Generac Power Systems Portable Generator 24L User Manual

Serial Number

2.4L

25kW

Models

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:



The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

• 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

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.

WARNING:



This product contains or emits chemicals

known to the state of California to cause

cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before install-

ing, operating or servicing this equipment. Become

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

The generator can operate safely, efficiently and reli-

ably only if it is properly installed, operated and

maintained. Many accidents are caused by failing to

follow simple and fundamental rules or precautions.

The 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.

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



• Keep the area around the generator clean and

uncluttered. Remove any materials that could

become hazardous.

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.

• 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.

FIRE HAZARDS



• Keep a fire extinguisher near the generator at all

times. Do NOT use any carbon tetra-chloride type

extinguisher. Its fumes are toxic, and the liquid

can deteriorate wiring insulation. Keep the extin-

guisher properly charged and be familiar with its

use. If there are any questions pertaining to fire

extinguishers, consult the local fire department.

• 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

Thank you for purchasing this model of the standby

generator set product line.

This symbol points out potential explosion

hazard.



 ^{This symbol points out potential fire 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.

This symbol points out potential electrical shock



hazard.

The operator is responsible for proper and safe use

of the equipment. The manufacturer strongly recom-

mends that the operator read this Owner's Manual

and thoroughly understand all instructions before

using this equipment. The manufacturer also strong-

ly recommends instructing other users to properly

start and operate the unit. This prepares them if they

need to operate the equipment in an emergency.

‹

READ THIS MANUAL THOROUGHLY

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

tact 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 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:

‹

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 responsibility of the owner/operator and, as

such, are not considered defects in materials or work-

manship within the terms of the warranty. Individual

operating habits and usage contribute to the need for

maintenance service.

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 a Service Dealer for ser-

vice aids and accessories.

After this heading, read instructions that, if not

strictly complied with, may result in personal

injury or property damage.

Operating instructions presented in this manual

assume that the standby 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.

After this heading, read instructions that, if not

strictly complied with, could result in damage to

equipment and/or property.

‹

HOW TO OBTAIN SERVICE

NOTE:

When the generator requires servicing or repairs,

simply contact a Service Dealer for assistance.

Service technicians are factory-trained and are capa-

ble of handling all service needs.

After this heading, read explanatory statements

that require special emphasis.

These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compli-

ance with the special instructions while performing

the service are essential to preventing accidents.

When contacting a Service Dealer 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.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type

of information each indicates is as follows:

This symbol points out important safety infor-



mation that, if not followed, could endanger

personal safety and/or property of others.

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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

MANUFACTURING INFORMATION

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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 classi-

fied “For Service SJ or SH.” 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

‹

COOLING SYSTEM

SPECIFICATIONS

Type...................................................Pressurized Closed Recovery

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

Fan Speed.........................................................................1000 rpm

Fan Diameter.....................................................................22 inches

Fan Mode ................................................................................Puller

Air Flow (inlet air including alternator and

‹

GENERATOR

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

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

Stator Insulation .................................................................. Class H

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

Telephone Interference Factor (TIF)..........................................< 50

Alternator Output Leads 3-phase........................................... 6-wire

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

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

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

combustion air)...........................................................1600 ft /min.

Coolant Capacity........................................................ (3.0 U.S. gal.)

Heat Rejection to Coolant ..........................................106,900 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

‹

FUEL SYSTEM

gas.

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

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

277/480V, 3-phase, 0.8 pf

Generator Locked Rotor KVA Available @ Voltage Dip of 35%

Single-phase ...................................................................... 50 KVA

208V, 3-phase .................................................................... 70 KVA

480V, 3-phase .................................................................... 70 KVA

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

Exercise

Cycle

42/16

25%

Load

50%

Load

75%

Load

100%

Load

375/142

107/41

204/77

293/111

‹

ENGINE

‹

ELECTRICAL SYSTEM

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

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

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

Displacement.......................................................................2.4 Liter

Bore...................................................................................... 3.41 in.

Stroke ................................................................................... 3.94 in.

Compression Ratio...............................................................8.5-to-1

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

Valve Seats....................................................................... Hardened

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

Battery Charge Alternator ............................................12V, 30 Amp

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

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

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

Voltage Regulator

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

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

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

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

Voltage and Gain LED Indicators

Engine Parameters

Rated Synchronous RPM..............................................60 Hz, 1800

HP at rated kW..................................................................60 Hz, 40

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

Exhaust System

Exhaust Flow at Rated Output 60 Hz.................................. 130 cfm

Exhaust Temperature at Rated Output.................................. 900° F

1% for every 100 m above m................................................... 183

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

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz ................................................... 70 cfm

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

Governor

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

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

Steady State Regulation...................................................... 0.25%

Engine Lubrication System

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

Oil Filter............................................... Full Flow Spin-on, Cartridge

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

. A v 0 5 / 0 7

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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

200

175

LUG SIZE

240 1 Ø

208 3 Ø

480 3 Ø

#6 to 300 mcm

Ground Level

Concrete Slab

STUB-UP AREA

See Install Dwg for

Dimensions

NOTE:

‹

COLD WEATHER KIT

The jet sizes are stamped on the individual jets.

The larger jet size is used for running on NG.

For cold climates, optional cold weather kit (part

number 0F6148) is recommended. The kit includes:

8. Install the previously removed NG jet into the jet

keeper port on the side of the regulator housing.

9. Install the previously removed black pipe onto

the outlet port of the demand regulator.

• Battery Warmer

• 4” Junction Box with hardware

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

10. Reverse steps 1-4 in this procedure to reactivate

‹

RECONFIGURING THE FUEL SYSTEM

the demand regulator.

NOTE:

Figure 6.2 — Reconfigure the Fuel System

All models are configured to run on natural gas

from the factory.

To reconfigure the fuel system from NG to LP, follow

these steps:

1. Turn the main gas supply off.

2. Remove the carburetor fuel hose from the outlet

port of the demand regulator (see Figure 6.2).

3. Disconnect the power wires from the fuel sole-

noid located on top of the regulator assembly.

4. Loosen the spring clamp on the small fuel enrich-

ment line and remove the hose from the hose

barb.

5. Remove the black pipe assembly from the outlet

port of the demand regulator.

6. Remove the NG fuel jet (loosen counter clock-

wise) from the outlet port.

7. Remove the LP fuel jet (loosen counter clockwise)

from the jet keeper port on the side of the regula-

tor housing. Install this jet into the outlet port in

the regulator casting.

DANGER

Serious injury or damage may occur if not con-

figured properly. Please consult an Authorized

Dealer with any questions.



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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” 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

NOTE:

Make sure the fuel supply system to the generator (a)

delivers the correct fuel at the correct pressure and (b)

is properly purged and leak tested according to code.

No fuel leakage is permitted. See “Specifications” for

more information.

Battery charger must be connected to 120 VAC, 15

amp circuit to operate.

Check to ensure that there are no loose electrical con-

nections. Restrain any loose wires to keep them clear

of any moving generator set components.

‹

GENERATOR SET LUBRICATION

Check the engine crankcase oil level before operating

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

mark. Never operate the engine with the oil level

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

and “Engine Oil Recommendations”.

INITIAL INSPECTION FOR GENSET

STARTUP

Inspect for the following.

• Freight Damage.

• Manuals present.

NOTE:

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

• Correct fuel piping.

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.

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Standby Generator Sets

Installation

• Open the valve to the engine fuel line.

• Battery charger connection to 120 VAC.

• Communication wires connected between transfer

switch and generator (HTS only).

• 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.

• Unit secured to pad.

START-UP CHECKLIST

• 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.

Before working on the generator, ensure the fol-

lowing:



• Check voltage at the generator terminals.

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

transfer switch terminals. The generator phase

rotation must match the utility phase rotation.

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

• Close the generators main line circuit breaker.

• Turn the generator set off.

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

position.

• The 120VAC supply to the battery charger is

switched OFF.

‹

PREPARATION FOR START-UP

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

tery charger is open.

• Remove the fuse from the the control panel. 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 UTILITY supply to the transfer

switch.

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

• Disconnect utility power before the transfer

switch.

• Connect the battery cables to the battery. Attach

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).

negative battery cable last.

• Close the 120VAC circuit breaker to the battery

charger.

• Measure the voltage at the battery before and after

• Reconnect Utility power

the charger is turned on.

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.

• 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.

• Install all covers, access plates and door panels.

• Put the Owners Manual in a safe and accessible

place.

• Check all hoses clamps fittings for leaks or dam-

age.

• Check all electrical plugs throughout the genera-

tor. Ensure each plug is seated correctly and fully

inserted into its receptacle.

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

the AUTO position.

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

position.

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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

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 melts,



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

2. Clean, inspect generator.

find the cause of the overload before resetting

the circuit breaker or replacing the fuse.

3. Flush cooling system.

CHECKING FLUID LEVELS

‹

FIRST 30 OPERATING HOURS

‹

CHECK ENGINE OIL

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

Check engine crankcase oil level (Figure 10.1) at least

every 20 hours of operation, or prior to use.

‹

FIRST 100 OPERATING HOURS

1. Change engine oil and oil filter. After initial

change, service engine oil and filter at 100 operat-

ing hours or six months, whichever comes first.

2. Retorque cylinder head.

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Oil Fill Cap

3. Retorque intake and exhaust manifold.

‹

EVERY 500 OPERATING HOURS

Oil

Dipstick

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

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

‹

INSPECT COOLING SYSTEM

free cloth.

• Inspect engine cooling system. See “Maintenance

Schedule”.

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

• 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.

Correct any discrepancies found.

• Check hose clamps for tightness.

‹

CHECK ENGINE COOLANT LEVEL

See “Checking Fluid Levels”.

‹

BATTERY FLUID

Check battery electrolyte fluid based on the

Maintenance Schedule. Fluid should cover 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.

‹

PERFORM VISUAL INSPECTION

Complete a thorough visual inspection of the entire

engine-generator monthly. Look for obvious damage,

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

teners. Look for fuel, oil or coolant leaks.

‹

ENGINE COOLANT

‹

INSPECT EXHAUST SYSTEM

Check coolant level in coolant recovery bottle. See

Specifications.

Inspect the exhaust system at least once every three

months. Check all exhaust system pipes, mufflers,

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

damage.

• 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 a Service Dealer.

Inspect cooling system and coolant recovery sys-

tem 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.

MAINTENANCE OWNER/

OPERATOR CAN PERFORM

‹

INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

‹

CHECK ENGINE OIL LEVEL

DANGER

Refer to “Checking Fluid Levels”.

Do not attempt to adjust the governor. Only

qualified service facilities should adjust the



‹

CHECK BATTERY

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.

• See “Checking Fluid Levels”.

• Check battery cables for condition, tightness, cor-

rosion or damage. Clean, tighten or replace as

necessary.

‹

EXERCISE SYSTEM

Start the generator engine at least once every seven

days and let it run at least 20 minutes. For more

detailed exercise information, see the respective sec-

tions in the Control Panel Technical Manual that is

supplied with the unit.

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Standby Generator Sets

Maintenance

Figure 10.3 – Engine Air Cleaner

‹

CHANGING ENGINE OIL

Refer to maintenance performed by 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

for recommended inspection.

Oil

Filter

3. Check the spark plug gap using a wire feeler

gauge. Adjust the gap to 1.07-1.17 mm (0.042-

0.046 inch) by carefully bending the ground elec-

trode (Figure 10.4).

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 1.07 - 1.17 mm

(0.042 - 0.046 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 a service facility drain, flush and

refill the cooling system. See “Specifications” for cool-

ing system recommendations.

To replace the engine air cleaner, remove the air

cleaner cover and replace the air filter making sure

it is positioned properly before reattaching the cover

(Figure 10.3).

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

nance.

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Standby Generator Sets

Maintenance

2. Check the battery fluid level of unsealed batteries

MISCELLANEOUS MAINTENANCE

and, if necessary, fill with DISTILLED WATER

ONLY. DO NOT USE TAP WATER IN BATTERIES.

3. Have the state of charge and condition checked.

This should be done with an automotive-type bat-

tery hydrometer.

‹

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

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.

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.

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. 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

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:



to crank and start the generator engine. If the

battery has completely discharged, remove it

from the generator for recharging.

• 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

• 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.

cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the

battery cables are connected.

Be sure the 120VAC power supply to the battery



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

tery posts as the cables are attached and cause

an explosion.

‹

BATTERY REPLACEMENT

NOTE:

• Always wear safety glasses, rubber apron and

Unit DOES NOT include battery.

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.

When supplying or replacing the battery, the recom-

mended number and type of battery is listed in the

Specifications Section.

NOTE:

The BCI number should be located directly on the

battery.

‹

BATTERY MAINTENANCE

The battery should be inspected per the "Scheduled

Maintenance" section. The following procedure should

be followed for inspection:

REPAIR PARTS

The later portion of this manuals consists of explod-

ed views, parts lists and electrical data pertaining to

this generator set.

1. Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.

. D v 0 6 / 0 7

M a i n t 0 1 2 R e

10-4

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Standby Generator Sets

Service Schedule

SERVICE SCHEDULE

30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS

The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to

150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used

in an average service application. They will need to be decreased (performed more frequently) if the unit is used

in a severe application. Use calendar time, from the previous maintenance interval to determine the next required

maintenance interval.

Service Maintenance Interval Information:

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

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

tial problem areas.

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

the engine from starting automatically without warning:

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

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

Manual switch to the “OFF” position.

• Remove the 15 amp control panel fuse.

• Turn off the battery charger.

• Remove the negative battery cable.

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

from burning out sensitive control panel components and circuits.

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

operation when required.

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

required, and to identify any potential problem areas.

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

the unit.

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

to accomplish and should be performed only by 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 or following each 50 hours of operation of the unit.

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

to accomplish and should be performed only by 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 or following each 100 hours of operation of the unit.

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

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

5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry

the load when required, and to identify any potential problem areas.

Performed annually or following each 250 hours of operation of the unit.

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

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

. B v 0 3 / 0 7

v S S c h r d 0 0 1 R e

11-1

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Standby Generator Sets

Service Schedule

Maintenance Level 1

Level 2

Level 3

Level 4

Level5

Tasks

Recom-

mended

Task

Required

Task

Required

Task

Required

Task

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

Required

Comp. to be done Comp.

Bi- (Date-

Annually/ Initials) annually/ Initials)

100 hrs. 250 hrs.

to be done (Date- 3 months/ (Date-

monthly/

10 hrs.

Semi-

(Date- to be done (Date-

Initials)

Initials) Break-in Initials) annually/

30 hrs. 50 hrs.

1. Disable the unit

from operating

per the first page

warning.

2. Check the engine

oil level. Adjust

as necessary.

3. Check the engine

coolant level.

Adjust as

necessary.

4. Check the engine

coolant thermal

protection level.

Correct as

necessary.

5. Check the natural

gas delivery

system for leaks

and correct

pressure on gas

engine driven

units. Tighten

connections as

necessary.

6. Check the air

inlets and outlets

for debris. Clean

as necessary.

7. Check the battery

electrolyte level

and specific

gravity if

accessible. Adjust

as necessary.

8. Check the battery

posts, cables,

and charger for

loose

connections,

corrosion, and

proper operation.

Correct as

necessary.

9. Check the unit

wiring for loose

connections,

corrosion, and

damage. Correct

as necessary.

. B v 0 3 / 0 7

v S S c h r d 0 0 1 R e

11-2

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Standby Generator Sets

Service Schedule

Maintenance Level 1

Level 2

Level 3

Level 4

Level5

Tasks

Recom-

mended

Task

Required

Task

Required

Task

Required

Task

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

Required

Comp. to be done Comp.

Bi- (Date-

Annually/ Initials) annually/ Initials)

100 hrs. 250 hrs.

to be done (Date- 3 months/ (Date-

monthly/

10 hrs.

Semi-

(Date- to be done (Date-

Initials)

Initials) Break-in Initials) annually/

30 hrs. 50 hrs.

10. Check the engine

accessory drive

belts and fan

coupling device

if equipped for

correct tension,

wear, weather

cracking, and

damage. Replace

as necessary.

11. Check the engine

valve clearance/

lash. Adjust as

necessary.

12. Visually inspect

the unit looking

for leaks, wear or

damage, loose

connections or

components, and

corrosion. Correct

as necessary.

13. Test the engine

and transfer

switch safety

devices. Correct

and/or adjust as

necessary.

14. Initiate an

automatic start

and transfer of

the unit to site

load and exercise

it for at least 1

hour looking for

leaks, loose

connections or

components, and

abnormal

operating

conditions.

Correct as

necessary.

15. Replace the

engine

accessory

drive belts.

16. Check gearbox

oil level (if

equipped).

17. Change gearbox

oil (if equipped).

. B v 0 3 / 0 7

v S S c h r d 0 0 1 R e

11-3

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Standby Generator Sets

Service Schedule

Maintenance Level 1

Level 2

Level 3

Level 4

Level5

Tasks

Recom-

mended

Task

Required

Task

Required

Task

Required

Task

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

Required

Comp. to be done Comp.

Bi- (Date-

Annually/ Initials) annually/ Initials)

100 hrs. 250 hrs.

to be done (Date- 3 months/ (Date-

monthly/

10 hrs.

Semi-

(Date- to be done (Date-

Initials)

Initials) Break-in Initials) annually/

30 hrs. 50 hrs.

18. Start and

exercise the unit

at full rated load

(use a load bank

if the site load is

not enough) for

at least 2 hours

looking for leaks,

loose

connections or

components, and

abnormal

operating

conditions.

Correct as

necessary.

19. Perform an

engine oil

analysis (send a

sample to a lab

for results).

Change the

engine oil and

filters if the

analysis results

indicate this is

required.

20. Change the

engine oil.

21. Replace the

engine oil filter(s).

22. Replace engine

spark plugs.

Clean and re-gap

or replace as

necessary.

23. Replace the

engine air

filter(s).

24. Perform a 5

minute no-load

operational run

of the unit

looking for any

post service

problems.

25. Return the unit

to standby setup

for operation

when required.

. B v 0 3 / 0 7

v S S c h r d 0 0 1 R e

11-4

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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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0F3137

0F3188

0F3189

023484N

0F6366B

0F6366A

043180

022264

0C3990

057701

022155

0C2428

0F3824

0A9457

057073

0D5466

0A7822

022237

022241

049226

0C2266

0C2454

022473

022097

0D4698

0F4464

025433

024469

067210A

0D6029

081008

077043J

051713

0F6156

029289

047411

0G0770

0G5952

036943

023897

022152

022158

REF

PAN CB CONN BOX

STAND RH CONTROL

STAND LH CONTROL

BUSHING SNAP SB-2.5-31

XFMR DUAL 120V/16V (FOR 120/240V & 277/480V UNITS)

XFMR DUAL 104V/16V (FOR 120/208V UNITS)

WASHER FLAT M4

UL CIRCUIT BREAKER (JD+LD)

0F3329

0D5577

0F2353

022770

022473

022097

022127

0C2454

029289

0F1733

COVER JD/LD CB SHRT STAND

CB 0300A 3P 600V S JD6 LL

INSULATOR CIRCUIT BR. JD/LD

SCREW RHM 1/4-20 X 3

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

WASHER LOCK #8-M4

NUT HEX 1/4-20 STEEL

SCREW PHTT M4-0.7 X 10 ZYC

BLOCK TERM 20A 8 X 6 X 1100V

WASHER LOCK #6

SCREW PHTT #6-32 X 1/2 ZYC

DECAL UTIL SENSE/CUST CONN

DECAL NEUTRAL

JUNCTION BLOCK 3/8-16

BUS BAR NEUTRAL BLOCK 390

LUG SLDLSS 600/250-1/0 X 1/4-28

WASHER LOCK 3/8

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

TAPE ELEC 1/2 FOAM (AS REQ’D)

DECAL CUSTOMER CONNECT INSIDE

(1) 9

UL CIRCUIT BREAKER (QN)

0F8135

0E7283

0E7284

0E3664

074908

0F8140

036261

0C2454

029289

0F1733

COVER QN FRM CB

CB 0150A 2P 240V S QN2 LL

CB 0175A 2P S QN2 LL 240V

BASE, QN CIRCUIT BREAKER

SCREW HHTT M5-0.8 X 10 BP

COVER QN CB DISH

(2) 15

(2) 16

(1) 26

(3) 39

(4) 40

(4) 41

(4) 42

(4) 43

(4) 44

REF

NUT HEX 3/8-16 STEEL

WASHER LOCK M5

RIVET POP .125 X .275 SS

SCREW PHTT M5-0.8 X 16 ZYC

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

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

BLOCK TERM 20A 6 X 3 X 1100V

DECAL CUST CONN 120V UTILITY

LUG SLDLSS #6-14 X 13/64 CU

SCREW HHTT #10-32 X 3/8 CZ

DECAL GROUND LUG

SCREW HHTT M6-1.0 X 16 ZYC

GROMMET 1.25 X .25 X .75

CONDUIT FLEX 2.0" ID (36” LG)

WASHER FLAT M5

PLATE WIRE SNGL GALV

TAPE ELEC 1/2 FOAM (AS REQ’D)

SCREW HHC M6-1.0 X 16 G8.8

HARNESS, TRANSFORMER ADAPTER

ASSY PCB IGN MOD 4.2L

SCREW THF M6-1X16 N WA Z/JS

TAPE ELEC 1/2 FOAM (AS REQ’D)

DECAL CUSTOMER CONNECT INSIDE

(1) ITEM INCLUDED WITH HARNESS

(2) ITEM INCLUDED WITH 0D5464B

(3) ITEM USED WITH EARLY MODEL 208V UNITS ONLY

(4) ITEMS USED ON 4.2L MODELS ONLY.

SCREW PPHM #10/32 X 2

WASHER FLAT #10 ZINC

WASHER LOCK #10

NUT HEX #10-32 STEEL

UL CIRCUIT BREAKER (ED)

0F3328

0D5552

0D5554

0D5556

0D9693

0F0492

048927

023897

022152

022158

0C2454

029289

0F1733

COVER ED CB SHORT STND

CB 0050A 3P 480V S ED4 LL

CB 0070A 3P 480V S ED4 LL

CB 0090A 3P 480V S ED4 LL

CB 0125A 3P 480V S ED4 LL

INSULATOR CB S (ED-3P)

SCREW RHM #10-32 X 4-1/2

WASHER FLAT #10 ZINC

WASHER LOCK #10

NUT HEX #10-32 STEEL

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

TAPE ELEC 1/2 FOAM (AS REQ’D)

DECAL CUSTOMER CONNECT INSIDE

UL CIRCUIT BREAKER (FD)

0F3138

0D5572

0D5573

0D5574

0D5575

0D5576

0F0199

081320

022473

022097

022127

0C2454

029289

0F1733

COVER CB CONN BOX

CB 0150A 3P 600V S FD6 LL

CB 0175A 3P 600V S FD6 LL

CB 0200A 3P 600V S FD6 LL

CB 0225A 3P 600V S FD6 LL

CB 0250A 3P 600V S FD6 LL

INSULATOR CB FD FRAME 30MIL

SCREW SHC 1/4-20 X 4.5 G8.8 NZ

WASHER 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

TAPE ELEC 1/2 FOAM (AS REQ’D)

DECAL CUSTOMER CONNECT INSIDE

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UL CIRCUIT BREAKER (QJ-2P)

NEUTRAL BLOCK 390 / 200-400A

0F8137

0E7994

0F8136

036261

022473

022097

022127

0F8139

0C2454

022237

048527

029289

022770

0F1733

COVER QJ 2P FRM CB

CB 0225A 240V 2P S QJ22

0D5466

039287

022145

022129

045771

045335

083896

0A7822

BUS BAR NEUTRAL BLOCK 390

SCREW HHC M8-1.25 X 45 G8.8 FT

WASHER FLAT 5/16-M8 ZINC

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

SCREW HHC 1/4-28 X 3/4 G5

WASHER LOCK 1/4-M6 SS

COVER QJ 2P CB DISH

RIVET POP .125 X .275 SS

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

NUT HEX 1/4-20 STEEL

INSUL CB 2P QJ

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

WASHER LOCK 3/8

SCREW SHC 3/8-16 X 3/4 G8.8 NZ

TAPE ELEC 1/2 FOAM (AS REQ’D)

SCREW RHM 1/4-20 X 3

LUG SLDLSS 600/250-1/0 X 1/4-28

UL CIRCUIT BREAKER (BQ)

0G1968

0G1970

0A2077

040532

0C3990

0E7890

0E6002

022859

0G0008

023897

022152

022158

0F1733

029289

0C2454

COVER BQ CIR BREAKER CPL 3P

COVER BQ CIR BREAKER CPL 2P

CB 0125A 2P 240V S BQ2 LL

CB 0100A 3P 240V S BQ3 LL

SCREW PHTT M4-0.7 X 10 ZYC

BRKT CB MTG BACK

MTG TRACK BQ SIEMENS CB 3P

SCREW RHM #10-32 X 3/4

BRKT BQ CB STANDOFF

WASHER FLAT #10 ZINC

WASHER LOCK #10

NUT HEX #10-32 STEEL

DECAL CUSTOMER CONNECT INSIDE

UL CIRCUIT BREAKER (225AF) (2P & 3P)

0F4185

058306

0F4165$

0F4143

0F4149

0F4151

0G5247$

0G5250

0G4478

0F4186

0F4186AGS0R

036261

053640

038150

022264

022471

029289

0F1733

022129

0F8432

0F8432A

0C2454

0F8451

049897

022145

045771

0F8843

W/CB

COVER CB C2-C4 (225AF)

SCREW SHC M8-1.25 X 25 G12.9

CIRCUIT BREAKERS 200A FRAME (3P)

CB 0040A 3P 480V 225AF (3P)

CB 0150A 3P 480V G 225AF

CB 0200A 3P 480V G 225AF

CB 200A FRAME G 240V (2P)

CB 175A 2 POLE 240V 225AF (2P)

CB 200A 2 POLE 240V 225AF (2P)

COVER CB DISH 225AF (3P)

COVER CB DISH 225AF (2P)

RIVET POP .125 X .275 SS

SCREW RHM #8-32 X 3-1/4

WASHER FLAT #8 ZINC

WASHER LOCK #8-M4

NUT HEX #8-32 STEEL

TAPE ELEC 1/2 FOAM

REF

TAPE ELEC 1/2 FOAM

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

2/4

(1) HARDWARE FOR MTG. CB TERMINAL COVERS IS

SUPPLIED WITH CIRCUIT BREAKERS.

(2) F

(2) G

(2) H

(2) J

(2) M

(2) QTY. REQ’D FOR “2POLE / 3POLE” BREAKER

6/9

DECAL CUSTOMER CONNECT INSIDE

WASHER LOCK M8-5/16

2/3

4/6

2/3

INSULATOR CB 225AF (3P)

INSULATOR CB 225AF (2P)

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

LUG SLDLSS 300 MCM-6 AL/CU

SCREW SHC M8-1.25 X 20 G8

WASHER FLAT 5/16-M8 ZINC

NUT HEX M8-1.25 G8 CLEAR ZINC

BUS BAR 200A LUG ADAPTOR

TERMINAL COVER CB

(2) R

(2) S

(2) T

(2) U

(2) V

(1) W

0G3259

DECAL TERMINAL SHOCK HZD BI

UL CIRCUIT BREAKER (400AF)

0F4187

0F4166$

0F1733

042419

023897

022152

022158

0C2454

029289

052647

046526

W/CB

0A7822

W/CB

023334

022097

022473

W/CB

REF

COVER CB C2-C4 400AF

CIRCUIT BREAKERS 400A FRAME

DECAL CUSTOMER CONNECT INSIDE

SCREW RHM 10-32 X 4

WASHER FLAT #10 ZINC

WASHER LOCK #10

NUT HEX #10-32 STEEL

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

TAPE ELEC 1/2 FOAM

(2) L

(2) M

(1) S

(2) W

(2) X

2/3

SCREW SHC M10-1.5 X 25 G12.9

WASHER LOCK M10

BUS BAR CB ADAPTER 225-400 A

LUG SLDLSS 600/250-1/0 X 1/4-28

TERM COVER CB

SCREW HHC 1/4-28 X 1/2 G5

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

SCREW SHC M10-1.5 X 25 G12.9

WASHER LOCK M10

2/3

W/CB

0G3259

DECAL TERMINAL SHOCK HZD BI

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0G0056

0G1155

0F9677

0G0959

0G2101

0G1931

0G0057

0F9664

ROTOR-2390-35KD1 CPL

ROTOR-2390-35KD1 CPL (G2)

ROTOR-2390-45KD1 CPL

ROTOR-2390-45KD1 CPL (G2)

ROTOR 25KW 1PH DIRECT 390 1800

ROTOR 25KW 3PH DIRECT 390 1800

STATOR-2390-35AD1 CPL

STATOR-390 45K 2P 1PH DIRECT

STATOR-2390-35KD1 CPL

STATOR-2309-45-KD1 CPL

STATOR-2390-35GD1 CPL

STATOR-2309-45KW 2P 3PH 208V

STR-2390--45JD1 CPL

ASSY STR 390 25AD1 CPL

ASSY STR 390 25JD3 CPL

ASSY STR 390 25GD3 CPL

ASSY STR 390 25KD3 CPL

INSTR HYPOT TEST (NOT SHOWN)

ENGINE ADAPTER

0G0058

0G0184

0G0059

0G0183

0G6104

0G2098

0G2100

0G1932

0G2099

0C9708

SEE ENGINE EV

0F5767B

0E5706

REF

FLEXPLATE

ASSY FLYWHEEL CPL W/40MM FAN B

REAR BEARING CARRIER 390/DRCT

ASSY BRUSH HOLDER 390/HSB

GUARD REAR BEARING CARRIER

WASHER FLAT #8 ZINC

0F7874

0G0587

038150

23 *

24 *

023454

KEY WOODRUFF #E

077043E

04576100BU

052646

043123

051779

0A2601

0A2602

0F8408

046526

0C3993

022264

CONDUIT FLEX 1.0" ID (35” LG)

STUD M14-2.0 570 G5 ZINC

WASHER FLAT M14

WASHER LOCK M14

NUT HEX M14-2.0 G8 YEL CHR

SCREW HHC M16-2.0 X 45 G8.8

WASHER FLAT .688 ID X 3.25 OD

SCREW HHC M10-1.50 X 16 G10.9

WASHER LOCK M10

SCREW HHTT M4-0.7 X 25 BP

WASHER LOCK #8-M4

BALL BEARING-45 MM

SLIP RING MACHINED

GUARD REAR BEARING CARRIER

CONDUIT FLEX .38" ID (60”)

047248

070892

0G0588

077043A

* ROTOR REPLACEMENT PARTS

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COMPONENTS INCLUDED IN 0G2283D

0F1823A

0F3078

0F2606

036261

0E7358

052777

0G1303C

0F1262

0F1263

0F1264

0F1725C

067680

0E6875A

055911

0F5459

0E3161

0F5462

0A5062J

029673

048467

0F1958

082573

0E4494

0F3215

0F6305

0F6305A

0F5886

051713

049226

0F5752F

0F5884

0F5896

0C2265

0C3990

091526

051716

079224

043182

051714

0F3192

0E7403C

0G2281

ENCL HSB CONTROL PANEL

COVER CONTROL PANEL

HINGE CONTINUOUS H-PANEL

RIVET POP .125 X .275 SS

SCREW PPPH HI-LO #4-24 X 3/8

WASHER FLAT M3

ASSY PCB R-200 1800 RPM 2.4L

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

ASSY PCB BOSCH GOV DRIVER

DECAL CPL 3.9L TB1

SPACER 9.5H 3.2 ID

DIO BRIDGE 25A 600V

CIRCT BRK 7 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

SCREW PPHM M5-0.8 X 30 SS

WASHER LOCK M3

NUT HEX M3-0.5 G8 YEL CHR

SUPPORT ANGLE PCB

FUSE ATO TYPE 15 AMP (BLUE)

HARN R-200 CTRL PNL 1800 RPM (NOT SHOWN)

COMPONENTS INSTALLED PER THIS DRAWING

056739

022287

022473

022097

022127

0F6145

0F2627A

091526

049226

051713

A/R

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

COVER CONTROL PANEL SIDE

SCREW PPHM M5-0.8 X 12 ZNC

WASHER LOCK M5

WASHER FLAT M5

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0F9517

052860

052251

052257

052252

052259

052891

0536210410

042909

047411

055414

022447

022097

022473

049813

022261

0F9597A

045764

062963

022302

022131

065852

0F9597

022129

026204

022145

045771

0F9596

0F9596A

WELDMENT FRAME 2.4L C2

NUT FLANGED HEX M12-1.75

DAMPENER VIBRATION 40 BLUE

SPACER .49 X .62 X 1.87 PWDR/ZNC

DAMPENER VIBRATION

WASHER FLAT M12

SCREW HHC M12-1.75 X 80 G8.8

ASSY WIRE 14.00"

SCREW HHC M8-1.25 X 30 G8.8

SCREW HHC M6-1.0 X 16 G8.8

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

WASHER SHAKEPROOF INT 1/4

WASHER LOCK M6-1/4

WASHER FLAT M6-1/4 ZINC

NUT HEX M6 -1.0 G8 YEL CHR

WASHER SHAKEPROOF INT 3/8

SUPPORT LH ENGINE 2.4L

SCREW HHTT M4-0.7 X 8 BP

SCREW HHC M10-1.25 X 30 G8.8

WASHER LOCK 7/16

WASHER FLAT 3/8-M10 ZINC

SPRING CLIP HOLDER .37-.62

SUPPORT RH ENGINE 2.4L

WASHER LOCK M8-5/16

WASHER SHAKEPROOF INT 5/16

WASHER FLAT 5/16-M8 ZINC

NUT HEX M8-1.25 G8 CLEAR ZINC

SPACER ENGINE MOUNT (2.4L G1)

SPACER LH ENGINE MOUNT (2.4L G2)

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0F3408B

0F3411

025507

052212

046526

022131

050331A

050331

038805Y

03880400AE

045771

BATTERY TRAY C1 CPL

STRAP BATTERY RETAINMENT

WASHER SHAKEPROOF EXT 7/16 STL

SCREW HHC M10-1.25 X 25 G8.8

WASHER LOCK M10

WASHER FLAT 3/8-M10 ZINC

BATTERY POST COVER RED +

BATTERY POST COVER BLACK -

CABLE BATTERY BLACK #1 X 18.00

CABLE BATT RED #1 X 18.00

NUT HEX M8-1.25 G8 YEL CHR

WASHER LOCK M8-5/16

REF

022129

0F3976

0C2454

022145

BOOT CONTACTOR CABLES

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

WASHER FLAT 5/16-M8 ZINC

BATTERY 12VDC 75-AH 26

077483

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0E6586

0E0519A

0C8127

052619

022127

062974

0G0190

037561

022097

GASKET BOSCH 32 & 40

ADAPTER CARBURETOR W/PVC CONN

ELEMENT AIR CLEANER

SCREW HHC M5-0.8 X 20 G8.8

NUT HEX 1/4-20 STEEL

STUD TH 1/4-20 X 4-1/2 G2 ZNC

PLATE, AIR CLEANER TOP 2.4L

NUT WING 1/4-20 NYLK

WASHER LOCK M6-1/4

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0G0408

046526

039414

0G0149

0E9868A

0F3217

042574

0A8584

0F4612

057772

057765

043790

0C7649

069860E

063076

0G1394

052830

025507

062963

049821

022129

0D6029

0A6751

0E0502

022145

045771

022131

049813

046525

058306

022097

022473

043116

026073A

052243

0A8258

0G0664

0G1502

047290

049340

045757

0G0951

0G3910

0G0608

0F9965E

0D2244M

0F9420

0E9747

0G1472A

0G1476

0G0707

0G0950

0F9583

0G0792

0G0792A

0G1501

0F9501

0G0952

0D3488S

0G0788

0G2750

049721

026925

0F2776

052203

0F2776D

ENGINE 2.4L MITSUBISHI 4G64

WASHER LOCK M10

SCREW HHC M8-1.25 X 35 G8.8

SCREW SHC M14-1.5 X 35 G10.9

ALTERNATOR DC W/OUT PULLEY

SPACER DC ALTERNATOR PULLEY

ADAPTOR 1/8 NPTF TO 1/8 BSPT

SWITCH OIL PRESSURE 10 PSI 2 POL (R-PANEL)

SENDER OIL PRESSURE 1/8" NPT (H-PANEL)

WASHER NYLON .565

(2) 6

ADAPTER M14-1.50 X 3/8 NPT

BARBED EL 90 3/8 NPT X 3/8

CLAMP HOSE .38-.87

HOSE DRAIN ASSY 28"

WASHER FLAT .531 ID X 1.062 OD

SCREW HHC M12-1.25 X 20 G10.9

SCREW HHC M10-1.25 X 45 G8.8

WASHER SHAKEPROOF EXT 7/16 STL

SCREW HHC M10-1.25 X 30 G8.8

SCREW SHC M8-1.25 X 30 G12.9

WASHER LOCK M8-5/16

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

SWITCH HI-TEMP 245D X 3/8 NPT (R-PANEL)

TEMPERATURE SENDER DELPHI (H-PANEL)

WASHER FLAT 5/16-M8 ZINC

NUT HEX M8-1.25 G8 CLEAR ZINC

WASHER FLAT 3/8-M10 ZINC

NUT HEX M6 X 1.0 G8 YEL CHR

NUT HEX M10-1.25 G8 YEL CHR

SCREW SHC M8-1.25 X 25 G12.9

WASHER LOCK M6-1/4

(1) 36

(3) 40

(1) 44

WASHER FLAT 1/4-M6 ZINC

SCREW HHC M6-1.0 X 12 G8.8

PLUG STD PIPE 1/4 STEEL SQ HD

SCREW HHC M10-1.5 X 60 G8.8

SCREW HHC M8-1.25 X 25 G10.9

OIL FILTER G2 ENGINE

1(REF)

COIL PACK

HOSE 3/8 ID SINGLE BRAID (15” LG)

BARBED EL 90 1/4 NPT X 3/8

SCREW HHC M6-1.0 X 25 G8.8

GASKET EXHAUST MANIFOLD

EXHAUST MANIFOLD G2 (MACHINE) (35KW & 45KW)

MANIFOLD EXHAUST (MACHINED) (25KW ONLY)

FLEX PLATE 2 POLE 2.4L G2

ASSY MAGPICKUP(3/8-24 MALE)

ADAPTER ENGINE 2.4L MACHINE

STARTER, 12 VOLT

CAM SENSOR PIN ASSY

COVER CAM GEAR G2 REWORKED

MANIFOLD INTAKE

GASKET INTAKE MANIFOLD

SPACER 2.4L G2 FLEX PLATE

SHIELD HEAT G2

1(REF)

(1) 53

(1) 60

SHIELD HEAT SML

BRACKET COIL PACK

ADAPTER 2.4L CRANKSHAFT MACH

POLY V-BELT G2 (3600 RPM)

BELT SERPENTINE 37.0" (1800 RPM)

PULLEY DC ALTERNATOR (3600 RPM)

PULLEY 69 OD DC ALTERNATOR (1800 RPM)

SCREW HHC M6-1.0 X 35 G8.8 BLK

PLUG STD PIPE 3/8 STEEL SQ HD

BRACKET, SIGNAL CONDITIONER

SCREW HHC M8-1.25 X 70 G8.8

BRACKET SIGNAL CONDITONER

(1) SUPPLIED WITH ENGINE.

1(REF)

(3) 64

(3) 66

(2) NOT USED ON 1800 RPM UNITS.

(3) USED WITH H-PANEL ONLY

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0F9529

0F2608

0F5263

046526

059981

0F2776A

WELDMENT RADIATOR SUPPORT 2.4L

RADIATOR 598 X 568 X 49 CPL RH

V-BELT 31/64" X 57-3/8"

0F2862

0F2560

022131

0E2507

035685

0F2561

0C8145

052250

0C7043

022473

0C8146

022097

076749

048031C

031971

0F4496

042911

0F2872

022304

022195

022196

0F8651

070015

0F9867

0F2461

022145

022129

039414

082774

0G0795

0G0816

049813

052644

0C8566

0C2454

090283

080713

0G4376

SPRING TENSION CPL

PULLEY V-BELT 4" FLANGED

WASHER FLAT 3/8-M10 ZINC

PROBE COOLANT LEVEL 3/8 NPTF

CLAMP HOSE #28 1.32-2.25

HUB FLEX PLATE

WASHER FLEX (THIN)

TAPE FOAM 1 X 1 (26.75” LG)

DISK FLEX

WASHER FLAT 1/4-M6 ZINC

SCREW HHC 5/16-24 X 1.124

WASHER LOCK M6-1/4

TANK COOLANT RECOVERY

CLAMP HOSE BAND 1/4

BEARING #6205 2NSE C3 E SRI2 S

PULLEY 4.5" DIA MACHINED

SCREW HHC M10-1.5 X 30 G8.8

SCREW HHC 1/2-13 X 2" G8

WASHER FLAT 1/2 ZINC

WASHER LOCK 1/2

NUT HEX 1/2-13 STEEL

SCREW HHFC M8-1.25 X 20 W/M6

NUT HEX LOCK 5/16-18 NY INS SS

SHAFT FAN DRIVE

RETAINER BEARING

WASHER FLAT 5/16-M8 ZINC

WASHER LOCK M8-5/16

WASHER LOCK M10

SCREW HHC M10-1.5 X 30 G10.9

BRACKET, SIGNAL CONDITIONER (USED ONLY

WITH QTA PRODUCT)

0F5050A

0F2573

0F4011

0F2572

0G2990

SHIELD RADIATOR C4

PULLEY FAN V-GROOVE 9"

FAN COOL 22" DIA 10 BLADE LH

ARM TENSIONER

SHOULDER BOLT 3/8 X 1/2"

SCREW HHC M8-1.25 X 35 G8.8

KEY WOODRUFF 4 X 19D

HOSE LOWER RADIATOR G2

HOSE UPPER RADIATOR G2

NUT HEX M6 X 1.0 G8 YEL CHR

SPACER .5 X 1.5 X .25 STL/ZINC

SCREW HHFC M6-1.0 X 20 G8.8

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

CAP RADIATOR 13 PSI

BRACKET COOLANT TANK

WASHER BELLEVILLE .75X.38X.028

BEARING PRESS NOTE:

APPLY LOCTITE 620 BEARING RETAINMENT

COMPOUND TO BEARING SURFACE ON ITEM 37

PRIOR TO PRESSING ITEM 28 ONTO ITEM 37.

ALSO APPLY LOCTITE 620 BEARING RETAINMENT

COMPOUND TO THE OUTSIDE OF 28 PRIOR TO

INSTALLING ITEM 28 INTO ITEM 38.

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026915

075580

0F6390C

0F6390B

039253

022145

022129

045771

0E8286

026812

0F8379

057823

059057

047527

0D1509

050279

050280

0F2119

0E6586

0E4394

0E4395

040105

057753B

0G4573C

0G4573B

0F7790E

0F7790H

0E7121

022097

046580

035685

0F6155

047290

057823

NIPPLE CLOSE 3/4 X 1.375

FLANGE FUEL INLET

REGULATOR ASSY 2.4L (25KW)

REGULATOR ASSY 2.4L (35KW & 45KW)

SCREW HHC M8-1.25 X 20 G8.8

WASHER FLAT 5/16-M8 ZINC

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 CLEAR ZINC

STREET EL 45D 1/2 NPT BRASS

ELBOW 90D 3/4 NPT

NIPPLE PIPE 3/4 NPT X 7

CLAMP HOSE #10 .56 - 1.06

HOSE 3/4 ID SAE-30R2 (18” LG)

BARBED STR 1/2 NPT X 3/4

DECAL INLET PRESSURE

DECAL FUEL INLET NG (NATURAL GAS APPLICATION)

DECAL FUEL INLET LPG (LP VAPOR APPLICATION)

O-RING 45.63 ID X 2.62 WIDTH

GASKET BOSCH 32

ACTUATOR BOSCH 40 GOVERNOR (45KW)

ACTUATOR BOSCH 32 GOVERNOR (25 & 35KW)

HOSE COOL 2 IN ID 20R4 (45KW)

HOSE 1.5 ID X 2 LG 20R4 (35KW)

MIXER ACTUATOR 32MM MACHINED (25KW)

MIXER ACTUATOR 40MM MACHINED (35 & 45KW)

VENTURI THROTTLE 26MM (35 & 45KW)

VENTURI THROTTLE 19MM (25KW)

O-RING 47.625 ID X 2.38 WIDTH

WASHER LOCK M6-1/4

SCREW SHC M6-1.0 X 45 G12.9

CLAMP HOSE #28 1.32-2.25

HARNESS CPL FUEL JUMPER

HOSE 3/8 ID SINGLE BRAID (18” LG)

CLAMP HOSE #10 .56-1.06

RECONFIGURING THE FUEL SYSTEM

Note: All models are configured to run on natural gas from the factory.

To reconfigure the fuel system from NG to LP, follow these steps:

1. Turn the main gas supply off.

2. Remove the carburetor fuel hose from the outlet port of the demand regulator (See Detail “A”).

3. Disconnect the power wires from the fuel solenoid located on top of the regulator assembly.

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.

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. Install the previously removed black iron pipe onto the outlet port of the demand regulator.

10. Reverse steps 1-4 in this procedure to reactivate the demand regulator.

11. For LP vapor application substitute LPG fuel inlet decal p/n 050280 for NG fuel inlet decal p/n 050279 (Item 17).

12. 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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0G0045 (XX)

0C2454

0F5849 (XX)

087233

REAR WRAP C2 CPL

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

DOOR C2

RIVET POP .1875 X .450 SS

SCREW TH-FRM M6 W/CAP SHKPRF W

DISCHARGE DUCT LH & RH SIDE C2

FRONT CORNERS C2

DISCHARGE CENTER DUCT C2

NUT HEX M6 X 1.0 G8 YEL CHR

NUT HEX LOCK M6-1.0 SS NY INS

ROOF C2

SLITTER C4

SPLITTER LOWER C4

SPLITTER STINGER C2

SUPPORT SPLITTER LH C2

TAB PULL

0E3257

0F5852 (XX)

0F9833 (XX)

0F5851 (XX)

049813

077992

0F9835 (XX)

0F2786

0F2785

0F3364

0F4880

0F5049

0C2634A

022473

022097

022127

0F3072

10 *

ASSEMBLY COVER ACCESS

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

NUT HEX 1/4-20 STEEL

INSULATION RETAINMENT HANGER

WASHER SELF LOCKING DOME #4-40

INSULATION DOOR C2

078115

0F4051

0F4051A

0F5048D

0E5968

0F3760K

0F3760E

0F4051C

0F3890B

0F4051B

0F3890

0F3890A

0F3760L

042568

0912970094

022447

INSULATION ROOF TOP

VISE-ACTION LATCH SLOTTED CIR

GASKET EXTRUDED TRIM (328” LG)

INSULATION SPLITTER

INSULATION DUCT

RETAINER INSULATION (820)

INSULATION DUCT SIDES

RETAINER INSULATION (450)

RETAINER INSULATION (740)

INSULATION LOWER SPLITTER

SCREW HHC M6-1.0 X 20 G8.8

ASSY WIRE 14 AWG 34.8" GRN/YEL

WASHER SHAKEPROOF INT 1/4

INSULATION REAR WRAP

KEY VISE-ACTION LATCH SLOT CIR

WASHER SELF LOCKING DOME #8-32

0F4051E

0F8869D

078115A

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.

0XXXXXSN

0XXXXXAN

0XXXXXSG

0XXXXXAG

MATERIAL

STEEL

ALUMINUM

STEEL

COLOR

TAN

GRAY

ALUMINUM

* ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO

THE BASE FRAME MUST BE SECURED USING ITEM 2 & 5 THREAD FORMING

FASTENER AND ITEM 39 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD

FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN

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

MANNER.

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0F9794

0G0113

0G1007

0F2830

0F2962

080762

0E0170A

0C2454

0G0776

0G0007

044149

085917

0D2611

0E8816

049721

022097

022473

036797

022259

070006

088775

022241

085917

0F2809

0F2808B

MUFFLER 7" X 9" X 18-1/2" 2" IN/OUT

EXHAUST ELBOW 2 1/4 OD 2 1/2OD

BRACKET MUFFLER

MUFFLER BRACKET STIFFENER

MUFFLER STRAP

BOLT U 3/8-16 X 2.62

EXHAUST BLANKET 988MM (C2)

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

PIPE EXHAUST G2

DIFFUSER EXHAUST WELDMENT

GASKET EXHAUST RING

WASHER LOCK 3/8 SS

SCREW HHC 3/8-16 X 1-3/4 SS

EXHAUST FLANGE 2" PIPE

SCREW HHC M6-1.0 X 35 G8.8 BLK

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

BOLT U 5/16-18 X 2.25

NUT HEX 5/16-18 STEEL

WASHER LOCK M8 SS

WASHER FLAT 3/8 SS

NUT HEX 3/8-16 STEEL

WASHER LOCK 3/8 SS

PIPE EXHAUST CROSSOVER

PIPE EXHAUST MUFFLER OUT

* NOT USED ON OPEN SET.

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1.)

C2 UNITS

0F9832

SHIELD CONN BOX C2

SHIELD CONTROL STAND C2

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

0F9832GGS0R

0C2454

2.)

C3 UNITS

0F9832B

SHIELD CONTROL STAND C3

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

0F9832KGS0R

0C2454

3.)

C4 UNITS

0F9832A

0C2454

SHIELD CONTROL STAND C4

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

4.)

C5 UNITS

0F9832C

SHIELD CONTROL STAND C5

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

0F9832D

0F9832EGS0R

0F9832HGS0R

0F9832JGS0R

0F9832FGS0R

0C2464

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. A v 0 4 / 0 7 k P g B 0 0 a 1 c R e

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