Generac Power Systems Portable Generator 005325 0 User Manual

Serial Number

1.6L

25kW

Models: 005324-0

005325-0

STANDBY GENERATOR

OWNER'S MANUAL

A new standard of reliability

Not intended for use in critical life support applications.



—CAUTION—

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

This manual should remain with the unit.

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Standby Generator Sets

Important Safety Instructions

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe

operation be copied and posted in potential hazard areas. Safety should be stressed to all

operators, potential operators, and service and repair technicians for this equipment.



GENERAL HAZARDS

WARNING:



• For safety reasons, the manufacturer recommends

that this equipment be installed, serviced and

repaired by an Authorized Service Dealer or other

competent, qualified electrician or installation tech-

nician who is familiar with applicable codes, stan-

dards and regulations. The operator also must

comply with all such codes, standards and regula-

tions.

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:



This product contains or emits chemicals

known to the state of California to cause

• Installation, operation, servicing and repair of this

(and related) equipment must always comply with

applicable codes, standards, laws and regulations.

Adhere strictly to local, state and national electri-

cal and building codes. Comply with regulations

the Occupational Safety and Health Administration

(OSHA) has established. Also, ensure that the

generator is installed, operated and serviced in

accordance with the manufacturer’s instructions

and recommendations. Following installation, do

nothing that might render the unit unsafe or in

noncompliance with the aforementioned codes,

standards, laws and regulations.

• The engine exhaust fumes contain carbon monox-

ide gas, which can be DEADLY. This dangerous gas,

if breathed in sufficient concentrations, can cause

unconsciousness or even death. For that reason,

adequate ventilation must be provided. Exhaust

gases must be piped safely away from any building

or enclosure that houses the generator to an area

where people, animals, etc., will not be harmed.

This exhaust system must be installed properly, in

strict compliance with applicable codes and stan-

dards.

cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before install-

ing, operating or servicing this equipment. Become

familiar with this Owner’s Manual and with the unit.

The generator can operate safely, efficiently and reli-

ably only if it is properly installed, operated and

maintained. Many accidents are caused by failing to

follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible

circumstance that might involve a hazard. The warn-

ings in this manual, and on tags and decals affixed

to the unit are, therefore, not all inclusive. If a pro-

cedure, work method or operating technique is used

that the manufacturer does not specifically recom-

mend, ensure that it is safe for others. Also make

sure the procedure, work method or operating tech-

nique utilized does not render the generator unsafe.

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 responsible

and capable persons to install, operate or main-

tain this equipment.



• Keep hands, feet, clothing, etc., away from drive

belts, fans, and other moving or hot parts. Never

remove any drive belt or fan guard while the unit

is operating.

• Adequate, unobstructed flow of cooling and venti-

lating air is critical in any room or building hous-

ing the generator to prevent buildup of explosive

gases and to ensure correct generator operation.

Do not alter the installation or permit even partial

blockage of ventilation provisions, as this can seri-

ously affect safe operation of the generator.

• Keep the area around the generator clean and

uncluttered. Remove any materials that could

become hazardous.

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.

• 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.

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Standby Generator Sets

Important Safety Instructions

• Before performing any maintenance on the gen-

• Generators installed with an automatic transfer

switch will crank and start automatically when

normal (utility) source voltage is removed or is

below an acceptable preset level. To prevent such

automatic start-up and possible injury to person-

nel, disable the generator’s automatic start circuit

(battery cables, etc.) before working on or around

the unit. Then, place a “Do Not Operate” tag on

the generator control panel and on the transfer

switch.

erator, disconnect its battery cables to prevent

accidental start-up. Disconnect the cable from the

battery post indicated by a NEGATIVE, NEG or (–)

first. Reconnect that cable last.

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

step. Stepping on the unit can stress and break

parts, and may result in dangerous operating con-

ditions from leaking exhaust gases, fuel leakage,

oil leakage, etc.

• In case of accident caused by electric shock, imme-

diately shut down the source of electrical power.

If this is not possible, attempt to free the victim

from the live conductor. AVOID DIRECT CONTACT

WITH THE VICTIM. Use a nonconducting imple-

ment, such as a dry rope or board, to free the vic-

tim from the live conductor. If the victim is uncon-

scious, apply first aid and get immediate medical

help.

• Never wear jewelry when working on this equip-

ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents causing injury.

ELECTRICAL HAZARDS



• All generators covered by this manual produce

dangerous electrical voltages and can cause fatal

electrical shock. Utility power delivers extremely

high and dangerous voltages to the transfer switch

as well as the standby generator. Avoid contact

with bare wires, terminals, connections, etc., on

the generator as well as the transfer switch, if

applicable. Ensure all appropriate covers, guards

and barriers are in place before operating the gen-

erator. If work must be done around an operating

unit, stand on an insulated, dry surface to reduce

shock hazard.

FIRE HAZARDS



• Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or

feet are wet. DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

• If personnel must stand on metal or concrete while

installing, operating, servicing, adjusting or repair-

ing this equipment, place insulative mats over a

dry wooden platform. Work on the equipment only

while standing on such insulative mats.

• Keep a fire extinguisher near the generator at all

times. Do NOT use any carbon tetra-chloride type

extinguisher. Its fumes are toxic, and the liquid

can deteriorate wiring insulation. Keep the extin-

guisher properly charged and be familiar with its

use. If there are any questions pertaining to fire

extinguishers, consult the local fire department.

• The National Electrical Code (NEC) requires the

frame and external electrically conductive parts

of the generator to be connected to an approved

earth ground. This grounding will help prevent

dangerous electrical shock that might be caused

by a ground fault condition in the generator set or

by static electricity. Never disconnect the ground

wire.

• Wire gauge sizes of electrical wiring, cables and

cord sets must be adequate to handle the maxi-

mum electrical current (ampacity) to which they

will be subjected.

• Before installing or servicing this (and related)

equipment, make sure that all power voltage

supplies are positively turned off at their source.

Failure to do so will result in hazardous and pos-

sibly fatal electrical shock.

• Connecting this unit to an electrical system nor-

mally supplied by an electric utility shall be by

means of a transfer switch so as to isolate the

generator electric system from the electric utility

distribution system when the generator is operat-

ing. Failure to isolate the two electric system power

sources from each other by such means will result

in damage to the generator and may also result

in injury or death to utility power workers due to

backfeed of electrical energy.

EXPLOSION HAZARDS



• Properly ventilate any room or building housing

the generator to prevent build-up of explosive gas.

• Do not smoke around the generator. Wipe up any

fuel or oil spills immediately. Ensure that no com-

bustible materials are left in the generator com-

partment, or on or near the generator, as FIRE or

EXPLOSION may result. Keep the area surround-

ing the generator clean and free from debris.

• These generator sets may operate using one of

several types of fuels. All fuel types are potentially

FLAMMABLE and/or EXPLOSIVE and should be

handled with care. Comply with all laws regulat-

ing the storage and handling of fuels. Inspect the

unit’s fuel system frequently and correct any leaks

immediately. Fuel supply lines must be prop-

erly installed, purged and leak tested according to

applicable fuel-gas codes before placing this equip-

ment into service.

• Diesel fuels are highly FLAMMABLE. Gaseous

fluids such as natural gas and liquid propane

(LP) gas are extremely EXPLOSIVE. Natural gas

is lighter than air, and LP gas is heavier than air;

install leak detectors accordingly.

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Standby Generator Sets

Important Safety Instructions

INTRODUCTION

 ^{This symbol points out potential fire hazard.}

Thank you for purchasing this model of the standby

generator set product line.

This symbol points out potential electrical shock



hazard.

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.

The operator is responsible for proper and safe use

of the equipment. The manufacturer strongly recom-

mends that the operator read this Owner's Manual

and thoroughly understand all instructions before

using this equipment. The manufacturer also strong-

ly recommends instructing other users to properly

start and operate the unit. This prepares them if they

need to operate the equipment in an emergency.

‹

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, con-

tact the nearest Authorized Service Dealer for start-

ing, operating and servicing procedures.

‹

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety

checks, to make sure that all maintenance for safe

operation is performed promptly, and to have the

equipment checked periodically by an Authorized

Service Dealer. Normal maintenance service and

replacement of parts are the responsibility of the

owner/operator and, as such, are not considered

defects in materials or workmanship within the terms

of the warranty. Individual operating habits and usage

contribute to the need for maintenance service.

Throughout this publication, and on tags and

decals affixed to the generator, DANGER, WARNING,

CAUTION and NOTE blocks are used to alert person-

nel to special instructions about a particular service

or operation that may be hazardous if performed

incorrectly or carelessly. Observe them carefully.

Their definitions are as follows:

DANGER

After this heading, read instructions that, if not

strictly complied with, will result in personal injury

or property damage.

Proper maintenance and care of the generator ensure

a minimum number of problems and keep operating

expenses at a minimum. See an Authorized Service

Dealer for service aids and accessories.

Operating instructions presented in this manual

assume that the standby electric system has been

installed by an Authorized Service Dealer or other

competent, qualified contractor. Installation of this

equipment is not a “do-it-yourself” project.

After this heading, read instructions that, if not

strictly complied with, may result in personal

injury or property damage.

‹

HOW TO OBTAIN SERVICE

After this heading, read instructions that, if not

strictly complied with, could result in damage to

equipment and/or property.

When the generator requires servicing or repairs,

simply contact an Authorized Service Dealer for

assistance. Service technicians are factory-trained

and are capable of handling all service needs.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

When contacting an Authorized Service Dealer or the

factory about parts and service, always supply the

complete model number of the unit as given on the

front cover of this manual or on the DATA LABEL

affixed to the unit.

These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compli-

ance with the special instructions while performing

the service are essential to preventing accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type

of information each indicates is as follows:

AUTHORIZED SERVICE DEALER LOCATION

To locate the nearest AUTHORIZED

This symbol points out important safety infor-



SERVICE DEALER, please call this number:

mation that, if not followed, could endanger

1-800-333-1322

or locate us on the web at:

personal safety and/or property of others.

This symbol points out potential explosion

hazard.



www.generac.com

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Standby Generator Sets

General Information

NOTE:

IDENTIFICATION RECORD

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.

‹

DATA LABEL

Every generator set has a DATA LABEL that contains

important information pertinent to the generator. The

data label, which can be found attached to the gen-

erator’s lower connection box, lists the unit’s serial

number and its rated voltage, amps, wattage capacity,

phase, frequency, rpm, power factor, etc.

Generator Model and Serial Number

This number is the key to numerous engineering and

manufacturing details pertaining to your unit. Always

supply this number when requesting service, order-

ing parts or seeking information.

Data Label

GENERATOR SET DATA

SERIAL

MADE IN USA

MODEL

RATED KVA

PHASE

RATED KW

RATED AMPS

RATED VOLTAGE

POWER FACTOR

ENGINE RPM

HERTZ

ALT RPM

PRODUCTION DATE

ALTERNATOR SUBTRANSIENT REACTANCE

ALTERNATOR TRANSIENT REACTANCE

CLASS

ROTOR

STATOR WINDING INSULATION AT 25°C AMBIENT

GENERAC POWER SYSTEMS, INC.

WAUKESHA, WI

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Standby Generator Sets

Equipment Description

EQUIPMENT DESCRIPTION

COOLANT RECOMMENDATIONS

This equipment is a revolving field, alternating cur-

rent generator set. It is powered by a gaseous fueled

engine operating at 1800 rpm for 4-pole direct drive

units, 3600 rpm for 2-pole direct drive units and

2300 - 3000 rpm for quiet drive gear units. See the

Specifications section for exact numbers. The unit

comes complete with a sound attenuated enclosure,

internally mounted muffler, control console, main-

line circuit breaker, battery charger, and protective

alarms as explained in the following paragraph.

Use a mixture of half low silicate ethylene glycol

base anti-freeze and deionized water. Cooling system

capacity is listed in the specifications. Use only deion-

ized water and only low silicate anti-freeze. If desired,

add a high quality rust inhibitor to the recommended

coolant mixture. When adding coolant, always add

the recommended 50-50 mixture.

Do not use any chromate base rust inhibitor



All AC connections, including the power leads from

the alternator, 120 volt battery charger input and

control connections to the transfer switch are avail-

able in the main connection box.

with ethylene glycol base anti-freeze or chro-

mium hydroxide (“green slime”) forms and will

cause overheating. Engines that have been oper-

ated with a chromate base rust inhibitor must

be chemically cleaned before adding ethylene

glycol base anti-freeze. Using any high silicate

anti-freeze boosters or additives will also cause

overheating. The manufacturer also recommends

that any soluble oil inhibitor is NOT used for this

equipment.

The generator incorporates the following generator

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 con-

structed.

• The voltage waveform deviation, total harmonic

content of the AC waveform and telephone influ-

ence factor have been evaluated and are acceptable

according to NEMA MG1-32.

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.

ENGINE OIL RECOMMENDATIONS

The unit has been filled with 15W-40 engine oil at

the factory. Use a high-quality detergent oil classified

“For Service CC, SD, SE, SF.” Detergent oils keep the

engine cleaner and reduce carbon deposits. Use oil

having the following SAE viscosity rating, based on

the ambient temperature range anticipated before the

next oil change:



Temperature

Above 80° F (27° C)

32° to 80° F (0° to 27° C)

Below 32° F (0° C)

Oil Grade (Recommended)

SAE 30W or 15W-40

SAE 20W-20 or 15W-40

See Note

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 recom-

mended to use the optional Cold Weather Start Kit

(part number listed in the Specification Section).

The oil grade for temperatures below 32° F is 5W-

30 synthetic oil.

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Standby Generator Sets

Engine Protective Devices

‹

OVERCRANK SHUTDOWN

ENGINE PROTECTIVE DEVICES

The standby generator may be required to operate for

long periods of time without an operator on hand to

monitor such engine conditions as coolant tempera-

ture, oil pressure or rpm. For that reason, the engine

has several devices designed to protect it against

potentially damaging conditions by automatically

shutting down the unit when the oil pressure is too

low, the coolant temperature is too high, the coolant

level is too low, or the engine is running too fast.

After a prespecified duration of cranking, this func-

tion ends the cranking if the engine has failed to

start. The overcrank LED will turn ON. Turn OFF the

AUTO/OFF/MANUAL switch, then turn switch back to

AUTO to reset the generator control board.

NOTE:

If the fault is not corrected, the overcrank feature

will continue to activate.

NOTE:

Approximate Crank Cycle Times

• 15 seconds ON

• 7 seconds OFF

• 7 seconds ON

Engine protective switches and sensors are men-

tioned here for the reader’s convenience. Also

refer to the applicable control panel manual for

additional automatic engine shutdown informa-

tion.

• 7 seconds OFF

• Repeat for 45 seconds

Approximately 90 seconds total.

‹

HIGH COOLANT TEMPERATURE SWITCH

This switches contacts close if the temperature should

exceed approximately 140° C (284° F), initiating an

engine shutdown. The generator will automatically

restart and the LED will reset once the temperature

has returned to a safe operating level.

‹

OVERSPEED SHUTDOWN

A speed circuit controls engine cranking, start-up,

operation and shutdown. Engine speed signals are

delivered to the circuit board whenever the unit is

running. Should the engine overspeed above a safe,

preset value, the circuit board initiates an automatic

engine shutdown. Contact the nearest Authorized

Dealer if this failure occurs.

‹

LOW COOLANT LEVEL SENSOR

Should the engine coolant level drop below the level

of the high coolant temperature switch, it is possible

for the engine to overheat without automatic shut-

down. To prevent such overheating, the engine has a

low coolant level sensor. If the level of engine coolant

drops below the level of the low coolant level sensor,

the engine automatically shuts down.

‹

RPM SENSOR LOSS SHUTDOWN

If the speed signal to the control panel is lost, engine

shutdown will occur.

‹

DC FUSE

‹

LOW OIL PRESSURE SWITCH

This fuse is located inside of the control panel. It

protects the panel wiring and components from

damaging overload. Always remove this fuse before

commencing work on the generator. The unit will

not start or crank if the fuse is blown. Replace the

fuse with one of the same size, type, and rating. (See

the exploded views and parts lists at the end of this

manual for replacement part number.)

This switch has normally closed contacts that are

held open by engine oil pressure during cranking and

operating. Should oil pressure drop below the 8 psi

range, switch contacts close, and the engine shuts

down. The unit should not be restarted until oil is

added, and the AUTO/OFF/MANUAL switch must be

turned to OFF and then back to AUTO.

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Standby Generator Sets

Fuel Systems

‹

PROPANE VAPOR WITHDRAWAL FUEL SYSTEM

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:

‹

FUEL REQUIREMENTS

The standby generator may be equipped with one of

the following fuel systems:

• Natural gas fuel system

• Propane vapor (PV) fuel system

The Manual Drawing Listing that is affixed to the

unit includes the “Identification Code,” which may be

used to identify the type of fuel system installed on

the unit.

• The natural gas and LP gas systems are similar.

However, the natural gas system delivers gas at a

pressure of approximately five inches water col-

umn to the carburetor.

Recommended fuels should have a Btu content of at

least 1,000 Btus per cubic foot for natural gas; or at

least 2,520 Btus per cubic foot for LP gas. Ask the

fuel supplier for the Btu content of the fuel.

• When ambient temperatures are low and engine

fuel consumption is high, the vapor withdrawal

system may not function efficiently.

• Ambient temperatures around the supply tank

must be high enough to sustain adequate vaporiza-

tion, or the system will not deliver the needed fuel

volume.

• In addition to the cooling effects of ambient air, the

vaporization process itself provides an additional

cooling effect.

Required fuel pressure for natural gas is 5 inches

to 14 inches water column (0.18 to 0.5 psi); and

for liquid propane, 5 inches to 14 inches of water

column (0.18 to 0.5 psi).

NOTE:

Any piping used to connect the generator to the

fuel supply should be of adequate size to ensure

the fuel pressure NEVER drops below five inches

water column for natural gas or 5 inches water

column for propane vapor for all load ranges.

‹

LP FUEL SYSTEM

LP is supplied as a liquid in pressure tanks. It is

usually made up of propane, butane, or a mixture of

the two gases. Propane tends to vaporize readily even

at temperatures as low as -20° F (-29° C). However,

butane reverts to its liquid state when temperatures

drop below 32° F (0° C).

NOTE:

It is the responsibility of the installer to make sure

that only the correct recommended fuel is sup-

plied to the generator fuel system. Thereafter, the

owner/operator must make certain that only the

proper fuel is supplied.

LP in a liquid withdrawal system must be converted

to its gaseous state before it is introduced into the

engine carburetor. A vaporizer-converter is generally

used to accomplish this. In such a converter, heated

engine coolant is ported through the converter to

provide the necessary heat for conversion of the fuel

from a liquid to a gaseous state.

‹

NATURAL GAS FUEL SYSTEM

Natural gas is supplied in its vapor state. In most

cases, the gas distribution company provides piping

from the main gas distribution line to the standby

generator site. The following information applies to

natural gas fuel systems.

• Gas pressure in a building is usually regulated by

national, state and local codes.

• To reduce gas pressure to a safe level before

the gas enters a building, a primary regulator is

needed. The natural gas supplier may or may not

supply such a regulator.

• It is the responsibility of the gas supplier to make

sure sufficient gas pressure is available to operate

the primary regulator.

• Gas pressure at the inlet to the fuel shutoff sole-

noid should not exceed approximately 14 inches

water column (0.5 psi). Optimum pressure at the

fuel shutoff solenoid is 11 inches water column

(0.4 psi).

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Standby Generator Sets

Specifications

Engine Lubrication System

SPECIFICATIONS

Type of Oil Pump...................................................................... Gear

Oil Filter.............................................................Full Flow, Cartridge

Crankcase Oil Capacity....................................................4 U.S. qts.

‹

GENERATOR

Type............................................................................. Synchronous

Rotor Insulation ....................................................................Class F

Stator Insulation ...................................................................Class F

Total Harmonic Distortion.........................................................< 5%

Alternator Output Leads 3-phase........................................... 4-wire

Bearings .........................................................................Sealed Ball

Coupling .......................................................................Flexible Disc

Load Capacity (Standby Rating) ............................................25kW*

‹

COOLING SYSTEM

Type.......................................................................................Closed

Water Pump.................................................................... Belt Driven

Fan Speed................................................................................ 2550

Fan Diameter.....................................................................15 inches

Fan Mode ..............................................................................Pusher

Air Flow (inlet air including alternator and

combustion air).......................................................... 1528 ft3/min.

Coolant Capacity...........................................................2.0 U.S. gal.

Heat Rejection to Coolant ..........................................117,000 Btu/h

Maximum Operating Air Temp. on Radiator ..............60° C (150° F)

Maximum Ambient Temperature................................50° C (140° F)

* ^{NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,}

ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural

gas.

Excitation System....................................................................Direct

Generator Output Voltage/kW - 60 Hz

120/240V, 1-phase, 1.0 pf

120/208V, 3-phase, 0.8 pf

Amp CB Size

104

125

100

Generator Locked Rotor KVA Available @ Voltage Dip of 35%

Single-phase or 208 3-phase............................................. 34 KVA

‹

FUEL SYSTEM

Type of Fuel.........................................Natural Gas, Propane Vapor

Carburetor ...................................................................... Down Draft

Secondary Fuel Regulator .................................................Standard

Fuel Shut-off Solenoid........................................................Standard

Operating Fuel Pressure ...................... 5 in. - 14 in. Water Column

‹

ENGINE

Make................................................................................... Generac

Model..................................................................................... In Line

Cylinders and Arrangement............................................................ 4

Displacement.......................................................................1.6 Liter

Bore...................................................................................... 3.15 in.

Stroke ................................................................................... 3.13 in.

Compression Ratio.............................................................9.75-to-1

Air Intake System ...............................................Naturally Aspirated

Valve Seats................................................................... Replaceable

Lifter Type.......................................................................... Hydraulic

Fuel Consumption - ft³/hr (Natural Gas/LPV)

Exercise

Cycle

60/24

25%

Load

161/64

50%

Load

253/101

75%

Load

345/138

100%

Load

437/175

‹

ELECTRICAL SYSTEM

Battery Charge Alternator ............................................12V, 15 Amp

Static Battery Charger............................................................2 Amp

Recommended Battery...................................... Group 26, 525CCA

System Voltage.....................................................................12 Volts

Engine Parameters

Rated Synchronous RPM..............................................60 Hz, 3600

HP at rated kW........................................................................45 Hz

Voltage Regulator

Exhaust System

Exhaust Flow at Rated Output 60 Hz.................................. 249 cfm

Exhaust Temperature at Rated Output................................ 1015° F

Type.................................................................................. Electronic

Sensing........................................................................ Single-phase

Regulation ................................................................................ 1%

Features .................................................V/F Adjustable, Adjustable

Voltage and Gain LED Indicators

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz ................................................... 90 cfm

Power Adjustment for Ambient Conditions

Temperature Deration

3% for every 10° C above °C..................................................... 25

1.65% for every 10° above °F.................................................... 77

Altitude Deration

Governor

Type.................................................................................. Electronic

Frequency Regulation ...................................................Isochronous

Steady State Regulation........................................................ .25%

Adjustments:

1% for every 100 m above m................................................... 182

3% for every 1000 ft. above ft. ................................................. 600

Speed............................................................................ Selectable

Controller.................................................R-200

. 0 v 0 4 / 0 6

G e n S p e c 0 2 2

6-1

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Standby Generator Sets

Specifications

Figure 1 — Interconnections

Utility In

Transfer Switch

CONTROL PANEL

NEUTRAL

ALTERNATOR

Gen

NEUTRAL

194

GENERATOR

CONNECTION

BOX

194

CIRCUIT

Load

Out

4- # 14 GA

WIRES TO

GENERATOR

CONNECTION

BOX

186

178

BREAKER

183

178

Battery

Charger

Input

GROUND

TO GENERATOR

120 Volt

CONNECTION BOX

Neutral

Grd

To Generator Control Panel

CIRCUIT BREAKER SIZE

FRAME RAIL

KW VOLTS

AMPS

125

100

LUG SIZE

#4 to 1/0

240 1 Ø

208 3 Ø

Ground Level

Concrete Slab

STUB-UP AREA

See Install Dwg for

Dimensions

10. Reverse the procedure to convert back to natural

‹

COLD WEATHER KIT

gas.

For cold climates, optional cold weather kit (part

number 0F6148) is recommended. The kit includes:

11. The Dip switch inside the control panel must be

in the LP or NG position when switching to differ-

ent fuels.

• Battery Warmer

• 4” Junction Box with hardware

• 6 qt. pack 5W-30 synthetic oil (engine)

Figure 6.2 — Reconfigure the Fuel System

Port 1

Port 2

‹

RECONFIGURING THE FUEL SYSTEM

FUEL HOSE

BRASS HOSE

FITTING

BRASS HOSE

FITTING

NOTE:

PLUG

OUT

PORT 1

OUT

PORT 2

All models are configured for natural gas or LP

vapor from the factory.

HOUSING

PORTS

HOUSING

PORTS

To reconfigure the fuel system from NG to LP, follow

these steps:

1. Turn the main gas supply off.

2. Remove the carburetor fuel hose from the outlet

port (Port 1) of the demand regulator (Figure

6.2).

NG FUEL SYSTEM

LP FUEL SYSTEM

3. Remove the brass hose fitting from the outlet port

(Port 1) of the demand regulator.

NOTE:

4. Remove pipe plug from Port 2.

5. Install brass hose fitting into Port 2.

6. Install pipe plug into Port 1.

Port 1 is for NG only and Port 2 is for LP vapor

only. No provision for dual fuel has been made.

7. Connect carburetor gas hose to brass fitting.

8. Tighten all clamps and plugs.

DANGER

Serious injury or damage may occur if not con-

figured properly. Please consult an Authorized

Dealer with any questions.

9. Make sure fuel supply is of the proper pressure



and type for configuration.

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Standby Generator Sets

General Information

GENERATOR AC LEAD CONNECTIONS

ALTERNATOR POWER WINDING

CONNECTIONS

See “Voltage Codes”. This generator may be rated

at any one of three voltages, either single-phase or

three-phase. The electrical wires in the unit’s AC con-

nection (lower) panel should be installed according to

the number of leads and the voltage/phase required

for the application. If there are any questions regard-

ing lead connection, refer to the wiring diagrams at

the back of this manual.

‹

3-PHASE ALTERNATORS

The generator is designed to supply 3-phase electri-

cal loads. Electric power is produced in the alterna-

tor power windings. These windings were connected

at the factory to the main circuit breaker with a “Y”

configuration as shown in Figures 7.2 and 7.3.

Voltage codes apply to the type of stator assembly

installed on a particular generator.

The rated voltage between circuit breaker terminals

E1-E2, E1-E3 and E2-E3 is either 480V or 208V

depending on the model.

‹

FOUR-LEAD, SINGLE-PHASE STATOR

The rated voltage between each circuit breaker termi-

nal and the neutral point 00 is either 277V or 120V

depending on the model.

Four-lead generators (see Figure 7.1) are designed to

supply electrical loads with voltage code “A” (240V,

1-phase, 60 Hz). Electrical power is produced in the

stator power windings. These windings were con-

nected at the factory to the main circuit breaker as

shown in Figure 7.1.

Figure 7.2 — Stator Power Winding

Connections - 3-phase, 277/480V (6 Lead)

The rated voltage between each circuit breaker ter-

minal is 240V. The rated voltage between each circuit

breaker terminal and the neutral point 00 is 120V.

S1 E1

Figure 7.1 — Four-lead, Single-phase Stator

INTERNAL

CONNECTIONS

L-L

NEUTRAL

E3 S3

S2 E2

L-N

Figure 7.3 — Stator Power Winding

Connections - 3-phase, 120/208V (6 Lead)

L-L

00 (NEUTRAL)

S6 S5

L-N

. 0 v 0 8 / 0 5

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Standby Generator Sets

Installation

‹

PRIOR TO INITIAL START-UP

INSTALLATION

Refer to the separate “Installation Guide QT Product

Line” supplied with the unit.

Prior to initially starting the generator, it must

be properly prepared for use. Any attempt to

crank or start the engine before it has been

properly serviced with the recommended types

and quantities of engine fluids (oil, coolant, fuel,

etc.) may result in an engine failure.



PREPARATION BEFORE START-UP

The instructions in this section assume that the

standby generator has been properly installed, ser-

viced, tested, adjusted and otherwise prepared for

use by a competent, qualified installation contractor.

Be sure to read the “Safety Rules”, as well as all other

safety information in this manual, before attempting

to operate this (and related) equipment.

‹

ENGINE COOLANT

Have the engine cooling system properly filled with

the recommended coolant mixture. Check the system

for leaks and other problems. See “Specifications”

and “Coolant” sections.

Before starting the generator for the first time, the

installer must complete the following procedures. For

follow-up maintenance information and/or service

intervals, please refer to the “Maintenance” section

and the “Service Schedule”.

‹

BELT TENSION

Check-the engine-fan belt tension and condition prior

to placing the unit into service and at recommended

intervals. Belt tension is correct when a force of

approximately 22 pounds (10 kg), applied midway

between pulleys, deflects the belt about 3/8- to 5/8-

inch (10 to 16 mm).

‹

TRANSFER SWITCH

If this generator is used to supply power to any elec-

trical system normally powered by an electric utility,

the National Electrical Code requires that a transfer

switch be installed. The transfer switch prevents elec-

trical backfeed between two different electrical sys-

tems. (For additional information, see the applicable

transfer switch manual for this unit.) The transfer

switch, as well as the generator and other standby

components, must be properly located and mounted

in strict compliance with applicable codes, standards

and regulations.

‹

ELECTRICAL SYSTEM

Make sure the generator is properly connected to an

approved earth ground.

Make sure the generator battery is fully charged,

properly installed and interconnected, and ready for

use.

‹

FUEL SYSTEM

Check to ensure that there are no loose electrical con-

nections. Restrain any loose wires to keep them clear

of any moving generator set components.

Make sure the fuel supply system to the genera-

tor (a) delivers the correct fuel at the correct pres-

sure and (b) is properly purged and leak tested

according to code. No fuel leakage is permitted. See

“Specifications” for more information.

INITIAL INSPECTION FOR QT GENSET

STARTUP

‹

GENERATOR SET LUBRICATION

Inspect for the following.

Check the engine crankcase oil level before operating

and add oil to the proper level – the dipstick “FULL”

mark. Never operate the engine with the oil level

below the dipstick “ADD” mark. See “Specifications”

and “Engine Oil Recommendations”.

• Freight Damage.

• Manuals present.

• Fluid Levels ( Oil, coolant, battery, Gear Drive).

• Correct fuel piping.

• Correct muffler installation for QT50, QT70,

NOTE:

QT100 - QT150.

This engine is shipped from the manufacturer

with “break-in” oil. This oil should be changed

after 30 hours of operation.

• Adequate air flow, clearances and ventilation per

installation drawings and applicable codes.

• Correct AC and DC wire size, connections and

grounding. Control and communication wiring to/

from the transfer switch must be run in a separate

conduit from the AC power leads.

• Battery charger connection to 120 VAC.

• Communication wires connected between transfer

switch and generator (HTS only).

Check the oil level in the generator gearbox (if so

equipped) prior to initial use and at the intervals

indicated by the “Service Schedule.” The recom-

mended oil is SAE 90 gear lubricant.

Also, if the engine is equipped with a mechanical gov-

ernor, make sure the governor is properly lubricated

with clean engine oil.

• Unit secured to pad.

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Standby Generator Sets

Installation

• Check voltage at the generator terminals.

START-UP CHECKLIST

• For 3-phase units, check phase rotation at the

transfer switch terminals. The generator phase

rotation must match the utility phase rotation.

• Check for coolant, fuel, oil, and exhaust leaks.

• Close the generators main line circuit breaker.

• Turn the generator set off.

Before working on the generator, ensure the fol-

lowing:



• The AUTO/OFF/MANUAL switch is in the OFF

position.

• Connect the UTILITY supply to the transfer

• The 120VAC supply to the battery charger is

switch.

switched OFF.

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

• Disconnect utility power before the transfer

switch.

‹

PREPARATION FOR START-UP

Engine should start, transfer to load.

Run at least 15 minutes on generator power.

Make certain all 3-phase loads are functioning

correctly (correct phase rotation).

• Ensure that the 120VAC circuit breaker to the bat-

tery charger is open.

• Remove the fuse from the the control panel. For

the H-100 and R-series: Open the front door of the

control box and remove the 15 Amp ATO fuse in

the lower left-hand corner of the control box.

• Connect the battery cables to the battery. Attach

negative battery cable last.

• Reconnect Utility power

Transfer switch will transfer back to Utility and

engine will shut down within the given time

parameters set up for the specific transfer switch

and controller.

• Close the 120VAC circuit breaker to the battery

• Install all covers, access plates and door panels.

• Put the Owners Manual in a safe and accessible

place.

charger.

• Measure the voltage at the battery before and after

the charger is turned on.

• Make certain the AUTO/OFF/MANUAL switch is in

• Verify all AC electrical connections are tight at the

circuit breaker and transfer switch.

• Visually inspect entire area looking for loose paper,

plastic wrappings, leaves, etc.

the AUTO position.

‹

START-UP INSPECTION

• Check all hoses clamps fittings for leaks or dam-

When a start-up is performed by an Authorized

Service Dealer, a standard three-part form titled

“Start-up Inspection for Standby Power Systems”

(part no. 067377), should be completed by the instal-

lation technician or engineer. See page 1-3 for infor-

mation on locating the nearest Authorized Service

Dealer. The installer should complete the form and

disseminate copies as follows:

age.

• Check all electrical plugs throughout the genera-

tor. Ensure each plug is seated correctly and fully

inserted into its receptacle.

• Verify the AUTO/OFF/MANUAL switch is in OFF

position.

• Open the valve to the engine fuel line.

• Bleed the fuel system of air. (necessary for long fuel

lines).

• Open the generator main line circuit breaker.

• Connect a manometer to the gas line and record

the static pressure. It must be as listed in the

Specifications.

• White copy: Mail to Generac Warranty Department,

P.O. Box 340, 211 Murphy Dr., Eagle, WI 53119-

2062.

• Pink Copy: For service file of installing dealer.

• Yellow Copy: For the customer’s records.

• Insert the fuse into the control panel.

• Move the AUTO/OFF/MANUAL switch to the MAN-

UAL position. The engine should now crank and

start.

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Standby Generator Sets

Operation

GENERATOR CONTROL AND

OPERATION

Do not crank the engine continuously for longer

than 30 seconds, or the heat may

damage the starter motor.



Refer to the appropriate control panel operator’s

manual for this unit.

• Let engine stabilize and warm up.

OPERATING UNIT WITH MANUAL

• Check all applicable instrument and gauge read-

ings. When certain that all readings are correct,

move the transfer switch manual handle to its

STANDBY (GENERATOR) position, i.e., load cir-

cuits supplied by the generator.

TRANSFER SWITCH

If the generator was installed in conjunction with a

transfer switch capable of manual operation only, the

following procedure applies. A manually operated

transfer switch is one that will not provide automatic

start-up and does not include an intelligence circuit.

• Set the standby generator’s main line circuit break-

er to its ON (or CLOSED) position.

• Load circuits are now powered by the standby

generator.

‹

ENGINE START-UP AND TRANSFER

For additional information, refer to the applicable

control panel manual for this unit, as well as any lit-

erature pertaining to the specific transfer switch.

‹

RETRANSFER AND SHUTDOWN

For additional information, refer to the applicable

control panel manual for this unit, as well as any lit-

erature pertaining to the specific transfer switch.

DANGER

To transfer the load back to the utility power source

and shut down the generator, follow these direc-

tions:

The Maintenance Disconnect Switch and the

AUTO/OFF/MANUAL switches (if so equipped)



must be set properly, or the generator will crank

and start as soon as the utility power to the

transfer switch is turned off. Refer to applicable

control panel and transfer switch manuals for

more information.

• Set the standby generator’s main line circuit break-

er to its OFF (or OPEN) position.

• Manually move the transfer switch handle to its

UTILITY (NORMAL) position, i.e., load circuits

connected to the utility.

• Turn ON the utility power supply to the transfer

switch, using the means provided (such as the util-

ity power source main line circuit breaker).

• Let the generator run at no-load for a few minutes

to stabilize internal temperatures.

Do not proceed until certain that utility source

voltage is available to the transfer switch and

the transfer switch main contacts are set to

UTILITY.



Do not attempt manual operation until all power



supplies to the transfer switch have been posi-

• Shut down the generator.

tively turned off, or extremely dangerous - pos-

sibly lethal - electrical shock will result.

OPERATING UNIT WITH AUTOMATIC

Transfer switch enclosure doors should be kept



TRANSFER SWITCH

closed and locked. Only authorized personnel

If the generator has been installed with an automatic

transfer switch, such as an RTS, HTS, or GTS-type

transfer switch, the engine may be started and

stopped automatically or manually.

should be allowed access to the transfer switch

interior. Extremely high and dangerous voltages

are present in the transfer switch.

In order to transfer load from the utility source to the

generator, follow these directions:

NOTE:

Refer to the applicable manual for your trans-

fer switch and to “Transfer Switch Start Signal

Connections”. In addition, please note the dangers

under “Engine Start-up and Transfer.”

• Turn OFF or disconnect the utility power circuit

to the transfer switch, using the means provided

(such as the utility source main line circuit break-

er).

• Set the transfer handle to its UTILITY (NORMAL)

position with load circuits connected to the utility

power supply.

• Set the standby generator’s main line circuit break-

er to its OFF (or OPEN) position.

• Start the generator.

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Standby Generator Sets

Maintenance

MAINTENANCE PERFORMED BY

AUTHORIZED SERVICE FACILITIES

COOLING SYSTEM

Air intake and outlet openings in the generator com-

partment must be open and unobstructed for contin-

ued proper operation. This includes such obstruc-

tions as high grass, weeds, brush, leaves and snow.

Before working on the generator, ensure the fol-

lowing:

Without sufficient cooling and ventilating air flow, the

engine/generator quickly overheats, which causes it

to shut down. (See the installation diagram.)



• The AUTO/OFF/MANUAL switch is in the OFF

position.

• The 15A fuse has been removed from the con-

trol box.

The exhaust system parts from this product get



• The 120VAC supply to the battery charger is

switched OFF.

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.

‹

EVERY THREE MONTHS

1. Check battery condition.

2. Inspect and test fuel system.

3. Check transfer switch.

4. Inspect exhaust system.

5. Check engine ignition system.

6. Check fan belts.

OVERLOAD PROTECTION FOR ENGINE

DC ELECTRICAL SYSTEM

Engine cranking, start up and running are controlled

by a solid state Engine Controller circuit board.

Battery voltage is delivered to that circuit board via

a 15 amp fuse. These overcurrent protection devices

will open if the circuit is overloaded.

‹

ONCE EVERY SIX MONTHS

1. Test Engine Safety Devices (low oil pressure, low

coolant level, high coolant temperature).

‹

ONCE ANNUALLY

If a circuit breaker opens or a fuse element



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

2. Clean, inspect generator.

3. Flush cooling system.

melts, find the cause of the overload before

resetting the circuit breaker or replacing the

fuse.

‹

FIRST 30 OPERATING HOURS

CHECKING FLUID LEVELS

1. Change engine "break-in" oil and filter.

‹

CHECK ENGINE OIL

‹

FIRST 100 OPERATING HOURS

Check engine crankcase oil level (Figure 10.1) at least

every 20 hours of operation, or prior to use.

1. Change engine oil and oil filter. After initial

change, service engine oil and filter at 100 operat-

ing hours or six months, whichever comes first.

2. Retorque cylinder head.

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

free cloth.

• Install oil dipstick, then remove again.

• Oil should be between FULL and ADD marks.

• If oil level is below the dipstick ADD mark, remove

oil fill cap-. Add the recommended oil to bring oil

level up to the FULL mark. DO NOT FILL ABOVE

THE “FULL” MARK. See “Engine Oil Recommen-

dations” for recommended oils.

3. Retorque intake and exhaust manifold.

‹

EVERY 500 OPERATING HOURS

1. Service air cleaner.

2. Check starter.

3. Check engine DC alternator.

‹

EVERY 800 OPERATING HOURS

1. Retorque cylinder head.

2. Retorque intake and exhaust manifold.

3. Check engine compression.

4. Check valve clearance.

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Standby Generator Sets

Maintenance

Figure 10.1 - Oil Dipstick and Oil Fill Cap

‹

EXERCISE SYSTEM

Start the generator engine at least once every seven

days and let it run at least 20 minutes. See “Weekly

Exercise Cycle”.

OIL FILL CAP

OIL DIPSTICK

‹

INSPECT COOLING SYSTEM

• Inspect engine cooling system. See “Maintenance

Schedule”.

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

Correct any discrepancies found.

• Check hose clamps for tightness.

‹

CHECK ENGINE COOLANT LEVEL

See “Checking Fluid Levels”.

‹

PERFORM VISUAL INSPECTION

‹

BATTERY FLUID

Complete a thorough visual inspection of the entire

engine-generator monthly. Look for obvious damage,

loose, missing or corroded nuts, bolts and other fas-

teners. Look for fuel, oil or coolant leaks.

Check battery electrolyte fluid based on the

Maintenance Schedule. Fluid should cover separa-

tors in all battery cells. If fluid level is low, add dis-

tilled water to cover tops of separators. DO NOT USE

TAP WATER IN BATTERY.

‹

INSPECT EXHAUST SYSTEM

Inspect the exhaust system at least once every three

months. Check all exhaust system pipes, mufflers,

clamps, etc. for condition, tightness, leaks, security,

damage.

‹

ENGINE COOLANT

Check coolant level in coolant recovery bottle. See

Specifications.

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap (only

when engine has cooled down) to make sure the

coolant recovery system is functioning properly.

Coolant should be at bottom of radiator filler neck.

If coolant level is low, inspect gasket in radiator

pressure cap. Replace cap, if necessary. To have

pressure cap tested, contact an Authorized Service

Dealer. Inspect cooling system and coolant recov-

ery system for leaks.

‹

CHECK FAN BELT

• Inspect fan belts every three months. Replace any

damaged, deteriorated, worn or otherwise defec-

tive belt.

• Check fan belt tension. Thumb pressure, exerted

midway between pulleys, should deflect about 3/8

to 5/8 of an inch. Adjust belt tension as required.

‹

INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

MAINTENANCE OWNER/

OPERATOR CAN PERFORM

DANGER

Do not attempt to adjust the governor. Only

qualified service facilities should adjust the

‹

CHECK ENGINE OIL LEVEL



Refer to “Checking Fluid Levels”.

governor. Excessively high operating speeds

are dangerous and increase the risk of personal

injury. Low speeds impose a heavy load on the

engine when adequate engine power is not

available and may shorten engine life. Correct

rated frequency and voltage are supplied only

at the proper governed speed. Some connected

electrical load devices may be damaged by incor-

rect frequency and/or voltage. Only qualified

service technicians should adjust the governed

speed.

‹

CHECK BATTERY

• See “Checking Fluid Levels”.

• Check battery cables for condition, tightness, cor-

rosion or damage. Clean, tighten or replace as

necessary.

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Standby Generator Sets

Maintenance

Figure 10.3 – Engine Air Cleaner

‹

CHANGING ENGINE OIL

Refer to maintenance performed by authorized service

facilities for engine oil and filter change frequencies.

Air Cleaner

Drain the oil while the engine is still warm from run-

ning. This means warm up the engine, shut it down

and drain immediately as follows:

1. Remove OIL DRAIN HOSE from its retaining

clip.

2. Loosen and remove OIL DRAIN HOSE CAP. Drain

oil completely into suitable container.

3. When all oil has drained, install and tighten OIL

DRAIN HOSE CAP, and re-install into its retaining

clip.

4. Turn OIL FILTER (Figure 10.2) counterclockwise

and remove. Properly dispose of old filter.

(Doors Removed for Clarity)

Figure 10.2 – Oil Filter

‹

SPARK PLUGS

Reset the spark plug gap or replace the spark plugs

as necessary (Figure 10.4).

1. Clean the area around the base of the spark plugs

to keep dirt and debris out of the engine. Clean

by scraping or washing using a wire brush and

commercial solvent. Do not blast the spark plugs

to clean.

2. Remove the spark plugs and check the condition.

Replace the spark plugs if worn or if reuse is

questionable. See the “Service Schedule,” Section

6, for recommended inspection.

3. Check the spark plug gap using a wire feeler

gauge. Adjust the gap to 0.5-0.6 mm (0.020-0.025

inch) by carefully bending the ground electrode

(Figure 10.4).

OIL FILTER

5. Apply light coating of new engine oil to seal of new

oil filter.-Install FILTER and tighten by hand only.

DO NOT OVER TIGHTEN.

6. Remove OIL FILL CAP. Add recommended oil (see

SPECIFICATIONS). DO NOT FILL ABOVE THE

DIPSTICK “FULL” MARK. Crankcase oil capacity

is 4.0 U.S. quarts (3.8 liters).

Figure 10.4 – Setting the Spark Plug Gap

SET PLUG GAP AT 0.5 - 0.6 mm

(0.020 - 0.025 inch)

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.

‹

COOLANT CHANGE

‹

CHANGING THE ENGINE AIR CLEANER

Every year, have an Authorized Service Facility drain,

flush and refill the cooling system. See “Specifications”

for cooling system recommendations.

To replace the engine air cleaner, (part number

059402), simply remove the air cleaner cover and

replace the air filter making sure it is positioned

properly before reattaching the cover (Figure 10.3).

See the “Service Schedule,” for air cleaner mainte-

nance.

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Standby Generator Sets

Maintenance

3. Have the state of charge and condition checked.

MISCELLANEOUS MAINTENANCE

This should be done with an automotive-type bat-

tery hydrometer.

‹

CLEANING THE GENERATOR

Keep the generator as clean and as dry as possible.

Dirt and moisture that accumulates on internal gen-

erator windings have an adverse effect on insulation

resistance.

DANGER

Storage batteries give off explosive hydrogen

gas. This gas can form an explosive mixture

around the battery for several hours after charg-

ing. The slightest spark can ignite the gas and

cause an explosion. Such an explosion can shat-

ter the battery and cause blindness or other

injury. Any area that houses a storage battery

must be properly ventilated. Do not allow smok-

ing, open flame, sparks or any spark producing

tools or equipment near the battery.





Periodically clean generator exterior surfaces. A soft

brush may be used to loosen caked on dirt. Use a

vacuum system or dry, low pressure air to remove

any accumulations of dirt. The generator is housed

inside an all-weather enclosure, clean the enclosure

with a soft, damp cloth or sponge and water.

Once each year have the generator cleaned and

inspected by an Authorized Service Dealer. That

dealer will use dry, low pressure air to clean internal

windings. Parts inside the control console should be

cleaned and inspected at this time as well.

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.

Finally, have the insulation resistance of stator and

rotor windings checked. If insulation resistances are

excessively low, the generator may require drying.

‹

BATTERY

Do not use any jumper cables or booster battery

to crank and start the generator engine. If the

battery has completely discharged, remove it

from the generator for recharging.



All lead-acid storage batteries discharge when not in

use. Refer to specific instructions and warnings that

accompany the battery. If such information is not

available, observe the following precautions when

handling a battery:

• DO NOT use jumper cables and a booster battery

to crank or start the generator engine.

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.

• DO NOT recharge a weak battery while it is

installed in the generator. Remove battery from

generator and recharge in a well-ventilated area,

away from fuel vapors, sparks, heat or flames.

• Battery electrolyte fluid is an extremely caustic

sulfuric solution that can cause severe burns. DO

NOT permit fluid to contact eyes, skin, clothing,

painted surfaces, wiring insulation, etc. If any bat-

tery fluid is spilled, flush the affected area with

clear water immediately.

Be sure the 120VAC power supply to the battery

is turned OFF, or sparking may occur at the bat-

tery posts as the cables are attached and cause

an explosion.



‹

BATTERY REPLACEMENT

• Always wear safety glasses, rubber apron and

When replacing batteries, use the same number and

the type of battery that follows:

gloves when handling a battery.

• Batteries give off explosive hydrogen gas while

charging. The gas can form an explosive mixture

around the battery for several hours after charging.

Any spark, heat or flames can ignite the gas and

cause an explosion which can shatter the battery,

causing blindness or other serious injury.

BCI Group No.

CCA

525 @ 0 deg. F

NOTE:

The BCI number should be located directly on the

battery.

‹

BATTERY MAINTENANCE

‹

REPAIR PARTS

The battery should be inspected per Section 4.7,

Scheduled Maintenance. The following procedure

should be followed for inspection:

The latter portion of this manual consists of exploded

views, parts lists and electrical data pertaining to this

generator set. The parts lists consist of (a) an item

number, (b) a part number, (c) the quantity required,

and (d) a description of the part. The item number

corresponds to an identical number on the exploded

view drawing.

1. Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries

and, if necessary, fill with DISTILLED WATER

ONLY. DO NOT USE TAP WATER IN BATTERIES.

. 0 v 0 4 / 0 6

M a i n t 0 1 1 R e

10-4

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Standby Generator Sets

Service Schedule

SERVICE SCHEDULE

The following is a recommended maintenance schedule for small standby and residential generator sets. The

established intervals in the schedule are the maximum recommended when the unit is used in an average service

application. They will need to be decreased (performed more frequently) if the unit is used in a severe applica-

tion. Use calendar time or accumulated run time, from the previous maintenance interval to determine the next

required maintenance interval.

Service Maintenance Interval Information:

The various service maintenance intervals are designated by interval numbers as follows:

1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten-

tial problem areas.

Performed monthly this requires approximately .5 man-hours per unit to complete.

This inspection may be performed by the end user providing the following safety steps are taken to prevent

the engine from starting automatically without warning:

To prevent injury, perform the following steps in the order indicated before starting any maintenance:

•

Disable the generator set from starting and/or connecting to the load by setting the control panel

AUTO/OFF/MANUAL switch to the OFF position.

•

Remove the 5 amp and 15 amp control panel fuses.

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

Remove the negative battery cable.

The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition

from burning out sensitive control panel components and circuits.

Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal

operation when required.

2 A break-in service inspection of the generator set to insure it is ready to operate and carry the load when

required, and to identify any potential problem areas.

Performed ONLY ONCE following the first three months, or 30 run time hours of operation after purchase of

the unit and requires approximately 2.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an Authorized Service Dealer.

3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required,

and to identify any potential problem areas.

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

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an Authorized Service Dealer.

4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required,

and to identify any potential problem areas.

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

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an Authorized Service Dealer.

. B v 1 2 / 0 5

v S S c h r d 0 0 2 R e

11-1

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Standby Generator Sets

Service Schedule

Maintenance

Tasks

Level 1

Recom-

mended

Level 2

Required

Level 3

Required

Level 4

Task

Comp.

Comp. to be done Comp. to be done Comp.

Required

to be done (Date-

3 months/

Break-in

30 Hrs.

(Date-

Initials)

Semi-

annually

50 Hrs.

(Date-

Initials)

to be done (Date-

monthly

10 Hrs.

Initials)

Annually

100 Hrs.

Initials)

1. Disable the unit from

operating per the first page

warning.

2. Check the engine oil level.

Adjust as necessary.

3. Check the engine coolant

level. Adjust as necessary.

4. Check the engine coolant

thermal protection level.

Correct as necessary.

5. Check the natural gas

delivery system on gas

engine driven units.

Tighten connections as

necessary.

6. Check the air inlets and

outlets for debris. Clean as

necessary.

7. Check the battery

electrolyte level if

accessible. Adjust as

necessary.

8. Check the battery posts,

cables, and charger for

loose connections,

corrosion, and proper

operation. Correct as

necessary.

9. Check the unit wiring for

loose connections,

corrosion, and damage.

Correct as necessary.

10. Check the engine

accessory drive belts for

wear, weather cracking,

and damage. Replace as

necessary.

11. Visually inspect the unit

looking for leaks, wear or

damage, loose connections

or components, and

corrosion. Correct as

necessary.

12. Test the engine and

transfer switch safety

devices. Correct and/or

adjust as necessary.

. B v 1 2 / 0 5

v S S c h r d 0 0 2 R e

11-2

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Standby Generator Sets

Service Schedule

Maintenance

Tasks

Level 1

Recom-

mended

Level 2

Required

Level 3

Required

Level 4

Task

Comp.

Comp. to be done Comp. to be done Comp.

Required

to be done (Date-

3 months/

Break-in

30 Hrs.

(Date-

Initials)

Semi-

annually

50 Hrs.

(Date-

Initials)

to be done (Date-

monthly

10 Hrs.

In itials)

Annually

100 Hrs.

Initials)

13. Initiate an automatic start

and transfer of the unit to

site load and exercise it for

at least 1 hour looking for

leaks, loose connections

or components, and

abnormal operating

conditions. Correct as

necessary.

14. Start and exercise the unit

at full rated load (use a

load bank if the site load is

not enough) for at least 2

hours looking for leaks,

loose connections or

components, and abnormal

operating conditions.

Correct as necessary.

15. Change the engine oil.

16. Replace the engine oil

filter(s).

17. Replace the engine air

filter(s).

18. Replace the engine fuel

filter(s) on diesel engine

driven units and re-prime

the fuel system.

19. Check the engine spark

plugs on gas engine driven

units. Clean and re-gap or

replace as necessary.

20. Perform a 5 minute no-load

operational run of the unit

looking for any post service

problems.

21. Return the unit to standby

setup for operation when

required.

. B v 1 2 / 0 5

v S S c h r d 0 0 2 R e

11-3

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Standby Generator Sets

Troubleshooting

TROUBLESHOOTING GUIDE

PROBLEM

Engine won’t crank.

CAUSE

1. 15 amp fuse blown.

CORRECTION

1. Replace fuse.

2. Loose or corroded or defective

battery cables.

2. Tighten, clean or replace

battery cables as necessary.

3. Replace contactor.*

3. Defective starter contactor.

4. Defective starter motor.

5. Dead or Defective Battery.

6. 5 amp fuse blown.

4. Replace starter motor.*

5. Remove, change or replace battery.

6. Replace fuse.*

Engine cranks but won't start

Engine starts hard, runs rough.

Engine starts then shuts down.

1. Out of fuel.

1. Replenish fuel.

2. Replace solenoid.*

3. Reconnect wire.

2. Fuel solenoid (FS) is defective

3. Open Wire #14A from Engine Control

circuit board.

4. Spark plugs defective.

5. Door on tank not closed.

4. Clean, regap or replace plugs.

5. Close door on tank.

1. Flame arrestor (air cleaner) plugged or

damaged.

2. Plugged fuel line.

1. Clean or replace as needed.

2. Unclog fuel line.

3. Defective spark plugs.

4. Fuel pressure incorrect.

3. Clean, regap or replace plugs.

4. Confirm fuel pressure to regulator is as

recommended in SPECIFICATIONS.

1. Engine oil level is low.

2. Engine is overheated.

1. Check oil and add oil as needed.

2. Check cooling system for leaks.

3. Replace switch.*

3. Defective Low Oil Pressure Switch

4. Defective Coolant Temperature Switch

5. Defective Control Module circuit board.

6. Coolant Level is Low.

4. Replace switch.*

5. Replace board.*

6. Repair leak - Add coolant.

7. Replace Switch.*

7. Defective Low Coolant Level Switch

AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch

1. Replace switch.*

2. Reconnect/close wire.

engine continues to run

2. Open/disconnected wire #15A between

AUTO/OFF/MANUAL switch and Control

Module circuit board.

3. Defective Control Module circuit board

3. Replace board.*

No AC output from generator.

1. Check main line circuit breaker.

2. Check circuit breaker & fuses.

3. Transfer switch set to NORMAL position

4. Generator internal failure.

1. Reset to ON or CLOSED.

2. Reset and replace, if necessary.

3. Set to GENERATOR position.

4. *

5. Thermal circuit breaker open.

5. Auto-reset - Wait 5 min. and

attempt restart.

*Contact the nearest Authorized Dealer for assistance.

. 0 v 0 8 / 0 5 l s b h r t T 0 0 1 R e

12-1

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Standby Generator Sets

Notes

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Standby Generator Sets

Notes

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Standby Generator Sets

Notes

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Standby Generator Sets

Notes

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0F7135

0F7022

0F7021

0F7260

0F7136

0F6156

0F4464

0D4698

0F3824

057701

0F6146

081008

0C2267

049226

051713

0C2212

022264

0F6366A

0F6366B

022241

022237

057329

057073

023484J

0E3257

0E7890

0E6002

0A2077

040532

052619

023897

049226

051716

025433

0A1354A

0E3257

022473

022097

067210A

0F7194

057593

0F1733

023762

REF

BREAKER TRAY BACK/BOTTOM

SUPPORT CONTROL PANEL SIDE RH

SUPPORT CONTROL PANEL SIDE LH

COVER CIRCUIT BREAKER 2P

COVER CIRCUIT BREAKER 3P

PLATE WIRE SNGL GALV

DECAL CUST CONN 120V UTILITY

BLOCK TERM 20A 6 X 3 X 1100V

DECAL UTIL SENSE/CUST CONN

BLOCK TERM 20A 8 X 6 X 1100V

HANG TAG 2 WIRE START (NOT SHOWN)

GROMMET 1.25 X .25 X .75

SCREW HHTT M5-0.8 X 12 BP

WASHER LOCK M5

WASHER FLAT M5

SCREW PHTT M4-0.7 X 16 ZYC

WASHER LOCK #8-M4

XFMR DUAL 104V/16V (3 PHASE)

XFMR DUAL 120V/16V (1 PHASE)

NUT HEX 3/8-16 STEEL

WASHER LOCK 3/8

LUG SLDLSS 350-#6 X 13/32 AL/CU

JUNCTION BLOCK 3/8-16

BUSHING SNAP SB-2000-26

SCREW HWHTF M6-1.0 X 16

REF

BRKT CB MTG BACK 2P

MTG TRACK BQ SIEMENS CB 3P

CB 0125A 2P 240V S BQ2 LL ( 2 POLE)

CB 0100A 3P 240V S BQ3 LL ( 3 POLE)

SCREW HHC M5-0.8 X 20 G8.8 (NOT SHOWN)

WASHER FLAT #10 ZINC (NOT SHOWN)

WASHER LOCK M5 (NOT SHOWN)

NUT HEX M5-0.8 G8 CLEAR ZINC (NOT SHOWN)

LUG SLDLSS #6-14 X 13/64 CU

REGULATOR - DC ALT

SCREW HWHTF M6-1.0 X 16

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

DECAL GROUND LUG

REF

BRACKET PANEL SUPPORT 1.5L C1

CABLE TIE MOUNT BLACK

DECAL CUSTOMER CONNECT INSIDE

WASHER SHAKEPROOF EXT #10 STL

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098936

0G0820

0G1019

020746

049226

051713

022129

0G1317

0G1316

0A5382

075591

051787

0A5601A

075554B

0A9375

022152

0G0430

042558

0G1452

0G0965

053557

051769

049541

046526

045772

0A8830

077043E

022131

072578

0F3353

023365

ASSY RTR 25KW 2PH

HOUSING BLOWER MACHINED 1.6L

GUARD BLOWER HOUSING 1.6L

SCREW PPHM M5-0.8 X 8 ZINC

WASHER LOCK M5

WASHER FLAT M5

WASHER LOCK M8-5/16

ASSY STATOR 25KW 1PH D

ASSY STATOR 25KW 3PH D

BEARING CARRIER REAR

ASSY HOLDER BRUSH

SCREW HHC M4-0.7 X 16 G8.8

COVER REAR BEARING

BOLT STATOR X 16" LG

SCREW RHM #10-24 X 2

WASHER LOCK #10

FLYWHEEL & RING GEAR ASSY 1.6L

KEY SQ 3/8 X 1 STEEL

PLATE SPACER 1.6L

PLATE FLEX 1.6L

SCREW HHC M12-1.75 X 40 G8.8

WASHER LOCK M12

SCREW HHC M10-1.5 X 35 G8.8

WASHER LOCK M10

30 *

NUT HEX M10-1.5 G8 YEL CHR

WASHER FLAT .34 ID X .75 OD

FLEX CONDUIT 1" BLACK (NOT SHOWN)

WASHER FLAT 3/8-M10 ZINC

SPACER ROTOR SHAFT

SCREW HHC M10-1.0 X 20 G10.9

WASHER SHAKEPROOF INT #8

* APPLY LOCTITE 242 TO I/N 30 BEFORE THREADING INTO CRANKSHAFT.

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COMPONENTS INCLUDED IN 0G1291E

0F1823A

0F3078

0F2606

036261

043181

052777

0G1303B

0F1262

0F1263

0F1264

0F1725C

067680

0E6875A

055911

0F5459

0F5462

0A5062J

029673

049350

0F1958

082573

0E4494

0F3215

0F6305

0F6305A

0F5886

051713

049226

0F5752F

0F5884

0F5896

0C2265

0C3990

091526

051716

043182

051714

0F3192

0E7403C

0F9785

0F2627

ENCL HSB CONTROL PANEL

COVER CONTROL PANEL

HINGE CONTINUOUS H-PANEL

RIVET POP .125 X .275 SS

SCREW PHM M3-0.5 X 10MM

WASHER FLAT M3

ASSY PCB CPL2 CTRLR 3600 RPM

HOLDER FUSE WICKMANN 178.6150

ADPTR RH SIDE WICKMAN 178.6191

ADPTR LH SIDE WICKMAN 178.6192

ASSY PCB 2AMP 12V UL BATT CHGR

ASSY VOLTAGE REGULATOR 60HZ

RELAY 12VDC C FORM W/DIODE

BLOCK TERM 20A 12 X 6 X 1100V

DECAL CPL CONTROL PANEL FUSES

DECAL CPL 3.9L TB1

SPACER 9.5H 3.2 ID

DIO BRIDGE 25A 600V

CIRCT BRK 4 X 1 ETA 46-500-P

PLATE HARNESS CLAMP

SWITCH RKR DPST 125V SPD

SWITCH RKR DPDT ON-OFF-ON

DECAL CONTROL HSB

SEAL COVER 3.18 X 12.7 X 382

SEAL COVER 3.18 X 12.7 X 283

SCREW HHPM M5-0.8 X 12

WASHER FLAT M5

WASHER LOCK M5

RES WW 15R 5% 25W QK CONN

SCREW PHTT M3.5-0.6 X 10

SCREW PHTT M3.5-0.6 X 16

SCREW PHTT M4-0.7 X 12 ZYC

SCREW PHTT M4-0.7 X 10 ZYC

SCREW PPHM M5-0.8 X 12 ZNC

NUT HEX M5-0.8 G8 CLEAR ZINC

WASHER LOCK M3

NUT HEX M3-0.5 G8 YEL CHR

SUPPORT ANGLE PCB

FUSE ATO TYPE 15 AMP (BLUE)

HARN 3600RPM R200 CONTROL PNL (NOT SHOWN)

PLATE COVER H PANEL

COMPONENTS INSTALLED PER THIS DRAWING

056739

022287

022473

022097

022127

0F6145

RELAY SOLENOID 12VDC PNL MNT

SCREW HHC 1/4-20 X 3/4 G5

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

NUT HEX 1/4-20 STEEL

SEAL WEATHER .45"DIA

A/R

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0F7211

0G0760

0F7210

0E9837B

0F0230B

046526

0G0910

099502

069860C

055596

0G0908

046627

052250

022473

022097

0C8566

049813

0C2454

042568

0G0932

0G0933

0C7649

0F7320

0F1433

076749

048031C

029032

050275

022131

029107

0G0568

0G0405

059980

051756

029333A

042907

026850

0A2628

0E2507

055934K

0E3257

SUPPORT RADIATOR LH SIDE

VENTURI 16" DIA FAN

SUPPORT RADIATOR RH SIDE

RADIATOR 1.6L CHY

FAN COOL 16" DIA 8 BLADE

WASHER LOCK M10

LOWER RADIATOR HOSE 1.6L

CLAMP HOSE #24 B1.06-2.00

HOSE OIL DRAIN ASSY 21"

BARBED STR 3/8 NPT X 3/8

UPPER RADIATOR HOSE 1.6L

CAP RADIATOR

TAPE FOAM 1 X 1 (24” LG)

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

SCREW HHFC M6-1.0 X 20 G8.8

NUT HEX M6 X 1.0 G8 YEL CHR

SCREW THF M6-1 X 16 N WA Z/JS

SCREW HHC M6-1.0 X 20 G8.8

GUARD FAN LH C1

GUARD FAN RH C1

CLAMP HOSE .38-.87

BLOCK OFF UPPER

BRACKET 2.5L FORD WATER BOTTLE

TANK COOLANT RECOVERY

CLAMP HOSE BAND 1/4

HOSE 9/32 ID (43” LG)

DECAL WARNING-FAN

WASHER FLAT 3/8-M10 ZINC

GROMMET 7/8 X 3/16 X 5/8

ASSY FAN BEARING SUPPORT

BRACKET FAN ALT ADAPTER 1.6L

SCREW HHC M10-1.5 X 25 G10.9

SCREW HHC M10-1.5 X 20 G8.8

TIE WRAP UL 7.4" X .19" BLK

SCREW HHC M8-1.25 X 16 G8.8

WASHER SHAKEPROOF EXT 1/4 STL

PULLEY - FAN 95 DIA

36 *

PROBE COOLANT LEVEL 3/8 NPTF

CLAMP VINYL 1.62 X .343 Z

SCREW HWHTF M6-1.0 X 16

* APPLY LOCTITE 242 TO I/N 36 BEFORE THREADING INTO I/N 31.

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0F3408B

0F3411

025507

059980

022129

077483

050331A

050331

038805J

038804N

045771

022129

027482

075763

0C2454

022145

REF

BATTERY TRAY C1 CPL

STRAP BATTERY RETAINMENT

WASHER SHAKEPROOF EXT 7/16 STL

SCREW HHC M10-1.5 X 25 G10.9

WASHER LOCK M8-5/16

BATTERY 12VDC 75-AH 26

BATT POST COVER RED +

BATT POST COVER BLK -

CABLE BATTERY BLK #1 X 30.00

CABLE BATT RED #1 X15.00

NUT HEX M8-1.25 G8 YEL CHR

WASHER LOCK M8-5/16

WASHER SHAKEPROOF EXT 5/16 STL

BOOT BATTERY CABLE

SCREW THF M6-1 X 16 N WA Z/JS

WASHER FLAT 5/16-M8 ZINC

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0G0759

027482

070936

070936C

039253

022145

022129

045771

071956

051730

021991

0F7194

026850

049813

055414

0E3257

022097

022473

MOUNTING BASE 1.6L

WASHER SHAKEPROOF EXT 5/16 STL

DAMPENER VIBRATION

VIB. ISO. 70-75 DURO

SCREW HHC M8-1.25 X 20 G8.8

WASHER FLAT 5/16 ZINC

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

WASHER FLAT M8

SCREW HHC M8-1.25 X 60 G8.8

EARTH STRAP

BRACKET PANEL SUPPORT

WASHER SHAKEPROOF EXT 1/4 STL

NUT HEX M6 X 1.0 G8 YEL CHR

LUG SLDLSS #2-#8 X 17/64 CU

SCREW HWHTF M6-1.0 X 16

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

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0G0207

0G0834

0G0820

0E9747

0G0839

0G0781

0G0722

0G0758

0G0431

0G0663

0G0786

0G0486

0F9617A

0A1354B

0G0823

0G1467

0D2244M

036710

0C5479

059980

046526

022131

045772

0G0464

0G0465

052858

061652

057644

049541

039414

022129

022145

029333A

057821

045771

022507

022097

022473

057823

077996

0A6751

035579

0A8584

0C1852

070928

069860C

069811

0G1241

0G0144

040173

0E3257

0A8830

0G0905

REF

ENGINE GENERAC 1.6L NG

ENGINE PLATE 1.6L

HOUSING BLOWER MACHINED 1.6L

STARTER 12 VOLT

ENGINE MOUNTING FOOT STAMPING

EXHAUST MANIFOLD 1.6L MACHINED

INTAKE MANIFOLD MACHINED 1.6L

HEAT SHIELD LOWER 1.6L

HEAT SHIELD UPPER 1.6L

PULLEY CRANKSHAFT MACHINED

WASHER PULLEY

BRACKET TENSIONER

SPACER ALTERNATOR

DC ALTERNATR HAN-KOK

V-BELT 3/8 X 30.6

HEAT SHIELD FRONT 1.6L

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 G8 YEL CHR

GASKET INTAKE MANIFOLD 1.6L

GASKET EXHAUST MANIFOLD 1.6L

NUT TOP LOCK FL M8-1.25

SCREW HHC M10-1.5 X 85 G8.8

SCREW HHC M10-1.5 X 100 G8.8

SCREW HHC M10-1.5 X 35 G8.8

SCREW HHC M8-1.25 X 35 G8.8

WASHER LOCK M8-5/16

WASHER FLAT 5/16-M8 ZINC

TIE WRAP UL 7.4" X .19" BLK

SCREW HHC M8-1.25 X 40 G8.8

NUT HEX M8-1.25 G8 CLEAR ZINC

SCREW HHC 1/4-20 X 1/2 G5

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

CLAMP HOSE #10 .56-1.06

CAP ANTIFREEZE RUBBER

SWITCH HI-TEMP 245 D X 3/8 NPT

BSHG RDCR HEX 1/4 TO 1/8

SWITCH OIL PRESSURE 10PSI 2POL

ADAPTER DRAIN OIL

CLAMP HOSE - OIL DRAIN

HOSE OIL DRAIN ASSY 21"

CAP HEX 1/4 NPT BRASS

THERMOSTAT HOUSNG MACHIND 1.6L

CAP BY-PASS COOLANT

CLAMP HOSE #5.5 .62-.62

SCREW HWHTF M6-1.0 X 16

WASHER FLAT .34 ID X .75 OD

HARN 1.6L R-200 CPL (NOT SHOWN)

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098290

098941A

098958A

098942A

098225

043146

022097

084543A

098783

037398

0E1326

0A7106

0G1381

029333A

022507

0E1694

064526

REF

ASM MOTOR STEPPER

HOUSING GOVERNOR CONNECTOR

CONNECTOR INTERFACE ASSEMBLY

COVER CONNECTOR HOUSING

SCREW FHM #2 X 5/8 SELF TAP

SCREW HHC M6-1.0 X 10 G8.8

WASHER LOCK M6-1/4

SCREW PHM M3-0.5 X 12MM

LEVER STEPPER MOTOR

NUT LOCK HEX #10-32 NYL INS

ASSY. CARBURETOR LINKAGE ROD

BRACKET STEPPER MOTOR

OIL DIP-STICK BRACKET 1.6L

TIE WRAP 7.4"X.19" BLK UL

SCREW HHC 1/4-20 X 1/2 G5

SPRING ANTI LASH

SCREW TAP HWH #6-25 X 3/8 ZINC

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(1) 8

026812

075580

0G1397

039253

022145

022129

045771

0F1570

0A6344

0C5210

025424

0C5210

0A5547

0G0321

0D1509

ELBOW 90D 3/4 NPT

FLANGE FUEL INLET

FUEL REGULATOR 1.6L REWORK

SCREW HHC M8-1.25 X 20 G8.8

WASHER FLAT 5/16 ZINC

(1) 16

(1) 21

(1) 22

0E0591

059402

037561

0E1028D

059401

091526

049226

026915

062522

022127

0E1339

050279

050280

030795

0F6155

0E1104

0E0668

0E0590A

0C5133

0E0665

0E1108

033138

022152

0E0645

034339

059194

057823

048031G

039450

029470

059057

0G1461

0F3994

0G1462

0E0568

0E0527

025105

0E0991

048031P

048031J

048031L

035579

ADAPTER CARB. TO AIR CLNR

FILTER ELEMENT

NUT WING 1/4-20 NYLK

ASSY CARBURETOR 1.6L

CARBURETOR GASKET

SCREW PPHM M5-0.8 X 12 ZNC

WASHER LOCK M5

NIPPLE CLOSE 3/4 X 1.375

STUD TH 1/4-20 X 3 G2 ZNC FULL

NUT HEX 1/4-20 STEEL

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

BODY CARBURETOR ASSEMBLY

BARBED EL 90 1/8NPT X 3/8

HOSE 3/8 ID LOW PRES OIL/WATER ( 8“LG)

NIPPLE PIPE 3/4 NPT X 6

HOSE 3/8 ID LOW PRES OIL/WATER (13“LG)

COVER AIR CLEANER

HOSE COOL 5/8"ID 250#WP ( 3”LG)

DECAL INLET PRESSURE

(1) 26

27 **

PIN SPRING 3/16 X 5/8

DECAL FUEL INLET NG

DECAL FUEL INLET LPG

SCREW HHC 5/16-18 X 1 G5

HARNESS FUEL JUMPER SINGLE REG

GASKET AIR CLEANER ADAPTER

O-RING 2-028 1.38 X 1.50 X .06

VENTURI 20MM

(1) 30

(1) 31

(1) 32

(1) 33

(1) 34

(1) 35

(1) 36

(1) 37

(1) 38

(1) 39

(1) 43

(1) 49

(1) 50

(1) 51*

(1) 52

O-RING 29.82 X 2.62

SCREW THROTTLE PIN STOP

THROTTLE ARM REWORK

SCREW HHM #10-32 X 5/8

WASHER LOCK #10

LEVER THROTTLE STOP

BARBED EL 90 3/8 NPT X 5/8

HOSE 5/8 ID LPG & NG (16” LG)

CLAMP HOSE #10 .56 - 1.06

CLAMP HOSE BAND .41

BARBED EL 90 3/16 X 1/8

HOSE 3/16 ID FUEL LINE (22 “LG)

HOSE 3/4 ID SAE-30R2 ( 3”LG)

HOSE BARB TEE 3/4" NYLON

PCV VALVE 2.5L FORD

HOSE BARB REDUCER 5/8"-3/8"ID

SHAFT, THROTTLE 1.5L

THROTTLE VALVE PLATE 27MM

SCREW RHMS 6-32 X 1/4 ZINC

SEAL, SHAFT COVER

CLAMP HOSE BAND .88"

CLAMP HOSE BAND .63

CLAMP HOSE BAND 1.0"

BSHG RDCR HEX 1/4 TO 1/8

(1) INCLUDED IN ITEM 19 (CARBURETOR ASSY )

NOTES:

1. REGULATOR (I/N 3) AS SHOWN IN ILLUSTRATION IS SET

UP FOR NATURAL GAS APPLICATION.

2. TO CONFIGURE REGULATOR FOR LP VAPOR, SWITCH

HOSE BARB, HOSE CLAMP (I/N 41) AND HOSE (I/N 40)

FROM “OUT-1” TO “OUT-2”. REPLACE PIPE PLUG FROM

“OUT-2” TO “OUT-1”. USE PIPE SEALANT ON HOSE BARB

AND PIPE PLUG. MAKE SURE TO KEEP PORTS FREE

FROM DEBRIS DURING RECONFIGURATION PROCESS.

3*. APPLY LOCTITE TO I/N 51 BEFORE THREADING INTO

I/N 49.

4**. FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL

INLET DECAL P/N 050280 FOR NG FUEL INLET DECAL P/N

050279 (ITEM 27).

5. WHEN SWITCHING FUEL TYPES, THE PROPER DIP

SWITCH SETTINGS MUST BE MADE TO THE CONTROL

PANEL. SEE OWNERS MANUAL, FUEL SECTION FOR

MORE DETAILS.

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12 **

0F7003 (XX)

0F7004 (XX)

0F7008 (XX)

0F7005 (XX)

0F7007 (XX)

0F7006 (XX)

0C2634A

0912970091

0912970090

0E5968

0E3257

077992

0F5049

0F5048D

022473

022097

022127

0C2454

078115

0F3890B

0F3890

0F7365

0F7365B

0F7365A

0F8869D

ROOF C1 CPL

CORNER POST LH SIDE C1 CPL

DOOR REAR C1 CPL

CORNER POST RH SIDE C1 CPL

DOOR LH & RH SIDE C1 CPL

DUCT FRONT DISCHARGE C1 CPL

ASSEMBLY COVER ACCESS

ASSY WIRE 14AWG 13.8" GRN/YEL

ASSY WIRE 14AWG 33.5" GRN/YEL

GASKET EXTRUDED TRIM (356” LG)

SCREW HWHTF M6-1.0 X 16

NUT HEX LOCK M6-1.0 SS NY INS

TAB PULL

VISE-ACTION LATCH SLOTTED CIR

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

NUT HEX 1/4-20 STEEL

SCREW THF M6-1 X 16 N WA Z/JS

WASHER SELF LOCKING DOME

RETAINER INSULATION (820)

RETAINER INSULATION (450)

INSULATION SIDE DOOR C1

INSULATION REAR DOOR C1 CPL

INSULATION ROOF C1 CPL

KEY VISE-ACTION LATCH SLOT CIR

OPTIONAL COMPARTMENT MATERIALS:

ALL P/N’S WITH AN (XX) SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION.

USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER:

PART NO.

MATERIAL

STEEL

ALUMINUM

STEEL

COLOR

TAN

GRAY

0XXXXXSN

0XXXXXAN

0XXXXXSG

0XXXXXAG

ALUMINUM

** ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO

THE BASE FRAME MUST BE SECURED USING ITEM 18 & 11 THREAD FORMING

FASTENER AND ITEM 12 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD

FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN

ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE SECURED IN THE SAME

MANNER.

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0F7366

0F7647

0F8095

0F7538

0E3257

0F7644

0C6119

036434

036449

022129

022259

038750

0G1043

0F3794

022097

049813

022473

MUFFLER C1

MUFFLER SADDLE

PIPE EXHAUST OUTLET

PIPE EXH INLET MUFLR SIDE 1.5L

SCREW HWHTF M6-1.0 X 16

MUFFLER STRAP

BOLT U 5/16-18 X 2-1/4

BOLT U 5/16-18 X 2.09

SADDLE 2 INCH

WASHER LOCK M8-5/16

NUT HEX 5/16-18 STEEL

SCREW HHC M6-1.0 X 30 G8.8

EXHAUST PIPE 1.6L

EXHAUST BLANKET 600MM LONG

WASHER LOCK M6-1/4

NUT HEX M6 X 1.0 G8 YEL CHR

WASHER FLAT 1/4-M6 ZINC

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Standby Generator Sets

Warranty

GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR

HOME STANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELOW

For a period of two (2) years from the date of sale, or start-up by Authorized/Certified Generac Power Systems Dealer, or branch thereof, Generac

Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or

an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with

the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/

Certified Generac Power Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Generators used in "Standby"

applications, as Generac Power Systems, Inc. has defined Standby, provided said generator has been properly installed and inspected on-site by

appropriate personnel. Scheduled maintenance, as outlined by the generator owner's manual, is highly recommended. This should be performed by

an Authorized/Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been performed on the unit throughout the

warranty period.

WARRANTY SCHEDULE

YEARS ONE and TWO — Limited comprehensive coverage on mileage, labor, and parts listed.

• - ALL COMPONENTS

*Start-up and/or On-line Registration, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.

Guidelines:

• Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer, or

branch thereof.

• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power

Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.

• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate Manual.

• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.

• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.

• Use of Non-Generac replacement part(s) will void the warranty in its entirety.

• Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision (If

applicable).

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

1. Any unit built/manufactured prior to January 1, 2005.

2. Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).

3. Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.

4. Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems have defined Prime Power,

Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition and warranty.

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

normally exist.

6. Failures caused by any external cause or act of God such as, but not limited to, collision, fire, theft, freezing, vandalism, riot or wars, lightning,

earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.

7. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.

8. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.

9. Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the

defective part(s).

10. Failure due to misapplication, misrepresentation, or bi-fuel conversion.

11. Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.

12. Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).

13. Overtime, holiday, or emergency labor.

14. Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.

15. Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct

cause of the problem.

16. Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS

MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow

limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.

GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT

SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A

DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/

owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner

specific legal rights. Purchaser/owner also may have other rights that vary from state to state.

Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187

Ph: (262) 544-4811 • Fax: (262) 544-4851

Bulletin 0171360SVE / Printed in U.S.A. 7.05

Printed in U.S.A.

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