Generac Portable Generator 25 30kW User Manual

Owner's Manual

Stationary Emergency Generator

1.6L

25/30kW Models

EPA Certified

n^{NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT}

APPLICATIONS.

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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Safety Instructions

n^{SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential}

hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this

equipment.

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

INTRODUCTION

Thank you for purchasing this model of the stationary emergency

generator product line.

^{This symbol points out potential electrical shock hazard.}

Every effort was expended to make sure that the information and

instructions in this manual were both accurate and current at the

time the manual was written. However, the manufacturer reserves

the right to change, alter or otherwise improve this product(s) at

any time without prior notice.

The operator is responsible for proper and safe use of the equip-

ment. The manufacturer strongly recommends that the operator

read this Owner's Manual and thoroughly understand all instruc-

tions before using this equipment. The manufacturer also strongly

recommends instructing other users to properly start and operate

the unit. This prepares them if they need to operate the equipment

in an emergency.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest

Service Dealer for starting, operating and servicing procedures.

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.

Throughout this publication, and on tags and decals affixed to the

generator, DANGER, WARNING, CAUTION and NOTE blocks are

used to alert personnel to special instructions about a particular

service or operation that may be hazardous if performed incor-

rectly or carelessly. Observe them carefully. Their definitions are

as follows:

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 workmanship within the

terms of the warranty. Individual operating habits and usage con-

tribute to the need for maintenance service.

INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF

NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

Indicates a hazardous situation or action which, if not

avoided, could result in death or serious injury.

Proper maintenance and care of the generator ensure a minimum

number of problems and keep operating expenses at a minimum.

See a Service Dealer for service aids and accessories.

Indicates a hazardous situation or action which, if not

avoided, could result in minor or moderate injury.

NOTE:

Operating instructions presented in this manual assume that the

generator electric system has been installed by a Service Dealer or

other competent, qualified contractor. Installation of this equipment

is not a “do-it-yourself” project.

Notes contain additional information important to a procedure

and will be found within the regular text body of this manual.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliance with the special

instructions while performing the service are essential to prevent-

ing accidents.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, simply contact

a Service Dealer for assistance. Service technicians are factory-

trained and are capable of handling all service needs.

Four commonly used safety symbols accompany the DANGER,

WARNING and CAUTION blocks. The type of information each

indicates is as follows:

When contacting a dealer about parts and service, always supply

the complete Model Number, Serial Number and Type Code (where

applicable) from the DATA LABEL that is affixed to the unit.

This symbol points out important safety information that,

if not followed, could endanger personal safety and/or

property of others.

^{This symbol points out potential explosion hazard.}



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Safety Instructions

• The engine exhaust fumes contain carbon monoxide gas, which

SAFETY RULES

can be DEADLY. This dangerous gas, if breathed in sufficient

concentrations, can cause unconsciousness or even death. For

that reason, adequate ventilation must be provided. This should

be considered prior to installing the generator. The unit should

be positioned to direct exhaust gasses safely away from any

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

exhaust stacks that ship loose with the unit must be installed

properly per the manufacturer's instruction, and in strict compli-

ance with applicable codes and standards.

Study these SAFETY RULES carefully before installing, operating

or servicing this equipment. Become familiar with this Owner’s

Manual and with the unit. The generator can operate safely, effi-

ciently and reliably only if it is properly installed, operated and

maintained. Many accidents are caused by failing to follow simple

and fundamental rules or precautions.

The manufacturer cannot anticipate every possible circumstance

that might involve a hazard. The warnings in this manual, and on

tags and decals affixed to the unit are, therefore, not all inclusive.

If a procedure, work method or operating technique is used that

the manufacturer does not specifically recommend, ensure that it

is safe for others. Also make sure the procedure, work method or

operating technique utilized does not render the generator unsafe.

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

and other moving or hot parts. Never remove any drive belt or

fan guard while the unit is operating.

• Adequate, unobstructed flow of cooling and ventilating air is

critical in any room or building housing the generator to prevent

buildup of explosive gases and to ensure correct generator

operation. Do not alter the installation or permit even partial

blockage of ventilation provisions, as this can seriously affect

safe operation of the generator.

• Keep the area around the generator clean and uncluttered.

Remove any materials that could become hazardous.

• When working on this equipment, remain alert at all times.

Never work on the equipment when physically or mentally

fatigued.

• Inspect the generator regularly, and promptly repair or replace

all worn, damaged or defective parts using only factory-

approved parts.

• Before performing any maintenance on the generator, discon-

nect its battery cables to prevent accidental start-up. Disconnect

the cable from the battery post indicated by a NEGATIVE, NEG

or (–) first. Reconnect that cable last.

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

on the unit can stress and break parts, and may result in dan-

gerous operating conditions from leaking exhaust gases, fuel

leakage, oil leakage, etc.

n^{Despite the safe design of this generator,}

operating this equipment imprudently, neglect-

ing its maintenance or being careless can cause

possible injury or death. Permit only respon-

sible and capable persons to install, operate or

maintain this equipment.

^{Potentially lethal voltages are generated by}

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.

n^{Parts of the generator are rotating and/or hot}

during operation. Exercise care near running

generators.

GENERAL HAZARDS

• For safety reasons, the manufacturer recommends that this

equipment be installed, serviced and repaired by a Service

Dealer or other competent, qualified electrician or installation

technician who is familiar with applicable codes, standards

and regulations. The operator also must comply with all such

codes, standards and regulations.

ELECTRICAL HAZARDS

• Installation, operation, servicing and repair of this (and related)

equipment must always comply with applicable codes, stan-

dards, laws and regulations. Adhere strictly to local, state and

national electrical and building codes. Comply with regulations

the Occupational Safety and Health Administration (OSHA) has

established. Also, ensure that the generator is installed, operat-

ed and serviced in accordance with the manufacturer’s instruc-

tions and recommendations. Following installation, do nothing

that might render the unit unsafe or in noncompliance with the

aforementioned codes, standards, laws and regulations.

• All stationary emergency generators covered by this manual

produce dangerous electrical voltages and can cause fatal

electrical shock. Utility power delivers extremely high and dan-

gerous voltages to the transfer switch as well as the generator.

Avoid contact with bare wires, terminals, connections, etc.,

on the generator as well as the transfer switch, if applicable.

Ensure all appropriate covers, guards and barriers are in place

before operating the generator. If work must be done around

an operating unit, stand on an insulated, dry surface to reduce

shock hazard.

• Do not handle any kind of electrical device while stand-

ing in water, while barefoot, or while hands or feet are wet.

DANGEROUS ELECTRICAL SHOCK MAY RESULT.

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Safety Instructions

• If personnel must stand on metal or concrete while installing,

FIRE HAZARDS

operating, servicing, adjusting or repairing this equipment,

place insulative mats over a dry wooden platform. Work on the

equipment only while standing on such insulative mats.

• The National Electrical Code (NEC) requires the frame and

external electrically conductive parts of the generator to be con-

nected to an approved earth ground. This grounding will help

prevent dangerous electrical shock that might be caused by a

ground fault condition in the generator or by static electricity.

Never disconnect the ground wire.

• Keep a fire extinguisher near the generator at all times. Do NOT

use any carbon tetra-chloride type extinguisher. Its fumes are

toxic, and the liquid can deteriorate wiring insulation. Keep the

extinguisher properly charged and be familiar with its use. If

there are any questions pertaining to fire extinguishers, consult

the local fire department.

EXPLOSION HAZARDS

• Wire gauge sizes of electrical wiring, cables and cord sets must

be adequate to handle the maximum electrical current (ampac-

ity) to which they will be subjected.

• Before installing or servicing this (and related) equipment, make

sure that all power voltage supplies are positively turned off at

their source. Failure to do so will result in hazardous and pos-

sibly fatal electrical shock.

• Properly ventilate any room or building housing the generator to

prevent build-up of explosive gas.

• Do not smoke around the generator. Wipe up any fuel or oil

spills immediately. Ensure that no combustible materials are left

in the generator compartment, or on or near the generator, as

FIRE or EXPLOSION may result. Keep the area surrounding the

generator clean and free from debris.

• Connecting this unit to an electrical system normally supplied

by an electric utility shall be by means of a transfer switch so as

to isolate the generator electric system from the electric utility

distribution system when the generator is operating. Failure to

isolate the two electric system power sources from each other

by such means will result in damage to the generator and may

also result in injury or death to utility power workers due to

backfeed of electrical energy.

• These generators may operate using one of several types

of fuels. All fuel types are potentially FLAMMABLE and/or

EXPLOSIVE and should be handled with care. Comply with all

laws regulating the storage and handling of fuels. Inspect the

unit’s fuel system frequently and correct any leaks immediately.

Fuel supply lines must be properly installed, purged and leak

tested according to applicable fuel-gas codes before placing

this equipment into service.

• Stationary emergency generators installed with an automatic

transfer switch will crank and start automatically when normal

(utility) source voltage is removed or is below an acceptable

preset level. To prevent such automatic start-up and possible

injury to personnel, disable the generator’s automatic start cir-

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

Then, place a “Do Not Operate” tag on the generator control

panel and on the transfer switch.

• 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.

• In case of accident caused by electric shock, immediately

shut down the source of electrical power. If this is not pos-

sible, attempt to free the victim from the live conductor. AVOID

DIRECT CONTACT WITH THE VICTIM. Use a nonconducting

implement, such as a dry rope or board, to free the victim from

the live conductor. If the victim is unconscious, apply first aid

and get immediate medical help.

• Never wear jewelry when working on this equipment. Jewelry

can conduct electricity resulting in electric shock, or may get

caught in moving components causing injury.

CALIFORNIA PROPOSITION 65 WARNING

Engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects

and other reproductive harm.

CALIFORNIA PROPOSITION 65 WARNING

This product contains or emits chemicals known to the

State of California to cause cancer, birth defects and

other reproductive harm.

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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 generator’s lower connection box, lists the

unit’s serial number and its rated voltage, amps, wattage capacity,

phase, frequency, rpm, power factor, production date, etc.

Stationary Emergency Generator Model and Serial

Number

This number is the key to numerous engineering and manufactur-

ing details pertaining to your unit. Always supply this number

when requesting service, ordering parts or seeking information.

Data Label

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Equipment Description

EQUIPMENT DESCRIPTION

COOLANT RECOMMENDATIONS

Use a mixture of half low silicate ethylene glycol base anti-freeze

and deionized water. Cooling system capacity is listed in the

specifications. Use only deionized water and only low silicate

anti-freeze. If desired, add a high quality rust inhibitor to the rec-

ommended coolant mixture. When adding coolant, always add the

recommended 50-50 mixture.

This equipment is a revolving field, alternating current Stationary

Emergency Generator. It is powered by a gaseous fueled engine

operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for

2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear

units. See the Specifications section for exact numbers. The unit

comes complete with a sound attenuated enclosure, internally

mounted muffler, control console, mainline circuit breaker, bat-

tery charger, and protective alarms as explained in the following

paragraph.

^{Do not use any chromate base rust inhibitor}

with ethylene glycol base anti-freeze or chro-

All AC connections, including the power leads from the alterna-

tor, 120 volt battery charger input and control connections to the

transfer switch are available in the main connection box.

mium hydroxide (“green slime”) forms and will

cause overheating. Engines that have been

operated with a chromate base rust inhibitor

must be chemically cleaned before adding eth-

ylene glycol base anti-freeze. Using any high

silicate anti-freeze boosters or additives will

also cause overheating. The manufacturer also

recommends that any soluble oil inhibitor is

NOT used for this equipment.

The Stationary Emergency Generator incorporates the following

alternator features:

• Rotor and Stator insulation is Class F rated as defined by NEMA

MG1-32.6, NEMA MG1-1.66. The generator is self ventilated

and drip-proof constructed.

• The voltage waveform deviation, total harmonic content of the

AC waveform and telephone influence factor have been evalu-

ated and are acceptable according to NEMA MG1-32.

^{Do not remove the radiator pressure cap while}

the engine is hot or serious burns from boiling

liquid or steam could result.

ENGINE OIL RECOMMENDATIONS

The unit has been filled with 5W-20 engine oil at the factory. Use

a high-quality detergent oil classified “For Service SJ or SH.”

Detergent oils keep the engine cleaner and reduce carbon deposits.

When changing the engine oil, be sure to use 5W-30 engine oil

(synthetic oil is recommended).

^{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.

^{Any attempt to crank or start the engine before}

it has been properly serviced with the recom-

mended oil may result in an engine failure.

NOTE:

For temperatures below 32° F, it is strongly recommended to

use the optional Cold Weather Start Kit. The oil grade for tem-

peratures below 32° F is 5W-30 synthetic oil.

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Engine Protective Devices

OVERCRANK SHUTDOWN

ENGINE PROTECTIVE DEVICES

The Stationary Emergency Generator may be required to operate

for long periods of time without an operator on hand to monitor

such engine conditions as coolant temperature, oil pressure or

rpm. For that reason, the engine has several devices designed to

protect it against potentially damaging conditions by automatically

shutting down the unit when the oil pressure is too low, the coolant

temperature is too high, the coolant level is too low, or the engine

is running too fast.

After a prespecified duration of cranking, this function ends the

cranking if the engine has failed to start. The overcrank message

will turn ON. Turn OFF the AUTO/OFF/MANUAL switch, then turn

switch back to AUTO to reset the generator control board.

NOTE:

If the fault is not corrected, the overcrank feature will continue

to activate.

NOTE:

Approximate Crank Cycle Times

• 15 seconds ON

• 7 seconds OFF

• 7 seconds ON

Engine protective switches and sensors are mentioned here for

the reader’s convenience. Also refer to the applicable control

panel manual for additional automatic engine shutdown infor-

mation.

• 7 seconds OFF

• Repeat for 45 seconds

• Approximately 90 seconds total.

HIGH COOLANT TEMPERATURE SENDER

An analog coolant temperture sender, located in the engine's

cooling system will cause an engine shutdown if the temperature

should exceed approximately 125° C (257° F). The generator will

automatically restart once the temperature has returned to a safe

operating level.

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

To prevent overheating, the engine has a low coolant level sensor.

If the level of engine coolant drops below the level of the low cool-

ant level sensor, the engine automatically shuts down.

RPM SENSOR LOSS SHUTDOWN

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

will occur.

LOW OIL PRESSURE SWITCH

This switch has normally closed contacts that are held open by

engine oil pressure during cranking and operating. Should oil pres-

sure drop below the 8 psi range, switch contacts close, and the

engine shuts down. The unit should not be restarted until oil is

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

and then back to AUTO.

DC FUSES

A fuse (7.5 amp) is located on the control panel. It protects the

panel components from damaging overload. Always remove this

fuse before commencing work on the generator. The unit will not

start or crank if the fuse is blown.

A fuse (25 amp) is located in the engine wire harness adjacent

to the DC alternator. It is used to prevent circuit failure due to DC

alternator falure. It will also protect the system in the event of a

wiring short-dircuit. If this fuse is blown, the generator will not

operate. Replace these fuses with the same size, type, and rating.

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Fuel System

NATURAL GAS FUEL SYSTEM

FUEL SYSTEM

Natural gas is supplied in its vapor state. In most cases, the gas

distribution company provides piping from the main gas distribu-

tion line to the standby generator site. The following information

applies to natural gas fuel systems.

FUEL REQUIREMENTS

The Stationary Emergency Generator may be equipped with one of

the following fuel systems:

• Gas pressure in a building is usually regulated by national, state

and local codes.

• To reduce gas pressure to a safe level before the gas enters a

building, a primary regulator is needed. The natural gas supplier

may or may not supply such a regulator.

• It is the responsibility of the gas supplier to make sure sufficient

gas pressure is available to operate the primary regulator.

• Gas pressure at the inlet to the fuel shutoff solenoid must never

exceed approximately 14 inches water column (0.5 psi).

• Natural gas fuel system

• Propane vapor (LPV) fuel system

Recommended fuels should have a Btu content of at least 1,000

Btu's per cubic foot for natural gas; or at least 2,520 Btu's per

cubic foot for LP gas. Ask the fuel supplier for the Btu content of

the fuel.

NOTE:

The fuel consumption requirements are identified in the

Specifications section of the Owner's Manual. Refer to the

Installation Manual if assistance is required for the sizing of

the pipe diameter for the generator. Any piping used to connect

the generator to the fuel supply should be of adequate size to

achieve the 100% load fuel consumption requirements identi-

fied in the Specifications section regardless of actual load.

PROPANE VAPOR WITHDRAWAL FUEL SYSTEM

This type of system utilizes the vapors formed above the liquid

fuel in the supply tank. Approximately 10 to 20 percent of the tank

capacity is needed for fuel expansion from the liquid to the vapor

state. The vapor withdrawal system is generally best suited for

smaller engines that require less fuel. The installer should be aware

of the following:

NOTE:

TherecommendedfuelpressureisidentifiedintheSpecifications

section this manual.

• When ambient temperatures are low and engine fuel consump-

tion is high, the vapor withdrawal system may not function

efficiently.

• Ambient temperatures around the supply tank must be high

enough to sustain adequate vaporization, or the system will not

deliver the needed fuel volume.

NOTE:

It is the responsibility of the installer to make sure that only

the correct recommended fuel is supplied to the generator fuel

system. Thereafter, the owner/operator must make certain that

only the proper fuel is supplied.

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

process itself provides an additional cooling effect.

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Specifications

Engine Lubrication System

SPECIFICATIONS

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

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

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

STANDBY EMERGENCY GENERATOR

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

Rotor Insulation.............................................................Class H

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

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

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

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

Load Capacity (Standby Rating)...............................25/30 kW*

COOLING SYSTEM

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

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

Fan Speed.........................................................................2484

Fan Diameter...........................................................17.7 inches

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

Air Flow (inlet air including alternator and

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

J1349, ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate

with natural gas.

combustion air) ..................................................1800 ft /min.

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

Generator Output Voltage/kW - 60 Hz

120/240V, 1-phase, 1.0 pf 25/30

120/208V, 3-phase, 0.8 pf 25/30

120/240V, 3-phase, 0.8 pf 25/30

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

Heat Rejection to Coolant (25/35kW) ....112,000/135,000 Btu/h

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

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

Amp

104/125

87/104

75/90

CB Size

125/150

100/125

90/100

FUEL SYSTEM

Generator Locked Rotor KVA Available @ Voltage Dip of 35%

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

25kW

35 KVA

30kW

45 KVA

ENGINE

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

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

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

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

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

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

Compression Ratio....................................................... 9.5-to-1

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

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

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

Spark Plug Gap........................................0.76mm (0.030 inch)

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

Exercise

Cycle

25%

Load

50%

Load

75%

Load

100%

Load

25kW

30kW

60/24

120/48 220/87 310/123 390/155

145/58 260/103 370/147 470/187

ELECTRICAL SYSTEM

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

Static Battery Charger ....................................... 2.0 or 2.5 Amp

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

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

Engine Parameters

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

Voltage Regulator

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

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

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

Features.........................Adjustable Voltage and Automatic Gain

Exhaust System

Exhaust Flow at Rated Output 60 Hz: 25kW

240 cfm

30kW

260 cfm

1025°F

Exhaust Temp. at Rated Output:

975°F

Power Adjustment for Ambient Conditions

Temperature Deration:

3% for every 10° C above °C

Combustion Air Requirements (Natural Gas)

25kW 30kW

Flow at rated power, 60 Hz:

25kW

90 cfm

30kW

95 cfm

104

1.65% for every 10° above °F

Altitude Deration:

1% for every 100 m above m

Governor

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

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

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

Adjustments:

25kW 30kW

915

2000

182

600

3% for every 1000 ft. above ft.

Controller ................................................................. Nexus

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

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Specifications

9. Install the previously removed black pipe onto the outlet

WEATHER AND MAINTENANCE KITS

To keep the generator running at its peak, the following kits are

offered:

port of the demand regulator. Use pipe sealant on the pipe

threads.

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

• Cold Weather Kit

regulator.

~ Recommended for climates with temperatures below 32° F.

• Extreme Cold Weather Kit

11. Follow the instructions in the Control Panel section.

~ Recommended Block Heater Kit for protection in tempera-

tures below 32° F.

• Scheduled Maintenance Kit

~ Kit includes the recommended parts to maintain the genera-

tor. Refer to the Service Schedule for regular maintenance

intervals.

^{Serious injury, including death, or damage}

will occur if not configured properly. Please

consult an Authorized Dealer with any ques-

tions.

For additional information, or to order any of these kits, please

contact an Authorized Service Dealer or Customer Service

Representative.

Figure 6.1 — Reconfigure the Fuel System

RECONFIGURING THE FUEL

SYSTEM

NOTE:

All models are configured to run on natural gas from the fac-

tory.

Before the generator can be operated using a LP fuel source, the

fuel system and control panel (refer to the installation drawing for

location) must be reconfigured. The steps to reconfigure the gen-

erator from a natural gas (NG) to a liquidified petroleum (LP) fuel

source are as follows:

FUEL SYSTEM

1. Turn the main gas supply off and disconnect the battery.

2. Remove the carburetor fuel hose from the outlet port of the

demand regulator (see Figure 6.1).

3. Disconnect the power wires from the fuel solenoid located

on top of the regulator assembly by removing the screw on

the front of the connector and pulling the connector forward,

away from the solenoid body.

CONTROL PANEL

The FUEL TYPE must be reconfigured in the control panel to final-

ize the conversion process. This generator is configured at the

factory to operate on natural gas. If conversion to LP is required,

please complete the mechanical conversion process and then call

888-9ACTIVATE for the control panel password. This fuel selection

conversion is required to be password protected by Environmental

Protection Agency [EPA] regulations.

4. Loosen the spring clamp on the small fuel enrichment line and

remove the hose from the hose barb.

5. Remove the black pipe assembly from the outlet port of the

demand regulator. The solenoid assembly may need to be

removed before performing this operation (Figure 6.1).

6. Remove the NG fuel jet (loosen counter clockwise) from the

outlet port.

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

keeper port on the side of the regulator housing. Install this jet

into the outlet port in the regulator casting.

^{Whenever the Generator’s Fuel Regulator is}

converted from one Fuel type to the other,

the Control Panel must be reconfigured for

the correct fuel type. Failure to convert both

the Regulator and Control Panel will result in

decreased performance and an increase in

emissions, and is a violation of EPA regula-

tions.

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.

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General Information

ALTERNATOR AC LEAD

ALTERNATOR POWER WINDING

CONNECTIONS

The electrical wires in the unit’s AC connection (lower) panel

should be installed according to the number of leads and the

voltage/phase required for the application. The voltage and phase

are described on the generator data label. The number of lead

wires can be identified using the Specifications section and the

power output rating on the generator data label. For example, if

the generator produces 130kW, 277/480 Volt, 3-phase power, the

generator has 12 alternator output leads. Figure 7.3 describes the

stator power winding connection for the generator.

3-PHASE ALTERNATORS ("Y" CONFIGURATION)

The Stationary Emergency Generator is designed to supply

3-phase electrical loads. Electric power is produced in the alterna-

tor power windings. These windings were connected at the factory

to the main circuit breaker with a “Y” configuration as shown in

Figures 7.2 through 7.6.

The rated voltage between circuit breaker terminals E1-E2, E1-E3

and E2-E3 is 480V, 208V or 600V depending on the model.

The rated voltage between each circuit breaker terminal and the

neutral point 00 is 277V, 120V, or 346V depending on the model.

FOUR-LEAD, SINGLE-PHASE STATOR

Four-lead alternators (see Figure 7.1) are designed to supply elec-

trical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical

power is produced in the stator power windings. These windings

were connected at the factory to the main circuit breaker as shown

in Figure 7.1.

Figure 7.2 — Stator Power Winding

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

The rated voltage between each circuit breaker terminal is 240V.

The rated voltage between each circuit breaker terminal and the

neutral point 00 is 120V.

INTERNAL

CONNECTIONS

Figure 7.1 — Four-lead, Single-phase Stator

L - L

00 (NEUTRAL)

L - N

Figure 7.3 — Stator Power Winding

Connections - 3-phase, 277/480V (12 Lead)

L - L

S12

S10

S11

L - N

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General Information

Figure 7.4 — Stator Power Winding

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

3-PHASE ALTERNATORS ("DELTA" CONFIGURATION)

The Stationary Emergency Generator is designed to supply

3-phase electrical loads. Electric power is produced in the alterna-

tor power windings. These windings were connected at the factory

to the main circuit breaker with a “Delta” configuration as shown

in Figures 7.7 and 7.8.

INTERNAL CONNECTIONS

The rated voltage between circuit breaker terminals E1-E2, E1-E3

and E2-E3 is 240V.

The rated voltage between E1 or E3 and the neutral point 00 is

120V.

L-L

00 (NEUTRAL)

Figure 7.7 — Stator Power Winding

Connections - 3-phase, 120/240V (6 Lead)

S6 S5

L-N

INTERNAL

CONNECTIONS

Figure 7.5 — Stator Power Winding

Connections - 3-phase, 120/208V (12 Lead)

L - L

L-L

S10

S12

L - N

00 (NEUTRAL)

S6 S11

Figure 7.8 — Stator Power Winding

Connections - 3-phase, 120/240V (12 Lead)

L-N

S12

Figure 7.6 — Stator Power Winding

Connections - 3-phase, 346/600V (6 Lead)

INTERNAL

L - L

CONNECTIONS

L - L

S11

00 (NEUTRAL)

S10

L - N

00 (NEUTRAL)

L - N

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Control Panel

Upon power up, this controller will go through a system self test

CONTROL PANEL INTERFACE

which will check for the presence of utility voltage on the DC

circuits. This is done to prevent damage if the installer mistakenly

connects AC utility power sense wires into the DC terminal block.

If utility voltage is detected, the controller will display a warning

message and lock out the generator, preventing damage to the

controller. Power to the controller must be removed to clear this

warning.

USING THE AUTO/OFF/MANUAL SWITCH

With the switch set to AUTO, the engine may

crank and start at any time without warning.



Such automatic starting occurs when utility

power source voltage drops below a preset

level or during the normal exercise cycle. To

prevent possible injury that might be caused

by such sudden starts, always set the switch

to OFF and remove the fuse before work-

ing on or around the generator or transfer

switch. Then, place a “DO NOT OPERATE”

tag on the generator panel and on the trans-

fer switch.

Utility voltage must be turned on and present at the N1 and N2

terminals inside the generator control panel for this test to be

performed and pass.

NOTE:

DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT

WIRES IS NOT WARRANTABLE!

This test will be performed each time the controller is powered

up.

Next, the user must enter the minimum settings to operate. These

settings are current date and time and exercise day and time. The

maintenance intervals will be initialized (i.e. started) the first time

the clock is set. If the clock is never set at power up, the mainte-

nance intervals will be reset every time power is applied.

1. “AUTO” Position – Selecting this switch activates fully auto-

matic system operation. It also allows the unit to automati-

cally start and exercise the engine every seven days with the

setting of the exercise timer (see the Setting the Exercise

Timer section).

2. “OFF” Position – This switch position shuts down the engine.

If a subsequent power loss (loss of battery power) occurs the

Installation assistant will operate upon power restoration. The self

test routine will be run and then the customer will be required to

re-enter the time and date, as this is not retained during a power

loss. The unit will not require re-activation.

This position also prevents automatic operation.

3. “MANUAL” Position – Set the switch to MANUAL to crank

and start the engine. Transfer to standby power will not occur

unless there is a utility failure.

ACTIVATE THE GENERATOR

When battery power is applied to the generator during the instal-

lation process, the controller will turn ON and the LCD screen will

illuminate. However, the generator still needs to be activated before

it will automatically run in the event of a power outage.

DISPLAY INTERFACE MENUS

The LCD display is organized as detailed below:

• The “Home” page, this page is the default page which will be

displayed if no keys are pressed for 30 seconds. This page

normally shows the current Status message and the current

date and time. The highest priority active Alarm and/or Warning

will be automatically posted on this page as well as flashing

the backlight when such an event is detected. In the case of

multiple Alarms or Warnings, only the first message will be

displayed. To clear an Alarm or Warning, see the Protection

Systems section - Clear Alarm.

• The display backlight is normally off. If the user presses any

key, the backlight will come on automatically and remain on for

30 seconds after the last key was pressed.

• The “Main Menu” page will allow the user to navigate to all other

pages or sub-menus by using the Left/Right and Enter keys.

This page can be accessed at any time with several presses of

the dedicated Escape key. Each press of the Escape key takes

you back to the previous menu until the main menu is reached.

This page displays the following options: HISTORY; STATUS;

EDIT; AND DEBUG. (See the Appendix - "Menu System".)

Activating the generator is a simple one time process that is guided

by the controller screen prompts. Once the product is activated,

the controller screen will not prompt you again, even if you discon-

nect the generator battery.

To obtain the activation code, record the generator serial number

and log onto www.activategen.com or call 1-888-9ACTIVATE and

follow the steps to retrieve the activation code.

After obtaining your activation code, please complete the following

steps at the generator’s control panel in the Activation Chart on the

following page.

NOTE:

The generator will only run in manual until the passcode has

been entered.

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Control Panel

ACTIVATION CHART

CHOOSE LANGUAGE

TROUBLESHOOTING

Display Reads:

Use ARROW keys to scroll to desired lan-

guage. Press ENTER to select.

If the wrong language is chosen, it can be

changed later using the “edit” menu.

Language

English

Escape

Enter

Display Reads:

Press ENTER to begin the activation pro-

cess.

If ESCAPE is pressed instead of ENTER,

your generator will only run in manual mode

(for test purposes) and NOT ACTIVATED will

be displayed. You will need to remove the

generator control panel fuse AND disconnect

the T1, N1 and N2 connector in the external

connection box (if equipped); or disconnect

utility input (main breaker) to the transfer

switch for 3-5 seconds and reconnect, then

begin with Step 1.

Activate me (ENT) or

ESC to run in manual

Escape

Enter

Display Reads:

If you do not have your activation code,

go to www.activategen.com or call

1-888-9ACTIVATE (922-8482).

To Activate go to

www.activategen.com

If you already have your activation code,

wait 3-5 seconds for the next display.

Escape

Enter

ENTER ACTIVATION CODE (Passcode)

TROUBLESHOOTING

Display Reads:

Use ARROW keys to scroll and find the first

number of your Activation Code.

Serial 123456789

Passcode XXXXX +/-

Press ENTER to select.

Repeat this step until all digits have been

entered.

Escape

Enter

Use ESCAPE to correct previous digits.

Display Reads:

Activation is complete when all digits are

entered above and your screen shows this

display.

What happens if “Wrong Passcode Try

Again” appears?

“SELECT HOUR (0-23)”

“-

Re-enter the activation code. If a second

attempt is unsuccessful, check the number

against the code given on activategen.com.

If it is correct and the generator will not

accept it, contact 1-888-9ACTIVATE (922-

8482).

+”

Follow the controller prompts to continue

setting the time function. Refer to your

Owner’s Manual with questions.

Escape

Enter

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Control Panel

• If utility is still lost after the “line interrupt period”, run the engine

INSTALLATION ASSISTANT

Interconnect System Self Test Feature (follow the on-screen

prompts).

up to normal RPM and transfer the load. At this time the con-

troller will exit the exercise routine and assume full automatic

operation.

Upon power up, this controller will go through a system self test

which will check for the presence of utility voltage on the DC

circuits. This is done to prevent damage if the installer mistakenly

connects AC utility power sense wires into the DC terminal block.

If utility voltage is detected, the controller will display a warning

message and lock out the generator, preventing damage to the

controller. Power to the controller must be removed to clear this

warning.

USER ADJUSTABLE SETTINGS

Factory

Default

Minimum

Setting

Maximum

Setting

Increment

1 min

Exercise

time

23:59

(11:59 pm)

2 pm

Wed

00:00 (12 am)

Sun

Exercise

day

Utility voltage must be turned on and present at the N1 and N2

terminals inside the generator control panel for this test to be

performed and pass.

Sat

1 day

Current

Time

23:59

(11:59 pm)

12 am 00:00 (12 am)

1 min

NOTE:

Current

Day

Sun

Jan

Sun

Jan

Sat

Dec

1 day

DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT

WIRES IS NOT WARRANTABLE!

Current

Month

1 month

1 year

This test will be performed each time the controller is powered

up.

Current

Year

2008

2100

Upon first power up of the generator, the display interface will

begin an installation assistant. The assistant will prompt the user

to set the minimum settings to operate. These settings are simply:

Current Date/Time and Exercise Day/Time. The maintenance inter-

vals will be initialized when the exercise time is entered.

Language

Contrast

English

80%

French

Spanish

100%

N/A

The exercise settings can be changed at any time via the "EDIT"

menu (see Appendix, "Menu System").

FUEL CONVERSION

For fuel conversion steps, refer to the GenSpec section,

RECONFIGURING THE FUEL SYSTEM.

If the 12 volt battery is disconnected or the fuse removed, the

Installation Assistant will operate upon power restoration. The

only difference is the display will only prompt the customer for the

current Time and Date.

OPERATION

IF THE INSTALLER TESTS THE GENERATOR PRIOR TO

INSTALLATION, PRESS THE “ENTER” KEY TO AVOID SETTING

UP THE EXERCISE TIME. THIS WILL ENSURE THAT WHEN

THE CUSTOMER POWERS UP THE UNIT, HE WILL STILL BE

PROMPTED TO ENTER AN EXERCISE TIME.

This system is intended to supply standby power in the event of a

utility failure. The control system will monitor the utility voltage to

determine if stand-by power is required. Should the utility voltage

fail, the generator will start and run normally, detaching from the

utility and supplying the customer load from the generator. When

utility power returns, the controller will re-transfer the customer

load back to utility and shut down the generator.

SETTING THE EXERCISE TIMER

This generator is equipped with an exercise timer. Once it is set,

the generator will start and exercise every seven days, on the day

of the week and at the time of day specified. During this exercise

period, the unit runs for approximately 12 minutes and then shuts

down. Transfer of loads to the generator output does not occur

during the exercise cycle unless utility power is lost.

AUTOMATIC TRANSFER OPERATION

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts are set to their

UTILITY position, i.e., loads connected to the utility power

source.

2. Be sure that normal UTILITY power source voltage is avail-

able to transfer switch terminal lugs N1 and N2 (Refer to the

Electrical Data section).

3. Set the generator’s AUTO/OFF/MANUAL switch to AUTO.

4. Set the generator’s main circuit breaker to its ON (or CLOSED)

position.

With the preceding steps complete, the generator will start auto-

matically when utility source voltage drops below a preset level.

After the unit starts, loads are transferred to the standby power

source. Refer to the Sequence of Automatic Operation section.

LOW SPEED EXERCISE

The standard start sequence will be initiated.

• All 1800 rpm units will exercise at 1400 RPM

• All 3600 rpm units will exercise at 1800 RPM

If utility is lost during exercise the controller will do the following:

• Wait for the “line interrupt period” for utility to return. If utility

returns within the “line interrupt period”, continue to exercise

at low RPM.

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Control Panel

SEQUENCE OF AUTOMATIC OPERATION

Initial Conditions: Generator in Auto ready to run, load being sup-

plied by the Utility Source through the transfer switch.

MANUAL START

Allows the user to start and run the generator manually.

Transfer of the load to the generator will occur if utility is lost while

the unit is running in the manual mode (only if activated).

1. When the utility voltage fails (falls below 60% of nominal), a

10-30 second (programmable) “line interrupt” delay timer is

started. The factory set time delay is 10 seconds. If at the

end of the line interrupt time the utility voltage is above 60%

the engine will not crank. If the utility voltage is still below

the 60% of nominal at the end of the line interrupt time, the

unit will crank and start. If the unit cranks for more than 10

seconds and the utility voltage rises above 80% of nominal

(programmed pickup voltage) and the unit has not started, the

crank cycle will abort.

2. As soon as the unit starts a 5 second “warm-up” timer is initi-

ated. When the warm-up timer expires the control will transfer

the load to the generator (through the RTS switch) if the utility

voltage is less than 80% of nominal. If the utility voltage is

greater than the 80% of nominal at the end of the warm-up

time the load will not be transferred to the generator and a one

minute low-speed cool down period will start. At the end of

the one minute cool down period the generator will stop.

3. Once the unit is running and the switch has transferred the

load to the generator the unit will monitor utility voltage.

When utility voltage returns (above the programmable pickup

voltage, normally 80% of nominal), a 15 second “Return to

Utility” timer will start. At the end of the return to utility time,

if the utility voltage is still above the pickup voltage, the unit

will transfer the load back to the utility source and run the unit

through a one minute cool down period. When the cool down

period is over the unit will shut down and be ready for the next

outage.

ALARM AND WARNING MESSAGES

Alarms are defined as “Latching” which means they must be

cleared before the alarm message on the screen will clear. They

can be of type “Shutdown” or not and are logged in the alarm log.

Alarms are all annunciated on the display).

Warnings are “Non Latching” meaning the message automati-

cally clears when the warning condition goes away. Warnings can

not be of type “Shutdown” but they are logged in the alarm log.

Warnings are all annunciated on the display.

LOW OIL PRESSURE SHUTDOWN ALARM

There is a 10 second delay before oil pressure is monitored.

HIGH COOLANT TEMPERATURE SHUTDOWN ALARM

There is a 10 second delay before engine temperature is moni-

tored.

Once running there is a 1/4 second delay before shut down. The

limit is set at 125° C or 257° F.

OVERCRANK SHUTDOWN ALARM

Occurs if the engine has not started within the specified crank

cycle.

4. If during the cool down period utility voltage should fall below

60% of nominal the 5 second warm-up timer is initiated and

the unit will transfer the load back to the generator and con-

tinue to monitor the utility.

OVERSPEED SHUTDOWN ALARM

Warning indicator is measured and calculated by the microproces-

sor. Overspeed is defined as +20% of nominal engine speed for 3

seconds, or +25% immediate.

CRANK CYCLES AND OVERCRANK SHUTDOWN

If the unit fails to start during a cranking period it will display the

Overcrank Shutdown Alarm. The system will control the cranking

cycles as follows:

Nominal engine speed = 60.0 Hz

RPM SENSOR FAILURE SHUTDOWN ALARM

During cranking: If the board does not see a valid RPM signal

within four (4) seconds of cranking it will shut down and lock out

on RPM sensor loss.

The first crank cycle is a 16 second crank time followed by a 7

second rest. The next 5 cycles will be 7 seconds of cranking time

each followed by a 7 second rest time.

If the unit fails to start by the end of the 6 crank/rest cycles

the Overcrank Shutdown Alarm will display and the unit will not

attempt to crank until the alarm is reset.

During running: If the RPM signal is lost for one full second the

board will shut the engine down, wait 15 seconds, then re-crank

the engine if in AUTO, it will not re-crank in MANUAL.

If no RPM signal is detected within the first four (4) seconds of

cranking, the control board will shut the engine down and latch out

on RPM sensor loss.

AUTO START

This unit is designed to automatically start in the event of a util-

ity failure or brown out condition. Brown out is defined as utility

voltage less than 60% nominal, while utility is considered good

when it is restored to at least the pickup value, 80% of nominal.

These levels are fixed. The “Line Interrupt period” is an adjustable

parameter by the dealer. If 2-wire start mode is activated, the unit

will start when 2-wire start is active.

If the RPM signal is detected the engine will start and run normally.

If the RPM signal is subsequently lost the control board will try

two more re-cranks before latching out and flashing the RPM

Sensor Failure message (if it is in AUTO).

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Control Panel

Figure 1 – Generator Control Panel

CHECK ENGINE MESSAGE

MISSING CAM PULSE ALARM

The control system has detected an emissions related fault. This

fault cannot be cleared using the control panel interface. The unit

will continue to operate in automatic mode. Contact your local

servicing dealer.

This is a shutdown alarm. The alarm will activate after five (5)

seconds of continuously missing cam pulses.

MISSING CRANK PULSE ALARM

This is a shutdown alarm. The alarm will activate after 12 con-

secutive revs where crank pulses are missing.

UNDER-FREQUENCY SHUTDOWN ALARM

After starting, if the generator stays under frequency for more than

30 seconds, it will shutdown.

LOW FUEL PRESSURE WARNING

Fuel pressure is monitored by a digital sensor with a fixed setpoint

of below five (5) inches water column.

LOW BATTERY ALARM

While running, if the average battery voltage falls below 11.9 volts

for one (1) minute, the low battery alarm will be displayed.

GOVERNOR SENSOR FAULT ALARM

The governor position is monitored by an analog feedback signal. If

the throttle position is seen outside of the normal operating range,

a shutdown alarm is displayed. If the throttle is commanded to

move, and no movement is seen, a shutdown alarm is displayed.

LOW BATTERY WARNING

The microprocessor will continually monitor the battery voltage

and display the Low Battery Voltage message if the battery voltage

falls below 12.2 Volts for one (1) minute.

WIRING ERROR ALARM

No other action is taken on a low battery warning condition. The

warning will automatically clear if the battery voltage rises above

12.2 volts.

When power is first apllied to the contoller, the software will per-

form a check on the wiring of the transfer output, and ensure it

does not have high voltage on the wire. If this is the case, it will

signal a miswire alarm and will not run. The test can be skipped

by use of the escape key.

NOTE:

The battery sentinel is a separate feature that monitors battery

condition.

UNDERVOLTAGE ALARM

If the generator voltage falls below 60% for >5 seconds, an alarm

will be issued.

LOW COOLANT LEVEL ALARM

This is a shutdown alarm. The sensor will be continuously moni-

tored. If an error condition is seen for five (5) consecutive sec-

onds, the alarm will be displayed.

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Control Panel

OVERVOLTAGE ALARM

ALARM CANCEL

If the generator voltage rises above 110% for >3 seconds, an

alarm will be issued.

When the generator is shut down due to a latching alarm, the Auto

/Off/ Manual switch must be set to the off position and the ENTER

key pressed to unlatch any active fault and clear the corresponding

fault alarm message.

If the generator voltage rises above 130% for >0.2 seconds, an

alarm will be issued.

INTERNAL FAILURE SHUTDOWN ALARM

Any internal failure that can be detected such as corrupted

firmware will cause this shutdown alarm. This alarm cannot be

cleared.

COMMON ALARM RELAY

The common alarm relay will be activated if there is a shutdown

alarm. It will not activate on warnings or indicate that the Auto/Off/

Manual switch is in the OFF position. The OFF position will clear

the alarms and the relay. The relay will not be used to indicate a

generator is not activated.

CANBUS ALARM

The common alarm connections are wired to a set of potential-

free (dry) contacts on the Nexus controller board. These Normally

Open (N.O.) contacts close when an alarm condition occurs and

are used to activate a remote signaling device. The circuit is rated

for a maximum of 130mA at 24 VDC. The connections are a short

set of free hanging wires that exit the engine harness loom directly

behind the Nexus Control Panel and are labeled numbers 209 and

210.

Where applicable, if the Canbus communications link fails to com-

municate, a “Canbus Alarm” will be generated. This only applies

to systems with external ignition modules. The alarm may be

generated if:

1. The physical link is broken.

2. The Ignition Module fails or resets.

3. The Nexus Controller fails or resets.

4. Having the Battery Chargers 120 VAC connected without a

battery installed.

MAINTENANCE ALERTS

Maintenance alerts will be provided for these conditions.

5. A blown 10 amp Ignition Module fuse (approximately 12

inches away from the starter).

6. A blown 25 amp system fuse (located approximately 12

inches away from the DC alternator).

NOTE:

SERVICE SCHEDULE ‘A’

Inspect Accessory Drive Alert

Coolant Change & Flush

1yr / 100hrs*

1yr / 100hrs

1yr / 100hrs*

1yr / 100hrs

6mo / 50hrs*

The “Canbus Alarm” will not clear on its own. To clear the

alarm, press the “enter” key to acknowledge the alarm. The

alarm will clear and if the fault is still present, the alarm will

reoccur.

Inspect Spark Plugs Alert

Change Oil & Filter Alert

IGNITION ALARM

When an ignition alarm occurs, a generic message “Ignition Fault”

will be displayed as the fault code.

Inspect Battery Alert

Change / Inspect Air Filter Alert

Clean/Inspect Air Inlet & Exhaust

* Items require a 3 month / 30 hour break-in change or check.

MAINTENANCE WARNING

When a maintenance period expires, a warning message will be

posted. The warning can be reset by hitting the Enter key. Resetting

will clear the warning and reset the maintenance counters for the

condition annunciated. The history log will reflect the maintenance

warning.

SERVICE SCHEDULE ‘B’

Change / Inspect spark plugs alert

2yr/ 250hr

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Operation

STATIONARY EMERGENCY

GENERATOR CONTROL AND

OPERATION

Do not crank the engine continuously for lon-

ger 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.

• Check all applicable instrument and gauge readings. When

certain that all readings are correct, move the transfer switch

manual handle to the STANDBY (or EMERGENCY STANDBY)

position, i.e., load circuits supplied by the generator.

• Set the generator’s main line circuit breaker to its ON (or

CLOSED) position.

OPERATING UNIT WITH MANUAL

TRANSFER SWITCH

If the Stationary Emergency Generator was installed in conjunction

with a transfer switch capable of manual operation only, the fol-

lowing procedure applies. A manually operated transfer switch is

one that will not provide automatic start-up and does not include

an intelligence circuit.

• Load circuits are now powered by the generator.

RETRANSFER AND SHUTDOWN

For additional information, refer to the applicable control panel

manual for this unit, as well as any literature pertaining to the

specific transfer switch.

ENGINE START-UP AND TRANSFER

For additional information, refer to the applicable control panel

manual for this unit, as well as any literature pertaining to the

specific transfer switch.

To transfer the load back to the utility power source and shut down

the generator, follow these directions:

• Set the generator’s main line circuit breaker to its OFF (or OPEN)

position.

• Manually move the transfer switch handle to its UTILITY

(NORMAL) position, i.e., load circuits connected to the utility.

• Turn ON the utility power supply to the transfer switch, using

the means provided (such as the utility power source main line

circuit breaker).

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

internal temperatures.

• Shut down the generator.

n^{The Maintenance Disconnect Switch and the}

AUTO/OFF/MANUAL switches (if so equipped)

must be set properly, or the generator will

crank and start as soon as the utility power to

the transfer switch is turned off. Refer to appli-

cable control panel and transfer switch manuals

for more information.

n^{Do not proceed until certain that utility source}

voltage is available to the transfer switch and

OPERATING UNIT WITH AUTOMATIC

the transfer switch main contacts are set to

UTILITY.

TRANSFER SWITCH

^{Do not attempt manual operation until all}

power supplies to the transfer switch have been

If the Stationary Emergency Generator has been installed with an

automatic transfer switch, the engine may be started and stopped

automatically or manually.

positively turned off, or extremely dangerous -

possibly lethal - electrical shock will result.

NOTE:

^{Transfer switch enclosure doors should be kept}

closed and locked. Only authorized personnel

Refer to the applicable manual for your transfer switch and to

“Transfer Switch Start Signal Connections”. In addition, please

note the dangers under “Engine Start-up and Transfer.”

should be allowed access to the transfer switch

interior. Extremely high and dangerous voltages

are present in the transfer switch.

In order to transfer load from the utility source to the generator,

follow these directions:

• Turn OFF or disconnect the utility power circuit to the transfer

switch, using the means provided (such as the utility source

main line circuit breaker).

• Set the transfer handle to its UTILITY (NORMAL) position with

load circuits connected to the utility power supply.

• Set the generator’s main line circuit breaker to its OFF (or OPEN)

position.

• Start the generator.

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Maintenance

Refer to the Service Schedule for engine oil and filter change fre-

quencies.

GENERAL MAINTENANCE

Drain the oil while the engine is still warm from running. This

means warm up the engine, shut it down and drain immediately

as follows:

^{Before working on the Stationary Emergency}

Generator, ensure the following:

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

• The control panel fuse has been removed from the control

box.

1. Remove the drain hose from its retaining clip or cut the zip-tie

securing the oil drain hose.

2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil com-

• The 120VAC supply to the battery charger is switched OFF.

• The negative battery cable has been removed.

pletely into suitable container.

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

CAP and secure drain hose with a new zip-tie, or place the

hose in its retaining clip.

CHECK ENGINE OIL

Check engine crankcase oil level (Figure 10.1) according to the

Service Schedule and SIB10-10-L24G.

4. Turn OIL FILTER (Figure 10.1) counterclockwise and remove.

Properly dispose of old filter.

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

ter. Install FILTER and tighten by hand only. DO NOT OVER

TIGHTEN.

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

• Install oil dipstick, then remove again.

• Oil should be between FULL and ADD marks.

• If oil level is below the dipstick ADD mark, remove oil fill cap-.

Add the recommended oil to bring oil level up to the FULL

mark. DO NOT FILL ABOVE THE “FULL” MARK. See “Engine Oil

Recommendations” for recommended oils.

6. Remove OIL FILL CAP and add recommended oil. Crankcase

oil capacity is listed in the "Specifications" section.

After refilling the crankcase with oil, always

check oil level on dipstick. NEVER OPERATE

ENGINE WITH OIL BELOW THE DIPSTICK “ADD”

MARK.

Figure 10.1 - Oil Dipstick and Oil Fill Cap

OIL FILL CAP

7. Start engine and check for oil leaks.

8. Shut OFF engine and wait 10 minutes for the oil to settle down

into the oil pan. Recheck oil level on dipstick. DO NOT fill

above the dipstick "FULL" mark.

9. Dispose of used oil at a proper collection center.

COOLING INTAKE/OUTLET

Air intake and outlet openings in the generator compartment must

be open and unobstructed for continued proper operation. This

includes such obstructions as high grass, weeds, brush, leaves

and snow.

OIL

Without sufficient cooling and ventilating air flow, the engine/gen-

erator quickly overheats, which causes it to shut down. (See the

installation diagram.)

DIPSTICK

The exhaust system parts from this product get

extremely hot and remains hot after shutdown.

High grass, weeds, brush, leaves, etc. must

remain clear of the exhaust. Such materials may

ignite and burn from the heat of the exhaust

system.

OIL

FILTER



CHANGING ENGINE OIL

INSPECT COOLING SYSTEM

• Inspect engine cooling system. See the Service Schedule.

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

discrepancies found.

Hot oil may cause burns. Allow engine to cool

before draining oil. Avoid prolonged or repeat-

ed skin exposure with used oil. Thoroughly

wash exposed areas with soap.

• Check hose clamps for tightness.

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Maintenance

ENGINE COOLANT

CHECK FAN BELT

Checkcoolantlevelincoolantrecoverybottle.See theSpecifications

and Service Schedule sections.

• Inspect fan belts every year. Replace any damaged, deterio-

rated, worn or otherwise defective belt.

• Check fan belt tension. Thumb pressure, exerted midway

between pulleys, should deflect about 3/8 to 5/8 of an inch.

Adjust belt tension as required.

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap (only when engine

has cooled down) to make sure the coolant recovery system

is functioning properly. Coolant should be at bottom of radia-

tor filler neck. If coolant level is low, inspect gasket in radiator

pressure cap. Replace cap, if necessary. To have pressure cap

tested, contact a Service Facility. Inspect cooling system and

coolant recovery system for leaks.

• Check fan belt alignment (see Figure 10.2).

Figure 10.2 – Fan Belt

COOLANT CHANGE

Every year, have a service facility drain, flush and refill the cooling

system. See the Specifications and Service Schedule for cooling

system recommendations.

OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL

SYSTEM

Engine cranking, start up and running are controlled by a solid

state Engine Controller circuit board. Battery voltage is delivered

to that circuit board via the control panel fuse. This overcurrent

protection device will open if the circuit is overloaded.

INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

If a circuit breaker opens or a fuse element

melts, find the cause of the overload before

resetting the circuit breaker or replacing the

fuse.

Do not attempt to adjust the governor. Only

EXERCISE SYSTEM

Starts the Stationary Emergency Generator engine once every

seven days and lets it run for 12 minutes.

qualified service facilities should adjust the

governor. Excessively high operating speeds

are dangerous and increase the risk of personal

injury. Low speeds impose a heavy load on the

engine when adequate engine power is not

available and may shorten engine life. Correct

rated frequency and voltage are supplied only

at the proper governed speed. Some connected

electrical load devices may be damaged by

incorrect frequency and/or voltage. Only quali-

fied service technicians should adjust the gov-

erned speed.

PERFORM VISUAL INSPECTION

Complete a thorough visual inspection of the entire engine-genera-

tor monthly. Look for obvious damage, loose, missing or corroded

nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.

INSPECT EXHAUST SYSTEM

Inspect the exhaust system at least once every year. Check all

exhaust system pipes, mufflers, clamps, etc. for condition, tight-

ness, leaks, security, damage.

CHANGING THE ENGINE AIR FILTER

To replace the engine air filter, remove the air filter cover and

replace the air filter making sure it is positioned properly before

reattaching the cover (Figure 10.3).

See the Service Schedule for air filter maintenance.

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Maintenance

n^{Battery electrolyte fluid is an extremely corro-}

sive sulfuric acid solution that can cause severe

Figure 10.3 – Engine Air Filter

burns. Do not permit fluid to contact eyes, skin,

clothing, painted surfaces, etc. Wear protective

goggles, protective clothing and gloves when

handling a battery. If fluid is spilled, flush the

affected area immediately with clear water.

Do not use any jumper cables or booster bat-

tery to crank and start the generator engine. If

the battery has completely discharged, remove

it from the generator for recharging.

AIR

FILTER

Be sure the AUTO/OFF/MANUAL switch is set

to the OFF position, before connecting the

battery cables. If the switch is set to AUTO or

MANUAL, the generator can crank and start as

soon as the battery cables are connected.

^{Be sure the 120VAC power supply to the battery}

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

tery posts as the cables are attached and cause

an explosion.

SPARK PLUGS

Reset the spark plug gap or replace the spark plugs as neces-

sary.

1. Clean the area around the base of the spark plugs to keep dirt

and debris out of the engine. Clean by scraping or washing

using a wire brush and commercial solvent. Do not blast the

spark plugs to clean.

2. Remove the spark plugs and check the condition. Replace

the spark plugs if worn or if reuse is questionable. See the

“Service Schedule” section for recommended inspection.

3. Check the spark plug gap using a wire feeler gauge. See the

Specifications section for the required spark plug gap.

BATTERY REPLACEMENT

NOTE:

Unit DOES NOT include battery.

When supplying or replacing the battery, the recommended num-

ber and type of battery is listed in the Specifications Section.

NOTE:

The BCI number should be located directly on the battery.

BATTERY MAINTENANCE

The battery should be inspected per the Service Schedule section.

The following procedure should be followed for inspection:

BATTERY FLUID

Check battery electrolyte fluid based on the Service Schedule.

Fluid should cover separators in all battery cells. If fluid level is

low, add distilled water to cover tops of separators. DO NOT USE

TAP WATER IN BATTERY.

1. Inspect the battery posts and cables for tightness and corro-

sion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries and, if

necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP

WATER IN BATTERIES.

CLEANING THE STATIONARY EMERGENCY GENERATOR

Keep the generator as clean and as dry as possible. Dirt and

moisture that accumulates on internal generator windings have an

adverse effect on insulation resistance.

3. Have the state of charge and condition checked. This should

be done with an automotive-type battery hydrometer.

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

charging. The slightest spark can ignite the gas

and cause an explosion. Such an explosion can

shatter the battery and cause blindness or other

injury. Any area that houses a storage battery

must be properly ventilated. Do not allow smok-

ing, open flame, sparks or any spark producing

tools or equipment near the battery.

Once each year have the generator cleaned and inspected by a

Service Dealer. That dealer will use dry, low pressure air to clean

internal windings.

Finally, have the insulation resistance of stator and rotor windings

checked. If insulation resistances are excessively low, the genera-

tor may require drying.

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Service Schedule

SERVICE SCHEDULE

System / Component

Frequency

Procedure

Weekly - W

Monthly - M

Yearly - Y

Inspect

Change

Clean

Fuel

Fuel Lines & Connections

Lubrication

Oil Level

Oil

X**

Oil Filter

Cooling

Engine Coolant Lines & Connections

Engine Coolant Level

Engine Coolant

Enclosure Louvers

Engine

Air Cleaner

X***

Spark Plugs

Battery

Remove Corrosion, Ensure Dryness

Clean & Tighten Battery Terminals

Check Charge State

Check Electrolyte Level

General Condition

Vibration, Noise, Leakage, Temperature

Generator System

Complete Tune-up and System Inspection

Footnotes

X***

To be completed by an Authorized Service Dealer.

* Inspect the oil level monthly or every 12 hours during continuous operation.

** Change oil and oil filter after the first 30 hours of operation and then every 100 hours or annually thereafter, whichever occurs first.

Change sooner when operating under heavy load or in a dusty or dirty environment or in high ambient temperatures.

*** Replace as necessary.

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Troubleshooting

TROUBLESHOOTING GUIDE

PROBLEM

Engine won’t crank.

CAUSE

CORRECTION

1. Control panel 7.5 amp fuse blown.

2. Loose or corroded or defective

battery cables.

1. Replace fuse.*

2. Tighten, clean or replace

battery cables as necessary.*

3. Replace contactor.*

4. Replace starter motor.*

5. Remove, change or replace battery.*

3. Defective starter contactor.

4. Defective starter motor.

5. Dead or Defective Battery.

Engine cranks but won't start.

Engine starts hard, runs rough.

1. Out of fuel.

2. Fuel solenoid (FS) is defective

3. Spark plugs defective.

1. Replenish fuel/turn on fuel valve.

2. Replace solenoid.*

3. Clean, regap or replace plugs.

1. Air cleaner plugged or damaged.

2. Defective spark plugs.

3. Fuel pressure incorrect.

1. Clean or replace as needed.

2. Clean, regap or replace plugs.

3. Confirm fuel pressure to regulator is as

recommended in SPECIFICATIONS.*

4. Confirm fuel pressure to regualtor is as

recommended in SPECIFICATIONS.*

5. Reconfigure the fuel system. (See

RECONFIGURING THE FUEL SYSTEM in

manual.*

4. Insufficient fuel supply.

5. Fuel system set to wrong fuel type.

Engine starts then shuts down.

1. Engine oil level is low.

2. Engine is overheated.

3. Defective Low Oil Pressure Switch

4. Defective Coolant Temperature Switch

5. Defective Control Module circuit board.

6. Coolant Level is Low.

1. Check oil and add oil as needed.

2. Check cooling system for leaks.

3. Replace switch.*

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 board.*

2. Replace board.*

engine continues to run.

2. Defective Control Module circuit board

No AC output from generator.

1. Main line circuit breaker is tripped/open.

2. Generator internal failure.

1. Reset to ON/CLOSED.

2. *

3. Thermal circuit breaker open.

3. Auto-reset - Wait 5 min. and attempt restart.

*Contact the nearest Dealer for assistance.

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Warranty

United States Environmental Protection Agency Warranty Statement

(Stationary Emergency Spark-Ignited Generators)

Warranty Rights, Obligations and Coverage

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the

Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system

or component on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diag-

nosis, replacement parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system

may include parts such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below.

Generac will warrant the emissions control systems on your 2009 and later model year engines provided there has been no abuse,

neglect, unapproved modification or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years

from the date of sale to the ultimate purchaser. For engines greater than or equal to 130 HP the warranty period is three years from the

date of the engine being placed into service.

Purchaser's/Owner's Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following. 1.) The engine must be installed and configured in accordance

to the Generac's installation specifications. 2.) The completion of all maintenance requirements listed in your Owner’s Manual. 3.) Any

engine setting adjustment must be done in accordance and consistent with the instructions in the Owner’s Manual. 4.) Any emission con-

trol system or component must be maintained and operated appropriately in order to ensure proper operation of the engine and control

system to minimize emissions at all times.

Generac may deny any/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system

or component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use

of counterfeit and/or 'gray market' parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting

either your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/

owner shall be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the

inspection or repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine

is being transported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control

System Warranty related information, Generac Power Systems, Inc. P.O. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www.

generac.com.

Important Note

This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by

Generac pursuant to federal law. Note that this warranty shall not apply to any incidental, consequential or indirect damages caused by

defects in materials or workmanship or any delay in repair or replacement of the defective part(s). This warranty is in place of all other

warranties, expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular pur-

pose. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Emission Related Parts Include the Following (if so equipped)

1) Fuel Metering System

Ignition System Including

1.1) Gasoline Carburetor Assembly And Internal

Components A) Fuel Filter, B) Carburetor, C) Fuel

Pump

1.2) Carburetion Assembly And Its Components

A) Fuel Controller, B) Carburetor And Its Gaskets, C)

Mixer And It Gaskets, D) Primary Gas Regulator E)

Liquid Vaporizer

1.3) Fuel Regulator

2) Air Induction System Including

A) Intake Pipe/Manifold,

A) Spark Plug, B) Ignition Module,

C) Ignition Coil, D) Spark Plug Wires

Exhaust System

A) Catalyst Assembly, B) Exhaust Manifold,

C) Muffler, D) Exhaust Pipe, E) Muffler Gasket

Crankcase Breather Assembly Including

A) Breather Connection Tube, B) Pcv Valve

Oxygen Sensor

Diagnostic Emission-Control System

B) Air Cleaner

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Warranty

United States Environmental Protection Agency Compliance Requirements

(Stationary Emergency Spark-Ignited Generators)

Purchaser's/Owner's Recordkeeping Responsibilities

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record-

keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion Engines

as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains their

certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in this

Owner's Manual, you are required to meet the following notification and recordkeeping requirements to demonstrate compliance. 1.) Maintain

documentation that the engine is certified to meet emission standards. 2.) Recordkeeping of maintenance conducted. 3.) Recordkeeping of

the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel solely dur-

ing emergency operations provided the engine is not certified to operate on propane. 4.) Meet all compliance notifications submitted to the

purchaser/owner and maintain all supporting documentation. 5.) Recordkeeping of hours of operation, including what classified the operation

as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130 HP, record-

keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, recordkeeping of hours of operation begins

January 1, 2009; Engines are equipped with non-resettable hour meters to facilitate recordkeeping.

Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements.

Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air

Quality Management or Air Pollution Control District for specific requirements.

Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing,

provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the en-

gine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emergency

stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be used for

maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal, State, or local

standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may operate up to 50

hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for maintenance and

testing.

The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to

an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/owner of emergency engines,

any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year, as

permitted in this section is prohibited.

If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance

to the specifications and guidelines in this Owner’s Manual EPA will not require engine performance testing. If not, your engine will be consid-

ered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Ignition

Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.

Emission-Related Installation Instructions

Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and

replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States

Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized

Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow these instructions when installing a certified engine in a

piece of nonroad equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.

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Notes

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0G4827

0G2927

0G2827

0G3451

0G0820A

0G4452

020746

049226

051713

022129

0G4825

0G4826

0G2926

0G3682

0G5584

0G3685

0G2826

0G3683

0G6573

0G3686

0G3684

0G3687

0G5909

0G6103

0A5382A

075591

051787

0A5601A

0G8827

0G8827A

0A9375

022152

0G4196

042558

0J6102

0G0965B

053607

051769

023365

0F3353

072578

0G3787

0A8830

077043E

0G2070

0G2070A

045771

0D8427

0J6853A

0J6853B

0J6853C

0C2454

ASSY RTR 104 KD1 HI EFF (18KW)

RTR-102-20.0AD1 CPL (2006) (20KW)

ASSY RTR 25KW 2P (2006) (25KW)

ASSY RTR 30KW 2P 10"(2006)

HOUSING BLOWER LG PILOT

BLOWER HOUSING SCREEN

SCREW PPHM M5-0.8 X 8 ZINC

WASHER LOCK M5

WASHER FLAT M5

WASHER LOCK M8-5/16

ASSY STR 104-18AD1 HI EFF (18KW)

ASSY STR 104 18GD1 HI EFF (18KW)

STR-102-20.0AD1 CPL (2006) (20KW)

STR-102-20.0GD1 CPL (2006) (20KW)

STR-102-20.0JD1 CPL (2006) (20KW)

STR-102-20.0KD1 CPL (2006) (20KW)

ASSY STR 102 25AD1 (2006) (25KW)

STR-102-25.0GD1 CPL (2006) (25KW)

STR-102-25.0-JD1 CPL (2006) (25KW)

STR-102-25.0KD1 CPL (2006) (25KW)

STR-102-30.0GD2 CPL (30KW)

STR-102-30.0KD2 CPL (30KW)

ASSY STR 102 30AD2 10" (30KW)

STR-102-30.0JD2

BEARING CARRIER REAR LG PILOT

ASSY HOLDER BRUSH

SCREW HHC M4-0.7 X 16 G8.8

COVER REAR BEARING

STUD M8-1.25 475 LONG

STUD M8-1.25 418 LONG

SCREW RHM #10-24 X 2

WASHER LOCK #10

FLYWHEEL & RINGGEAR ASSY 1.6L

KEY SQ 3/8 X 1 STEEL

SCREW HHFC M10-1.5 X 16 C10.9

PLATE FLEX 1.6L R12.7

SCREW HHC M12-1.75 X 35 G8.8

WASHER LOCK M12

WASHER SHAKEPROOF INT #8

SCREW HHC M10-1.0 X 20 G10.9

SPACER ROTOR SHAFT

WASHER .41 ID .94 OD .12 THK

WASHER FLAT .34 ID X .75 OD

FLEX CONDUIT 1" BLACK (NOT SHOWN)

PLATE SPACER 14GA 1.6L (TO BE USED WITH ENGINE PLATE P/N 0G0834.)

PLATE SPACER 16GA 1.6L (TO BE USED WITH ENGINE PLATE P/N 0G0834A.)

NUT HEX M8-1.25 G8 CLEAR ZINC

WASHER LOCK M10 RIBBED ZINC

SUPPORT LH ALT COVER

(1) 23

(2)31

(2)32

(2)33

(2)34

SUPPORT RH ALT COVER

COVER REAR 10" ALT

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

(1) APPLY LOCTITE 242 BEFORE THREADING SCREW INTO CRANKSHAFT.

(2) ALTERNATE CONFIGURATION REQUIRES ALL NOTED PARTS.

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EXPLODED VIEW: CONNECTION BOX C1 CPL

DRAWING #: 0H7234

APPLICABLE TO:

GROUP A

ITEM

PART#

QTY.

DESCRIPTION

(4)3

0H6795

0H6796

0H67330ST0R

0H7115

022097

CONBOX BACK/SIDES C1 CPL

CONBOX TOP C1 CPL

BRACKET GIMBAL CONTROL PNL RAW

KNOB M6-1.0 CONTROL PANEL

WASHER LOCK M6-1/4

(3)7

022473

SEE CHART

052777

WASHER FLAT 1/4-M6 ZINC

CIRCUIT BREAKER

WASHER FLAT M3

043182

WASHER LOCK M3

(4)11

051714

0H81040AS0R

045764

NUT HEX M3-0.5 G8 CLEAR ZINC

COVER DPE BREAKER NEXUS

SCREW HHTT M4-0.7 X 8 ZP

WASHER LOCK #8-M4

022264

0A9457

DECAL NEUTRAL

(2)17

(4)19

REF

ASSY CTRL PROGRAMMED

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

REGULATOR - DC ALT

NUT FLANGE M6-1.0 NYLOK

SHIELD HIGH/LOW C1 RAW

RELAY SOLENOID 12VDC PNL MNT

SCREW HHSP #10 X 3/8 HI-LOW

SCREW HHC M6-1.0 X 20 C8.8

NUT HEX M5-0.8 G8 CLEAR ZINC

WASHER LOCK M5

0C2454

0A1354A

0D3700

0H88380ST0R

056739

0F5458

042568

051716

049226

051713

WASHER FLAT M5

0D7177V

0F5752F

0H6267

056326

0G3524

0D7393T

0D7393U

0F5376S0AR

0F5396S0AR

057073

DIODE BRIDGE 1P 35A 1000V

RES WW 15R 5% 25W QK CONN

COVER VOLTAGE SHIELD

TRIM VINYL BLACK 1/8GP (3”LG)

COVER BELL HOUSING CONBOX

TERM BLOCK 3P UL 12-20AWG

TERM BLOCK 4P UL 12-20AWG

MX150L SLRRMNT 22-18 8P W/O GA

MX150L SLRRMNT 22-18 12P W/OGA

JUNCTION BLOCK 3/8-16

(1)31

(1)32

(1)33

(1)34

REF

0C2265

057329

022237

SCREW PHTT M4-0.7 X 12 ZP

LUG SLDLSS 350-#6X13/32 AL/CU

WASHER LOCK 3/8

022241

NUT HEX 3/8-16 STEEL

025433

023762

0H7292

0H7293

029289

LUG SLDLSS #6-14 X 13/64 CU

WASHER LOCK EXT #10 STL

DECAL CUSTOMER CONTROL CONNECT

DECAL CONBOX TB1 CONNECTIONS

TAPE ELEC 1/2 FOAM (62” LG)

DECAL CUSTOMER POWER CONNECT

WASHER NYLON .257

0J0489

0A2115

0F6146

REF

HANG TAG 2 WIRE START (NOT SHOWN)

HARN CONBOX NEXUS (NOT SHOWN)

FUSE ATO TYPE 7.5AMP (BROWN)

DECAL GROUND LUG

GASKET WIRE ENTRY COVER

DECAL CAUTION ELEC SHOCK SM

0H6692

0D7178T

067210A

0J6701

0H8006

UL CIRCUIT BREAKER (225AF)

0G5249

REF

CB 150A 2 POLE 240V 225AF

COVER CB G 225AF C1 CONBOX

INSULATOR CB 2P 225AF

SPRT CIRCUIT BREAKER G 225AF

WASHER FLAT #8 ZINC

WASHER LOCK #8-M4

NUT HEX #8-32 STEEL

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

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

BUS BAR 200A LUG ADAPTOR

SCREW SHC M8-1.25 X 20 G8

0H6846

0F8432A

0G5734

038150

022264

022471

0C2454

053640

0F8843

049897

REVISION: J-1182-J

DATE: 12/16/11

Page 4 of 8

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EXPLODED VIEW: CONNECTION BOX C1 CPL

DRAWING #: 0H7234

APPLICABLE TO:

GROUP A

ITEM

PART#

QTY.

DESCRIPTION

022129

022145

045771

058306

0F8451

WASHER LOCK M8-5/16

WASHER FLAT 5/16-M8 ZINC

NUT HEX M8-1.25 G8 CLEAR ZINC

SCREW SHC M8-1.25 X 25 C12.9

LUG SLDLSS 300 MCM-6 AL/CU

DECAL TERMINAL SHOCK HZD BI

SHIELD CB HANDLE CONBOX

TAPE ELEC 1/2 FOAM

0G3259

0J78230AS0R

029289

036261

RIVET POP .125 X .275 SS

(1) ITEMS INCLUDED WITH HARNESS P/N 0H6692.

(2) ITEMS USED ON 1.6L MODELS ONLY.

(3) SEE “C1 DPE BREAKER SELECTION” TABLE.

(4) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)

•

MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.

CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE

SYSTEM FOR CORRECT MATERIAL AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

REVISION: J-1182-J

DATE: 12/16/11

Page 5 of 8

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EXPLODED VIEW: CONNECTION BOX C1 CPL

DRAWING #: 0H7234

APPLICABLE TO:

GROUP A

ITEM

PART#

QTY.

DESCRIPTION

UL CIRCUIT BREAKER (CC 2P)

0H4745

REF

CB 0100A 2P 240V E CC LL

CB 0125A 2P 240V E CC LL

CB 0150A 2P 240V E CC LL

COVER CB E CC 2P C1 CONBOX

NUT HEX M5-0.8 G8 CLEAR ZINC

CIRCUIT BREAKER SUPPORT (CC)

WASHER FLAT #8 ZINC

WASHER LOCK #8-M4

NUT HEX #8-32 STEEL

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

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

SCREW PPHM M5-0.8 X 12 ZNC

WASHER FLAT #10 ZINC

0H4746

0H4747

0H6847

051716

0H4656

038150

022264

022471

0C2454

053640

091526

023897

049226

0H4698

0J78230AS0R

029289

036261

REF

WASHER LOCK M5

INSULATOR CB 2P E TYPE CC

SHIELD CB HANDLE CONBOX

TAPE ELEC 1/2 FOAM

RIVET POP .125 X .275 SS

UL CIRCUIT BREAKER (CC/FG (3P) )

0H4913

REF

CB 0100 3P 240V E CC LL

CB 0125 3P 240V E CC LL

CB 0080 3P 600V E FG LL

CB 0090 3P 600V E FG LL

CB COVER E CC/FG 3P C1 CONBOX

INSULATOR CB 3P E TYPE CC/FG

CIRCUIT BREAKER SUPPORT (CC)

CIRCUIT BREAKER SUPPORT (FG)

WASHER FLAT #8 ZINC

WASHER LOCK #8-M4

NUT HEX #8-32 STEEL

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

SCREW RHM #8-32 X 3-1/4 (CC)

0H4914

0H5488

0H5489

0H7294

0H4698A

0H4656

0H5604

038150

022264

022471

0C2454

053640

REF

0H5721

091526

023897

SCREW PPHM #8-32 X 1-3/4 ZINC (FG)

SCREW PPHM M5-0.8 X 12 ZNC

WASHER FLAT #10 ZINC

049226

051716

0J78230AS0R

029289

WASHER LOCK M5

NUT HEX M5-0.8 G8 CLEAR ZINC

SHIELD CB HANDLE CONBOX

TAPE ELEC 1/2 FOAM

036261

RIVET POP .125 X .275 SS

REVISION: J-1182-J

DATE: 12/16/11

Page 6 of 8

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EXPLODED VIEW: CONNECTION BOX C1 CPL

DRAWING #: 0H7234

APPLICABLE TO:

GROUP A

ITEM

PART#

QTY.

DESCRIPTION

UL CIRCUIT BREAKER (BQ 2P)

0D5543

REF

CB 0090A 2P 240V S BQ2 LL

CB 0100A 2P 240V S BQ2 LL

CB 0125A 2P 240V S BQ2 LL

COVER CB S BQ2 C1 CONBOX

BRKT CB MTG BACK

CIRCUIT BREAKER SUPPORT (BQ)

SCREW HHC M5-0.8 X 20 G8.8

WASHER FLAT #10 ZINC

0D5544

0A2077

0H6842

0E7890

0G4497

052619

REF

023897

049226

0C2454

051716

0G9708

022264

WASHER LOCK M5

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

NUT HEX M5-0.8 G8 CLEAR ZINC

SCREW PHTT M4-0.7 X 8 ZP

WASHER LOCK #8-M4

0J78230AS0R

029289

SHIELD CB HANDLE CONBOX

TAPE ELEC 1/2 FOAM

RIVET POP .125 X .275 SS

036261

UL CIRCUIT BREAKER (BQ 3P)

062812

053691

040532

0H6843

0E6002

0G4497

052619

REF

CB 0080A 3P 240V S BQ3 LL

CIRCT BRK 90 X 3 ITE BQ3-B090

CB 0100A 3P 240V S BQ3 LL

COVER CB S BQ3 C1 CONBOX

MTG TRACK BQ SIEMENS CB 3P

CIRCUIT BREAKER SUPPORT (BQ)

SCREW HHC M5-0.8 X 20 G8.8

WASHER FLAT #10 ZINC

REF

023897

049226

0C2454

051716

0G9708

022264

WASHER LOCK M5

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

NUT HEX M5-0.8 G8 CLEAR ZINC

SCREW PHTT M4-0.7 X 8 ZP

WASHER LOCK #8-M4

0J78230AS0R

029289

SHIELD CB HANDLE CONBOX

TAPE ELEC 1/2 FOAM

RIVET POP .125 X .275 SS

036261

UL CIRCUIT BREAKER (ED 3P)

0D5552

REF

CB 0050A 3P 480V S ED4 LL

CB 0090A 3P 480V S ED4 LL

CB 0100A 3P 480V S ED4 LL

CB 0125A 3P 480V S ED4 LL

COVER CB S ED3 C1 CONBOX

CIRCUIT BREAKER SUPPORT (ED)

WASHER FLAT #8 ZINC

0D5556

0D5557

0D9693

0H6844

0G4498

038150

022264

022471

WASHER LOCK #8-M4

NUT HEX #8-32 STEEL

0A8278

0C2454

066715

SCREW SHC 1/4-28 X 3/4 G8.8 NZ

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

SCREW RHM #8-32 X 4-1/2

WASHER LOCK M6-1/4

WASHER-STEP 1/2ODX9/32ID BRASS

SHIELD CB HANDLE CONBOX

TAPE ELEC 1/2 FOAM

022097

0D5621

0J78230AS0R

029289

036261

RIVET POP .125 X .275 SS

UL CIRCUIT BREAKER (QN2 2P)

0E7283

0H6845

0E3664

0G4112

074908

REF

CB 0150A 2P 240V S QN2 LL

COVER CB S QN2 C1 CONBOX

BASE, QN CIRCUIT BREAKER

BREAKER SUPPORT BRACKET 30KW

SCREW HHTT M5-0.8 X 10 BP

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

SHIELD CB HANDLE CONBOX

TAPE ELEC 1/2 FOAM

0C2454

0J78230AS0R

029289

036261

RIVET POP .125 X .2

REVISION: J-1182-J

DATE: 12/16/11

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EXPLODED VIEW: CONNECTION BOX C1 CPL

DRAWING #: 0H7234

APPLICABLE TO:

GROUP A

THIS PAGE LEFT INTENTIONALLY BLANK

REVISION: J-1182-J

DATE: 12/16/11

Page 8 of 8

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0G3418

0G3421

0G3419

0E9837B

0G3553

0E3257

0G4080

099502

0G4070

0G4072

0G4071

046627

052250

022473

022097

0C8566

045771

0C2454A

042568

0G3573

0G3574

0G3420

080713

076749

048031C

029032

0G4451

055934N

0F9504

0G0568

0G3433

0E2507

0H1827

0A2628

029333A

042907

027482

022129

039253

0H1851

REF

RADIATOR SUPPORT LH SIDE 1.6L

VENTURI 1.6L

RADIATOR SUPPORT RH SIDE 1.6L

RADIATOR 1.6L CHY

FAN COOL 450MM DIA 7 BLADE

SCREW HWHTF M6-1.0 X 16

HOSE LOWER RADIATOR 1.6L

CLAMP HOSE #24 B1.06-2.00

HOSE REAR COOLANT 1.6L

TUBE ENGINE COOLANT 1.6L

HOSE UPPER RADIATOR 1.6L

CAP RADIATOR

TAPE FOAM 1 X 1 (24” LG)

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

SCREW HHFC M6-1.0 X 20 G8.8

NUT HEX M8-1.25 G8 CLEAR ZINC

SCREW THF M6-1 X 12 N WA Z/JS

SCREW HHC M6-1.0 X 20 G8.8

GUARD FAN LH C1

GUARD FAN RH C1

RADIATOR BLOCK-OFF

BRACKET COOLANT TANK

TANK COOLANT RECOVERY

CLAMP HOSE BAND 1/4

HOSE 9/32 ID (43” LG)

BRACKET STEPPER MOTOR COOLANT

CLAMP VINYL 1.31 X .281 Z

GROMMET 5/8"X 1 1/8"X 5/16"

ASSY FAN BEARING SUPPORT

BRACKET FAN ALT ADAPTER 1.6L

PROBE COOLANT LEVEL 3/8NPTF

PROBE COOLANT LEVEL 3/8-18NPTF (USE WITH I/N 40, P/N 0H1851)

PULLEY - FAN 95 DIA

TIE WRAP UL 7.4" X .19" BLK (NOT SHOWN)

SCREW HHC M8-1.25 X 16 G8.8

WASHER SHAKEPROOF EXT 5/16 STL

WASHER LOCK M8-5/16

(1) 36

SCREW HHC M8-1.25 X 20 G8.8

ASSY PCB LCL SENSOR (USE WITH I/N 33, P/N 0H1827 ONLY)

(2) 40

(1) APPLY LOCTITE 242 TO I/N 36 BEFORE THREADING INTO I/N 31.

(2) USE WITH R-200 CONTROL PANEL ONLY.

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EXPLODED VIEW: MOUNTING BASE 1.6L

DRAWING #: 0G3531

APPLICABLE TO:

GROUP C

ITEM

PART#

QTY.

DESCRIPTION

0G3343

027482

070936

070936C

039253

022145

022129

045771

071956

051730

021991

026850

0G3461

055414

047411

022097

022473

025507

MOUNTING BASE 1.6L 2007 C1

WASHER SHAKEPROOF EXT 5/16 STL

DAMPENER VIBRATION

VIB. ISO. 70-75 DURO

SCREW HHC M8-1.25 X 20 G8.8

WASHER FLAT 5/16 ZINC

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

WASHER FLAT M8

SCREW HHC M8-1.25 X 60 G8.8

EARTH STRAP

WASHER SHAKEPROOF EXT 1/4 STL

ALTERNATOR SUPPORT BLOCK OFF

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

SCREW HHC M6-1.0 X 16 G8.8

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK EXT 7/16 STL

REVISION: H-5975-B

DATE: 2/5/10

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0F3408C

0F3411

025507

059980

046526

077483

050331A

050331

038805J

038804M

045771

022131

027482

0F3976

0C2454

022145

REF

BATTERY TRAY, C1 & C2

STRAP BATTERY RETAINMENT

WASHER SHAKEPROOF EXT 7/16 STL

SCREW HHC M10-1.5 X 25 G10.9

WASHER LOCK M10

BATTERY 12VDC 75-AH 26

BATTERY POST COVER RED +

BATTERY POST COVER BLK -

CABLE BATTERY BLACK #1 X 30.00

CABLE BATTERY RED #1 X 21.00

NUT HEX M8-1.25 G8 YEL CHR

WASHER FLAT 3/8-M10 ZINC

WASHER SHAKEPROOF EXT 5/16 STL

BOOT CONTACTOR CABLES

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

WASHER FLAT 5/16-M8 ZINC

REF

NOTE: WHEN INSTALLING BATTERY, TUCK BATTERY’S LIFTING STRAP ALONG

THE LEFT SIDE OF BATTERY ( SIDE OPPOSITE RADIATOR) BEFORE

CONNECTING THE BATTERY CABLES.

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EXPLODED VIEW: ENGINE COMMON PARTS 1.6L

DRAWING #: 0H7219

APPLICABLE TO:

GROUP D

ITEM

PART#

QTY.

DESCRIPTION

0H1734

0G0834A

0G0820A

0G7461

0G0839

0G0781

0G0722

0G4059

0G4604

0G3424

0G0786

0G4605

0F9617A

0A1354B

0G0823

0G3900

0D2244M

036710

REF

ENGINE GENERAC 1.6L G11 CERT

ENGINE PLATE 1.6L 6MM (TO BE USED WITH PLATE SPACER P/N 0G2070A.)

HOUSING BLOWER LG PILOT

STARTER MOTOR 12V

ENGINE MOUNTING FOOT STAMPING

EXHAUST MANIFOLD 1.6L MACHINED

INTAKE MANIFOLD MACHINED 1.6L

SHIELD 1.6L EXHAUST HEAT

DC ALTERNATOR ADAPTER MACHINED

PULLEY CRANKSHAFT MACHINED

WASHER PULLEY

BRACKET TENSIONER DC ALT

SPACER ALTERNATOR

DC ALTERNATR HAN-KOK

V-BELT 3/8 X 30.6

CAP, 1.5" HOLE SHALLOW

ASSY MAGPICKUP (3/8-24 MALE)

PIN SPRING 1/4 X 3/4

SCREW HHC M12-1.5 X 40 G10.9

SCREW HHC M10-1.5 X 25 G10.9

WASHER LOCK M10

WASHER FLAT 3/8-M10 ZINC

NUT HEX M10-1.5 CLASS 10 ZINC

GASKET INTAKE MANIFOLD 1.6L

GASKET EXHAUST MANIFOLD 1.6L

NUT TOP LOCK FL M8-1.25

SCREW HHC M10-1.5 X 70 G8.8

SCREW HHC M10-1.5 X 110 G10.9

SCREW HHC M10-1.5 X 40 G10.9

SCREW HHC M8-1.25 X 35 G8.8

WASHER LOCK M8-5/16

0C5479

059980

046526

022131

0G3922

0G0464

0G0465

052858

051735

0G3920

0A7387

039414

022129

022145

029333A

057821

045771

022507

022097

WASHER FLAT 5/16-M8 ZINC

TIE WRAP UL 7.4" X .19" BLK

SCREW HHC M8-1.25 X 40 G8.8

NUT HEX M8-1.25 G8 CLEAR ZINC

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

WASHER LOCK M6-1/4

022473

090388

WASHER FLAT 1/4-M6 ZINC

SCREW HHTT M6-1.0 X 12 ZINC

WASHER FLAT M10 HEAVY DUTY

TEMPERATURE SENDER, DELPHI

BSHG RDCR HEX 1/4 TO 1/8

HARN LOW OIL PRESS SWITCH ASSY

ADAPTER DRAIN OIL

0A5768

0E0502

035579

0H7435

0C1852

069860C

069811

HOSE OIL DRAIN ASSY 21"

CAP HEX 1/4 NPT BRASS

0G38580ST03

025065

STRUT LH 1.6L ENG ADAPT PLATE

NIPPLE PIPE 3/8 NPT X 1-1/2

PIPE TEE 3/8 NPT

SCREW HWHTF M6-1.0 X 16

WASHER FLAT .34 ID X .75 OD

HARN ENG G1.6L G11 NEXUS (NOT SHOWN)

OIL FILTER 1.6L

CONDUIT FLEX .25"ID (6” LG)

STRUT RH 1.6L ENG ADAPT PLATE

BARBED STR 3/8 NPT X 3/8

027738A

0E3257

0A8830

0H6690

0G02070100

077043H

0G38620ST03

055596

0C7649

0H2250

0G3433

049541

0G7311

0G4451

0F4001E

REF

CLAMP HOSE .38-.87

HOSE COOLANT 3/8 ID 20R3 (11” LG)

BRACKET FAN ALT ADAPTER 1.6L

SCREW HHC M10-1.5 X 35 G8.8

DECAL EMISSION CTRL INFO 1.6L

BRACKET STEPPER MOTOR COOLANT

ANCHOR HARNESS

REVISION: H-8414-C

DATE: 3/1/11

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EXPLODED VIEW: FUELSYS NG/LPV 1.6L CPL

DRAWING #: 0H6671

APPLICABLE TO:

GROUP E

ITEM

PART#

QTY.

DESCRIPTION

037561

0A5547

062522

022127

059402

091526

049226

0E0519A

048031J

0E6586

0G1397E

0F7790

0E7121

0G4573C

0E8286

047527

057823

035685

057753B

0E4395

022129

0A6344

048031L

0G1985

047290

0F3994

0G3178

048031P

057147

045771

051767

022097

039253

0G9348

026812

076691

026490

075580

0D1509

075436

022145

026915

0E6586A

NUT WING 1/4-20 NYLK

COVER AIR CLEANER

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

NUT HEX 1/4-20 STEEL

FILTER ELEMENT

SCREW PPHM M5-0.8 X 12 ZNC

WASHER LOCK M5

ADAPTER, CARBURETOR W/PVC CONN

CLAMP HOSE BAND .63

(1)36

(1)37

(1)38

(1)39

(1)43

GASKET BOSCH 32 & 40

FUEL REG. REWORK 1.6L

VENTURI THROTTLE 21MM

O-RING 47.625 ID X 2.38 WIDTH

MIXER ACTUATOR 32MM MACHINED

STREET EL 45D 1/2 NPT BRASS

BARBED STR 1/2 NPT X 3/4

CLAMP HOSE #10 .56-1.06

CLAMP HOSE #28 1.32-2.25

HOSE 1.5 ID X 2 LG 20R4

ACTUATOR BOSCH 32 GOVERNOR

WASHER LOCK M8-5/16

BARBED EL 90 1/8 NPT X 3/8

CLAMP HOSE BAND 1.0"

HOSE BARB REDUCR TEE 3/4"-3/8"

HOSE 3/8 ID SINGLE BRAID (11.5” LG)

HOSE 3/8 ID SINGLE BRAID (12” LG)

PCV VALVE 2.5L FORD

HOSE BREATHER 1.6L

CLAMP HOSE BAND .88"

HOSE 3/4 ID LPG & NG (16"LG)

NUT HEX M8-1.25 G8 YEL CHR

SCREW HHC M6-1.0 X 45 C8.8 FTH

WASHER LOCK M6-1/4

SCREW HHC M8-1.25 X 20 G8.8

ASSY REG INLET NPT FITTINGS

ELBOW 90D 3/4 NPT

NIPPLE PIPE 3/4NPTX4.5 BLK IRN

NIPPLE PIPE 3/4NPT X 2

FLANGE FUEL INLET

DECAL INLET PRESSURE

DECAL FUEL INLET

WASHER FLAT 5/16 ZINC

NIPPLE CLOSE 3/4 X 1.375

GASKET BOSCH 32

(1) INCLUDED IN ITEM 35 (ASSY REG INLET NPT FITTINGS)

REVISION: H-9610-B

DATE: 9/9/11

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EXPLODED VIEW: EV ENCLOSURE C1 CPL

DRAWING #: 0G3534

GROUP F

ITEM

PART#

QTY.

DESCRIPTION

(2) 1

(2) 2

(1) 3

(2) 4

0G33370AL0R

0J14640AL0R

077992

0J14630AL0R

0F4487A

022127

ROOF 1.6L C1

REAR INTAKE WRAP C1

NUT HEX LOCK M6-1.0 SS NY INS

DOOR LEFT/RIGHT SIDE C1

ASSY ACCESS COVER

NUT HEX 1/4-20 STEEL

022097

022473

0C2454

0F5048D

0F5049

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

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

VISE-ACTION LATCH, SLOTTED CIR

TAB PULL

(1)10

(1)19

0F8869D

089961

078115

0H7518

0H7518A

0E3257

0912970090

0H7518B

0C8566

0H0412

022097

KEY VISE-ACTION LATCH,SLOT CIR

FOAM STRIP 3/4"WIDE X 3/16"THK (294”LG)

WASHER SELF LOCKING DOME

INSULATION SIDE DOOR C1

INSULATION ROOF C1

SCREW HWHTF M6-1.0 X 16

ASSY WIRE 14AWG GRN/YEL (32.25”LG)

INSULATION REAR C1

SCREW HHFC M6-1.0 X 20 G8.8

NUT SPRINGCLIP M6-1.0

WASHER LOCK M6-1/4

(3) 26

0H7529

FOIL ALUMINUM WITH ADHESIVE

RF COVER PLATE-PLASTIC-BISQUE

RF COVER PLATE-PLASTIC-GREY

FRONT DISCHARGE WRAP 1.6L C1

WASHER LOCK SPECIAL 1/4"

0H1208A

0H1208B

0G33350AL0R

0A1658

(2) 28

(1)29

(1)ENCLOSURE NOTE: ALL PANELS THAT FASTEN TO THE ROOF MUST BE SECURED USING I/N 10 (THREAD FORMING FASTENER) AND I/N 3 (LOCK NUT) AND

TO INCLUDE AT LEAST ONE CONNECTION POINT USING I/N 19 (THREAD FORMING FASTENER) WITH I/N 3 (LOCK NUT) TO EACH PANEL. LOCK NUT IS TO BE

INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSION IN ENCLOSURE PANELS. ALL PANEL TO BASEFRAME

CONNECTIONS TO INCLUDE AT LEAST ONE CONNECTION POINT USING I/N 29 (WASHER SPECIAL).

(2) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS (NO COLOR)

•

MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM.

CUSTOMER: WHEN ORDERING REPLACEMENT PARTS ENTER BASE NUMBER (FIRST 6 DIGITS ONLY) IN THE SYSTEM FOR CORRECT MATERIAL

AND COLOR (FOR REFERENCE SEE GUIDELINE 0H7169).

(3) USED ON 1.5L / 1.6L UNITS ONLY.1

REVISION: -A-

DATE: 11/14/11

Page 2 of 2

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0F7366

0F7647

0F8095

0G3576

0E3257

0F7644

0C6119

036434

036449

022129

022259

038750

0G3575

0F3794A

022097

049813

022473

MUFFLER C1

MUFFLER SADDLE

PIPE EXHAUST OUTLET

EXHAUST PIPE LOWER 1.6L

SCREW HWHTF M6-1.0 X 16

MUFFLER STRAP

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

BOLT U 5/16-18 X 2.09

SADDLE 2 INCH

WASHER LOCK M8-5/16

NUT HEX 5/16-18 STEEL

SCREW HHC M6-1.0 X 30 G8.8

EXHAUST PIPE UPPER 1.6L SS

EXHAUST BLANKET 500MM LONG

WASHER LOCK M6-1/4

NUT HEX M6 X 1.0 G8 YEL CHR

WASHER FLAT 1/4-M6 ZINC

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Owner's Manual

Stationary Emergency Generator

1.6L

25/30kW Models

EPA Certified

n^{NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT}

APPLICATIONS.

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST

FUMES! OUTDOOR INSTALLATION ONLY!

This manual should remain with the unit.

. 0 H 7 t N 2 r 3 o a 0 P

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Table of Contents

SECTION

PAGE

Alarm and Warning Messages..........................................................8-4

INTRODUCTION ........................................................... 1-1

Read this Manual Thoroughly.......................................................1-1

Operation and Maintenance..........................................................1-1

How to Obtain Service .................................................................1-1

SAFETY RULES ............................................................ 1-2

GENERAL INFORMATION............................................ 2-1

Identification Record ........................................................................2-1

Data Label ...................................................................................2-1

EQUIPMENT DESCRIPTION ........................................ 3-1

Equipment Description .....................................................................3-1

Engine Oil Recommendations...........................................................3-1

Coolant Recommendations ..............................................................3-1

ENGINE PROTECTIVE DEVICES ................................. 4-1

Engine Protective Devices ................................................................4-1

High Coolant Temperature Sender ................................................4-1

Low Coolant Level Sensor............................................................4-1

Low Oil Pressure Switch ..............................................................4-1

Overcrank Shutdown....................................................................4-1

Overspeed Shutdown...................................................................4-1

RPM Sensor Loss Shutdown........................................................4-1

DC Fuses.....................................................................................4-1

FUEL SYSTEM .............................................................. 5-1

Fuel Requirements .......................................................................5-1

Natural Gas Fuel System..............................................................5-1

Propane Vapor Withdrawal Fuel System........................................5-1

LP Liquid Fuel System..................................................................5-1

SPECIFICATIONS......................................................... 6-1

Stationary Emergency Generator ..................................................6-1

Engine .........................................................................................6-1

Cooling System............................................................................6-1

Fuel System.................................................................................6-1

Electrical System .........................................................................6-1

Weather and Maintenance Kits .....................................................6-2

Reconfiguring the Fuel System.........................................................6-2

Fuel System.................................................................................6-2

Control Panel ...............................................................................6-2

GENERAL INFORMATION............................................ 7-1

Alternator AC Lead Connections.......................................................7-1

Four-lead, Single-phase Stator......................................................7-1

Alternator Power Winding Connections.............................................7-1

3-phase Alternators ("Y" Configuration) ........................................7-1

3-phase Alternators ("Delta" Configuration)...................................7-2

CONTROL PANEL......................................................... 8-1

Control Panel Interface.....................................................................8-1

Using the Auto/Off/Manual Switch................................................8-1

Activate the Generator......................................................................8-1

Display Interface Menus...................................................................8-1

Activation Chart ...........................................................................8-2

Setting the Exercise Timer................................................................8-3

Low Speed Exercise.....................................................................8-3

User Adjustable Settings ..................................................................8-3

Fuel Conversion ...............................................................................8-3

Operation.........................................................................................8-3

Automatic Transfer Operation .......................................................8-3

Sequence of Automatic Operation ................................................8-4

Crank Cycles and Overcrank Shutdown........................................8-4

Auto Start........................................................................................8-4

Manual Start....................................................................................8-4

Low Oil Pressure Shutdown Alarm ...............................................8-4

High Coolant Temperature Shutdown Alarm..................................8-4

Overcrank Shutdown Alarm..........................................................8-4

Overspeed Shutdown Alarm.........................................................8-4

RPM Sensor Failure Shutdown Alarm...........................................8-4

Under-frequency Shutdown Alarm................................................8-5

Low Battery Alarm.......................................................................8-5

Low Battery Warning....................................................................8-5

Low Coolant Level Alarm .............................................................8-5

Missing Cam Pulse Alarm............................................................8-5

Missing Crank Pulse Alarm ..........................................................8-5

Low Fuel Pressure Warning..........................................................8-5

Governor Sensor Fault Alarm........................................................8-5

Wiring Error Alarm .......................................................................8-5

Undervoltage Alarm .....................................................................8-5

Overvoltage Alarm .......................................................................8-6

Internal Failure Shutdown Alarm...................................................8-6

Canbus Alarm..............................................................................8-6

Ignition Alarm ..............................................................................8-6

Maintenance Warning...................................................................8-6

Alarm Cancel ...............................................................................8-6

Common Alarm Relay......................................................................8-6

Maintenance Alerts ..........................................................................8-6

Menu System...................................................................................8-7

OPERATION.................................................................. 9-1

Stationary Emergency Generator Control and Operation....................9-1

Operating Unit with Manual Transfer Switch......................................9-1

Engine Start-up and Transfer........................................................9-1

Retransfer and Shutdown.............................................................9-1

Operating Unit with Automatic Transfer Switch .................................9-1

MAINTENANCE........................................................... 10-1

General Maintenance......................................................................10-1

Check Engine Oil........................................................................10-1

Changing Engine Oil...................................................................10-1

Cooling Intake/Outlet..................................................................10-1

Inspect Cooling System .............................................................10-1

Engine Coolant...........................................................................10-2

Coolant Change .........................................................................10-2

Overload Protection for Engine DC Electrical System ..................10-2

Exercise System ........................................................................10-2

Perform Visual Inspection ..........................................................10-2

Inspect Exhaust System.............................................................10-2

Check Fan Belt...........................................................................10-2

Inspect Engine Governor ............................................................10-2

Changing the Engine Air Filter.....................................................10-2

Spark Plugs ...............................................................................10-3

Battery Maintenance ..................................................................10-3

Battery Replacement..................................................................10-3

Battery Fluid...............................................................................10-3

Cleaning the Stationary Emergency Generator ............................10-3

SERVICE SCHEDULE ................................................. 11-1

TROUBLESHOOTING................................................. 12-1

Troubleshooting Guide....................................................................12-1

EMISSIONS WARRANTY............................................ 13-1

NOTES

EXPLODED VIEWS & PARTS LISTS

WIRING DIAGRAMS & SCHEMATICS

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