75 DURO SCREW HHC 8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX 8 1 25 G8 YEL CHR WASHER FLAT M8 SCREW HHC 8 1 25 X 60 G8 8 EARTH STRAP WASHER SHAKEPROOF EXT 1 4 STL ALTERNATOR SUPPORT BLOCK OFF LUG SLDLSS 2 8 X 17 64 CU SCREW 6 1 0 X 16 G8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC WASHER LOCK EXT 7 16 STL Page 2 of 2 GROUP C TO STARTER CONTACTOR HARNESS WIRE 10 SEE NOTE EXPLODED VIEW BATTERY C1 1 6L REVISION A 004067 DRAWING PAGE 1 OF 2 10 27 06 DATE EXPLODED VIEW BATTERY C1 1 6L DRAWING 064067 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F3408C 1 BATTERY TRAY C1 amp C2 2 0F3411 1 STRAP BATTERY RETAINMENT 3 025507 1 WASHER SHAKEPROOF EXT 7 16 STL 4 059980 1 SCREW HHC M10 1 5 X 25 G10 9 5 046526 1 WASHER LOCK M10 6 077483 REF BATTERY 12VDC 75 AH 26 7 050331 REF BATTERY POST COVER RED 8 050331 REF BATTERY POST COVER BLK 9 038805J 1 CABLE BATTERY BLACK 1 X 30 00 10 038804M 1 CABLE BATTERY RED 1 X 21 00 11 045771 REF NUT HEX 8 1 25 G8 YEL CHR 12 022131 1 WASHE
74. 5 SS ITEMS INCLUDED WITH HARNESS P N 0H6692 ITEMS USED ON 1 6L MODELS ONLY 1 2 3 SEE C1 SELECTION TABLE 4 SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS NO COLOR MANUFACTURING FOR CORRECT MATERIAL AND COLOR REFER 5400 BOM e CUSTOMER WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER FIRST 6 DIGITS ONLY IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR FOR REFERENCE SEE GUIDELINE 0H7169 REVISION J 1182 J Page 5 of 8 DATE 12 16 11 EXPLODED VIEW CONNECTION BOX CPL DRAWING 0H7234 GROUP A APPLICABLE TO ITEM DESCRIPTION UL CIRCUIT BREAKER CC 2P A 0H4745 REF CB 0100A 2P 240V E CC LL 0H4746 REF CB 0125A 2P 240V E CC LL 0H4747 REF CB 0150A 2P 240V E CC LL B 0H6847 1 COVER CB E CC 2P C1 CONBOX 051716 2 NUT HEX 5 0 8 G8 CLEAR ZINC D 0H4656 1 CIRCUIT BREAKER SUPPORT CC E 038150 2 WASHER FLAT 8 ZINC F 022264 2 WASHER LOCK 8 4 G 022471 2 NUT HEX 8 32 STEEL H 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS J 053640 2 SCREW RHM 8 32 X 3 1 4 K 091526 2 SCREW PPHM M5 0 8 X 12 ZNC L 023897 4 WASHER FLAT 10 ZINC M 049226 2 WASHER LOCK M5 N 0H4698 1 INSULATOR CB 2P E TYPE CC P 0J78230ASOR 1 SHIELD CB HANDLE CONBOX Q 029289 1 TAPE ELEC 1 2 FOAM R 036261 4 RIVET POP 125 X 275 SS UL CIRCUIT BREAKER CC FG 3P A 0H4913 REF CB 0100 3P 240V E CC LL 0H4914 REF CB 0125 3P 240V E CC LL 0H5488 REF 0080 600V E FG LL 0H5489 REF CB 0
75. 787 6 WASHER 41 ID 94 OD 12 THK 26 0A8830 4 WASHER FLAT 34 ID X 75 OD 27 077043E 1 FLEX CONDUIT 1 BLACK NOT SHOWN 28 062070 1 PLATE SPACER 1464 1 6L TO BE USED WITH ENGINE PLATE P N 060834 0G2070A 1 PLATE SPACER 16GA 1 6L TO BE USED WITH ENGINE PLATE P N 0G0834A 29 045771 4 NUT HEX 8 1 25 G8 CLEAR ZINC 30 0D8427 4 WASHER LOCK M10 RIBBED ZINC 2 31 0J6853A 1 SUPPORT LH ALT COVER 2 32 0J6853B 1 SUPPORT RH ALT COVER 2 33 0J6853C 1 COVER REAR 10 ALT 2 34 002454 6 SCREW HWHT M6 1 X 16 WA Z JS 1 APPLY LOCTITE 242 BEFORE THREADING SCREW INTO CRANKSHAFT 2 ALTERNATE CONFIGURATION REQUIRES ALL NOTED PARTS REVISION H 9869 N DATE 10 28 11 GROUP A PAGE 2 OF 2 8 Jo eyeg 142 12 NOILOANNOD 28 2811 FA ONILVY Wall 7300W 1 23135 34012 YEZLHO 8 10 9 1191 eveg 149 12 2811 142 NOILO3NNOO 01 Gg 487 8 Jo 9 01 01 281 EXPLODED VIEW CONNECTION BOX CPL DRAWING 0H7234 GROUP A APPLICABLE TO ITEM P
76. 96 of nominal These levels are fixed The Line Interrupt period is an adjustable parameter by the dealer If 2 wire start mode is activated the unit will start when 2 wire start is active 3 LoosnxeNunu 8 4 MANUAL START Allows the user to start and run the generator manually Transfer of the load to the generator will occur if utility is lost while the unit is running in the manual mode only if activated ALARM AND WARNING MESSAGES Alarms are defined as Latching which means they must be cleared before the alarm message on the screen will clear They can be of type Shutdown or not and are logged in the alarm log Alarms are all annunciated on the display Warnings are Non Latching meaning the message automati cally clears when the warning condition goes away Warnings can not be of type Shutdown but they are logged in the alarm log Warnings are all annunciated on the display LOW OIL PRESSURE SHUTDOWN ALARM There is a 10 second delay before oil pressure is monitored HIGH COOLANT TEMPERATURE SHUTDOWN ALARM There is a 10 second delay before engine temperature is moni tored Once running there is a 1 4 second delay before shut down The limit is set at 125 C or 257 F OVERCRANK SHUTDOWN ALARM Occurs if the engine has not started within the specified crank cycle OVERSPEED SHUTDOWN ALARM Warning indicator is measured and calculated by the microproces sor Overspeed is defined
77. 97 1 CIRCUIT BREAKER SUPPORT BQ E 052619 2 SCREW HHC M5 0 8 X 20 G8 8 F 023897 4 WASHER FLAT 10 ZINC G 049226 2 WASHER LOCK M5 H 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS J 051716 2 NUT HEX M5 0 8 G8 CLEAR ZINC K 0G9708 2 SCREW PHTT M4 0 7 X 8 ZP L 022264 2 WASHER LOCK 8 4 M 0J78230ASOR 1 SHIELD CB HANDLE CONBOX N 029289 1 TAPE ELEC 1 2 FOAM P 036261 4 RIVET POP 125 X 275 SS R 0K4772 1 DECAL SERVICE DISCONNECT UL CIRCUIT BREAKER BQ 3P A 062812 REF CB 0080A 3P 240V S BQ3 LL 053691 REF CIRCT BRK 90 X 3 ITE BQ3 B090 040532 REF CB 0100A 3P 240V S BQ3 LL B 0 6843 1 COVER 5 C1 CONBOX 0 6002 1 TRACK SIEMENS CB 3P D 0G4497 1 CIRCUIT BREAKER SUPPORT BQ E 052619 3 SCREW HHC M5 0 8 X 20 G8 8 F 023897 6 WASHER FLAT 10 ZINC G 049226 3 WASHER LOCK M5 H 002454 10 SCREW HWHT 6 1 X 16 N WA Z JS J 051716 3 NUT HEX M5 0 8 G8 CLEAR ZINC K 0G9708 2 SCREW PHTT M4 0 7 X 8 ZP L 022264 2 WASHER LOCK 8 M4 M 0J78230ASOR 1 SHIELD CB HANDLE CONBOX N 029289 1 TAPE ELEC 1 2 FOAM P 036261 4 RIVET POP 125 X 275 SS R 0K4772 1 DECAL SERVICE DISCONNECT UL CIRCUIT BREAKER ED 3P A 0D5552 REF 0050A 480V S ED4 LL 0D5556 REF CB 0090A 480V S ED4 LL 0D5557 REF CB 0100A 480V S ED4 LL 0D9693 REF CB 0125A 3P 480V S ED4 LL B 0H6844 1 COVER CB S ED3 C1 CONBOX 064498 1 CIRCUIT BREAKER SUPPORT ED D 038150 4 WASHER FLAT 8 ZINC E 022264 4 WASHER LOCK 8 4 F 022471 4 NUT HEX 88 32 STEEL G 0A8278 3 SCREW SHC 1 4 28
78. APOR 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 consump tion is high the vapor withdrawal system may not function efficiently Ambient temperatures around the supply tank must be high enough to sustain adequate vaporization or the system will not deliver the needed fuel volume In addition to the cooling effects of ambient air the vaporization process itself provides an additional cooling effect LL VO 4 10054519 4 Specifications SPECIFICATIONS STANDBY EMERGENCY GENERATOR TY DOs EET Synchronous Rotor 5 1 Class Stator Insulation Class Alternator Output Leads 3 4 wire Sealed Ball GOUDIING crier s ems Flexible Disc Load Capacity Standby Rating 25 30 kW 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 g
79. ART QTY DESCRIPTION 1 0 6795 1 BACK SIDES C1 CPL 2 0H6796 1 CONBOX TOP C1 CPL 4 3 0H67330STOR 1 BRACKET GIMBAL CONTROL PNL RAW 4 0H7115 2 KNOB M6 1 0 CONTROL PANEL 5 022097 2 WASHER LOCK M6 1 4 6 022473 4 WASHER FLAT 1 4 M6 ZINC 3 7 SEE CHART 1 CIRCUIT BREAKER 8 052777 3 WASHER FLAT M3 9 043182 3 WASHER LOCK M3 10 051714 3 NUT HEX M3 0 5 G8 CLEAR ZINC 4011 0H81040ASOR 1 COVER DPE BREAKER NEXUS 12 045764 2 SCREW M4 0 7 X 8 ZP 13 022264 3 WASHER LOCK 8 M4 14 0A9457 1 DECAL NEUTRAL 15 REF 1 ASSY CTRL PROGRAMMED 16 002454 18 SCREW HWHT 6 1 X 16 N WA Z JS 2 17 0A1354A 1 REGULATOR DC ALT 18 0D3700 6 NUT FLANGE M6 1 0 NYLOK 4 19 OH88380STOR 1 SHIELD HIGH LOW C1 RAW 20 056739 1 RELAY SOLENOID 12VDC MNT 21 OF 5458 12 SCREW HHSP 10 X 3 8 HI LOW 22 042568 2 SCREW HHC M6 1 0 X 20 C8 8 23 051716 2 NUT HEX M5 0 8 G8 CLEAR ZINC 24 049226 2 WASHER LOCK M5 25 051713 2 WASHER FLAT M5 26 0D7177V 2 DIODE BRIDGE 1P 35A 1000V 27 0 5752 1 RES WW 158 5 25W CONN 28 0H6267 1 COVER VOLTAGE SHIELD 29 056326 1 TRIM VINYL BLACK 1 8GP 3 LG 30 0G3524 1 COVER BELL HOUSING CONBOX 1 31 0D7393T REF TERM BLOCK 3P UL 12 20AWG 1 32 0D7393U REF TERM BLOCK 4P UL 12 20AWG 1 33 0F5376S0AR REF MX150L SLRRMNT 22 18 8P W O GA 1 34 0F5396S0AR REF MX150L SLRRMNT 22 18 12P W OGA 35 057073 1 JUNCTION BLOCK 3 8 16 36 0C2265 3 SCREW PHTT M4 0 7 X 12 ZP 37 057329 1 LUG SLDLSS 350 6X13 32 AL CU 38 022237 1 WASHER LOCK 3 8 39 022241 1
80. 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 A Be sure the 120VAC power supply to the battery Ais turned OFF or sparking may occur at the bat tery posts as the cables are attached and cause an explosion BATTERY REPLACEMENT NOTE Unit DOES NOT include battery When supplying or replacing the battery the recommended num ber and type of battery is listed in the Specifications Section NOTE The BCI number should be located directly on the battery BATTERY FLUID Check battery electrolyte fluid based on the Service Schedule Fluid should cover separators in all battery cells If fluid level is low add distilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY CLEANING THE STATIONARY EMERGENCY GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by a Service
81. BA 1 BLACK 1 ss BRUSHLESS 1 BLACK s ieg iim NOTE USED 55 N3 N3 2 2 2 51 54 57 GEARBOX PS O 2 56 DRIVE d 59 5 MLCB NB lt 5 58 O O IO O 2 a 1 EGE GENERATOR OUTPUT CUSTOMER CONNECTIONS AR ALTERNATOR ROTOR E2 AS ALTERNATOR STATOR E2 TO Es 240VAC BRUSH ASSEMBLY FCN OR EDEN OR 120VAC MAN UNE CIRCUIT BREAKER NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES NB NEUTRAL BLOCK OUTPUT VOLTAGE TERMINAL BLOCK J 120 240VAC 6082 4 OF 4 2 22 o um o m m m ee y exec to pu Rie emm 21 REVISION H 9868 D DATE 10 18 11 PAGE 4 OF 4 WIRING DIAGRAM CPL ALTERNATOR DRAWING 0H6342 GROUP G L1 L2 13 00 0 2 gt ss o g 2 Bz 2 at VS f z NS 9 e 2 hd hd hd hd 5 N 1 gt O ALON 2 O m E lt lt 2 9 zh 2 zd E 85 If VS Wr ALTERNATOR MAIN WIRES L1 d 00 A d L3
82. C VOLTAGE REGULATOR MOV METAL OXIDE VARISTOR AFS AIR FUEL SOLENOID EXCITER 1 MAGNETIC PICKUP ALT DC CHARGE ALTERNATOR EC EMISSIONS CONNECTOR OS OXYGEN SENDER BAT BATTERY F1 FUSE INLINE RI RESISTOR BWR BASIC WIRELESS RECEPTACLE FS FUEL SOLENOID SC STARTER CONTACTOR CAMSHAFT SENSOR GOV ELECTRONIC GOVERNOR ACTUATOR SHLD SHIELD CAR COMMON ALARM RELAY gt ENGINE CONTROL MODULE CONNECTOR SM STARTER MOTOR CB CIRCUIT BREAKER LFP LOW FUEL PRESSURE SWITCH SP SPARK PLUG CP COIL PACK LOS LOW OIL PRESSURE SWITCH WLS COOLANT LEVEL SENDER DB DIODE BRIDGE MLCB MAIN LINE CIRCUIT BREAKER WTS COOLANT TEMPERATURE SENDER SCHEMATIC DIAGRAM G1 6L 611 NEXUS DRAWING 0H6684 1 LEGEND NOTE ALL WIRES 18 AWG AFS AIR FUEL SOLENOID HVR HIGH VOLTAGE RECEPTACLE 12 PIN 300V UL LISTED UNLESS ALT DC CHARGE ALTERNATOR ENGINE CONTROL MODULE 35 CONNECTOR SHOWN OTHERWISE AS ALTERNATOR STATOR J2 ENGINE CONTROL MODULE 23 PIN CONNECTOR BA BRUSH ASSEMBLY LFP LOW FUEL PRESSURE SWITCH AWG SIZE BATTERY 105 LOW OIL PRESSURE SWITCH 12 BWR BASIC WIRELESS RECEPTACLE LVP LOW VOLTAGE PLUG 8 BULKHEAD CAM CAMSHAFT SENSOR LVR LOW VOLTAGE RECEPTACLE 8 CAR COMMON ALARM RELAY MLCB MAIN LINE CIRCUIT BREAKE
83. CK 4P UL 12 20AWG 1 33 0F5376S0AR REF MX150L SLRRMNT 22 18 8P W O GA 1 34 0F5396S0AR REF MX150L SLRRMNT 22 18 12P W OGA 35 057073 1 JUNCTION BLOCK 3 8 16 36 0C2265 3 SCREW PHTT M4 0 7 X 12 ZP 37 057329 1 LUG SLDLSS 350 6X13 32 AL CU 38 022237 1 WASHER LOCK 3 8 39 022241 1 NUT HEX 3 8 16 STEEL 40 025433 1 LUG SLDLSS 6 14 X 13 64 CU 41 023762 1 WASHER LOCK EXT 10 STL 42 0H7292 1 DECAL CUSTOMER CONTROL CONNECT 43 0H7293 1 DECAL CONBOX TB1 CONNECTIONS 44 029289 1 TAPE ELEC 1 2 FOAM 62 LG 45 0J0489 1 DECAL CUSTOMER POWER CONNECT 46 0A2115 2 WASHER NYLON 257 47 0F6146 1 HANG TAG 2 WIRE START NOT SHOWN 48 0H6692 1 HARN CONBOX NEXUS NOT SHOWN 49 0D7178T REF FUSE ATO TYPE 7 5AMP BROWN 50 067210A 1 DECAL GROUND LUG 51 0J6701 1 GASKET WIRE ENTRY COVER 52 0H8006 1 DECAL CAUTION ELEC SHOCK SM UL CIRCUIT BREAKER 225AF A 0G5249 REF CB 150A 2 POLE 240V 225AF B 0H6846 1 COVER CB G 225AF C1 CONBOX 0F8432A 1 INSULATOR CB 2P 225AF D 0G5734 1 SPRT CIRCUIT BREAKER G 225AF E 038150 2 WASHER FLAT 8 ZINC F 022264 2 WASHER LOCK 8 4 G 022471 2 NUT HEX 8 32 STEEL H 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS J 053640 2 SCREW RHM 8 32 X 3 1 4 K 0 8843 2 BUS BAR 2004 LUG ADAPTOR L 049897 4 SCREW SHC 8 1 25 X 20 G8 REVISION J 6101 L Page 4 of 8 DATE 8 12 13 EXPLODED VIEW CONNECTION BOX CPL DRAWING 0H7234 APPLICABLE TO ITEM M N P R S T U V Ww X IT IT PART 022129 022145 045771 058306 0F8451 0G
84. CK NUT AND TO INCLUDE AT LEAST ONE CONNECTION POINT USING 19 THREAD FORMING FASTENER WITH LOCK NUT TO EACH PANEL LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSION IN ENCLOSURE PANELS ALL PANEL TO BASEFRAME CONNECTIONS TO INCLUDE AT LEAST ONE CONNECTION POINT USING 29 WASHER SPECIAL 2 SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS NO COLOR MANUFACTURING FOR CORRECT MATERIAL AND COLOR REFER 5400 BOM CUSTOMER WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER FIRST 6 DIGITS ONLY IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR FOR REFERENCE SEE GUIDELINE 0H7169 3 USED ON 1 5L 1 6L UNITS ONLY 1 REVISION A DATE 11 14 11 Page 2 of2 468690 4 DNIA VIG C JO I HOVd 90 1 6 197 WALSAS LSNVHX4 NOISIATY AHIA QHGO Id XH dowd EXPLODED VIEW EXHAUST SYSTEM 1 6L DRAWING 063535 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F7366 1 MUFFLER C1 2 0F7647 1 MUFFLER SADDLE 3 0 8095 1 PIPE EXHAUST OUTLET 4 0G3576 1 EXHAUST PIPE LOWER 1 6L 5 0E3257 4 SCREW HWHTF M6 1 0 X 16 6 0F7644 2 MUFFLER STRAP 7 0 6119 1 BOLT U 5 16 18 X 2 1 4 8 036434 3 BOLT U 5 16 18 X 2 09 9 036449 3 SADDLE 2 INCH 10 022129 6 WASHER LOCK M8 5 16 11 022259 6 NUT HEX 5 16 18 STEEL 12 038750 1 SCREW 6 1 0 X 30 68 8 13 063575 1 EXHAUST PIPE UPPER 1 6L SS 14 0F3794A 1 EXHAUST BLANKET 500
85. Control Module circuit board Replace board Coolant Level is Low Repair leak Add coolant Defective Low Coolant Level Switch Replace Switch AUTO OFF MANUAL Switch at OFF 1 Defective AUTO OFF MANUAL switch 1 Replace board engine continues to run 2 Defective Control Module circuit board 2 Replace board No AC output from generator 1 Main line circuit breaker is tripped open 1 Reset to ON CLOSED 2 Generator internal failure 3 Thermal circuit breaker open 3 Auto reset Wait 5 min and attempt restart Contact the nearest Dealer for assistance 12 1 01 60 8 60014811 United States Environmental Protection Agency Warranty Statement Stationary Emergency Spark Ignited Generators Warranty Rights Obligations and Coverage The United States Environmental Protection Agency EPA and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new stationary emergency engine If during the warranty period any emission control system or component on your engine is found defective in materials or workmanship Generac will repair your engine at no cost to you for diag nosis replacement parts and labor provided it be done by a Generac Authorized Warranty Service Facility Your emission control system may include parts such as the fuel metering ignition and exhaust systems and other related emission related components listed below Generac will warrant the emissions
86. Dealer That dealer will use dry low pressure air to clean internal windings Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the genera tor may require drying 01 90 v SERVICE SCHEDULE Weekly W Monthly M Inspect Change Clean Yearly Y ss Ir W x d w De SOS vY w Engine Coolant nes amp Comectons Emo Mw x EO v j x x x T Sp v x gt j Battery Remove Corrosion Ensure Dryness X C X amp Tighten eminas m x T x Check Charge State x J J check Ekctrovielevel Mw x x J General Condition Vibration Noise Leakage Temperature Generator System Complete Tune up and System Inspection To be completed by an Authorized Service Dealer Footnotes the oil level monthly or every 12 hours during continuous operation Change oil and oil filter after the first 30 hours of operation and then every 100 hours or annually thereafter whichever occurs first Change sooner when operating under heavy load or in a dusty or dirty environment or in high ambient temperatures Replace as necessary 1
87. E FUEL SYSTEM NOTE All models are configured to run on natural gas from the fac tory Before the generator can be operated using a LP fuel source the fuel system and control panel refer to the installation drawing for location must be reconfigured The steps to reconfigure the gen erator from a natural gas NG to a liquidified petroleum LP fuel source are as follows FUEL SYSTEM 1 the main gas supply off and disconnect the battery 2 Remove the carburetor fuel hose from the outlet port of the demand regulator see Figure 6 1 3 Disconnect the power wires from the fuel solenoid located on top of the regulator assembly by removing the screw on the front of the connector and pulling the connector forward away from the solenoid body 4 Loosen the spring clamp on the small fuel enrichment line and remove the hose from the hose barb 5 Remove the black pipe assembly from the outlet port of the demand regulator The solenoid assembly may need to be removed before performing this operation Figure 6 1 6 Remove the NG fuel jet loosen counter clockwise from the outlet port 7 Remove the LP fuel jet loosen counter clockwise from the jet keeper port on the side of the regulator housing Install this jet into the outlet port in the regulator casting NOTE The jet sizes are stamped on the individual jets The larger jet size is used for running on NG 8 Install the previously removed NG jet into the jet k
88. ENANCE 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 a 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 con tribute 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 a Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the generator electric system has been installed by a 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 a Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting a dealer about parts and service always supply the complete Model Number Serial Number and Type Code where applicable from the DATA LABEL that is affixed to the unit 01 50 00 2 Safety Instructions SAFETY RULES Study these SAFETY RULES carefully before installing operating or servici
89. ER NUT HEX 1 4 20 STEEL WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW THF M6 1 X 16 WA 2 8 VISE ACTION LATCH SLOTTED CIR PULL TAB DOOR LOCK SS KEY VISE ACTION LATCH SLOT CIR FOAM STRIP 3 4 WIDE X 3 16 THK 294 LG WASHER SELF LOCKING DOME INSULATION SIDE DOOR C1 INSULATION ROOF C1 SCREW HWHTF M6 1 0 X 16 ASSY WIRE 14AWG GRN YEL 32 25716 INSULATION REAR C1 SCREW HHFC M6 1 0 X 20 G8 8 NUT SPRINGCLIP M6 1 0 WASHER LOCK M6 1 4 FOIL ALUMINUM WITH ADHESIVE RF COVER PLATE PLASTIC BISQUE RF COVER PLATE PLASTIC GREY FRONT DISCHARGE WRAP 1 6L C1 WASHER LOCK SPECIAL 1 4 1 ENCLOSURE NOTE ALL PANELS THAT FASTEN TO THE ROOF MUST BE SECURED USING 10 THREAD FORMING FASTENER AND LOCK NUT AND TO INCLUDE AT LEAST ONE CONNECTION POINT USING 19 THREAD FORMING FASTENER WITH LOCK NUT TO EACH PANEL LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSION IN ENCLOSURE PANELS ALL PANEL TO BASEFRAME CONNECTIONS TO INCLUDE AT LEAST ONE CONNECTION POINT USING 29 WASHER SPECIAL 2 SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS NO COLOR MANUFACTURING FOR CORRECT MATERIAL AND COLOR REFER 5400 BOM CUSTOMER WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER FIRST 6 DIGITS ONLY IN THE SYSTEM FOR CORRECT MATERIAL AND COLOR FOR REFERENCE SEE GUIDELINE 0H7169 3 USED ON 1 5L 1 6L UNITS ONLY 1 REVISION J 1720 K DATE 3
90. ER RADIATOR 1 6L CLAMP HOSE 24 B1 06 2 00 HOSE REAR COOLANT 1 6L TUBE ENGINE COOLANT 1 6L HOSE UPPER RADIATOR 1 6L CAP RADIATOR TAPE FOAM 1 X 1 24 LG WASHER FLAT 1 4 M6 ZINC WASHER LOCK 6 1 4 SCREW 6 1 0 20 68 8 NUT HEX 8 1 25 G8 CLEAR ZINC SCREW THF M6 1 X 12 WA Z JS SCREW HHC 6 1 0 X 20 68 8 GUARD FAN LH C1 GUARD FAN RH C1 RADIATOR BLOCK OFF BRACKET COOLANT TANK TANK COOLANT RECOVERY CLAMP HOSE BAND 1 4 HOSE 9 32 ID 43 LG BRACKET STEPPER MOTOR COOLANT CLAMP VINYL 1 31 2812 GROMMET 5 8 X 1 1 8 X 5 16 ASSY FAN BEARING SUPPORT BRACKET FAN ALT ADAPTER 1 6L PROBE COOLANT LEVEL 3 8NPTF PROBE COOLANT LEVEL 3 8 18NPTF USE WITH I N 40 P N 0H1851 PULLEY FAN 95 DIA TIE WRAP UL 7 4 X 19 BLK NOT SHOWN SCREW 8 1 25 X 16 68 8 WASHER SHAKEPROOF EXT 5 16 STL WASHER LOCK 8 5 16 SCREW HHC M8 1 25 X 20 G8 8 ASSY LCL SENSOR USE WITH 33 P N 0H1827 ONLY 00 00 mana 2 gt lt gt 5 1 APPLY LOCTITE 242 36 BEFORE THREADING INTO 31 2 USE WITH R 200 CONTROL PANEL ONLY PAGE 2 OF 2 GROUP C Revision H 5975 B Date 2 5 10 Exploded View MOUNTING BASE 1 6L Drawing No 0G3531 Page 1 of 2 EXPLODED VIEW MOUNTING 1 6L DRAWING 7 063531 APPLICABLE TO ITEM PART 1 0G3343 2 027482 3 070936 4 070936C 5 039253 6 02214
91. Generator is designed to supply 3 phase electrical 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 Delta configuration as shown in Figures 7 7 and 7 8 The rated voltage between circuit breaker terminals E1 E2 E1 E3 and E2 E3 is 240V The rated voltage between E1 or E3 and the neutral point 00 is 120V Figure 7 7 Stator Power Winding Connections 3 phase 120 240V 6 Lead E2 S2 N S6 INTERNAL CONNECTIONS L L S5 S3 si 54 E3 L N 00 NEUTRAL Figure 7 8 Stator Power Winding Connections 3 phase 120 240V 12 Lead HAN 00 NEUTRAL Control Panel CONTROL PANEL INTERFACE USING THE AUTO OFF MANUAL SWITCH A WARNING With the switch set to AUTO the engine may crank and start at any time without warning Such automatic starting occurs when utility power source voltage drops below a preset level or during the normal exercise cycle To prevent possible injury that might be caused by such sudden starts always set the switch to OFF and remove the fuse before work ing on or around the generator or transfer Switch Then place a NOT OPERATE tag on the generator panel and on the trans fer switch 1 AUTO Position Selecting this switch activates fully auto matic system operation It also allows the unit to automati cally start and exercise the engine every seven days wit
92. L 023897 4 WASHER FLAT 10 ZINC M 049226 2 WASHER LOCK M5 N 0H4698 1 INSULATOR CB 2P E TYPE CC P 0J78230ASOR 1 SHIELD CB HANDLE CONBOX Q 029289 1 TAPE ELEC 1 2 FOAM R 036261 4 RIVET POP 125 X 275 SS 5 0K4772 1 DECAL SERVICE DISCONNECT UL CIRCUIT BREAKER CC FG 3P A 0H4913 REF CB 0100 3P 240V E CC LL 0H4914 REF CB 0125 3P 240V E CC LL 0H5488 REF CB 0080 3P 600V E FG LL 0H5489 REF CB 0090 3P 600V E FG LL B 0H7294 1 CB COVER E CC FG 3P C1 CONBOX 0 4698 1 INSULATOR 3P E CC FG D 0H4656 REF CIRCUIT BREAKER SUPPORT CC 0H5604 REF CIRCUIT BREAKER SUPPORT FG E 038150 4 WASHER FLAT 8 ZINC F 022264 4 WASHER LOCK 8 4 G 022471 4 NUT HEX 8 32 STEEL H 0C2454 10 SCREW HWHT M6 1 X 16 N WA Z JS J 053640 4 SCREW RHM 8 32 X 3 1 4 CC 0H5721 4 SCREW PPHM 8 32 X 1 3 4 ZINC FG K 091526 3 SCREW PPHM M5 0 8 X 12 ZNC L 023897 6 WASHER FLAT 10 ZINC M 049226 3 WASHER LOCK M5 N 051716 3 NUT HEX M5 0 8 G8 CLEAR ZINC P 0J78230ASOR 1 SHIELD CB HANDLE CONBOX Q 029289 1 TAPE ELEC 1 2 FOAM R 036261 4 RIVET POP 125 X 275 SS 5 0K4772 1 DECAL SERVICE DISCONNECT REVISION J 6101 L Page 6 of 8 DATE 8 12 13 EXPLODED VIEW CONNECTION BOX CPL DRAWING 0H7234 GROUP A APPLICABLE TO ITEM PART QTY DESCRIPTION UL CIRCUIT BREAKER BQ 2P A 0D5543 REF CB 0090A 2P 240V S BQ2 LL 0D5544 REF CB 0100A 2P 240V S BQ2 LL 0A2077 REF CB 0125A 2P 240V S BQ2 LL B 0 6842 1 COVER CB 5 802 C1 CONBOX 0 7890 1 BRKT MTG BACK D 0G44
93. L UNITS 55 55 ONLY 52 52 56 56 55 55 54 54 99 DIRECT DRIVE 25 Rol AS 4 MLCB NB El E2 GENERATOR OUTPUT CUSTOMER CONNECTIONS E1 TO E2 2 3 240VAC OR TO 120VAC NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE J 120 240VAC 60HZ L PAGE 2 OF 4 WIRING DIAGRAM REVISION H 9868 D CPL ALTERNATOR DATE 10 18 11 PAGE 2 OF 4 DRAWING 0H6342 GROUP G m XUI mM C TIENE Mu MC EE IM aa 71 OPTION 5 THREE PHASE CPL CONTROL PANEL GEARBOX REVERSE ROTATION SA SA SB SB TB DIRECT lt AR BA 4 BRUSHLESS 1 BLACK m ig 1 RED NOTE USED ss WITH G6 8L 53 53 UNITS ONLY S9 S9 58 58 52 52 51 51 57 57 54 2 55 5 Pell 56 DRIVE S10 AS MLCB NB 511 512 1 2 L J LEGEND GENERATOR OUTPUT CUSTOMER CONNECTIONS AR ALTERNATOR ROTOR TO E2 AS ALTERNATOR STATOR E2 TO 3 208VAC BA BRUSH ASSEMBLY E1 TO E3 EF EXCITER FIELD E1 E2 OR TO NB 120VAC MLCB MAIN LINE CIRCUIT BREAKER NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES NB NEUTRAL BLOCK OUTPU
94. M6 1 0 X 16 WASHER FLAT 34 ID X 75 OD HARN ENG G1 6L G11 NEXUS NOT SHOWN OIL FILTER 1 6L CONDUIT FLEX 25 ID 6 LG STRUT RH 1 6L ENG ADAPT PLATE BARBED STR 3 8 NPT X 3 8 CLAMP HOSE 38 87 HOSE COOLANT 3 8 ID 20R3 11 LG BRACKET FAN ALT ADAPTER 1 6L SCREW M10 1 5 X 35 08 8 DECAL EMISSION CTRL INFO 1 6L BRACKET STEPPER MOTOR COOLANT ANCHOR HARNESS Page 2 of 2 GROUP E EXISTING HOSE FROM CRANKCASE INSTALLED WITH FLOW ARROW POINTING IN DIRECTION SHOWN IN ILLUSTRATION BELOW gt a a o n SEE REGULATOR NOTES FOR INFORMATION Revision H 9610 B Date 9 9 11 Exploded View FUELSYS NG LPV 1 6L CPL Drawing No 0H6671 Page 1 of 2 EXPLODED VIEW FUELSYS NG LPV 1 6L CPL DRAWING 0H6671 APPLICABLE TO ITEM PART 1 037561 2 0 5547 3 062522 4 022127 5 059402 6 091526 7 049226 8 0 0519 9 048031 10 0 6586 11 0G1397E 12 0F7790 13 0E7121 14 0G4573C 15 0E8286 16 047527 17 057823 18 035685 19 057753B 20 0E4395 21 022129 22 0A6344 23 048031L 24 0G1985 25 047290 26 047290 27 0F3994 28 0G3178 29 048031P 30 057147 31 045771 32 051767 33 022097 34 039253 35 069348 1 36 026812 1 37 076691 1 38 026490 1 39 075580 40 001509 41 075436 42 022145 143 026915 44 0 6586
95. MANUAL switch is in the OFF position The control panel fuse has been removed from the control box The 120VAC supply to the battery charger is switched OFF The negative battery cable has been removed CHECK ENGINE OIL Check engine crankcase oil level Figure 10 1 according to the Service Schedule and SIB10 10 L24G Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again e Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Engine Oil Recommendations for recommended oils Figure 10 1 Oil Dipstick and Oil Fill Cap OIL FILL CAP DIPSTICK CHANGING ENGINE 011 A CAUTION Hot oil may cause burns Allow engine to cool before draining oil Avoid prolonged or repeat ed skin exposure with used oil Thoroughly wash exposed areas with soap 10 1 Refer to the Service Schedule for engine oil and filter change fre quencies Drain the oil while the engine is still warm from running This means warm up the engine shut it down and drain immediately as follows 1 Remove the drain hose from its retaining clip or cut the zip tie securing the oil drain hose 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil com pletely into suitable container 3 When all oil has drained i
96. NGNOD 4931 0907 99 303 dn anis 3015 1 WANVW NIHLIM 133HS 119014103 5 335 NOILVYWAOANT 3293238 1119419 53401121418 3 10 S3ONVISIG WAWINIW 403 55400 19001 NV 319615 1943433 SV 1138 SV SISVINVIS OZ VddN NV ZE VddN 3184921 ddy HLIM 0 440009 NI 0311916 38 LSAW LINN NV 403 01943 3 0 3Hl 83415 119 NO WODO 1 31314 4 5 MOTIVY SJNII301I05 313382NDO 203 LINA HLIM 031199405 30119 NOILVVIVISNI 339N3234329 OND 5 7 2 681 X JAIM 0 Tv 1901 3715 31332NDO9 G3IN3WNWNDO38 WNWINIW I D df1OID SIIN 911890 DNIAA VICI Z JO 7 30Vd 0L 0 ALYA 199 15 NOLLVTTVISNI 2796C9 H NOISIATH 9 335 AND CUN dd nu LINGNOD 1 102 01314 379W34 LdN S83 1330W 1S0WHX3 NOILOSNNOD ANIT 13114 LIZ 0 084 SNHISN3WIQ 30 31N39 JION 335 530914 b DNIL3I1 MATA 3015 1H5I3 6 6 91 Lb L2 d E 335 41384344 1119412 33S 93 00 LINDA 4000 L 20 90v 691 0851 53015 ANY 1 043 86 80 962 ANY 15 G3SD 19N
97. OXYGEN SENSOR RETURN 5 0 GND NOTE 1 6 804 OXYGEN SENSOR 4 ENGINE CONTROL MODULE CONNECTIONS J1 J2 PIN WIRE TO FUNCTION PIN TO FUNCTION 1 178 CUST CON REMOTE START RETURN 1 770 GOV 4 THROTTLE DRIVE 4 817 BWR 2 REMOTE DISPLAY SYSTEM READY 2 808 EC 4 AIR FUEL RATIO SOLENOID DRIVER 5 818 BWR 3 __ REMOTE DISPLAY ALARM 5 568 FS2 STARTING FUEL SOLENOID CONTROL 8 15 Fi NOTE 4 4 25A GNITION COIL DRIVE 1 AND 4 7 15 Fi NOTE 4 5 25B 2 DRIVE 2 3 a 0 GND NOTE 1 8 14 1 5 2 NOTE 9 0 GND NOTE 1 9 771 GOV 1 THROTTLE DRIVE 1010 1 2 FLYWHEEL SENSOR 10 402 CAM 2 HALL FFFECT CAMSHAFT SENSOR SIGNAL 3 HALL EFFECT CAMSHAFT SENSOR 111 209 CAR COMMON ALARM RELAY 12 820 BWR 1 5V POWER FOR BASIC REMOTE 12 25 CUST CON TRANSFER RELAY COIL CONTROL 15 SA MLCB OUTPUT VOLTAGE SENSING A 13 194 CUST CON TRANSFER RELAY 14 183 CUST CON REMOTE START 601 LFP LOW FUEL PRESSURE 16 SHLD 1 1 FLYWHEEL SENSOR DRAIN 15 210 CAR COMMON ALARM RELAY 17 819 BWR 4 REMOTE DISPLAY MAINTENANCE 16 6 DPE EXCITER RETURN 18 767 COV 2 THROTTLE POSITION FEEDBACK RETURN 17 162 CB EXCITER OUTPUT BREAKER PROTECTED 19 765 GOV 3 THROTTLE POSITION FEEDBACK SOURCE 4 FIELD FIELD BRUSH 20 766 0 6 THROTTLE POSITION FEEDBACK SIGNAL 19 1 FIELD FIELD B
98. Owner s Manual Stationary Emergency Generator f a E cl C Cul c CL CIA gt CL CI CI Em C e CL C ez CL 225 25223 Cu CL LIA CL Y else 2 SS ele 2 22 0 A CAUTION 1 BL NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS 25 30kW M ode Is ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST ifi FUMES OUTDOOR INSTALLATION ONLY EPA Certified This manual should remain with the unit ON Hed 0 70 V ed 16148009 Table of Contents SECTION PAGE INTRODUCTION 1 1 Read this Manual Thoroughly 1 1 Operation and 1 1 How to Obtain Service 1 1 SAFETY RULES ceri rdiet GENERAL Identification Record een Data Label EQUIPMENT DE
99. R FLAT 3 8 M10 ZINC 13 027482 1 WASHER SHAKEPROOF EXT 5 16 STL 14 0F3976 1 BOOT CONTACTOR CABLES 15 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 16 022145 REF WASHER FLAT 5 16 M8 ZINC NOTE WHEN INSTALLING BATTERY TUCK BATTERY S LIFTING STRAP ALONG THE LEFT SIDE OF BATTERY SIDE OPPOSITE RADIATOR BEFORE CONNECTING THE BATTERY CABLES REVISION A DATE 10 27 06 GROUP C PAGE 2 OF 2 GROUP D TORQUE POUND FEET 45 6 45 6 QTY BELT TENSION LBS QTY 1 Exploded View ENGINE COMMON PARTS 1 6L Drawing No 0H7219 Page 1 of 2 47 Revision H 8414 C Date 3 1 11 EXPLODED VIEW ENGINE COMMON PARTS 1 61 DRAWING 0H7219 APPLICABLE TO ITEM PART 1 0H1734 2 0G0834A 3 0G0820A 4 0G7461 5 0G0839 6 0G0781 7 0G0722 8 0G4059 9 0G4604 10 0G3424 11 0G0786 12 0G4605 13 0 9617 14 0A1354B 15 0G0823 16 0G3900 17 0D2244M 18 036710 19 0C5479 20 059980 21 046526 22 022131 23 0G3922 24 0G0464 25 0G0465 26 052858 27 051735 28 0G3920 29 0A7387 30 039414 31 022129 32 022145 33 029333A 34 057821 35 045771 36 022507 37 022097 38 022473 39 090388 40 0A5768 41 0E0502 42 035579 43 0H7435 44 0C1852 46 069860C 47 069811 48 0G38580ST03 49 025065 50 027738A 51 0E3257 52 0A8830 53 OH6690 54 0G02070100 55 077043H 56 0G38620ST03 57 055596 58 0C7649 59 0H2250 61 0G3433 62 049541 63 0G7311 64 0G4451 65 0 4001 REVI
100. R SET 210 _0 210 250 FOR FIELD WIRING TO CUSTOMER CONNECTIONS TERMINAL BLOCKS m 4 WIRE SIZE 12 AWG ul E a o 9 9 gt 2 14 19 15 12345 48 48 48 F 15 13 25 12VDC 49 49 0 0 0 2 4 EN cc DTE cc S NA 4 SCHEMATIC DIAGRAM REVISION H 7738 C G1 6L G11 NEXUS DATE 10 29 10 PAGE 2 OF 4 DRAWING 0H6684 GROUP G 25 SP1 5 4 5 5 2 5 15 AGE 3 OF 4 LP SCHEMATIC DIAGRAM G1 6L 611 NEXUS DRAWING 0H6684 REVISION H 7738 C DATE 10 29 10 PAGE 3 OF 4 GROUP G 54 a LL LK EE EM 7 5 1 WIRE 0 UNLESS 2 WIRE 13 3 WIRE 14 IS CRAN 4 WIRE 15 S CHASSIS GROUND BATTERY NOTED OTHERWISE IS UNFUSED 12VDC BATTERY IS FUSED 12VDC WHEN GENERATOR KING OR RUNNING IS FUSED 12VDC FOR GENERAL USE 5 WIRE 15A IS FUSED 12VDC FOR THE IGNITION L SOLENOID OPTION AND FOR THE COILS
101. R SPLICE CB CIRCUIT BREAKER MOV METAL OXIDE VARISTOR NUMBER CP COIL PACK MP1 MAGNETIC PICKUP DB DIODE BRIDGE NB NEUTRAL BLOCK DCVR DC VOLTAGE REGULATOR 05 EMISSIONS CONNECTOR R1 RESISTOR WIRE F1 FUSE INLINE 25A ATO SC STARTER CONTACTOR SPLICE FS_ FUEL SOLENOID SM STARTER MOTOR GND GROUND CONNECTION TERMINAL BLOCK CAGE CLAMP GOV ELECTRONIC GOVERNOR ACTUATOR WLS COOLANT LEVEL SENDER NOTE ALL WIRES ON THIS HIGH VOLTAGE PLUG 12 PIN BULKHEAD WTS COOLANT TEMPERATURE SENDER ARE 600V RATED COMPONENTS LOCATED IN CUSTOMER CONNECTION BOX x 14 ORANGE _ LvP 2 N1 N1 1 49 BLUE Lvp 3 UTILITY FROM TRANSFER SWITCH 6 2 2
102. RUSH 21 68 WTS 2 COOLANT TEMP SIGNAL 201777 CUST CON 120 SOURCE FOR BATTERY CHARGER 22 0 GND NOTE 1 21 NEU CUST CON 120 RETURN FOR BATTERY CHARGER 23 79 MP1 3 FLYWHEEL SENSOR 22 56 5 STARTER CONTACTOR DRIVER 24 SB MLCB OUTPUT VOLTAGE SENSING B 23 15A 3 3 NOTE 5 25 NI CUST CON UTILITY VOLTAGE SENSING 1 26 CUST CON UTILITY VOLTAGE SENSING 2 50 158 1 HALL EFFECT CAMSHAFT SENSOR 31 573A WLS A COOLANT LEVEL SIGNAL RETURN 32 575 WLS B COOLANT LEVEL SIGNAL 33 86 LOS NC LOW PRESSURE SIGNAL 34 804 FC 6 OXYGEN SENSOR 35 805 5 OXYGEN SENSOR RETURN LEGEND 00 NEUTRAL DCVR DC VOLTAGE REGULATOR MOV METAL OXIDE VARISTOR AFS AIR FUEL SOLENOID EXCITER 1 MAGNETIC PICKUP ALT DC CHARGE ALTERNATOR EC EMISSIONS CONNECTOR OS OXYGEN SENDER BAT BATTERY F1 FUSE INLINE RI RESISTOR BWR BASIC WIRELESS RECEPTACLE FS FUEL SOLENOID SC STARTER CONTACTOR CAMSHAFT SENSOR GOV ELECTRONIC GOVERNOR ACTUATOR SHLD SHIELD CAR COMMON ALARM RELAY gt ENGINE CONTROL MODULE CONNECTOR SM STARTER MOTOR CB CIRCUIT BREAKER LFP LOW FUEL PRESSURE SWITCH SP SPARK PLUG CP COIL PACK LOS LOW OIL PRESSURE SWITCH WLS COOLANT LEVEL SENDER DB DIODE BRIDGE MLCB MAIN LINE CIRCUIT BREAKER WTS COOLANT TEMPERATURE SENDER
103. S23 gt a J X J JjALTRPM ENG RPM TYPE CODE ALTSUBTRANSREACTANCE TRANS CLASS STATOR WINDING INS 25 a 062110 2 1 01 50 ed 00 Equipment Description EQUIPMENT DESCRIPTION This equipment is a revolving field alternating current Stationary Emergency Generator It is powered by a gaseous fueled engine operating at 1800 rpm for 4 pole direct drive units 3600 rpm for 2 pole direct drive units and 2300 3000 rpm for quiet drive gear units See the Specifications section for exact numbers The unit comes complete with a sound attenuated enclosure internally mounted muffler control console mainline circuit breaker bat tery charger and protective alarms as explained in the following paragraph All AC connections including the power leads from the alterna tor 120 volt battery charger input and control connections to the transfer switch are available in the main connection box The Stationary Emergency Generator incorporates the following alternator features Rotor and Stator insulation is Class F rated as defined by NEMA MG1 32 6 NEMA MG1 1 66 The generator is self ventilated and drip proof constructed The voltage waveform deviation total harmonic content of the AC waveform and telephone
104. SCRIPTION Equipment DeScfIplOri L Engine Oil Recommendations Coolant Recommendations ENGINE PROTECTIVE DEVICES Engine Protective Devices sss High Coolant Temperature Sender Low Coolant Level 0 Low Oil Pressure Switch Overcrank Shutdown Overspeed Shutdown ess RPM Sensor Loss Shutdown Fuel Requirements Natural Gas Fuel System Propane Vapor Withdrawal Fuel System Liquid Fuel SPECIFICATIONS uu uu uiaiia auqa sssssqauasass Stationary Emergency ENQING us Cooling 5 Fuel System Weather and Maintenance Kits Reconfiguring the Fuel System Fuel System Control Panel GENERAL INFORMATION Alternator AC Lead Four lead Single phase 1 Alternator Power Winding Connections 3 phase Alternators Y
105. SE TIME THIS WILL ENSURE THAT WHEN THE CUSTOMER POWERS UP THE UNIT HE WILL STILL BE PROMPTED TO ENTER AN EXERCISE TIME SETTING THE EXERCISE TIMER This generator is equipped with an exercise timer Once it is set the generator will start and exercise every seven days on the day of the week and at the time of day specified During this exercise period the unit runs for approximately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle unless utility power is lost LOW SPEED EXERCISE The standard start sequence will be initiated All 1800 rpm units will exercise at 1400 RPM All 3600 rpm units will exercise at 1800 RPM If utility is lost during exercise the controller will do the following Wait for the line interrupt period for utility to return If utility returns within the line interrupt period continue to exercise at low RPM 8 3 If utility is still lost after the line interrupt period run the engine up to normal RPM and transfer the load At this time the con troller will exit the exercise routine and assume full automatic operation USER ADJUSTABLE SETTINGS Factory Maximum Default Setting Exercise 23 59 Exercise Current 23 59 Current Current Current 2008 2008 2100 English 100 FUEL CONVERSION For fuel conversion steps refer to the GenSpec section RECONFIGURING THE FUEL SYSTEM OPERATION This system is int
106. SION H 8414 C DATE 3 1 11 QTY REF REF n EL ODORE in GROUP D DESCRIPTION ENGINE 1 6L G11 CERT ENGINE PLATE 1 6L 6MM TO BE USED WITH PLATE SPACER P N 0G2070A HOUSING BLOWER LG PILOT STARTER MOTOR 12V ENGINE MOUNTING FOOT STAMPING EXHAUST MANIFOLD 1 6L MACHINED INTAKE MANIFOLD MACHINED 1 6L SHIELD 1 6L EXHAUST HEAT DC ALTERNATOR ADAPTER MACHINED PULLEY CRANKSHAFT MACHINED WASHER PULLEY BRACKET TENSIONER DC ALT SPACER ALTERNATOR DC ALTERNATR HAN KOK V BELT 3 8 X 30 6 CAP 1 5 HOLE SHALLOW ASSY MAGPICKUP 3 8 24 MALE PIN SPRING 1 4 X 3 4 SCREW HHC M12 1 5 X 40 G10 9 SCREW HHC M10 1 5 X 25 G10 9 WASHER LOCK M10 WASHER FLAT 3 8 M10 ZINC NUT HEX M10 1 5 CLASS 10 ZINC GASKET INTAKE MANIFOLD 1 6L GASKET EXHAUST MANIFOLD 1 6L NUT TOP LOCK FL M8 1 25 SCREW HHC M10 1 5 X 70 G8 8 SCREW HHC M10 1 5 X 110 G10 9 SCREW HHC M10 1 5 X 40 G10 9 SCREW HHC 8 1 25 X 35 G8 8 WASHER LOCK M8 5 16 WASHER FLAT 5 16 M8 ZINC TIE WRAP UL 7 4 X 19 BLK SCREW 8 1 25 X 40 G8 8 NUT HEX 8 1 25 G8 CLEAR ZINC SCREW HHC 1 4 20 X 1 2 G5 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW HHTT M6 1 0 X 12 ZINC WASHER FLAT M10 HEAVY DUTY TEMPERATURE SENDER DELPHI BSHG RDCR HEX 1 4 TO 1 8 HARN LOW OIL PRESS SWITCH ASSY ADAPTER DRAIN OIL HOSE OIL DRAIN ASSY 21 CAP HEX 1 4 NPT BRASS STRUT LH 1 6L ENG ADAPT PLATE NIPPLE PIPE 3 8 NPT X 1 1 2 PIPE TEE 3 8 NPT SCREW HWHTF
107. SOR SIGNAL 3 HALL EFFECT CAMSHAFT SENSOR 111 209 CAR COMMON ALARM RELAY 12 820 BWR 1 5V POWER FOR BASIC REMOTE 12 25 CUST CON TRANSFER RELAY COIL CONTROL 15 SA MLCB OUTPUT VOLTAGE SENSING A 13 194 CUST CON TRANSFER RELAY 14 183 CUST CON REMOTE START 601 LFP LOW FUEL PRESSURE 16 SHLD 1 1 FLYWHEEL SENSOR DRAIN 15 210 CAR COMMON ALARM RELAY 17 819 BWR 4 REMOTE DISPLAY MAINTENANCE 16 6 DPE EXCITER RETURN 18 767 COV 2 THROTTLE POSITION FEEDBACK RETURN 17 162 CB EXCITER OUTPUT BREAKER PROTECTED 19 765 GOV 3 THROTTLE POSITION FEEDBACK SOURCE 4 FIELD FIELD BRUSH 20 766 0 6 THROTTLE POSITION FEEDBACK SIGNAL 19 1 FIELD FIELD BRUSH 21 68 WTS 2 COOLANT TEMP SIGNAL 201777 CUST CON 120 SOURCE FOR BATTERY CHARGER 22 0 GND NOTE 1 21 NEU CUST CON 120 RETURN FOR BATTERY CHARGER 23 79 MP1 3 FLYWHEEL SENSOR 22 56 5 STARTER CONTACTOR DRIVER 24 SB MLCB OUTPUT VOLTAGE SENSING B 23 15A 3 3 NOTE 5 25 NI CUST CON UTILITY VOLTAGE SENSING 1 26 CUST CON UTILITY VOLTAGE SENSING 2 50 158 1 HALL EFFECT CAMSHAFT SENSOR 31 573A WLS A COOLANT LEVEL SIGNAL RETURN 32 575 WLS B COOLANT LEVEL SIGNAL 33 86 LOS NC LOW PRESSURE SIGNAL 34 804 FC 6 OXYGEN SENSOR 35 805 5 OXYGEN SENSOR RETURN LEGEND 00 NEUTRAL DCVR D
108. SYSTEM Battery Charge 12V 15 Amp Static Battery Charger 2 0 or 2 5 Amp Recommended Group 26 525CCA System Voltage essere 12 Volts Voltage Regulator Electronic SENSN Single phase Regulation 2 211 5 oe amas 1 Adjustable Voltage and Automatic Gain Power Adjustment for Ambient Conditions Temperature Deration 396 for every 10 C above 25kW 30kW 40 25 1 6596 for every 10 above F 104 77 Altitude Deration 196 for every 100 m above m 25kW 30kW 915 182 396 for every 1000 ft above ft 2000 600 eese ter EVA VE EUN VERS Nexus LL cL 9 2802908090 Specifications WEATHER AND MAINTENANCE KITS To keep the generator running at its peak the following kits are offered Cold Weather Kit Recommended for climates with temperatures below 32 F Extreme Cold Weather Kit Recommended Block Heater Kit for protection in tempera tures below 32 F Scheduled Maintenance Kit Kit includes the recommended parts to maintain the genera tor Refer to the Service Schedule for regular maintenance intervals For additional information or to order any of these kits please contact an Authorized Service Dealer or Customer Service Representative RECONFIGURING TH
109. T VOLTAGE TERMINAL BLOCK G 120 208VAC 60HZ OPTION 6 THREE PHASE CPL CONTROL PANEL GEARBOX REVERSE ROTATION 515 515 516 516 DIRECT 1 lt 515 515 TRLTSIE 516 6 516 1 BLACK 1 0240 1 4 RED 4 09509 4 2 peor 2 ENS BRUSHLESS s ee 4 RED NOTE USED WITH G6 8L S3 S3 UNITS ONLY 52 52 51 51 2 GEARBOX 512 DRIVE S6 5 54 MLCB NB mo lu 55 E2 516 515 GENERATOR OUTPUT CUSTOMER CONNECTIONS E2 2 Es E2 TO NB 277VAC NOTE THE DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE WIRING DIAGRAM REVISION H 9868 D CPL ALTERNATOR DATE 10 18 11 PAGE 3 OF 4 DRAWING 0H6342 OPTION 7 THREE PHASE SERIES DELTA CPL CONTROL PANEL GEARBOX REVERSE ROTATION SA SA 18 lt AR
110. USE WITH 33 P N 0H1827 ONLY 00 00 mana 2 gt lt gt 5 1 APPLY LOCTITE 242 36 BEFORE THREADING INTO 31 2 USE WITH R 200 CONTROL PANEL ONLY PAGE 2 OF 2 GROUP C Revision H 5975 B Date 2 5 10 Exploded View MOUNTING BASE 1 6L Drawing No 0G3531 Page 1 of 2 EXPLODED VIEW MOUNTING 1 6L DRAWING 7 063531 APPLICABLE TO ITEM PART 1 0G3343 2 027482 3 070936 4 070936C 5 039253 6 022145 7 022129 8 045771 9 071956 10 051730 11 021991 13 026850 14 0G3461 15 055414 16 047411 17 022097 18 022473 19 025507 REVISION H 5975 B DATE 2 5 10 QTY BPRQONNNAA GROUP C DESCRIPTION MOUNTING BASE 1 6L 2007 C1 WASHER SHAKEPROOF EXT 5 16 STL DAMPENER VIBRATION VIB ISO 70 75 DURO SCREW HHC 8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX 8 1 25 G8 YEL CHR WASHER FLAT M8 SCREW HHC 8 1 25 X 60 G8 8 EARTH STRAP WASHER SHAKEPROOF EXT 1 4 STL ALTERNATOR SUPPORT BLOCK OFF LUG SLDLSS 2 8 X 17 64 CU SCREW 6 1 0 X 16 G8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC WASHER LOCK EXT 7 16 STL Page 2 of 2 GROUP C TO STARTER CONTACTOR HARNESS WIRE 10 SEE NOTE EXPLODED VIEW BATTERY C1 1 6L REVISION A 004067 DRAWING PAGE 1 OF 2 10 27 06 DATE EXPLODED
111. VIEW BATTERY C1 1 6L DRAWING 064067 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F3408C 1 BATTERY TRAY C1 amp C2 2 0F3411 1 STRAP BATTERY RETAINMENT 3 025507 1 WASHER SHAKEPROOF EXT 7 16 STL 4 059980 1 SCREW HHC M10 1 5 X 25 G10 9 5 046526 1 WASHER LOCK M10 6 077483 REF BATTERY 12VDC 75 AH 26 7 050331 REF BATTERY POST COVER RED 8 050331 REF BATTERY POST COVER BLK 9 038805J 1 CABLE BATTERY BLACK 1 X 30 00 10 038804M 1 CABLE BATTERY RED 1 X 21 00 11 045771 REF NUT HEX 8 1 25 G8 YEL CHR 12 022131 1 WASHER FLAT 3 8 M10 ZINC 13 027482 1 WASHER SHAKEPROOF EXT 5 16 STL 14 0F3976 1 BOOT CONTACTOR CABLES 15 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 16 022145 REF WASHER FLAT 5 16 M8 ZINC NOTE WHEN INSTALLING BATTERY TUCK BATTERY S LIFTING STRAP ALONG THE LEFT SIDE OF BATTERY SIDE OPPOSITE RADIATOR BEFORE CONNECTING THE BATTERY CABLES REVISION A DATE 10 27 06 GROUP C PAGE 2 OF 2 GROUP D TORQUE POUND FEET 45 6 45 6 QTY BELT TENSION LBS QTY 1 Exploded View ENGINE COMMON PARTS 1 6L Drawing No 0H7219 Page 1 of 2 47 Revision H 8414 C Date 3 1 11 EXPLODED VIEW ENGINE COMMON PARTS 1 61 DRAWING 0H7219 APPLICABLE TO ITEM PART 1 0H1734 2 0G0834A 3 0G0820A 4 0G7461 5 0G0839 6 0G0781 7 0G0722 8 0G4059 9 0G4604 10 0G3424 11 0G0786 12 0G4605 13 0 9617 14 0A1354B 15 0G082
112. WER WINDING CONNECTIONS 3 PHASE ALTERNATORS Y CONFIGURATION The Stationary Emergency Generator is designed to supply 3 phase electrical 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 through 7 6 The rated voltage between circuit breaker terminals E1 E2 E1 E3 E2 E3 is 480V 208V or 600V depending on the model The rated voltage between each circuit breaker terminal and the neutral point 00 is 277V 120V or 346V depending on the model Figure 7 2 Stator Power Winding Connections 3 phase 277 480V 6 Lead E1 INTERNAL CONNECTIONS 94 S6 2 00 NEUTRAL 52 22 53 1 Figure 7 3 Stator Power Winding Connections 3 phase 277 480V 12 Lead E1 2 2 3 E3 lt L N 7 1 01 60 8 00u0029V General Information Figure 7 4 Stator Power Winding Connections 3 phase 120 208V 6 Lead INTERNAL CONNECTIONS 51 51 54 54 E 00 NEUTRAL 53 Figure 7 5 Stator Power Winding Connections 3 phase 120 208V 12 Lead Figure 7 6 Stator Power Winding Connections 3 phase 346 600V 6 Lead E1 1 INTERNAL CONNECTIONS E3 E2 01 80 8 ed LOQUUODDY 3 PHASE ALTERNATORS DELTA CONFIGURATION The Stationary Emergency
113. able Voltage Dip of 35 25 30kW 35 KVA 45 KVA ENGINE M Generac Mir uuu In Line Cylinders and 4 Displacement sess 1 6 Liter IU PE C 3 15 in SD c 3 13 in Compression 9 5 to 1 Air Intake 5 Naturally Aspirated Replaceable il TYDE u etre rere Hydraulic Spark Plug 0 76mm 0 030 inch Engine Parameters Rated Synchronous RPM 60 Hz 3600 Exhaust System Exhaust Flow at Rated Output 60 Hz 25kW 30kW 240 cfm 260 cfm Exhaust Temp at Rated Output 975 F 1025 F Combustion Air Requirements Natural Gas Flow at rated power 60 Hz 25kW 30kW 90 cfm 95 cfm Governor E T E E A Electronic Frequency Regtulalign Isochronous Steady State Regulation 25 Adjustments DPOB jius una wayua Selectable 6 1 Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Cartridge Crankcase Oil 4 U S qts
114. ace before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while stand ing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT Safety Instructions If personnel must stand on metal or concrete while installing Operating servicing adjusting or repairing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be con nected to an approved earth ground This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator or by static electricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maximum electrical current ampac ity 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 normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric
115. age the starter motor e Let engine stabilize and warm up e Check all applicable instrument and gauge readings When certain that all readings are correct move the transfer switch manual handle to the STANDBY or EMERGENCY STANDBY position i e load circuits supplied by the generator e Set the generator s main line circuit breaker to its ON 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 literature pertaining to the specific transfer switch To transfer the load back to the utility power source and shut down the generator follow these directions Setthe generator s main line circuit breaker to its OFF or OPEN position Manually move the transfer switch handle to its UTILITY NORMAL position i e load circuits connected to the utility Turn ON the utility power supply to the transfer switch using the means provided such as the utility power source main line circuit breaker Let the generator run at no load for a few minutes to stabilize internal temperatures Shut down the generator OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If the Stationary Emergency Generator has been installed with an automatic transfer switch the engine may be started and stopped automatically or manually NOTE Refer to the applicable manual for your transfer switch and to Tr
116. ally shows the current Status message and the current date and time The highest priority active Alarm and or Warning will be automatically posted on this page as well as flashing the backlight when such an event is detected In the case of multiple Alarms or Warnings only the first message will be displayed To clear an Alarm or Warning see the Protection Systems section Clear Alarm The display backlight is normally off If the user presses any key the backlight will come on automatically and remain on for 30 seconds after the last key was pressed The Main Menu page will allow the user to navigate to all other pages or sub menus by using the Left Right and Enter keys This page can be accessed at any time with several presses of the dedicated Escape key Each press of the Escape key takes you back to the previous menu until the main menu is reached This page displays the following options HISTORY STATUS EDIT AND DEBUG See the Appendix Menu System LOOSNSNX NIJUJ Control Panel ACTIVATION CHART CHOOSE LANGUAGE Display Reads Language English PY ALI Display Reads Activate me ENT or ESC to run in manual TA TY Yes Display Reads To Activate go to www activategen com ef A Use ARROW keys to scroll to desired lan guage Press ENTER to select Press ENTER to begin the activation pro Cess If you do not have your activation code go to
117. aner and reduce carbon deposits When changing the engine oil be sure to use 5W 30 engine oil synthetic oil is recommended A CAUTION Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure NOTE For temperatures below 32 F it is strongly recommended to use the optional Cold Weather Start Kit The oil grade for tem peratures below 32 F is 5W 30 synthetic oil 3 1 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is listed in the specifications Use only deionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolant mixture When adding coolant always add the recommended 50 50 mixture A CAUTION 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 operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment A DANGER Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid
118. ansfer Switch Start Signal Connections In addition please note the dangers under Engine Start up and Transfer 01 00 ed 1002990 Maintenance GENERAL MAINTENANCE A WARNING Before working on the Stationary Emergency Generator ensure the following The AUTO OFF MANUAL switch is in the OFF position The control panel fuse has been removed from the control box The 120VAC supply to the battery charger is switched OFF The negative battery cable has been removed CHECK ENGINE OIL Check engine crankcase oil level Figure 10 1 according to the Service Schedule and SIB10 10 L24G Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again e Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Engine Oil Recommendations for recommended oils Figure 10 1 Oil Dipstick and Oil Fill Cap OIL FILL CAP DIPSTICK CHANGING ENGINE 011 A CAUTION Hot oil may cause burns Allow engine to cool before draining oil Avoid prolonged or repeat ed skin exposure with used oil Thoroughly wash exposed areas with soap 10 1 Refer to the Service Schedule for engine oil and filter change fre quencies Drain the oil while the engine is still warm from running This means war
119. applicable emission related guidelines as specified in this Owner s Manual you are required to meet the following notification and recordkeeping requirements to demonstrate compliance 1 Maintain documentation that the engine is certified to meet emission standards 2 Recordkeeping of maintenance conducted 3 Recordkeeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel solely dur ing emergency operations provided the engine is not certified to operate on propane 4 Meet all compliance notifications submitted to the purchaser owner and maintain all supporting documentation 5 Recordkeeping of hours of operation including what classified the operation as emergency and how many hours are spent for non emergency operation For emergency engines greater than or equal to 130 HP record keeping of hours of operation begins January 1 2011 For emergency engines less than 130 HP recordkeeping of hours of operation begins January 1 2009 Engines are equipped with non resettable hour meters to facilitate recordkeeping Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping reporting requirements Your permit to construct and or operate the engine may be contingent upon compliance with those requirements Check with your local Air Quality Management or Air Pollution Control District for specific requirements Emerg
120. as Excitation SYSIGITI icr tare bie Direct Generator Output Voltage kW 60 Hz kW Amp CB Size 120 240V 1 phase 1 0 pf 25 30 104 125 125 150 120 208 3 phase 0 8 pf 25 30 87 104 100 125 120 240V 3 phase 0 8 pf 25 30 75 90 90 100 Generator Locked Rotor KVA Available Voltage Dip of 35 25 30kW 35 KVA 45 KVA ENGINE M Generac Mir uuu In Line Cylinders and 4 Displacement sess 1 6 Liter IU PE C 3 15 in SD c 3 13 in Compression 9 5 to 1 Air Intake 5 Naturally Aspirated Replaceable il TYDE u etre rere Hydraulic Spark Plug 0 76mm 0 030 inch Engine Parameters Rated Synchronous RPM 60 Hz 3600 Exhaust System Exhaust Flow at Rated Output 60 Hz 25kW 30kW 240 cfm 260 cfm Exhaust Temp at Rated Output 975 F 1025 F Combustion Air Requirements Natural Gas Flow at rated power 60 Hz 25kW 30kW 90 cfm 95 cfm Governor E T E E A Electronic Frequency Regtulalign Isochronous Steady State Regulation
121. as 20 of nominal engine speed for 3 seconds or 25 immediate Nominal engine speed 60 0 Hz RPM SENSOR FAILURE SHUTDOWN ALARM During cranking If the board does not see a valid RPM signal within four 4 seconds of cranking it will shut down and lock out on RPM sensor loss During running If the RPM signal is lost for one full second the board will shut the engine down wait 15 seconds then re crank the engine if in AUTO it will not re crank in MANUAL If no RPM signal is detected within the first four 4 seconds of cranking the control board will shut the engine down and latch out on RPM sensor loss If the RPM signal is detected the engine will start and run normally If the RPM signal is subsequently lost the control board will try two more re cranks before latching out and flashing the RPM Sensor Failure message if it is in AUTO Control Panel Figure 1 Generator Control Panel GENERATOR MAINTENANCE SCHEDULE CHECK ENGINE MESSAGE The control system has detected an emissions related fault This fault cannot be cleared using the control panel interface The unit will continue to operate in automatic mode Contact your local servicing dealer UNDER FREQUENCY SHUTDOWN ALARM After starting if the generator stays under frequency for more than 30 seconds it will shutdown LOW BATTERY ALARM While running if the average battery voltage falls below 11 9 volts for one 1 minute th
122. ases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts Before performing any maintenance on the generator discon nect 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 dan gerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS All stationary emergency generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dan gerous voltages to the transfer switch as well as the generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appropriate covers guards and barriers are in pl
123. atic Operation section 3 Control Panel SEQUENCE OF AUTOMATIC OPERATION Initial Conditions Generator in Auto ready to run load being sup plied by the Utility Source through the transfer switch 1 When the utility voltage fails falls below 60 of nominal 10 30 second programmable line interrupt delay timer is started The factory set time delay is 10 seconds If at the end of the line interrupt time the utility voltage is above 60 the engine will not crank If the utility voltage is still below the 60 of nominal at the end of the line interrupt time the unit will crank and start If the unit cranks for more than 10 seconds and the utility voltage rises above 80 of nominal programmed pickup voltage and the unit has not started the crank cycle will abort 2 As soon as the unit starts a 5 second warm up timer is initi ated When the warm up timer expires the control will transfer the load to the generator through the RTS switch if the utility voltage is less than 80 of nominal If the utility voltage is greater than the 80 of nominal at the end of the warm up time the load will not be transferred to the generator and a one minute low speed cool down period will start At the end of the one minute cool down period the generator will stop 3 Once the unit is running and the switch has transferred the load to the generator the unit will monitor utility voltage When uti
124. ay from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ventilating air is critical in any room or building housing the generator to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts Before performing any maintenance on the generator discon nect 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 dan gerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS All stationary emergency generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility powe
125. be removed to clear this warning Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass NOTE DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT WIRES IS NOT WARRANTABLE This test will be performed each time the controller is powered up Next the user must enter the minimum settings to operate These settings are current date and time and exercise day and time The maintenance intervals will be initialized i e started the first time the clock is set If the clock is never set at power up the mainte nance intervals will be reset every time power is applied If a subsequent power loss loss of battery power occurs the Installation assistant will operate upon power restoration The self test routine will be run and then the customer will be required to re enter the time and date as this is not retained during a power loss The unit will not require re activation DISPLAY INTERFACE MENUS The LCD display is organized as detailed below The Home page this page is the default page which will be displayed if no keys are pressed for 30 seconds This page normally shows the current Status message and the current date and time The highest priority active Alarm and or Warning will be automatically posted on this page as well as flashing the backlight when such an event is detected In the case of multiple Alarms or Warnings only the first
126. c Authorized Warranty Service dealer 1 800 333 1322 for the dealer nearest you The purchaser owner shall be responsible for any expenses or other charges incurred for service calls and or transportation of the product to from the inspection or repair facilities The purchaser owner shall be responsible for any and or all damages or losses incurred while the engine is being transported shipped for inspection or warranty repairs Contact Generac Power Systems Inc for additional Emission Control System Warranty related information Generac Power Systems Inc PO Box 8 Waukesha WI 53187 or call 1 800 333 1322 or www generac com Important Note This warranty statement explains your rights and obligations under the Emission Control System Warranty which is provided to you by Generac pursuant to federal law Note that this warranty shall not apply to any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s This warranty is in place of all other warranties expressed or implied Specifically Generac makes no other warranties as to the merchantability or fitness for a particular pur pose Any implied warranties which are allowed by law shall be limited in duration to the terms of the express warranty provided herein Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you Emission Related
127. cause cancer birth defects and other reproductive harm CALIFORNIA PROPOSITION 65 WARNING This product contains or emits chemicals known to the State of California to cause cancer birth defects and other reproductive harm 01 50 00 2 General Information IDENTIFICATION RECORD DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator The data label which can be found attached to the generator s lower connection box lists the unit s serial number and its rated voltage amps wattage capacity phase frequency rpm power factor production date etc NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Stationary Emergency Generator Model and Serial Number This number is the key to numerous engineering and manufactur ing details pertaining to your unit Always supply this number when requesting service ordering parts or seeking information Data Label MODEL _____ PROD DATE SERIAL Kw 8 SSS SS SSS S23 gt a J X J JjALTRPM ENG RPM TYPE CODE ALTSUBTRANSREACTANCE TRANS CLASS STATOR WINDING INS 25 a
128. circuit breaker terminals E1 E2 E1 E3 and E2 E3 is 240V The rated voltage between E1 or E3 and the neutral point 00 is 120V Figure 7 7 Stator Power Winding Connections 3 phase 120 240V 6 Lead E2 S2 N S6 INTERNAL CONNECTIONS L L S5 S3 si 54 E3 L N 00 NEUTRAL Figure 7 8 Stator Power Winding Connections 3 phase 120 240V 12 Lead HAN 00 NEUTRAL Control Panel CONTROL PANEL INTERFACE USING THE AUTO OFF MANUAL SWITCH A WARNING With the switch set to AUTO the engine may crank and start at any time without warning Such automatic starting occurs when utility power source voltage drops below a preset level or during the normal exercise cycle To prevent possible injury that might be caused by such sudden starts always set the switch to OFF and remove the fuse before work ing on or around the generator or transfer Switch Then place a NOT OPERATE tag on the generator panel and on the trans fer switch 1 AUTO Position Selecting this switch activates fully auto matic system operation It also allows the unit to automati cally start and exercise the engine every seven days with the setting of the exercise timer see the Setting the Exercise Timer section 2 OFF Position This switch position shuts down the engine This position also prevents automatic operation 3 MANUAL Position Set the switch to MANUAL to crank and start the engine
129. control systems on your 2009 and later model year engines provided there has been no abuse neglect unapproved modification or improper maintenance of your engine For engines less than 130 HP the warranty period is two years from the date of sale to the ultimate purchaser For engines greater than or equal to 130 HP the warranty period is three years from the date of the engine being placed into service Purchaser s Owner s Warranty Responsibilities As the engine purchaser owner you are responsible for the following 1 The engine must be installed and configured in accordance to the Generac s installation specifications 2 The completion of all maintenance requirements listed in your Owner s Manual 3 Any engine setting adjustment must be done in accordance and consistent with the instructions in the Owner s Manual 4 Any emission con trol system or component must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize emissions at all times Generac may deny any or all Emission Control System Warranty coverage or responsibility of the engine or an emission control system or component on your engine thereof if it has failed due to abuse neglect unapproved modification or improper maintenance or the use of counterfeit and or gray market parts not made supplied or approved by Generac Warranty service can be arranged by contacting either your selling dealer or a Genera
130. e low battery alarm will be displayed LOW BATTERY WARNING The microprocessor will continually monitor the battery voltage and display the Low Battery Voltage message if the battery voltage falls below 12 2 Volts for one 1 minute No other action is taken on a low battery warning condition The warning will automatically clear if the battery voltage rises above 12 2 volts NOTE The hattery sentinel is a separate feature that monitors battery condition LOW COOLANT LEVEL ALARM This is a shutdown alarm The sensor will be continuously moni tored If an error condition is seen for five 5 consecutive sec onds the alarm will be displayed 8 5 AUTO OFF MANUAL MISSING CAM PULSE ALARM This is a shutdown alarm The alarm will activate after five 5 seconds of continuously missing cam pulses MISSING CRANK PULSE ALARM This is a shutdown alarm The alarm will activate after 12 con secutive revs where crank pulses are missing LOW FUEL PRESSURE WARNING Fuel pressure is monitored by a digital sensor with a fixed setpoint of below five 5 inches water column GOVERNOR SENSOR FAULT ALARM The governor position is monitored by an analog feedback signal If the throttle position is seen outside of the normal operating range a shutdown alarm is displayed If the throttle is commanded to move and no movement is seen a shutdown alarm is displayed WIRING ERROR ALARM When power is first apllied to the contoll
131. edule section The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corro sion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type battery hydrometer A DANGER Storage batteries give off explosive hydrogen sAgas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smok ing open flame sparks or any spark producing tools or equipment near the battery 10 3 Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging AWARNING Be sure the
132. eeper port on the side of the regulator housing 9 2802905 99 9 Install the previously removed black pipe onto the outlet port of the demand regulator Use pipe sealant on the pipe threads 10 Reverse steps 1 4 in this procedure to reactivate the demand regulator 11 Follow the instructions in the Control Panel section A DANGER Serious injury including death or damage will occur if not configured properly Please consult an Authorized Dealer with any ques tions Figure 6 1 Reconfigure the Fuel System CARBURETDR FUEL Y BLAC FUEL SOLENOID __ lt ASSEMBLY NZ FUEL JET SPRING 5 CLAMP U PDR EL KEEPER PIO MENI PUR CONTROL PANEL The FUEL TYPE must be reconfigured in the control panel to final ize the conversion process This generator is configured at the factory to operate on natural gas If conversion to LP is required please complete the mechanical conversion process and then call 888 9ACTIVATE for the control panel password This fuel selection conversion is required to be password protected by Environmental Protection Agency EPA regulations CAUTION Whenever the Generator s Fuel Regulator is converted from one Fuel type to the other the Control Panel must be reconfigured for the correct fuel type Failure
133. ency stationary internal combustion engines ICE may be operated for the purpose of maintenance checks and readiness testing provided that the tests are recommended by Federal State or local government Generac or the insurance company associated with the en gine Maintenance checks and readiness testing of such units is limited to 100 hours per year There is no time limit on the use of emergency stationary ICE in emergency situations The purchaser owner may petition the Administrator for approval of additional hours to be used for maintenance checks and readiness testing but a petition is not required if the owner maintains records indicating that Federal State or local standards require maintenance and testing of emergency ICE beyond 100 hours per year Emergency stationary ICE may operate up to 50 hours per year in non emergency situations but those 50 hours are counted towards the 100 hours per year provided for maintenance and testing The 50 hours per year for non emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to an electric grid or otherwise supply power as part of a financial arrangement with another entity For purchaser owner of emergency engines any operation other than emergency operation maintenance and testing and operation in non emergency situations for 50 hours per year as permitted in this section is prohibited If you operate and maintain your certified emergency stati
134. ended to supply standby power in the event of a utility failure The control system will monitor the utility voltage to determine if stand by power is required Should the utility voltage fail the generator will start and run normally detaching from the utility and supplying the customer load from the generator When utility power returns the controller will re transfer the customer load back to utility and shut down the generator AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their UTILITY position i e loads connected to the utility power source 2 Be sure that normal UTILITY power source voltage is avail able to transfer switch terminal lugs N1 and N2 Refer to the Electrical Data section 3 the 5 AUTO OFF MANUAL switch to AUTO 4 Set the generator s main circuit breaker to its ON or CLOSED position With the preceding steps complete the generator will start auto matically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to the Sequence of Automatic Operation section 3 Control Panel SEQUENCE OF AUTOMATIC OPERATION Initial Conditions Generator in Auto ready to run load being sup plied by the Utility Source through the transfer switch 1 When the utility voltage fails fa
135. enerator voltage falls below 60 for gt 5 seconds an alarm will be issued 3 LOOSNX NMUJ Control Panel OVERVOLTAGE ALARM If the generator voltage rises above 110 for gt 3 seconds an alarm will be issued If the generator voltage rises above 130 for gt 0 2 seconds an alarm will be issued INTERNAL FAILURE SHUTDOWN ALARM Any internal failure that can be detected such as corrupted firmware will cause this shutdown alarm This alarm cannot be cleared CANBUS ALARM Where applicable if the Canbus communications link fails to com municate a Canbus Alarm will be generated This only applies to systems with external ignition modules The alarm may be generated if 1 The physical link is broken 2 The Ignition Module fails or resets 3 The Nexus Controller fails or resets 4 Having the Battery Chargers 120 VAC connected without a battery installed 5 A blown 10 amp Ignition Module fuse approximately 12 inches away from the starter 6 A blown 25 amp system fuse located approximately 12 inches away from the DC alternator NOTE The Canbus Alarm will not clear on its own To clear the alarm press the enter key to acknowledge the alarm The alarm will clear and if the fault is still present the alarm will reoccur IGNITION ALARM When an ignition alarm occurs a generic message Ignition Fault will be displayed as the fault code MAINTENANCE WARNING When a maintenance pe
136. er the software will per form a check on the wiring of the transfer output and ensure it does not have high voltage on the wire If this is the case it will signal a miswire alarm and will not run The test can be skipped by use of the escape key UNDERVOLTAGE ALARM If the generator voltage falls below 60 for gt 5 seconds an alarm will be issued 3 LOOSNX NMUJ Control Panel OVERVOLTAGE ALARM If the generator voltage rises above 110 for gt 3 seconds an alarm will be issued If the generator voltage rises above 130 for gt 0 2 seconds an alarm will be issued INTERNAL FAILURE SHUTDOWN ALARM Any internal failure that can be detected such as corrupted firmware will cause this shutdown alarm This alarm cannot be cleared CANBUS ALARM Where applicable if the Canbus communications link fails to com municate a Canbus Alarm will be generated This only applies to systems with external ignition modules The alarm may be generated if 1 The physical link is broken 2 The Ignition Module fails or resets 3 The Nexus Controller fails or resets 4 Having the Battery Chargers 120 VAC connected without a battery installed 5 A blown 10 amp Ignition Module fuse approximately 12 inches away from the starter 6 A blown 25 amp system fuse located approximately 12 inches away from the DC alternator NOTE The Canbus Alarm will not clear on its own To clear the alarm press the en
137. er governed speed Some connected electrical load devices may be damaged by incorrect frequency and or voltage Only quali fied service technicians should adjust the gov erned speed CHANGING THE ENGINE AIR FILTER To replace the engine air filter remove the air filter 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 filter maintenance Maintenance Figure 10 3 Engine Air Filter FILTER SPARK PLUGS Reset the spark plug gap or replace the spark plugs as neces sary 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 for recommended inspection 3 Check the spark plug gap using a wire feeler gauge See the Specifications section for the required spark plug gap BATTERY MAINTENANCE The battery should be inspected per the Service Schedule section The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corro sion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY
138. ere 12 Volts Voltage Regulator Electronic SENSN Single phase Regulation 2 211 5 oe amas 1 Adjustable Voltage and Automatic Gain Power Adjustment for Ambient Conditions Temperature Deration 396 for every 10 C above 25kW 30kW 40 25 1 6596 for every 10 above F 104 77 Altitude Deration 196 for every 100 m above m 25kW 30kW 915 182 396 for every 1000 ft above ft 2000 600 eese ter EVA VE EUN VERS Nexus LL cL 9 2802908090 Specifications WEATHER AND MAINTENANCE KITS To keep the generator running at its peak the following kits are offered Cold Weather Kit Recommended for climates with temperatures below 32 F Extreme Cold Weather Kit Recommended Block Heater Kit for protection in tempera tures below 32 F Scheduled Maintenance Kit Kit includes the recommended parts to maintain the genera tor Refer to the Service Schedule for regular maintenance intervals For additional information or to order any of these kits please contact an Authorized Service Dealer or Customer Service Representative RECONFIGURING THE FUEL SYSTEM NOTE All models are configured to run on natural gas from the fac tory Before the generator can be operated using a LP fuel source the fuel system and control panel refer to the installation drawing for location must be reconfigured The steps to reconfigu
139. governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incorrect frequency and or voltage Only quali fied service technicians should adjust the gov erned speed CHANGING THE ENGINE AIR FILTER To replace the engine air filter remove the air filter 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 filter maintenance Maintenance Figure 10 3 Engine Air Filter FILTER SPARK PLUGS Reset the spark plug gap or replace the spark plugs as neces sary 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 for recommended inspection 3 Check the spark plug gap using a wire feeler gauge See the Specifications section for the required spark plug gap BATTERY MAINTENANCE The battery should be inspected per the Service Sch
140. h the setting of the exercise timer see the Setting the Exercise Timer section 2 OFF Position This switch position shuts down the engine This position also prevents automatic operation 3 MANUAL Position Set the switch to MANUAL to crank and start the engine Transfer to standby power will not occur unless there is a utility failure ACTIVATE THE GENERATOR When battery power is applied to the generator during the instal lation process the controller will turn ON and the LCD screen will illuminate However the generator still needs to be activated before it will automatically run in the event of a power outage Activating the generator is a simple one time process that is guided by the controller screen prompts Once the product is activated the controller screen will not prompt you again even if you discon nect the generator battery To obtain the activation code record the generator serial number and log onto www activategen com or call 1 888 9ACTIVATE and follow the steps to retrieve the activation code After obtaining your activation code please complete the following steps at the generator s control panel in the Activation Chart on the following page NOTE The generator will only run in manual until the passcode has been entered 8 1 Upon power up this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits This is done
141. hall be responsible for any and or all damages or losses incurred while the engine is being transported shipped for inspection or warranty repairs Contact Generac Power Systems Inc for additional Emission Control System Warranty related information Generac Power Systems Inc PO Box 8 Waukesha WI 53187 or call 1 800 333 1322 or www generac com Important Note This warranty statement explains your rights and obligations under the Emission Control System Warranty which is provided to you by Generac pursuant to federal law Note that this warranty shall not apply to any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s This warranty is in place of all other warranties expressed or implied Specifically Generac makes no other warranties as to the merchantability or fitness for a particular pur pose Any implied warranties which are allowed by law shall be limited in duration to the terms of the express warranty provided herein Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you Emission Related Parts Include the Following if so equipped 1 Fuel Metering System 3 Ignition System Including 1 1 Gasoline Carburetor Assembly And Internal A Spark Plug B Ignition Module Components A Fuel Filter B Carburetor C Fuel C Ignition Coil D Spark Plug Wires Pump 4 Exhau
142. icable codes stan dards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operat ed and serviced in accordance with the manufacturer s instruc tions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations 01 60 4 0019425 The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided This should be considered prior to installing the generator The unit should be positioned to direct exhaust gasses safely away from any building where people animals etc will not be harmed Any exhaust stacks that ship loose with the unit must be installed properly per the manufacturer s instruction and in strict compli ance with applicable codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ventilating air is critical in any room or building housing the generator to prevent buildup of explosive g
143. ician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations Installation operation servicing and repair of this and related equipment must always comply with applicable codes stan dards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operat ed and serviced in accordance with the manufacturer s instruc tions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations 01 60 4 0019425 The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided This should be considered prior to installing the generator The unit should be positioned to direct exhaust gasses safely away from any building where people animals etc will not be harmed Any exhaust stacks that ship loose with the unit must be installed properly per the manufacturer s instruction and in strict compli ance with applicable codes and standards Keep hands feet clothing etc aw
144. influence factor have been evalu ated and are acceptable according to NEMA MG1 32 ENGINE OIL RECOMMENDATIONS The unit has been filled with 5W 20 engine oil at the factory Use a high quality detergent oil classified For Service SJ or SH Detergent oils keep the engine cleaner and reduce carbon deposits When changing the engine oil be sure to use 5W 30 engine oil synthetic oil is recommended A CAUTION Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure NOTE For temperatures below 32 F it is strongly recommended to use the optional Cold Weather Start Kit The oil grade for tem peratures below 32 F is 5W 30 synthetic oil 3 1 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is listed in the specifications Use only deionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolant mixture When adding coolant always add the recommended 50 50 mixture A CAUTION 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 operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base anti freeze Using any high
145. ions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If a procedure work method or operating technique is used that the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique utilized does not render the generator unsafe A DANGER 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 respon sible and capable persons to install operate or maintain this equipment Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators GENERAL HAZARDS For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by a Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations Installation operation servicing and repair of this and related equipment must always comply with appl
146. itch A DANGER The Maintenance Disconnect Switch and the AUTO OFF MANUAL switches if so equipped must be set properly or the generator will crank and start as soon as the utility power to the transfer switch is turned off Refer to appli cable control panel and transfer switch manuals for more information Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to UTILITY Do not attempt manual operation until all power supplies to the transfer switch have been positively turned off or extremely dangerous possibly lethal electrical shock will result An anaa 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 order to transfer load from the utility source to the generator follow these directions e Turn OFF or disconnect the utility power circuit to the transfer switch using the means provided such as the utility source main line circuit breaker Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the generator s main line circuit breaker to its OFF or OPEN position Start the generator 9 1 A CAUTION Do not crank the engine continuously for lon ger than 30 seconds or the heat may dam
147. itch manuals for more information Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to UTILITY Do not attempt manual operation until all power supplies to the transfer switch have been positively turned off or extremely dangerous possibly lethal electrical shock will result An anaa 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 order to transfer load from the utility source to the generator follow these directions e Turn OFF or disconnect the utility power circuit to the transfer switch using the means provided such as the utility source main line circuit breaker Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the generator s main line circuit breaker to its OFF or OPEN position Start the generator 9 1 A CAUTION Do not crank the engine continuously for lon ger than 30 seconds or the heat may damage the starter motor e Let engine stabilize and warm up e Check all applicable instrument and gauge readings When certain that all readings are correct move the transfer switch manual handle to the STANDBY or EMERGENCY STANDBY position i e load circuits supplied by the ge
148. ite and burn from the heat of the exhaust system INSPECT COOLING SYSTEM e Inspect engine cooling system See the Service Schedule e Check hoses for damage deterioration leaks etc Correct any discrepancies found e Check hose clamps for tightness 01 90 v ENGINE COOLANT Check coolantlevelin coolant recovery bottle See the Specifications and Service Schedule sections 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 radia tor filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact a Service Facility Inspect cooling system and coolant recovery system for leaks COOLANT CHANGE Every year have a service facility drain flush and refill the cooling system See the Specifications and Service Schedule for cooling system recommendations 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 the control panel fuse This overcurrent protection device will open if the circuit is overloaded CAUTION If a circuit breaker opens or a fuse element melts fi
149. ker with a Y configuration as shown in Figures 7 2 through 7 6 The rated voltage between circuit breaker terminals E1 E2 E1 E3 E2 E3 is 480V 208V or 600V depending on the model The rated voltage between each circuit breaker terminal and the neutral point 00 is 277V 120V or 346V depending on the model Figure 7 2 Stator Power Winding Connections 3 phase 277 480V 6 Lead E1 INTERNAL CONNECTIONS 94 S6 2 00 NEUTRAL 52 22 53 1 Figure 7 3 Stator Power Winding Connections 3 phase 277 480V 12 Lead E1 2 2 3 E3 lt L N 7 1 01 60 8 00u0029V General Information Figure 7 4 Stator Power Winding Connections 3 phase 120 208V 6 Lead INTERNAL CONNECTIONS 51 51 54 54 E 00 NEUTRAL 53 Figure 7 5 Stator Power Winding Connections 3 phase 120 208V 12 Lead Figure 7 6 Stator Power Winding Connections 3 phase 346 600V 6 Lead E1 1 INTERNAL CONNECTIONS E3 E2 01 80 8 ed LOQUUODDY 3 PHASE ALTERNATORS DELTA CONFIGURATION The Stationary Emergency Generator is designed to supply 3 phase electrical 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 Delta configuration as shown in Figures 7 7 and 7 8 The rated voltage between
150. l should be installed according to the number of leads and the voltage phase required for the application The voltage and phase are described on the generator data label The number of lead wires can be identified using the Specifications section and the power output rating on the generator data label For example if the generator produces 130kW 277 480 Volt 3 phase power the generator has 12 alternator output leads Figure 7 3 describes the stator power winding connection for the generator FOUR LEAD SINGLE PHASE STATOR Four lead alternators see Figure 7 1 are designed to supply elec trical loads with voltage code 240V 1 phase 60 Hz Electrical power is produced in the stator power windings These windings were connected at the factory to the main circuit breaker as shown in Figure 7 1 The rated voltage between each circuit breaker terminal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator c 120 VOLTS 33 10015 120 10118 Y 1 CIRCUIT BREAKER ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS Y CONFIGURATION The Stationary Emergency Generator is designed to supply 3 phase electrical loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit brea
151. lity source and run the unit through a one minute cool down period When the cool down period is over the unit will shut down and be ready for the next outage 4 If during the cool down period utility voltage should fall below 60 of nominal the 5 second warm up timer is initiated and the unit will transfer the load back to the generator and con tinue to monitor the utility CRANK CYCLES AND OVERCRANK SHUTDOWN If the unit fails to start during a cranking period it will display the Overcrank Shutdown Alarm The system will control the cranking cycles as follows The first crank cycle is a 16 second crank time followed by a 7 second rest The next 5 cycles will be 7 seconds of cranking time each followed by a 7 second rest time If the unit fails to start by the end of the 6 crank rest cycles the Overcrank Shutdown Alarm will display and the unit will not attempt to crank until the alarm is reset AUTO START This unit is designed to automatically start in the event of a util ity failure or brown out condition Brown out is defined as utility voltage less than 6096 nominal while utility is considered good when it is restored to at least the pickup value 8096 of nominal These levels are fixed The Line Interrupt period is an adjustable parameter by the dealer If 2 wire start mode is activated the unit will start when 2 wire start is active 3 LoosnxeNunu 8 4 MANUAL START Allows the user to start and run
152. lity voltage returns above the programmable pickup voltage normally 8096 of nominal a 15 second Return to Utility timer will start At the end of the return to utility time if the utility voltage is still above the pickup voltage the unit will transfer the load back to the utility source and run the unit through a one minute cool down period When the cool down period is over the unit will shut down and be ready for the next outage 4 If during the cool down period utility voltage should fall below 60 of nominal the 5 second warm up timer is initiated and the unit will transfer the load back to the generator and con tinue to monitor the utility CRANK CYCLES AND OVERCRANK SHUTDOWN If the unit fails to start during a cranking period it will display the Overcrank Shutdown Alarm The system will control the cranking cycles as follows The first crank cycle is a 16 second crank time followed by a 7 second rest The next 5 cycles will be 7 seconds of cranking time each followed by a 7 second rest time If the unit fails to start by the end of the 6 crank rest cycles the Overcrank Shutdown Alarm will display and the unit will not attempt to crank until the alarm is reset AUTO START This unit is designed to automatically start in the event of a util ity failure or brown out condition Brown out is defined as utility voltage less than 6096 nominal while utility is considered good when it is restored to at least the pickup value 80
153. lls below 60 of nominal 10 30 second programmable line interrupt delay timer is started The factory set time delay is 10 seconds If at the end of the line interrupt time the utility voltage is above 60 the engine will not crank If the utility voltage is still below the 60 of nominal at the end of the line interrupt time the unit will crank and start If the unit cranks for more than 10 seconds and the utility voltage rises above 80 of nominal programmed pickup voltage and the unit has not started the crank cycle will abort 2 As soon as the unit starts a 5 second warm up timer is initi ated When the warm up timer expires the control will transfer the load to the generator through the RTS switch if the utility voltage is less than 80 of nominal If the utility voltage is greater than the 80 of nominal at the end of the warm up time the load will not be transferred to the generator and a one minute low speed cool down period will start At the end of the one minute cool down period the generator will stop 3 Once the unit is running and the switch has transferred the load to the generator the unit will monitor utility voltage When utility voltage returns above the programmable pickup voltage normally 8096 of nominal a 15 second Return to Utility timer will start At the end of the return to utility time if the utility voltage is still above the pickup voltage the unit will transfer the load back to the uti
154. loride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris These generators may operate using one of several types of fuels All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks immediately Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detectors accordingly CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known to the State of California to
155. m up the engine shut it down and drain immediately as follows 1 Remove the drain hose from its retaining clip or cut the zip tie securing the oil drain hose 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil com pletely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and secure drain hose with a new zip tie or place the hose in its retaining clip 4 Turn OIL FILTER Figure 10 1 counterclockwise and remove Properly dispose of old filter 5 Apply light coating of new engine oil to seal of new oil fil ter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP and add recommended oil Crankcase oil capacity is listed in the Specifications section A CAUTION 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 8 Shut OFF engine and wait 10 minutes for the oil to settle down into the oil pan Recheck oil level on dipstick DO NOT fill above the dipstick FULL mark 9 Dispose of used oil at a proper collection center COOLING INTAKE OUTLET Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation This includes such obstructions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine gen erator quickly
156. mbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety information that if not followed could endanger personal safety and or property of others A This symbol points out potential explosion hazard 1 1 This symbol points out potential fire hazard Q This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equip ment The manufacturer strongly recommends that the operator read this Owner s Manual and thoroughly understand all instruc tions before using this equipment The manufacturer also strongly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by a Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations 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 a Service Dealer Normal maintenance service and replacement of parts are the respo
157. message will be displayed To clear an Alarm or Warning see the Protection Systems section Clear Alarm The display backlight is normally off If the user presses any key the backlight will come on automatically and remain on for 30 seconds after the last key was pressed The Main Menu page will allow the user to navigate to all other pages or sub menus by using the Left Right and Enter keys This page can be accessed at any time with several presses of the dedicated Escape key Each press of the Escape key takes you back to the previous menu until the main menu is reached This page displays the following options HISTORY STATUS EDIT AND DEBUG See the Appendix Menu System LOOSNSNX NIJUJ Control Panel ACTIVATION CHART CHOOSE LANGUAGE Display Reads Language English PY ALI Display Reads Activate me ENT or ESC to run in manual TA TY Yes Display Reads To Activate go to www activategen com ef A Use ARROW keys to scroll to desired lan guage Press ENTER to select Press ENTER to begin the activation pro Cess If you do not have your activation code go to www activategen com or call 1 888 9ACTIVATE 922 8482 If you already have your activation code wait 3 5 seconds for the next display TROUBLESHOOTING If the wrong language is chosen it can be changed later using the edit menu If ESCAPE is pressed instead of ENTER y
158. n com If it is correct and the generator will not accept it contact 1 888 9ACTIVATE 922 8482 Control Panel INSTALLATION ASSISTANT Interconnect System Self Test Feature follow the on screen prompts Upon power up this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block If utility voltage is detected the controller will display a warning message and lock out the generator preventing damage to the controller Power to the controller must be removed to clear this warning Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass NOTE DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT WIRES IS NOT WARRANTABLE This test will be performed each time the controller is powered up Upon first power up of the generator the display interface will begin an installation assistant The assistant will prompt the user to set the minimum settings to operate These settings are simply Current Date Time and Exercise Day Time The maintenance inter vals will be initialized when the exercise time is entered The exercise settings can be changed at any time via the EDIT menu see Appendix Menu System If the 12 volt battery is disconnected or the fuse
159. n of the Owner s Manual Refer to the Installation Manual if assistance is required for the sizing of the pipe diameter for the generator Any piping used to connect the generator to the fuel supply should be of adequate size to achieve the 100 load fuel consumption requirements identi fied in the Specifications section regardless of actual load NOTE The recommended fuel pressure is identified in the Specifications section this manual NOTE It is the responsibility of the installer to make sure that only the correct recommended fuel is supplied to the generator fuel system Thereafter the owner operator must make certain that only the proper fuel is supplied 5 1 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 distribu tion line to the standby generator site The following information applies to natural gas fuel systems Gas pressure in a building is usually regulated by national state and local codes To reduce gas pressure to a safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff solenoid must never exceed approximately 14 inches water column 0 5 psi PROPANE V
160. nals are delivered to the circuit board whenever the unit is running Should the engine overspeed above a safe preset value the circuit board initiates an automatic engine shutdown Contact the nearest Authorized Dealer if this failure OCCUIS RPM SENSOR LOSS SHUTDOWN If the speed signal to the control panel is lost engine shutdown will occur DC FUSES A fuse 7 5 amp is located on the control panel It protects the panel 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 A fuse 25 amp is located in the engine wire harness adjacent to the DC alternator It is used to prevent circuit failure due to DC alternator falure It will also protect the system in the event of a wiring short dircuit If this fuse is blown the generator will not operate Replace these fuses with the same size type and rating 01 80 8 Fuel System FUEL SYSTEM FUEL REQUIREMENTS The Stationary Emergency Generator may be equipped with one of the following fuel systems Natural gas fuel system Propane vapor LPV fuel system Recommended fuels should have a Btu content of at least 1 000 Btu s per cubic foot for natural gas or at least 2 520 Btu s per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel NOTE The fuel consumption requirements are identified in the Specifications sectio
161. nd the cause of the overload before resetting the circuit breaker or replacing the fuse EXERCISE SYSTEM Starts the Stationary Emergency Generator engine once every seven days and lets it run for 12 minutes PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine genera tor monthly Look for obvious damage loose missing or corroded nuts bolts and other fasteners Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every year Check all exhaust system pipes mufflers clamps etc for condition tight ness leaks security damage 01 90 ed 201 CHECK FAN BELT nspect fan belts every year Replace any damaged deterio rated worn or otherwise defective belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 of an inch Adjust belt tension as required Check fan belt alignment see Figure 10 2 Figure 10 2 Fan Belt INSPECT ENGINE GOVERNOR Visually inspect electronic governor DANGER Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the prop
162. nerator e Set the generator s main line circuit breaker to its ON 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 literature pertaining to the specific transfer switch To transfer the load back to the utility power source and shut down the generator follow these directions Setthe generator s main line circuit breaker to its OFF or OPEN position Manually move the transfer switch handle to its UTILITY NORMAL position i e load circuits connected to the utility Turn ON the utility power supply to the transfer switch using the means provided such as the utility power source main line circuit breaker Let the generator run at no load for a few minutes to stabilize internal temperatures Shut down the generator OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If the Stationary Emergency Generator has been installed with an automatic transfer switch the engine may be started and stopped automatically or manually NOTE Refer to the applicable manual for your transfer switch and to Transfer Switch Start Signal Connections In addition please note the dangers under Engine Start up and Transfer 01 00 ed 1002990 Maintenance GENERAL MAINTENANCE A WARNING Before working on the Stationary Emergency Generator ensure the following The AUTO OFF
163. ng this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely effi ciently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If a procedure work method or operating technique is used that the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique utilized does not render the generator unsafe A DANGER 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 respon sible and capable persons to install operate or maintain this equipment Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators GENERAL HAZARDS For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by a Service Dealer or other competent qualified electr
164. ng to Subpart JJJJ Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60 Emission Related Installation Instructions Your certified emergency stationary engine has pre set emission control systems or components that require no adjustment Inspection and replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service dealer 1 800 333 1322 for the dealer nearest you Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates federal law 40 CFR 1068 105 b subject to fines or penalties as described in the Clean Air Act LL 60 LOD QUUMUSUI 13 2 800790 ONIA 1 4 11 87 01 ALYA 9 MASZ MAOZ SLYYd NOWWOO LTV 555 31ON 33S IV m M M 0 ve 14 5 3NION3 OL V 4 EXPLODED VIEW ALT COMMON PARTS 18KW 20KW 25KW amp 30KW DRAWING 064008 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 064827 1 ASSY 104 KD1 EFF 18KW 062927 1 RTR 102 20 0AD1 CPL 2006 20KW 062827 1 ASSY
165. ning condition The warning will automatically clear if the battery voltage rises above 12 2 volts NOTE The hattery sentinel is a separate feature that monitors battery condition LOW COOLANT LEVEL ALARM This is a shutdown alarm The sensor will be continuously moni tored If an error condition is seen for five 5 consecutive sec onds the alarm will be displayed 8 5 AUTO OFF MANUAL MISSING CAM PULSE ALARM This is a shutdown alarm The alarm will activate after five 5 seconds of continuously missing cam pulses MISSING CRANK PULSE ALARM This is a shutdown alarm The alarm will activate after 12 con secutive revs where crank pulses are missing LOW FUEL PRESSURE WARNING Fuel pressure is monitored by a digital sensor with a fixed setpoint of below five 5 inches water column GOVERNOR SENSOR FAULT ALARM The governor position is monitored by an analog feedback signal If the throttle position is seen outside of the normal operating range a shutdown alarm is displayed If the throttle is commanded to move and no movement is seen a shutdown alarm is displayed WIRING ERROR ALARM When power is first apllied to the contoller the software will per form a check on the wiring of the transfer output and ensure it does not have high voltage on the wire If this is the case it will signal a miswire alarm and will not run The test can be skipped by use of the escape key UNDERVOLTAGE ALARM If the g
166. nsibility 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 con tribute 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 a Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the generator electric system has been installed by a 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 a Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting a dealer about parts and service always supply the complete Model Number Serial Number and Type Code where applicable from the DATA LABEL that is affixed to the unit 01 50 00 2 Safety Instructions SAFETY RULES Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely effi ciently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precaut
167. nstall and tighten OIL DRAIN HOSE CAP and secure drain hose with a new zip tie or place the hose in its retaining clip 4 Turn OIL FILTER Figure 10 1 counterclockwise and remove Properly dispose of old filter 5 Apply light coating of new engine oil to seal of new oil fil ter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP and add recommended oil Crankcase oil capacity is listed in the Specifications section A CAUTION 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 8 Shut OFF engine and wait 10 minutes for the oil to settle down into the oil pan Recheck oil level on dipstick DO NOT fill above the dipstick FULL mark 9 Dispose of used oil at a proper collection center COOLING INTAKE OUTLET Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation This includes such obstructions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine gen erator quickly overheats which causes it to shut down See the installation diagram AWARNING AN 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 ign
168. ntrol Module circuit board 2 Replace board No AC output from generator 1 Main line circuit breaker is tripped open 1 Reset to ON CLOSED 2 Generator internal failure 3 Thermal circuit breaker open 3 Auto reset Wait 5 min and attempt restart Contact the nearest Dealer for assistance 12 1 01 60 8 60014811 United States Environmental Protection Agency Warranty Statement Stationary Emergency Spark Ignited Generators Warranty Rights Obligations and Coverage The United States Environmental Protection Agency EPA and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new stationary emergency engine If during the warranty period any emission control system or component on your engine is found defective in materials or workmanship Generac will repair your engine at no cost to you for diag nosis replacement parts and labor provided it be done by a Generac Authorized Warranty Service Facility Your emission control system may include parts such as the fuel metering ignition and exhaust systems and other related emission related components listed below Generac will warrant the emissions control systems on your 2009 and later model year engines provided there has been no abuse neglect unapproved modification or improper maintenance of your engine For engines less than 130 HP the warranty period is two years from the date of sale to the ultimate purchaser For engines
169. onary SI internal combustion engine and emissions control systems in accordance to the specifications and guidelines in this Owner s Manual EPA will not require engine performance testing If not your engine will be consid ered non certified and you must demonstrate compliance according to Subpart JJJJ Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60 Emission Related Installation Instructions Your certified emergency stationary engine has pre set emission control systems or components that require no adjustment Inspection and replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service dealer 1 800 333 1322 for the dealer nearest you Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates federal law 40 CFR 1068 105 b subject to fines or penalties as described in the Clean Air Act LL 60 LOD QUUMUSUI 13 2 800790 ONIA V3IG 91 21 9 MASZ MAOZ MA8 SLYYd NOWWOO LTV 14 5 OL V 4 EXPLODED VIEW ALT COMMON PARTS 18KW 20KW 25KW
170. ory Maximum Default Setting Exercise 23 59 Exercise Current 23 59 Current Current Current 2008 2008 2100 English 100 FUEL CONVERSION For fuel conversion steps refer to the GenSpec section RECONFIGURING THE FUEL SYSTEM OPERATION This system is intended to supply standby power in the event of a utility failure The control system will monitor the utility voltage to determine if stand by power is required Should the utility voltage fail the generator will start and run normally detaching from the utility and supplying the customer load from the generator When utility power returns the controller will re transfer the customer load back to utility and shut down the generator AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their UTILITY position i e loads connected to the utility power source 2 Be sure that normal UTILITY power source voltage is avail able to transfer switch terminal lugs N1 and N2 Refer to the Electrical Data section 3 the 5 AUTO OFF MANUAL switch to AUTO 4 Set the generator s main circuit breaker to its ON or CLOSED position With the preceding steps complete the generator will start auto matically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to the Sequence of Autom
171. oss During running If the RPM signal is lost for one full second the board will shut the engine down wait 15 seconds then re crank the engine if in AUTO it will not re crank in MANUAL If no RPM signal is detected within the first four 4 seconds of cranking the control board will shut the engine down and latch out on RPM sensor loss If the RPM signal is detected the engine will start and run normally If the RPM signal is subsequently lost the control board will try two more re cranks before latching out and flashing the RPM Sensor Failure message if it is in AUTO Control Panel Figure 1 Generator Control Panel GENERATOR MAINTENANCE SCHEDULE CHECK ENGINE MESSAGE The control system has detected an emissions related fault This fault cannot be cleared using the control panel interface The unit will continue to operate in automatic mode Contact your local servicing dealer UNDER FREQUENCY SHUTDOWN ALARM After starting if the generator stays under frequency for more than 30 seconds it will shutdown LOW BATTERY ALARM While running if the average battery voltage falls below 11 9 volts for one 1 minute the low battery alarm will be displayed LOW BATTERY WARNING The microprocessor will continually monitor the battery voltage and display the Low Battery Voltage message if the battery voltage falls below 12 2 Volts for one 1 minute No other action is taken on a low battery war
172. our generator will only run in manual mode for test purposes and NOT ACTIVATED will be displayed You will need to remove the generator control panel fuse AND disconnect the T1 N1 and N2 connector in the external connection box if equipped or disconnect utility input main breaker to the transfer switch for 3 5 seconds and reconnect then begin with Step 1 ENTER ACTIVATION CODE Passcode TROUBLESHOOTING Display Reads Passcode XXXXX ef A LW le Display Reads SELECT HOUR 0 23 _ 6 3 1008 9 00 Use ARROW keys to scroll and find the first number of your Activation Code Press ENTER to select Repeat this step until all digits have been entered Use ESCAPE to correct previous digits Activation is complete when all digits are entered above and your screen shows this display Follow the controller prompts to continue setting the time function Refer to your Owner s Manual with questions 8 2 What happens if Wrong Passcode Try Again appears Re enter the activation code If a second attempt is unsuccessful check the number against the code given on activategen com If it is correct and the generator will not accept it contact 1 888 9ACTIVATE 922 8482 Control Panel INSTALLATION ASSISTANT Interconnect System Self Test Feature follow the on screen prompts Upon power up this controller will go through a system self tes
173. overheats which causes it to shut down See the installation diagram AWARNING AN 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 INSPECT COOLING SYSTEM e Inspect engine cooling system See the Service Schedule e Check hoses for damage deterioration leaks etc Correct any discrepancies found e Check hose clamps for tightness 01 90 v ENGINE COOLANT Check coolantlevelin coolant recovery bottle See the Specifications and Service Schedule sections 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 radia tor filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact a Service Facility Inspect cooling system and coolant recovery system for leaks COOLANT CHANGE Every year have a service facility drain flush and refill the cooling system See the Specifications and Service Schedule for cooling system recommendations OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are cont
174. p Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury 1 3 FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris These generators may operate using one of several types of fuels All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks immediately Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natu
175. peed signal to the control panel is lost engine shutdown will occur DC FUSES A fuse 7 5 amp is located on the control panel It protects the panel 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 A fuse 25 amp is located in the engine wire harness adjacent to the DC alternator It is used to prevent circuit failure due to DC alternator falure It will also protect the system in the event of a wiring short dircuit If this fuse is blown the generator will not operate Replace these fuses with the same size type and rating 01 80 8 Fuel System FUEL SYSTEM FUEL REQUIREMENTS The Stationary Emergency Generator may be equipped with one of the following fuel systems Natural gas fuel system Propane vapor LPV fuel system Recommended fuels should have a Btu content of at least 1 000 Btu s per cubic foot for natural gas or at least 2 520 Btu s per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel NOTE The fuel consumption requirements are identified in the Specifications section of the Owner s Manual Refer to the Installation Manual if assistance is required for the sizing of the pipe diameter for the generator Any piping used to connect the generator to the fuel supply should be of adequate size to achieve the 100 load fuel consumption requirements iden
176. r AC Lead Four lead Single phase 1 Alternator Power Winding Connections 3 phase Alternators Y 3 phase Alternators Delta Configuration CONTROL PANELIL J Q Control Panel 1 Using the Auto Off Manual Switch Activate the Display Interface Menus Activation Chart Setting the Exercise Timer LOW Speed EXGrCISB cot t e ene teh User Adjustable Settings Fuel GOMVERSION s iicet teer re eee 2 C UR Automatic Transfer Operation Sequence of Automatic Operation Crank Cycles and Overcrank Auto Start Manual Alarm and Warning 5 5 Low Oil Pressure Shutdown Alarm High Coolant Temperature Shutdown Alarm 8 4 Overcrank Shutdown Alarm Overspeed Shutdown Alarm RPM Sensor Failure Shutdown Alarm Under frequency Shutdown
177. r delivers extremely high and dan gerous voltages to the transfer switch as well as the generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while stand ing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT Safety Instructions If personnel must stand on metal or concrete while installing Operating servicing adjusting or repairing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be con nected to an approved earth ground This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator or by static electricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maximum electrical current ampac ity to which they will be subjected Before installing or servicing this and related equipment make sure that all power voltage supplies are po
178. ral 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 CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm CALIFORNIA PROPOSITION 65 WARNING This product contains or emits chemicals known to the State of California to cause cancer birth defects and other reproductive harm 01 50 00 2 General Information IDENTIFICATION RECORD DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator The data label which can be found attached to the generator s lower connection box lists the unit s serial number and its rated voltage amps wattage capacity phase frequency rpm power factor production date etc NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Stationary Emergency Generator Model and Serial Number This number is the key to numerous engineering and manufactur ing details pertaining to your unit Always supply this number when requesting service ordering parts or seeking information Data Label MODEL _____ PROD DATE SERIAL Kw 8 SSS SS SSS
179. re the gen erator from a natural gas NG to a liquidified petroleum LP fuel source are as follows FUEL SYSTEM 1 the main gas supply off and disconnect the battery 2 Remove the carburetor fuel hose from the outlet port of the demand regulator see Figure 6 1 3 Disconnect the power wires from the fuel solenoid located on top of the regulator assembly by removing the screw on the front of the connector and pulling the connector forward away from the solenoid body 4 Loosen the spring clamp on the small fuel enrichment line and remove the hose from the hose barb 5 Remove the black pipe assembly from the outlet port of the demand regulator The solenoid assembly may need to be removed before performing this operation Figure 6 1 6 Remove the NG fuel jet loosen counter clockwise from the outlet port 7 Remove the LP fuel jet loosen counter clockwise from the jet keeper port on the side of the regulator housing Install this jet into the outlet port in the regulator casting NOTE The jet sizes are stamped on the individual jets The larger jet size is used for running on NG 8 Install the previously removed NG jet into the jet keeper port on the side of the regulator housing 9 2802905 99 9 Install the previously removed black pipe onto the outlet port of the demand regulator Use pipe sealant on the pipe threads 10 Reverse steps 1 4 in this procedure to reactivate the demand regula
180. regular text body of this manual These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the service are essential to prevent ing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety information that if not followed could endanger personal safety and or property of others A This symbol points out potential explosion hazard 1 1 This symbol points out potential fire hazard Q This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equip ment The manufacturer strongly recommends that the operator read this Owner s Manual and thoroughly understand all instruc tions before using this equipment The manufacturer also strongly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by a Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations OPERATION AND MAINT
181. removed the Installation Assistant will operate upon power restoration The only difference is the display will only prompt the customer for the current Time and Date IF THE INSTALLER TESTS THE GENERATOR PRIOR TO INSTALLATION PRESS THE ENTER KEY TO AVOID SETTING UP THE EXERCISE TIME THIS WILL ENSURE THAT WHEN THE CUSTOMER POWERS UP THE UNIT HE WILL STILL BE PROMPTED TO ENTER AN EXERCISE TIME SETTING THE EXERCISE TIMER This generator is equipped with an exercise timer Once it is set the generator will start and exercise every seven days on the day of the week and at the time of day specified During this exercise period the unit runs for approximately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle unless utility power is lost LOW SPEED EXERCISE The standard start sequence will be initiated All 1800 rpm units will exercise at 1400 RPM All 3600 rpm units will exercise at 1800 RPM If utility is lost during exercise the controller will do the following Wait for the line interrupt period for utility to return If utility returns within the line interrupt period continue to exercise at low RPM 8 3 If utility is still lost after the line interrupt period run the engine up to normal RPM and transfer the load At this time the con troller will exit the exercise routine and assume full automatic operation USER ADJUSTABLE SETTINGS Fact
182. riod expires a warning message will be posted The warning can be reset by hitting the Enter key Resetting will clear the warning and reset the maintenance counters for the condition annunciated The history log will reflect the maintenance warning 3 LoosnxeNuu ALARM CANCEL When the generator is shut down due to a latching alarm the Auto Off Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding fault alarm message COMMON ALARM RELAY The common alarm relay will be activated if there is a shutdown alarm It will not activate on warnings or indicate that the Auto Off Manual switch is in the OFF position The OFF position will clear the alarms and the relay The relay will not be used to indicate a generator is not activated The common alarm connections are wired to a set of potential free dry contacts on the Nexus controller board These Normally Open N O contacts close when an alarm condition occurs and are used to activate a remote signaling device The circuit is rated for a maximum of 130mA at 24 VDC The connections are a short set of free hanging wires that exit the engine harness loom directly behind the Nexus Control Panel and are labeled numbers 209 and 210 MAINTENANCE ALERTS Maintenance alerts will be provided for these conditions SERVICE SCHEDULE SERVICE SCHEDULE B Change Inspect spark plugs alert
183. rolled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via the control panel fuse This overcurrent protection device 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 EXERCISE SYSTEM Starts the Stationary Emergency Generator engine once every seven days and lets it run for 12 minutes PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine genera tor monthly Look for obvious damage loose missing or corroded nuts bolts and other fasteners Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every year Check all exhaust system pipes mufflers clamps etc for condition tight ness leaks security damage 01 90 ed 201 CHECK FAN BELT nspect fan belts every year Replace any damaged deterio rated worn or otherwise defective belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 of an inch Adjust belt tension as required Check fan belt alignment see Figure 10 2 Figure 10 2 Fan Belt INSPECT ENGINE GOVERNOR Visually inspect electronic governor DANGER Do not attempt to adjust the governor Only qualified service facilities should adjust the
184. s and readiness testing of such units is limited to 100 hours per year There is no time limit on the use of emergency stationary ICE in emergency situations The purchaser owner may petition the Administrator for approval of additional hours to be used for maintenance checks and readiness testing but a petition is not required if the owner maintains records indicating that Federal State or local standards require maintenance and testing of emergency ICE beyond 100 hours per year Emergency stationary ICE may operate up to 50 hours per year in non emergency situations but those 50 hours are counted towards the 100 hours per year provided for maintenance and testing The 50 hours per year for non emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to an electric grid or otherwise supply power as part of a financial arrangement with another entity For purchaser owner of emergency engines any operation other than emergency operation maintenance and testing and operation in non emergency situations for 50 hours per year as permitted in this section is prohibited If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance to the specifications and guidelines in this Owner s Manual EPA will not require engine performance testing If not your engine will be consid ered non certified and you must demonstrate compliance accordi
185. 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 A DANGER Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result Ethylene glycol base antifreeze is poisonous Do not use mouth to siphon coolant from the radiator recovery bottle or any container Wash hands thoroughly after handling Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them 1 Engine Protective Devices ENGINE PROTECTIVE DEVICES The Stationary Emergency Generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature oil pressure or rpm For that reason the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low the coolant temperature is too high the coolant level is too low or the engine is running too fast NOTE Engine protective switches and sensors are mentioned here for the reader s convenience Also refer to the applicable control panel manual for additional automatic engine shutdown infor mation HIGH COOLANT TEMPERATURE SENDER An analog coolant temper
186. sitively 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 normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Stationary emergency generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel disable the generator s automatic start cir cuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and on the transfer switch In case of accident caused by electric shock immediately shut down the source of electrical power If this is not pos sible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical hel
187. ssary 3 Defective starter contactor 3 Replace contactor 4 Defective starter motor 4 Replace starter motor 5 Dead or Defective Battery 5 Remove change or replace battery Engine cranks but won t start 1 Out of fuel 1 Replenish fuel turn on fuel valve 2 Fuel solenoid FS is defective 2 Replace solenoid 3 Spark plugs defective 3 Clean regap or replace plugs Engine starts hard runs rough 1 Air cleaner plugged or damaged 1 Clean or replace as needed 2 Defective spark plugs 2 Clean regap or replace plugs 3 Fuel pressure incorrect 3 Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS 4 Insufficient fuel supply 4 Confirm fuel pressure to regualtor is as recommended in SPECIFICATIONS 5 Fuel system set to wrong fuel type 5 Reconfigure the fuel system See RECONFIGURING THE FUEL SYSTEM in manual Check oil and add oil as needed Engine is overheated Check cooling system for leaks Defective Low Oil Pressure Switch Replace switch Engine starts then shuts down 1 1 2 2 3 3 4 Defective Coolant Temperature Switch 4 Replace switch 5 5 6 6 7 7 Engine oil level is low Defective Control Module circuit board Replace board Coolant Level is Low Repair leak Add coolant Defective Low Coolant Level Switch Replace Switch AUTO OFF MANUAL Switch at OFF 1 Defective AUTO OFF MANUAL switch 1 Replace board engine continues to run 2 Defective Co
188. st System 1 2 Carburetion Assembly And Its Components A Catalyst Assembly B Exhaust Manifold A Fuel Controller B Carburetor And Its Gaskets C C Muffler D Exhaust Pipe E Muffler Gasket Mixer And It Gaskets D Primary Gas Regulator E Crankcase Breather Assembly Including Liquid Vaporizer A Breather Connection Tube B Pcv Valve 1 3 Fuel Regulator 6 Oxygen Sensor 2 Air Induction System Including Diagnostic Emission Control System A Intake Pipe Manifold B Air Cleaner 13 1 1 60 1OOQuiMWusui3 United States Environmental Protection Agency Compliance Requirements Stationary Emergency Spark Ignited Generators Purchaser s Owner s Recordkeeping Responsibilities The United States Environmental Protection Agency EPA and Generac Power Systems Inc Generac are pleased to explain your record keeping requirements for compliance with Subpart JJJJ Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60 As the engine purchaser owner who operates and maintains their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in this Owner s Manual you are required to meet the following notification and recordkeeping requirements to demonstrate compliance 1 Maintain documentation that the engine is certified to meet emission standards 2 Recordkeeping
189. system from the electric utility distribution system when the generator is operating Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Stationary emergency generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel disable the generator s automatic start cir cuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and on the transfer switch In case of accident caused by electric shock immediately shut down the source of electrical power If this is not pos sible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury 1 3 FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra ch
190. t which will check for the presence of utility voltage on the DC circuits This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block If utility voltage is detected the controller will display a warning message and lock out the generator preventing damage to the controller Power to the controller must be removed to clear this warning Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass NOTE DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT WIRES IS NOT WARRANTABLE This test will be performed each time the controller is powered up Upon first power up of the generator the display interface will begin an installation assistant The assistant will prompt the user to set the minimum settings to operate These settings are simply Current Date Time and Exercise Day Time The maintenance inter vals will be initialized when the exercise time is entered The exercise settings can be changed at any time via the EDIT menu see Appendix Menu System If the 12 volt battery is disconnected or the fuse removed the Installation Assistant will operate upon power restoration The only difference is the display will only prompt the customer for the current Time and Date IF THE INSTALLER TESTS THE GENERATOR PRIOR TO INSTALLATION PRESS THE ENTER KEY TO AVOID SETTING UP THE EXERCI
191. ted for smaller engines that require less fuel The installer should be aware of the following When ambient temperatures are low and engine fuel consump tion is high the vapor withdrawal system may not function efficiently Ambient temperatures around the supply tank must be high enough to sustain adequate vaporization or the system will not deliver the needed fuel volume In addition to the cooling effects of ambient air the vaporization process itself provides an additional cooling effect LL VO 4 10054519 4 Specifications SPECIFICATIONS STANDBY EMERGENCY GENERATOR TY DOs EET Synchronous Rotor 5 1 Class Stator Insulation Class Alternator Output Leads 3 4 wire Sealed Ball GOUDIING crier s ems Flexible Disc Load Capacity Standby Rating 25 30 kW 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 SYSIGITI icr tare bie Direct Generator Output Voltage kW 60 Hz kW Amp CB Size 120 240V 1 phase 1 0 pf 25 30 104 125 125 150 120 208 3 phase 0 8 pf 25 30 87 104 100 125 120 240V 3 phase 0 8 pf 25 30 75 90 90 100 Generator Locked Rotor KVA Avail
192. ter key to acknowledge the alarm The alarm will clear and if the fault is still present the alarm will reoccur IGNITION ALARM When an ignition alarm occurs a generic message Ignition Fault will be displayed as the fault code MAINTENANCE WARNING When a maintenance period expires a warning message will be posted The warning can be reset by hitting the Enter key Resetting will clear the warning and reset the maintenance counters for the condition annunciated The history log will reflect the maintenance warning 3 LoosnxeNuu ALARM CANCEL When the generator is shut down due to a latching alarm the Auto Off Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding fault alarm message COMMON ALARM RELAY The common alarm relay will be activated if there is a shutdown alarm It will not activate on warnings or indicate that the Auto Off Manual switch is in the OFF position The OFF position will clear the alarms and the relay The relay will not be used to indicate a generator is not activated The common alarm connections are wired to a set of potential free dry contacts on the Nexus controller board These Normally Open N O contacts close when an alarm condition occurs and are used to activate a remote signaling device The circuit is rated for a maximum of 130mA at 24 VDC The connections are a short set of free hanging wires
193. the generator manually Transfer of the load to the generator will occur if utility is lost while the unit is running in the manual mode only if activated ALARM AND WARNING MESSAGES Alarms are defined as Latching which means they must be cleared before the alarm message on the screen will clear They can be of type Shutdown or not and are logged in the alarm log Alarms are all annunciated on the display Warnings are Non Latching meaning the message automati cally clears when the warning condition goes away Warnings can not be of type Shutdown but they are logged in the alarm log Warnings are all annunciated on the display LOW OIL PRESSURE SHUTDOWN ALARM There is a 10 second delay before oil pressure is monitored HIGH COOLANT TEMPERATURE SHUTDOWN ALARM There is a 10 second delay before engine temperature is moni tored Once running there is a 1 4 second delay before shut down The limit is set at 125 C or 257 F OVERCRANK SHUTDOWN ALARM Occurs if the engine has not started within the specified crank cycle OVERSPEED SHUTDOWN ALARM Warning indicator is measured and calculated by the microproces sor Overspeed is defined as 20 of nominal engine speed for 3 seconds or 25 immediate Nominal engine speed 60 0 Hz RPM SENSOR FAILURE SHUTDOWN ALARM During cranking If the board does not see a valid RPM signal within four 4 seconds of cranking it will shut down and lock out on RPM sensor l
194. ti fied in the Specifications section regardless of actual load NOTE The recommended fuel pressure is identified in the Specifications section this manual NOTE It is the responsibility of the installer to make sure that only the correct recommended fuel is supplied to the generator fuel system Thereafter the owner operator must make certain that only the proper fuel is supplied 5 1 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 distribu tion line to the standby generator site The following information applies to natural gas fuel systems Gas pressure in a building is usually regulated by national state and local codes To reduce gas pressure to a safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff solenoid must never exceed approximately 14 inches water column 0 5 psi 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 sui
195. tor 11 Follow the instructions in the Control Panel section A DANGER Serious injury including death or damage will occur if not configured properly Please consult an Authorized Dealer with any ques tions Figure 6 1 Reconfigure the Fuel System CARBURETDR FUEL Y BLAC FUEL SOLENOID __ lt ASSEMBLY NZ FUEL JET SPRING 5 CLAMP U PDR EL KEEPER PIO MENI PUR CONTROL PANEL The FUEL TYPE must be reconfigured in the control panel to final ize the conversion process This generator is configured at the factory to operate on natural gas If conversion to LP is required please complete the mechanical conversion process and then call 888 9ACTIVATE for the control panel password This fuel selection conversion is required to be password protected by Environmental Protection Agency EPA regulations CAUTION Whenever the Generator s Fuel Regulator is converted from one Fuel type to the other the Control Panel must be reconfigured for the correct fuel type Failure to convert both the Regulator and Control Panel will result in decreased performance and an increase in emissions and is a violation of EPA regula tions 6 2 General Information ALTERNATOR AC LEAD CONNECTIONS The electrical wires in the units AC connection lower pane
196. tructions in this manual were both accurate and current at the time the manual was written However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the nearest Service Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incor rectly or carelessly Observe them carefully Their definitions are as follows A DANGER INDICATES A HAZARDOUS SITUATION OR ACTION WHICH IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY A WARNING Indicates a hazardous situation or action which if not avoided could result in death or serious injury A CAUTION Indicates a hazardous situation or action which if not avoided could result in minor or moderate injury NOTE Notes contain additional information important to a procedure and will be found within the regular text body of this manual These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the service are essential to prevent ing accidents Four commonly used safety sy
197. ture sender located in the engine s cooling system will cause an engine shutdown if the temperature should exceed approximately 125 C 257 F The generator will automatically restart once the temperature has returned to a safe operating level LOW COOLANT LEVEL SENSOR To prevent overheating the engine has a low coolant level sensor If the level of engine coolant drops below the level of the low cool ant 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 pres sure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO OVERCRANK SHUTDOWN After a prespecified duration of cranking this function ends the cranking if the engine has failed to start The overcrank message 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 speed circuit controls engine cranking start up operation and shutdown Engine speed sig
198. vent overheating the engine has a low coolant level sensor If the level of engine coolant drops below the level of the low cool ant 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 pres sure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO OVERCRANK SHUTDOWN After a prespecified duration of cranking this function ends the cranking if the engine has failed to start The overcrank message 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 speed circuit controls engine cranking start up operation and shutdown Engine speed signals are delivered to the circuit board whenever the unit is running Should the engine overspeed above a safe preset value the circuit board initiates an automatic engine shutdown Contact the nearest Authorized Dealer if this failure OCCUIS RPM SENSOR LOSS SHUTDOWN If the s
199. www activategen com or call 1 888 9ACTIVATE 922 8482 If you already have your activation code wait 3 5 seconds for the next display TROUBLESHOOTING If the wrong language is chosen it can be changed later using the edit menu If ESCAPE is pressed instead of ENTER your generator will only run in manual mode for test purposes and NOT ACTIVATED will be displayed You will need to remove the generator control panel fuse AND disconnect the T1 N1 and N2 connector in the external connection box if equipped or disconnect utility input main breaker to the transfer switch for 3 5 seconds and reconnect then begin with Step 1 ENTER ACTIVATION CODE Passcode TROUBLESHOOTING Display Reads Passcode XXXXX ef A LW le Display Reads SELECT HOUR 0 23 _ 6 3 1008 9 00 Use ARROW keys to scroll and find the first number of your Activation Code Press ENTER to select Repeat this step until all digits have been entered Use ESCAPE to correct previous digits Activation is complete when all digits are entered above and your screen shows this display Follow the controller prompts to continue setting the time function Refer to your Owner s Manual with questions 8 2 What happens if Wrong Passcode Try Again appears Re enter the activation code If a second attempt is unsuccessful check the number against the code given on activatege

Generac 25/30kW Portable Generator User Manual

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