Generac 13694330200 User Manual

-------------------

Model: 13694330200

Type:

Engine: D6.

SDI00

7.1

GENERAC®

Owner's

Stationary

Manual

Emergency

Generator

This

manual

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unit.

INTRODUCTION

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CANBEOBTAINEDATTHIS

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INFORMATION

the

website

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Safety Rules

It..

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.

It..

SAVE

THESE INSTRUCTIONS - This manual contains Important Instructions that should be followed

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Despite the safe design of this genera·

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tor, operating this equipment Imprudently, neglecting Its maintenance or being careless can cause possible Injury or death. Permit only responsible and capable persons to Install, operate or maintain this equipment.

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Potentially lethal voltages are generated by

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render the machine safe before attempting to

work on the generator.

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Parts of the generator are rotating and/or hot

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during operation. Exercise care near running generators.

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For

equipmentbeinstalled, Service installation standards all

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system

assembly

refertoexploded

specific

back

kilowatt

following

Broad Broad Broad

current

power

UTILITY

rpmtosupply

the

features: and

constructed.

MG1-22.

protection

gen-

halfofthis

rating

voltage

Range Range Range

generator

for

the

power

level.

driven

withafour-

data

label

number

the

stator

MG1-22.4

content

have

of

been

sym-

and

is

ENGINE

The

stationary

for

long

such

engine

rpm.

For

protectitagainst

shutting temperatureistoo is

running

Engine the

reader's

panel

manual

mation.

COOLANT

This

sender

coolant

LOW

COOLANT

Should

coolant without engine

hasalow

drops

below

automatically

OIL

PRESSURE

This

sender

drops

a

belowasafe

down

the

OVERSPEED

A

speed shutdown. whenever

a

safe,

shutdown.

OVERCRANK

Afteraprespecified

crankingifthe

RPM

SENSOR

If

the

speed

will

occur.

DC

FUSES

These

fuses

tem.

They

ing

overload.

PROTECTIVE

emergency

periodsoftime

conditionsascoolant

that

reason,

the

potentially

down

the

unit

when

high,

too

fast.

protective

temperature

the temperature

automatic

engine.

circuit

the

preset

switches

convenience.

for

additional

TEMPERATURE

automatically

rises

LEVEL

engine

coolant

switch,itis

shutdown.Toprevent

coolant

the

levelofthe

shuts

down.

SENDER

monitors

oil

level,

SHUTDOWN

controls

Engine

speed unitisrunning. value,

the

SHUTOOWN

durationofcranking,

engine

has

LOSS

SHUTDOWN

signaltothe

are

located

protect

the

panel

DEVICES

generator

withoutanoperatoronhandtomonitor

engine

damaging

the

coolant

and Also

SENDER

shuts

aboveasafe

SENSOR

level

low

pressureinthe the

engine

signals

circuit

failedtostart.

control

inside

wiring

mayberequiredtooperate

temperature,

has

several

devices

conditionsbyautomatically

oil

pressureistoo

levelistoo

NOTE:

sensors

refertothe

automatic

down

level.

drop

below

possible

sensor.Ifthe

coolant

control

system

cranking,

are

deliveredtothe

Should

the

board

initiatesanautomatic

panelislost,

the

front

and

low,orthe

are

mentioned

applicable

engine

the

engineifthe

the

for

the

enginetooverheat

such

levelofengine

level

sensor,

engine.Ifoil

automatically

start-up,

engine

overspeed

this

function

engine

panelofthe

components

oil

pressure

designed

low,

the

coolant

engine

here

control

shutdown

levelofthe overheating,

infor-

engine

coolant

the

engine

pressure

operation

circuit

board

above

engine

ends

shutdown

control

from

damag-

shuts

high

the

and

the

sys-

or

to

for

5

General Information

FUEL

DIESR

Diesel fuel

Diesel installation with

Appropriate extremely temperatureofthe where

SYSTEM

FUEL

SYSTEM

fuelissuppliedtothe

tankorexternal

fuels

are

can

engine/generator

low

"gelling"

source.

less

volatile

leadtosafety

care

shouldbetakeninapplications

ambient

diesel

could

than

performance

temperatures

fuelisnot

occur.

SPECIFICATIONS

GENERATOR

Refertothe frequency, the

drawingsinthe

and

ENGINE

The

unit

a

high-quality Detergent Use

ambient (Figure

voltage,

exhaust

OIL

has

oils

oil

having

temperature

1.3).

data

plateonthe

phase

and

backofthis

system

specifications.

RECOMMENDATIONS

been

filled

with detergent keep

the

oil

the

engine

following

range

classified

anticipated

generator

gaseous

hazards

and

NOTE:

generator

other

manual

15W-40

cleaner SAE

viscosity

set

fromabase-mounted

fuels,

however,

and/or

serious

reliability.

are

possibletoensure

allowedtofall

for

rated

watts,

pertinent

"For

information.

for

engine,

engine

oilatthe

ServiceSJand

and

reduce

cooling

carbon

rating,

before

the

careless

problems

where

below

levels

amperes,

Refer system,

factory.

CG/CH".

deposits.

basedonthe

change

the

to

Use

COOLANT

Use

only

de-ionized

glycol

can

alsobeused

col-see

DANGER

recommended

50-50

water

but

below).

mixture.

and

should When

Ethylene

notbemixed

adding

glycol

coolant,

antifreeze

with

always

~

A.

Do not remove the radiator pressure cap

....

while the engine is hot or serious burns from boiling liquid or steam could result.

A.

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. store used antifreeze because animals are attracted to the smell and taste of

antifreeze even though It is poi-

sonoustothem.

ACAUTIONI

A.

Do not use any chromate base rust Inhibitor

....

with propylene glycol base antifreeze. Using any high silicate antifreeze boosters or additives also will cause overheating. We also recommend that any soluble NOT USED for this equipment.

GEARBOX

If

the

lubricantisSAE90gear

LUBBICATION

generator

setisequipped

oil.

in an open container

011

Inhibitor Is

withagearbox,

the

(Propylene

Ethylene

gly-

add

Never

appropriate

the

Figure

-35

-30

-25

-20

-31

-22 -13

6

-15

SAE

1.3

-10

lOW

SAEOW·30

14

-

Engine

·5

SAE

SAE1OW

SAE

15W

SAE5W-30

23

32

I

20W

I I

SAE

-40

synthetic

41

Oil

Recommendations

15

20

SAE

30

-30 lOW

-40

SAE

10W

·60

l5W

-40

mineral

base

semisynthetic

SAE

base

20W base

50

base

·60

semisynthetic

59

68

25

SAE

77

base

30

35

40

45

50'C

40

86

95

104

113 122

'F

FUEL

SYSTEM

Diesel

Fuel

Emergency Manual

(part

1.

Beginning diesel

A.

Sulfur

B.

Cetane

2.

Beginning

diesel A.

Sulfur

B.

Cetane

BATTERY

Whenaunitissupplied use

the

following

mum

Cold

Diesel

6.7L

(100,

6.7L

(150,

10.3L

12.9L

13.0L

16.0L

18.0L

22.0L

Fill

the

battery

have

the

REDUIREMENTS

System:

Electric

fuel

• A

fuel

• A

See

Power

no.

046622).

October1,2007,

must

use

contentof500

indexoraromatic

minimum maximum

October1,2010,

must

use

contentof15

indexoraromatic

minimum maximum

INSTALLATION

tabletoproperly

Cranking

Engine

2.4L

3.4L

4.5L

8.7L

battery

Ampere

130Kw)1or2XGRP 175Kw)

with

the

fUlly

charged

AND

Chapter8of

Systems

diesel

cetane

aromatic

diesel

cetane

aromatic

with

Battery

GRP27or

GRP31or

2X

2x

proper

Installer's

owners

fuel

that

parts

per

contentasfollows:

indexof40

contentof35

owners

fuel

that

parts

per

contentasfollows:

indexof40

contentof35

outabatteryorduring

select

required

Size

GRP

31E

GRP

31

GRP31or

GRP

80

electrolyte

before

RECOMMENDATIONS

Engine-Generator

Guide

and

operators

meets:

million

or;

volume

and

operators

meets:

million

(ppm)

or;

volume

the

battery

foraparticular

31

2x

fluidifnecessary

installing

it.

Stationary

and

Reference

(ppm)

maximum.

percent.

maximum.

percent.

replacement

size

and

unit.

Minimum

650or925

925 925

925

925or1155

that

CCA

use

mini-

and

General

Before

installing

ing

steps:

1.

Set

the

2.

Turn

3.

Remove panel.

Battery

cables

1.4).

Connect

4.

Connect battery

5.

Connect battery

Damage

The

generatorisequipped

active

when

battery

installed

battery

receivesatrickle ning,toprevent to

help

extend

when

the

be

usedtorechargeadischarged

and

generator's

off

utility

power

the

10A

were

cablestobattery

Figure

1.4

---<~~

BLACK

the

red

post

indicatedbya

the

black

post

indicatedbya

will

resultifbattery

the

unitissetupfor

and

self-discharge.

the

lifeofthe

unitisnot

connecting

AUTO/OFF/MANUAL

supplytothe

and

15A

factory

-

Battery

~

___________

battery

withabattery

utility

charge

running.

Information

the

battery,

fuses

connectedatthe

postsasfollows:

Cable

complete

switchtoOFF.

transfer

from

switch.

the

generator generator

Connections

BLACK

LEAD

(FROM

FRAME)

RED

(FROM

CONTACTOR)

+

BATTERY

cable

(from

starter

contactor)tothe

positive,

cable

negative,

NOTE:

connections

NOTE:

power

batterybymaintaining

The

pas

(from

automatic

source while

The

trickle

battery.

or

(+).

frame

NEGor(-).

are

madeinreverse.

trickle

charger

operation.

voltage

the

engineisnot

chargerisdesigned

charge

feature

the

follow-

control (Figure

LEAD

STARTER

ground)tothe

that

is

With

the

available,

the

run-

battery

cannot

7

General Information

THE

BATTERY

~

A Do

tAbattery

/r\ A

illand

• Remove

• Use

• Wear

• Do

• Disconnect

Jt..

....

A The

....

The

• Wear

•

&.

Lmbecause

• DO NOT SMOKE

• DO NOT

and

•

A Be

....

not

disposeofthe

Is

capableofexploding.

battery

precautions ingonbatteries:

erator

tools

rubber

not

battery; or

disconnecting

Do electrolyte the

harmfultothe conductive

following

full Where Immediately Where thoroughly seek

medical

Spilled an

acid

Istouseasolutionof1

bicarbonateofsodato1

water. The

be

added

ing)

has

flushed

lead-acid

following

Discharge touching ed

metal

to

the battery or

MANUAL, startassoonasthe nected.

presentsariskofelectrical

high

short

circuit

aretobe

the

10A

and

control

lay

not

skin

electrolyteIsa

electrolyte electrolyte

electrolyteIstobewashed

neutralizing

sure

panel.

watches,

with

toolsormetal

and

charging

openormutilate

and

eye

and

bicarbonateofsoda

until

ceased.

with

they

cause

static

the

surface.

the

OFF

cables.Ifthe

ringsorother

Insulated

gloves

battery

IA

WARNING!1

has

been

eyes,

skin

and

procedures

protection

contacts

with

water;

contacts

Immediately

attention;

the

The

water batteries

generate

procedures

when

flameorsparkinbattery

electricity

batterybyfirst

AUTO/OFF/MANUAL

position

the

battery

current. observed

15A

fuses

handles;

and

boots;

parts

source

terminals.

knowntobe

andtobe

dilute and

corrosive.

aretobe and

and

agent.Acommon

pound

gallon(4liters)

evidenceofreaction

resulting

and

the

presentariskoffire

hydrogen

aretobe

near

before

switchissettoAUTO

generator

battery

In a

fire.

The

following

when

from

the

metal

on

topofthe

priortoconnecting

the

battery.

harmful

toxic.

sulfuric

eyes.Itis

protective

the the

with

area

the

from

touchingaground-

connecting

can

acid electrically

observed:

skin,

washItoff

eyes,

flush

water

down

(500

grams)

solutionisto

liquidIsto

dried.

gas.

followed:

battery;

body

switchisset

crank

cables

The

shock

work-

gen-

objects;

Released

that

clothing;

and

with

practice

of

(foam-

be

The

area;

before

the

and

are

con-

to

Is

A Be

tAand

Servicingofthe sonnel Keep

A on nected necting

GENERATOR

sure

the

utility

the

10A

and

the

generator occuratthe attached

knowledgeableofbatteries

unauthorized

negative

the

ground

wiring

and

terminals

the

batterytothe

battery

and

batteryistobeperformedorsupervisedbyper-

personnel

systemisused.

diagrams.

are

control

causeanexplosion.

AC

CONNECTIONS

See

"Voltage several wiresinthe accordingtothe for

the

tion,

refertoFigures

Voltage particular

fOUR-LEAD,

Four-lead

1.5).

Units

•

"{:>:.'

•

"M"

Each

output; or

240

The

neutral

33.

Therefore, Hertz) neutral

Codes".

voltages,

unit'sAGconnection

application.Ifthereisany

codes

generator

This

either

single-phaseorthree-phase.

numberofleads

1.4

through

applytothe

.

SINGLE-PHASE

generators

maybeassigned

units

are

units

are

stator

windinginthis

connecting

VAC

output. lineisformedbya

loads

across

canbemade.

Figure

are

rated

120/240

rated

110/220

the

two

connectionof120

leads11and

1.5

-

Four-lead,

44~EJ

E

JJ ] I : 22

E

11~E1

power

15A

fuses

panel,orsparking

postsasthe

away

Make

sure

tight.

Observe

generator

LEAD

generator

(lower)

question

1.9

typeofstator

STATOR

dual

voltage

anyofthe

VAG,

case

deliversa110

windings

junctionofstator

VAG

neutral,oracross

I I I

I

I I

I I :

I

I I

l _

CIRCUIT

BREAKER

supplyisturned

are

removed

cables

and

the

required

from

batteries.

Battery

connections

the

batteryiscorrectly

battery

set.

mayberatedatanyone

panel

and

the

voltage/phase

regarding

.

assembly

coilsorwindings

following

single-phase,60Hertz.

single-phase,50Hertz.

series

resultsina

(60

Hertz)or110

Single-phase

II

00

NEUTRAL:lloLTS

110/120

I

precautions.

polarity

when

The

shouldbeinstalled

lead

installedona

voltage

VAGor120

leads22and

leads44and

Stator

110/120

VOLTS

b20h40

VOLTS

off

from

may

are

shown

concon-

electrical

required

connec-

(Figure

codes:

220

VAC

of

VAG VAG

(50

8

General Information

Figure

240V

SIX-LEAD.

This

maybeassigned

•

"1.:'

•

"5"

FIELD

SeriesG-JG SeriesG-LG

600

typeofstator

units

are

units

are

WIRING

Breaker

Frame

1.9

-

Single-/Three-phase

Delta

Stator

Connection

E2

SII

--

VAG,

has

anyofthe

rated

346/600

rated

240V

----J

THREE-PHASE

three

coils

and

following

VAG,

277/480

VAG,

REQUIREMENTS

Gircuit

Breaker

(A)

Frame Frame

20-250

160-600

S6

S3~

STATOR

six

leads

(Figure

1.10).

voltage

codes:

three-phase,60Hertz.

three-phase,50Hertz.

TABLE

Range

Wire

Cu/AI

Cu

240V

I

Units

Type

Figure

FIELD

1.10-Six-lead

WIRING

REQUIREMENTS

The

table

shouldbeusedasa

rating,

and

size

rangeofoutput breakers. the

Wire

sizes

National

Temperature

Rating

Electric

75cC 75CC

shouldbein

Gode

Circuit

Lug

Range/(Number

4-350 2-500

Stator

Connection

51

1 1

277V

50HZ

346V60HZ

480V50HZ

600V60HZ

!

S2

CONNECTIONS

reference

wirestobe

(NEG).

Breaker

AWG

Gonductors)

kemil kemil

for:

connectedtothe

accordance

Wire

of

(1) (2)

wire

type,

with

TorquetoWire

temperature

table

310.16

180

in-Ib

3751n-lb

circuit

of

Series

Series Series

NOTE:

10

All

C- F

C-J

C- K

C- L

C- M

C- N C- R

field

Frame

Frame Frame Frame

installations

must

15-100

60-200

100-225

250 225

300 350-400 450-500

600 700-800

900-1000

1200

1400-1600

meet

the

National

Electric

Code

for

Cu/AI

CulAl Cu/AI

Cu CulAl CulAl Cu/AI

Cu/AI Cu/AI Cu/AI

Cu/AI Cu/AI Cu/AI wire

size

and

bending

75cC

75cC 75°C 75°C 75°C 75DC 75DC 75°C 75°C WC 75°C WC 75°C

space

requirements.

14-1/0

4-4/0 6-300 4-350 3-350

250-500

3/0-250 3/0-350

400-550

3/0-400 4/0-500

500-750

500-1000

(1) kemll kemll kemll

kemll kemil kemil kemll kemll kemll kemil

kemil

(1)

(1) (1) (1)

(2) (2)

(2) (3) (4)

(3)

(1)

(4)

(#14-10)35In-Ib

(#8)40In-Ib

(#6-4)45in-Ib

(#3-1/0)50in-Ib

120

in-Ib

120

in-Ib

275

in-Ib

275

in-Ib

375

In-Ib 2751n-lb 275

in-Ib 275

in-Ib 3751n-lb 375

In-Ib 450

In-Ib

550

in-Ib

General

Information

FIELD

WIRING

500Kw with 2500A connectionofthe shouldbefollowedinordertoobtainasuitable tiontothe

Volvo

Series

have

•

Conductor

accept aluminum

•

Suggested

•

Manufacturers

•

Type

-

•

Wire

Size

Required

Belowisthe

to

the

Buss

•

M12x65mm Washers,

CONNECTIONSTOBUSS

and

500/600Kw

C- R

Frame

Breakers

Buss

Bars

suppliedinthe

Field

Conductors.

Buss

Bars.

Lugs

-

The

Buss

Aluminum

stranded

Dual

-

Compression

wire

.

Manufacturer

Part

No.

-

Rated

(Al/CU),

600

kcmil

-

BLUA060D2

Hardware

recommended

Bars,

Grade

Lock

Washer

hardware

8,8

and

Doosan

Bars

PENN

Two

Hex Nut

BARS

powered

rated

1400,

connection

The

following

have

Lugs

suitable

UNION

CORP

Studs

requiredtoattach

Head

Cap

or

•

1/2"-20x2.5" Washers,

Required

M12

1/2"

Torque

Lock

Grade

SAE5Hex

Washer

-

Tighten

Dry75Ft-Lbs Dry85FHbs

and

Nut

fasteners

Head

to:

Cap

units

supplied

1600,

2000

Module

for

information

electrical

been

spaced13/4"

Screw,

Lubed58FHbs Lubed65FHbs

connec-

configured

for

copper

the

M12

and

the

to or

Apart

Lugs

Flat

ENGINE

If

1.11),itis supply.

ing,

helpingtoensure rises constant

COOLANT

the

unitisequipped

poweredbya

This

heats

This

action

continuously

flowofwarm

Figure

1.11-

HEATERS

withanengine

circuit

the

engine

keeps

the

quicker

drawing

coolant

Typical

OUTLET

coolant

engine

starts,

cold

through

TYPE

coolant

normally

when

warm

Heated

coolant

Engine

A

(block)

fedbythe

the

evenincold

coolantinthe

into

the

engine

Coolant

heater

utility

unitisnot

heater,

creating

.

Heaters

(Figure

power

operat-

weather,

engine

a

GENERATOR

AND

COMPATIBILITY

The

generator

phase

and

erator,

connected

voltage,

This

manual

has

been competent, the

installationiscomplete,donothing compatibility loads.

STARTING

The

stationary

more

starting

varying This

generator heater, tery

charger.

source

mustbefully

frequencyofthe

electrical

phase

and

assumes

properly

qualified

between

emergency

aids

that

climactic

(b)anengine

during

conditions.

may

These

nonoperating

compatible

connected

devices,orboth,

frequency

are

NOTE:

that

the

selected,

installed

electricianorinstallation

the

generator

AIDS

generator

servetoprovide

have

been

mounted

oil

heater,

aids

are

poweredbya

periods.

LOAD

with

electrical

not

compatible,

stationary

(c)abattery

emergency

and

that

and

maybeequipped

quicker,

with

the

rated

voltage,

loads.

The

gen-

canbedamaged

generator

interconnectedbya

contractor.

may

resultinnon-

connected

easier

(a)anengine

warmeror(d)abat-

normal

(utility)

Once

electrical

with

one

starts

under

coolant

power

or

TYPES

ENGINE

if

The oil with edinthe heater

1.

2.

3.

4.

5.

OIL

HEATER

engine

oil

heaterisdesigned

mustbekept

this

and

Disconnect Disconnect post

Make To

connect placeawire all

these

Connect ground

Using wire

•

near

unit,alow-watt

engine's

indicatedby(-)orNEG,

from

The to1st The oil

oil

thermostatdonot

battery

the

sure

powerisoff

the

nut

connections,

the

ground

wire

from

wire

nuts

the

oil

white

(common)

wire

from

heater.

(OPTIONAL)

for

operating sumporon

negative

wires,

over

provided heaterasfollows:

from

temperatureatall

density

heater

the

require

cablestoprevent

battery

from

the

hold

the

them,

then

use

the

wire

from

oil

heater,

connect

power

the

oil

heater.

load

sideofthermostatto2nd

installations

and

thermostat

sump

pan

maintenance.

accidental

cable

first

appropriate

bare

metal

twist

clockwise

wire

nuts

provided.

120V

power

the

white

wire

from

where

the

engine

times.Ifincluded

are

mount-

(Figure

1.12).

start-up.

from

the

battery

power

source.

leads

together

until

tight.

sourcetothe

wire

and

120V

power

source

wire

from

The

and

For

black

the

11

-------_.

__

_--_

..

_-------

FIELD

WIRING

Units

supplied

and

2500A

the

connectionofthe

shouldbefollowedinordertoobtainasuitable

tiontothe

•

Conductor

accept aluminum

•

Suggested

•

Manufacturers

•

Type

-

•

Wire

Size

Required

Belowisthe

to

the

Buss

•

M12x65mm Washers,

or

•

1/2"-20x2.5" Washers,

Required

M12

1/2"

CONNECTIONSTOBUSS

with

Series

C- R

have

Buss

Bars

suppledinthe

Field

Conductors.

Buss

Bars.

lugs

-

The

Buss

Aluminum

stranded

Dual

-

Compression

wire.

Manufacturer

Part

No.

-

Rated

(AL/CU),

600

kcmil

-

BLUA060D2

Hardware

recommended

Bars.

Grade

Lock

Washer

Grade

Lock

Washer

Torque

-

Tighten

hardware

8.8 and

SAE5Hex

and

fasteners Dry75Ft-Lbs Dry85Ft-Lbs

Frame

Bars

PENN

Two

Hex Nut

Nut

BARS

Breakers

connection

The

following

have

Lugs

suitable

UNION

CORP

1/2"

Studs

requiredtoattach

Head

Cap

Head

Cap

to:

rated

1600,

2000

Module

information

electrical

been

spaced13/4"

Screw,

Lubed58Ft-Lbs Lubed65Ft-Lbs

connec-

configured

for

copper

Apart

the

Lugs

M12

1/2"

for

to or

Flat

ENGINE

If

1.11),itis supply. ing. helpingtoensure rises constant

COOLANT

the

unitisequipped

poweredbya

This

heats

This

action

continuously

flowofwarm

Figure

1.11-

HEATERS

withanengine

circuit

the

engine

keeps

the

quicker

drawing

coolant

Typical

OUTLET

General

coolant

normally

coolant

when

engine

warm

starts.

Heated

cold

coolant

through

TYPE

the

Engine

A

Information

(block)

heater

fedbythe

the

evenincold

coolantinthe

into

the

engine.

Coolanl

utility

unitisnot

heater,

Healers

(Figure

power

operat-

weather,

engine

creating

a

GENERATOR

AND

COMPATIBILITY

The

generator

phase

and

erator,

connected

voltage,

This

manual

has

been competent, the

installationiscomplete,donothing compatibility loads.

STARTING

The

stationary

more

starting

varying This

generator heater, tery

charger.

source

mustbefully

frequencyofthe

electrical

phase

and

frequency

assumes

properly

qualified

between

emergency

aids

that

climactic

(b)anengine during

conditions.

may

These

nonoperating

compatible

connected

devices,orboth,

are

NOTE:

that

the

selected,

electricianorinstallation

the

generator

installed

AIDS

generator

servetoprovide

have

been

mounted

oil

heater,

(c)abattery

aids

are

poweredbya

periods.

LOAD

with

electrical

not

compatible.

stationary

emergency

and

that

and

maybeequipped

quicker,

with

normal

the

rated

voltage,

loads.

The

gen-

canbedamaged

generator

interconnectedbya

contractor.

may

resultinnon-

connected

easier

(a)anengine warmeror(d)abat-

(utility)

electrical

with

one

starts

under

coolant

power

Once

or

1~'_KE

if

The oil with edinthe heater

1.

2.

3.

4.

5.

ENGINE

OIL

HEATER

engine

oil

heaterisdesigned

mustbekept

this

and

Disconnect Disconnect post

Make To

connect placeawire all

these Connect ground Using

wire

•

near

unit,alow-watt

engine's

indicatedby(-)orNEG.

from

The

to1st

The oil

oil

thermostatdonot

battery

the

sure

powerisoff

the

nut

connections,

the

ground

wire

from

wire

nuts

the

white

(common)

wire

from

heater.

(OPTIONALl

operating

density

sumporon

cablestoprevent

negative

wires,

over

them,

oil

heater.

provided

oil

heaterasfollows:

from

the

load

__

TYPEB

for

temperatureatall

heater

the

require

battery

from

the

hold

the

bare

then

use

the

wire

from

connect

power

wire

oil

heater.

sideofthermostatto2nd

~

installations

and

thermostat

sump

pan

(Figure

maintenance.

accidental

cable

first

appropriate

metal

leads

twist

clockwise

nuts

provided.

120V

power

the

white

from

120V

where

the

engine

times.Ifincluded

are

mount-

1.12).

The

start-up.

from

the

battery

power

source.

together

until

sourcetothe

wire

power

wire

tight.

and

from

and

For

black

source

the

11

General Information

A.

Be

surenobare wire or wire strands are vis-

~Ible

6.

Push

all

7.

Assemble

8.

Reconnect tive

cable

ACAUTIONI

after making connections.

wires

and

wire

nuts

into

junction

firsttothe

box

battery

cablestobattery

Figure

covertojunction

battery

post

1.12

-

Oil

Heater

posts.

indicated

box.

box

Connect by

Kit

(+)

the

or

posi-

POS.

ACAUTIONI

A.

Be

surenobare wire or wire strands are vis-

~

Ible after making connections.

6.

Push

all

wires

and

wire

nuts

7.

Assemble

8,

Reconnect tive

cable

junction

battery

firsttothe

Figure

box

covertojunction

cablestobattery

battery

1.13

-

Battery

into

post

junction

posts,

indicated

Warmer

box,

Connect by

Kit

(+)

or

the

posi-

POS,

BATTERY

When warmers maximum

1,

2. 3,

4, 5,

WARMERS

usedinconjunction

(Figure

cranking

Disconnect Disconnect

post

indicatedby(-)orNEG,

Make

sure

To

connect placeawire all

these Connect ground Using

wire

from

•

The to1st

•

The

battery

1.13) speed.

battery

the

negative

powerisoff

the

wires,

nut

over

connections,

the

ground

wire

from

battery

nuts

provided

the

battery

white

(common)

wire

from

wire

from

load

heater,

(OPTIONAL)

withacoolant

aidinensuring

cablestoprevent

battery

from

hold

them,

use

the

wire

heater.

connect

heaterasfollows:

power

the

battery

sideofthermostatto2nd

the

then from

bare

wire

heater,

that

cable

appropriate

metal

twist

clockwise

nuts

120V

the

from

(block)

the

engine

accidental

first

from

power

leads

provided.

power

white

120V

heater,

battery

will

reach

start-up.

the

battery

source,

together

until

tight.

sourcetothe

wire

and

black

power

source

wire

from

and

For

the

BATTERY

There

10-amp only. ate component

Bothofthe

fuse

limitingtoreduce

tenanceofcharge

batteries The

on, pletely requiredisapproximately and18to22volts boost

They resistant

CHARGERS

are

two

typesofbattery

(nine-amp

The1Q-ampisavailableas12

for

the

engine'sDCsystem recognized

protected

continuously,

chargers

The

battery

dead

voltage,itneedstobe

are

not enclosure.

UL)

rated,

for

chargers

battery

water

are

(input

and riskofovercharging, voltage.

require

the

provides

will

not

fora24

resistant,sothey

chargers

The

2,5-amp VDCor24

voltage,

useonthese

fully

automatic

output),

Therefore,

connectionofa

boost

allow

nineto11

VDC

They

they

voltage

the

chargertooperate.

volts

system,Ifthe

replaced.

mustbeinstalled

available:

These

generator

float

have

and

have

canbeconnectedtothe

batteryinordertoturn

for

the

fora12

2,5-amp

chargeris12

VDC,asappropri-

chargers

sets.

types

and

are

automatic

charger,soa

The

VDC

batteryisbelow

withinarain

and

VDC

are

UL

fully

current

main-

com-

boost

system

the

12

STATIONARY GENERATOR

EMERGENCY

INSTALLATION

~

k..

Connecting this generator to an electrical

illsystem

ity shall

(such as the "GTS" type transfer switch), so as to isolate the electric system from the utility distribution system when the generator is operating. Failure to isolate the electric

system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy.

t

If

Lmator

materials and should be located such that

combustible materials are not capable of

accumulating under the generator set.

Only

qualified,

thoroughly tions

should

tem.

The

and

regulations

This

genset

mustbelevel

A After the system has been installed, do noth-

.....

ing that might render the installation in non· compliance with such codes, standards and regulations.

For

more

emergency

gency

Electric

Manual

normally supplied by an electric util-

be

by means of a transfer switch

ACAUTIONI

an open bottom is used, the engine-gener-

is to be installed over non-combustible

competent

familiar

install

installation

pertainingtothe

mustbeinstalledona

within

with

this

must

two

installation

applicable

stationary

comply

(2)

inches

contractorsorelectricians

codes,

standards

emergency

strictly

with

electric

all

codes,

installation.

level

all

around.

surface.

The

and

regula-

power

standards

base

ACAUTIONI

NOTE:

information

system,

Power

(part

#046622)

about

the

installationofa

order

Engine-Generator

Systems

Installer's

fromanAuthorized

Stationary

Guide

Service

and

Reference

Dealer.

stationary

emer-

sys-

frame

•

NFPA

No.

30,

CODE.

•

NFPA

No.

10,

INSTALLATION,

PORTABLE

OTHER

In

additiontoNFPA

ingtothe

FIRE

EXTINGUISHERS.

PUBLISHED

installation

systemsisavailable:

•

ArticleX,NATIONAL

American NY

o

AGRICULTURAL

and

10038,

Energy

Insurance

Council,

65201.

•

ASAE

EP-364.2,

STANDBY

ELECTRIC SocietyofAgricultural M149085.

•

A52.1,

AMERICAN FIREPLACES American York,

N.Y

BASIC ELECTRIC

Figure

2.1 emergency the

STANDBY transfer and

o

Notice

the

circuit

switch.

serves

Permits

supplyata

Prevents

UTILITY

that

transfer

breaker.

Figure

AND

National

10018.

STATIONARY

SYSTEM

showsaschematic electric

(GENERATOR)

The

the

following

the

LOAD

time

.

electrical

power

circuits.

both

the

switch

2.1

-

Basic

FLAMMABLE

AND

STANDARDS

standards,

and

WIRING

INSTALLATION

VENTING

Standard

system.

transfer

circuitstobe

backfeed

STANDBY

are

the

useofstationary

BUILDING

Association,85John

HANDBOOK,

909

University

POWER,

Engineers,

NATIONAL

SYSTEMS,

Institute,

diagramofa

Both

the output switchisrequiredbyelectrical

functions:

between

and

protected

against

Stationary

System

Installation

COMBUSTIBLE

MAINTENANCE

following

AND

information

emergency

CODE,

available

Street,

New

obtainable

Avenue,

AND

MAINTENANCEOFFARM

available

2950

Niles

STANDARD

from

Road,

FOR

from

Columbia,

the

St.

CHIMNEYS,

available

1430

Broadway,

EMERGENCY

basic

UTILITY

are

connectedtoonly

the

Emergency

power

connectedtoan

the

generator

UTILITY

power

overloadbya

Electric

supply

one

supplies

LIQUIDS

USE

OF

pertain-

electric

from

the

York,

the

Food

MO,

American

Joseph,

from

the

New

stationary

and

approved

code

power

and

the

to

main

line

NFPA

STANDARDS

The

following

ary

emergency

Protection

published

electric

Association

systems

02269orwww.nfpa.org.

o

NFPA

No.

37,

STATIONARY

TURBINES.

o

NFPA

No.

76A,

ESSENTIAL

HEALTH

o

NFPA

o

NFPA

o

NFPA

No.

No. No.

CARE

FACILITIES.

220,

STANDARD

68,

GUIDE

70,

NATIONAL

standards

(NFPA),

booklets

are

available

Batterymarch

COMBUSTION

ELECTRICAL

TYPESOFBUILDING

FOR

EXPLOSION

ELECTRICAL

pertainingtostationfrom

the

National

Park,

Quincy,

ENGINES

AND

SYSTEMS

CONSTRUCTION

VENTING

CODE.

Fire MA

GAS

FOR

UTIUTY POWER

--t-/

SUPPLY

STANDBY

GENERATOR

OUTPUT

--~'

MAIN

CIRCUIT

'- - - -

--,

MAIN

CIRCUIT

UNE

BREAKER

--

TRANSFER

SWITCH

-,..;.-'

~

UNE

BREAKER

r---+-~

I-

I

,

. _ J

c--f---CIRCUITS

,

'-

-

--1

TO

LOAD

13

Installation

EMERGENCY

CIRCUIT

ISOLATION

METHOD

This

prevents

loads

below

the

generatorispowering

amperage

the

emergency

Critical rate

"Emergency

panel

are

set.

When

erator,

The

•Itmust of

the

•

Haveitinstalled

and

the

TOTAL

overloading

the

wattage/amperage

capacity,

circuit

electrical

loads

Distribution

within

the

this

methodisused,itis

transfer

haveanampere

emergency

CIRCUIT

the

generatorbykeeping

only

critical

during

utility

power

isolation

wattage/amperage

switch

distribution

between

method,

are

grouped

Panel."

must

meet

rating

the

building's

distribution

together

Load

equaltothe

panel

panel.

ISOLATION

capacityofthe

loads,

outages,

and

circuits

capacityofthe

difficulttooverload

the

total

circuit.

main

generator,

within

the

consider

wired

intoasepa-

poweredbythat

requirements:

amperage

distribution

electrical

generator

METHOD

Whenagenerator circuitistobeinstalled, is

possible methodisemployed, this

typeofsystem,

•

Ampere

ratingofthe

•

The

transfer

entrance

GROUNDING

The

generator

National

~that

Electrical

A Do not connect the ground wire to any pipe

stance - FIRE or an EXPLOSION may result.

Figure

2.2 -

14

capableofpowering

for

the

generatortobe

The

ratingofthe

normal

incoming

switchisinstalled

and

the

building

THE

set

mustbegroundedinaccordance

Code

use

the

"Total

following

transfer

distribution

GENERATOR

and

any

all

electrical

Circuit

overloaded

applytothe

switch

must

utility

service,

between

panel.

stateorlocal

loadsinthe

Isolation

Method,"

when

this

transfer

the

requirements,

switch

the

utility

~

carries a flammable or explosive sub-

Grounding

Base

Grounding

Electrode

Frame

Electrode

Terminal

(typical)

wattage/

using

the

gen-

rating

panel

isolation

in

ampere

service

with

the

GENERATOR

AC

NEUTRAL

CONNECTIONS

Groundingisrecommended

If

Consult ments,

TRANSFER

local

building

codes

SWITCH

onlyatone

for

proper

START

pointinthe

neutral

grounding

SIGNAL

system, require-

CONNECTIONS

If

the

generatoristobeinstalled

switch,

suchasa

the

two-wire

Connect switchtothe lower 183Inthe

In

mustbein If

a

It

communications nection connection between be

HTS transfer

Engine AC respective

shieldatthe

the

rearoftheACconnection

the

connection

the

generatoristobeinstalled

different

from

the

connectedasfollows:

transfer

switch

generator-terminal

connection

BATTERY

GTS

type

start

control

two-wire

automatic

transfer

their

connection

the

panel.

HTS

switch-4position

enclosure

terminalsinswitch

transfer

start

SWitchto178

box,

The

own

conduit.

cable

(suchaBelden

HTS

This

cableistoberoutedina

transfer

panel.

Connect

switch

INSTALLATION

~

A Stationary emergency generators installed

....

with automatic transfer switches will crank and start ITY)

acceptable preset level.Toprevent such

an automatic start-up and possible injury to personnel, do not connect battery cables until certain that normal source voltage at the transfer switch is ready

A Storage batteries give off explosive hydrogen

~gas.

around the battery for several hours after charging. The slightest spark gas and cause an explosion. Such an explosion ness storage battery mustbeproperly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.

automatically when NORMAL (UTIL-

source voltage is removed or is below

to be placed Into operation.

This gas can form an explosive mixture

can shatter the battery and cause blind-

or

other injury. Any area that houses a

withastandard

switch,itwillbenecessarytoconnect

system,

signal

from

start

connection,

panel. (0)

and

conductors

methodisneeded,

transfer

switch

(labeled

strip

end.

for

withanHTS-type

switchtothe

and

the

terminal

"comm,

locatedinthe

the

RS485+

and

generator.Donot

correct and the system Is

automatic

the

automatic

whichislocatedinthe

Match

wires

178

183onthe

the

#9460)tomake

generator,

block,inthe

Ports"),

terminal

two-wire

Use

can ignite the

start

transfer

shielded

engine

separate

The

bottomofthe

lower

and

RS485-tothe

connect

the

generator

cableisto

rearofthe

transfer

(0)

and

strip

circuit

switch

2-wir~

con-

conduit

the

Operation

A Battery electrolyte fluid is an extremely

....

caustic sulfuric acid solution that can cause

severe burns. Do not permit fluid to contact

eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid

is spilled, flush the affected area immediately with clear water.

IAWARNINGII

A Do not dispose of the battery in a fire. The

~battery

is capable of exploding.

A Do not open or mutilate the battery.

....

Released electrolyte can be toxic and harmful to the skin and eyes.

Ir\

The battery represents a risk of high short

illcircuit

always remove watches, rings or other metal objects, and only use tools that have insu-

lated handles.

VENTED

current. When working on the battery,

BATTERIES

ACAUTIONI

A The electrolyte is a dilute sulfuric acid that is

....

harmful to the skin and eyes. It is electrically

conductive and corrosive. The following pro-

cedures are to be observed:

o Wear full eye protection and protective cloth-

ing,

o Where electrolyte contacts the skin, wash it off

immediately with water,

o Where electrolyte contacts the eyes, flush thor-

oughly and immediately with

medical attention, and

o Spilled electrolyte is to be washed down with

an acid-neutralizing agent. A common practice is

to use a solution of one pound (500 grams) bicarbonate of soda to one gallon (4 liters) of water. The bicarbonate of soda solution is to be

added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed

with

water

and the area dried.

water

and

seek

A Lead acid batteries present a risk of fire

~because

following procedure are to be followed:

o DO NOT SMOKE when

o DO

NOT

and

o Discharge static electricity from body before

touching batteries by first touching a grounded

metal surface.

they generate hydrogen gas. The

near

batteries,

cause flame or spark in battery area,

Servicingofbatteriesistobeperformedorsupervisedbypersonnel

knowledgeableofbatteries

unauthorized For

recommended mustbeat100 on

the

When to

check

procedures

personnel

percent

generator.

using

maintenance-free

the

specific

performedatthe

batteries,

"Maintenance,"Anegative nections are polarity

Damage

are

correctly

when

will

shownonthe

connected

connecting

resultifthe

and

the

required

away

from

batteries.

see

"Specifications,"

state-of

-charge

before

batteries,itis

gravityorelectrolyte

intervals

ground

wiring

diagrams,

and

terminals

batteriestothe

NOTE:

battery

specifiedinSection

systemisused.

Make

are

tight.

generator

connections

precautions,

All

batteries

they

are

installed

not

necessary

level.

Have

Battery

sure

all

batteries

Observe

set.

are

made

Keep

these

4,

con-

battery

in

reverse.

PREPARATION

The

instructionsinthis

gency

generator

adjusted

and installation 2

and3,as

before

attemptingtooperate

PRIORTOINITIAL

has

otherwise

contractor.Besuretoread

wellasall

BEFORE

section

assume

been

properly

prepared

START-UP

other

this

for

safety

(and

START-UP

that

the

stationary

installed,

usebya

the"

informationinthis

related)

serviced,

competent,

Safety

Rules"onPages

equipment.

emer-

tested,

qualified

manual,

ACAUTIONI

A Prior to initially starting the generator, it

....

must be properly prepared for use. Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) engine failure.

Before

starting complete information "Maintenance,"

Transfer

If

this

generatorisusedtosupply normally requires vents

electrical

(For

additional manual tor

and

mountedinstrict

the

generator

the

following

and/or

and

Switch

poweredbyan

thatatransfer

backfeed

information,

for

this

unit.)

other

standby

compliance

procedures.

service

the

intervals,

"Service

electric

switchbeinstalled,

between

The

transfer

components,

with

regulations,

for

the

Schedule",

powertoany

utility,

two

see

the

switch,aswellasthe

mustbeproperly

applicable

may

first

time,

For

follow-up

please

the

National

The

different

applicable

codes,

result in an

the

installer

must

maintenance

refertoSection

electrical

transfer

electrical

transfer

system

Electrical

switch

systems.

Code

switch

genera-

located

standards

4,

pre-

and and

15

Operation

Fuel

System

Make

sure

the

fuel

supply

correct

fuelatthe

leak

tested

"Specifications" If

the

unit

has

or

system

may

the

fuel

system

lines

shownosignofleakage,

correct

accordingtocode.Nofuel

for

more

been

idle

foralong

components

require

mustbeinstalled

have

bleedingtoremove

causes

systemtothe

pressure

information

been

hard

starting

and

but

may

generator

and

(b)isproperly

leakageispermitted.

periodoftime,orif removed

draw

and

reinstalled,

air

from

the

and

rough

operation.

mustbetight A

air

into

the

(a)

the

system.

loose

system.

ACAUTIONI

A Use a suitable container to catch the fuel

....

that will spill during system bleeding process. Clean up all spilled fuel after bleeding.

Generator

Check oiltothe

the

"Specifications" Check

initial The

Also,ifthe sure

Engine

Have mended problems.

Belt

Check the

unit correct midway

(10to16

systems.

Electrical

Make earth

Make and

Checktoensure Restrain tor

set

Set

Lubrication

the

engine

proper

level-the

engine

with

the

and

the

oil

levelinthe

use

andatthe

recommended

engineisequipped

the

governorisproperly

crankcase

oil

"Engine

intervals

oilisSAE90gear

oil

dipstick

level

below

Oil

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generator

indicatedbythe"

withamechanical

lubricated

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"FULL'

the

dipstick

gearbox

lubricant

with

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the

engine

cooling

coolant

mixture.

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system

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and

properly

the

system

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the

engine

fan

belt

tension

and

condition

into

service

andatrecommended

whenaforceofapproximately22pounds

between

mm).

pulleys,

This

does

deflects

the

not

applytoautomatic

belt

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sure

the

generatorisproperly

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sure

the

generator

interconnected,

that

any

loose

wirestokeep

components.

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and

ready

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connectedtoan

for

use.

them

clearofany

charged,

operating

mark.

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(ifsoequipped)

Service

governor,

clean

engine

filled

with

for

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priortoplacing

intervals.

about

electrical

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(10

3/8-to5/8-inch

belt

properly

connections,

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delivers

the

purged

and See

fuel

lines

the

fuel

Air

All

fuel

line

may

and add

operate

mark.

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prior

to

Schedule."

make

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the

recom-

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tension

kg),

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installed

genera-

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frame

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in

specification

STA8r-UP

A Power installation

tions The

the

be

is

GENERATOR

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sure (Figure

rodents

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BASE

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standard

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aretobe

technician

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filled

outata

the

four,

3-inch

tie-down

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from

units,

limits.

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holesinthe

The

cap

connection

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cap

plugs

2.3

-

diameter

plugs

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side

are

shippedina

box.

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the

interiorofthe

are

neededtostay

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cap

plugs

railsofthe

plugs

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3-INCH CIA.

INSPECTION

form

titled

"Start-up

(part

technicianorengineer.Asstatedonthe

accomplished

performing

formtoservice@generac.com.

dealer's

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no.

067377)

the

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shouldbecompletedbythe

onlybyfactory-trained

install

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website.

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for

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then

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are

unit's

plastic

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needed

generator

within

PLUG

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form,

personnel.

scan

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base

bag

to

set

noise

inspec-

e-mail

can

also

OPERATION

Refertothe unit

OPERATING TRANSFER

If

the capableofmanual A

manually

automatic

appropriate

generator

operated

start-up

control

UNIT

WITH

SWITCH

was

installedinconjunction

operation

and

transfer

does

only,

switchisone

not

panel

operator's

manual

MANUAL

withatransfer

the

following

includeanintelligence

procedure

that

will

not

circuit

for

this

switch

applies.

provide

ENGINE

For manual transfer

16

STA8T-UP

additional

for

this

switch.

AND

TRANSFE8

information,

unit,aswellasany

refertothe

applicable

literature

control

panel

pertainingtothe

~

A The Maintenance Disconnect Switch and

....

the AUTO/OFF/MANUAL switches (if so equipped) must be set properly, or the generator will crank and start as soon as the UTILITY power to the transfer switch is turned off. Refer to applicable control panel and transfer switch manuals for more infor-

mation.

A Do not proceed until certain that utility

....

source voltage is available to the transfer switch and the transfer switch main contacts

are set to UTILITY.

/r\ Do not attempt manual operation until all

illpower

been positively turned off, gerous - possibly lethal - electrical shock

will result.

/i).

Transfer switch enclosure doors should be

~kept

personnel should be allowed access to the

transfer switch Interior. Extremely high and

dangerous voltages are present in the trans-

fer switch.

In

ordertomanually

generator,

•

Turn switch, main

•

Set load

•

Set breakertoits

•

Start

•

Let

•

Check certain manual load

•

Set breakertoitsON(or

•

Load

generator.

RETRANSFER

For

additional

manual

transfer To

manually

shut

down

•

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•

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supplies to the transfer switch have

or

extremely dan-

closed and locked. Only authorized

transfer

follow

these

OFFordisconnect

using

the

means

line

circuit

breaker).

the

transfer

circuits

the

engine

all

that

circuits

the

circuits

for switch.

the

position,

handletoits

connectedtothe

stationary

OFF

(or

generator.

stabilize applicable

all

readings

handletoits

suppliedbythe

stationary

are

now

AND

SHUTDOWN

information,

this

unit,aswellasany

transfer

the

stationary

move

the

generator,

OFF

(or

the i.e.,

and

transfer

load

directions:

the

utility

provided

UTILITY

utility

emergency

OPEN)

position.

warm

up.

instrument

are

correct,

STANDBY

generator.

emergency

CLOSED)

poweredbythe

refertothe

load

backtothe

follow

these

emergency

OPEN)

position.

switch

load

cirCUits

from

the

power

circuittothe

(suchasthe

(NORMAL)

power

generator's

and

gauge

move

(GENERATOR)

generator's

position.

stationary

applicable

literature

utility

directions:

generator's

handletoits

connectedtothe

utility

sourcetothe

utility position

supply.

main

readings.

the

transfer

position,

main

control

pertainingtothe

power

main

UTILITY

utility.

transfer

source

with

line

circuit

When

switch

i.e,

line

circuit

emergency

panel

source

and

line

circuit (NOR-

•

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the

means

circuit

•

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the

internal

•

Shut

OPERATING TRANSFER

If

the

generator

switch,

suchasa

stopped

Refertothe "Transfer note

the

SERVICE

AUTHORIZED

Every

Monthor100Hours

•

Test

stationary

•

Inspect

•

Check

•

Check

•

Check

•

Check

•

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Every

Three

•

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•

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•

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AUTHORIZED

utility

power

provided

breaker)

generator

temperatures.

down

the

(suchasthe

.

runatno-load

generator.

UNIT

SWITCH

has

been

installed

GTS-type

automaticallyormanually.

applicable

Switch

Start

Signal

dangers

under

"Engine

SCHEDULE

OPERATOR

emergency

battery

(batteries)

engine

oil

level. gearbox engine generator

oil

level

coolant

level.

ground

starting

aids.

MonthsorEvery

and

test

fuel

system

exhaust

fuel

system.

supply

SERVICE

FUNCTIONS

After

First30HoursofOperation

•

Inspect

Wiring.

•

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engine

crankcase

•

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engine

fan

belts.

•

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battery

(batteries)

Every

Six

MonthsorEvery

•

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•

Service

•

Service

•

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•

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•

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•

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•

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engine engine engine

engine

fan

engine

air fuel

safety

belts.

coolant

cooling

controls.

cleaner.

filter.

controls.

level.

Maintenance

supplytothe

WITH

along

switch,

NOTE:

manual

for

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Start-up

MAINTENANCE

(whichever

generator

and

cables.

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connections.

120

and

system.

TECHNICIAN

oil

and

cables.

200

system

hoses.

transfer

utility

power

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minutestostabilize

AUTOMATIC

withanautomatic

the

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the

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and

FUNCTIONS

comes

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system.

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MAINTENANCE

oil

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source

main

transfer

maybestarted

switch

and please

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comes

first)

using

line

and

to

first)

17

Maintenance

•

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optional

•

Check

battery

•

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engine

•

Check

electrical

•

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•

Perform

AnnuallyorEvery

•

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•

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•

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engine

•

Drain

water

•

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•

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and

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Two

•

Replace

•

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•

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•

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flush,

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1,000

•

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•

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•

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•

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•

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As

Required

•

Bleed

engine

PERIODIC

A

rigorous

be

established diligently, functions

Keepinga"Maintenance log

shouldbea

gauge

and

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manufacturer

be

established

ing

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053263),anAuthorized engine

running

vals.

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tasks

recommended

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that

tobeperformed

capacities specifications,

starting

(batteries).

compression.

connections.

annunciator

operational

test

600

engine

oil

and

all

wiring.

starter

operation.

from

fuel

fan

bolts.

refill

gearbox

Years

all

rubber

hoses.

engine

fan

belts.

the

Stationary

refill

cooling

Operating

engineDCalternator. engine

starter.

engine

mounting

fuel

injection

cooling

system

fuel

system.

MAINTENANCE

programofscheduled

and

maintained.

will

provide

properly

instrument

between

listedinthe

maintenance

manyofthe

and

are

added

whenitis

continuous

readings

requires

the

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tests

and

tests

onlybyan

recommendations,aswellasother

listedin"Specifications".

aids.

panel.

Hours

(whichever

filter.

tank.

(ifsoequipped).

Emergency

system.

Generator

Hours

brackets.

pump.

thermostat.

periodic

Suchaprogram,ifadhered

assurance

needed.

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recordofrepairs,

during

thata"Scheduled

userofthis

Dealer.

Under

Service

Technician

checksatsix-month

Service

Dealer

"Service

requirements and

checks

Authorized

that

recommended.

operational

equipment

this

about

Schedule"

for

listedinthe

Service

comes

first)

System.

maintenance

the

power

parts

tests,

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and

agreement,

performs

and

one-year

this

agreement

cover

this

equipment.

Technician.

should

to

system

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a

replacements,

etc.

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the

install-

(Part

No.

prestart

the

schedule

and

inter-

minimum

are

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applicable

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STATIONARY

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An

authorized

ary

emergency

monthly

fer

inspecting Generator"); During shouldberecordedina also 30

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(or

100

switch

for wiring

this

operational

shouldbetestedatthis

minutes

and

six

months

performasystem

BAUERY

EMERGENCY

AND

COMPONENTS

operator

evidenceofarcing,

and

should generator hours).

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and

grounding

ensuring

test,

any

discrepancies

(or

200

system

that

"Maintenance

time;

hours),anAuthorized

operational

GENERATOR

test

the

operationofthe

and

should

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and

pittedorburned

connections

starting

all

instrument

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the

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corrected

test

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inspect

devices

its

components

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and

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immediately.

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the

contacts;

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are

operational.

gauge

readings

transfer

Technician

station-

trans-

system

A Stationary emergency generators Installed

....

with automatic transfer switches will crank and start automatically when NORMAL (UTIL-

ITY) source voltage Is removed or Is below

an

acceptable preset level.Toprevent such

automatic start-up and possible Injury to

personnel, do not connect battery cables until certain that normal source voltage at

the transfer switch Is correct and the system

Is ready to be placed Into operation.

A 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 sion can shatter the battery and cause blind-

ness or other Injury. Any area that houses a storage battery must be properly ventilated. Do

not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.

an

explosion. Suchanexplo-

A Battery electrolyte fluid Is an extremely

....

caustic sulfuric acid solution that can cause

Do

severe burns. eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling Is spilled, flush the affected area Immediately with clear water.

not permit fluid to contact

a battery. If fluid

IAWARNINGII

A

Do

not dispose of the batteryIna fire. The

~battery

A

Do

....

Released electrolyte can be toxic and harmful to the skin and eyes.

Is capable of exploding.

not open or mutilate the battery.

the

18

/;\

The battery represents a risk of high short

illcircuit

always remove watches, rings or other metal objects, and only use tools that have insulated handles.

An

authorized monthly be

checked and

connections

corrosion. Once

Technician battery battery required.

CHECK

An

authorized engine maintained dipstick. section.

Once

annually

vice

technician

equipped)

1.

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2.

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3.

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4.

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5.

To

current. When working on the battery,

operator

(or

100

and

every

six

'should

condition

hydrometer.

should

hours).Atthis

distilled

months

and

water

also

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200

inspect

the

stateofcharge

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battery

inspect

the

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time,

the

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hours),anAuthorized

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shouldberechargeorreplaced

FLUIDS

operator

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monthly

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600

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system

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6.

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7.

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check

INSPECT

Every

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a

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REPAIR

The

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lists

parts

lists

the

quantity number drawing.

HOWTOORDER

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•

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•

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ing

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the

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negative

for

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number

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number

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19

Maintenance

500

KW

TO

600

KW

STATIONARY

EMERGENCY

DIESEL

ENGINE

DRIVEN

GENERATOR

FollowingIsa size.

The

tobedecreased

occurs

NOTE:

A

To

~

control panel Auto-Oft-Manual switch to the "Off' position, removing the control panel fuse, turning oft the battery charger, and removing the negative battery cable before performing any maintenance. NOTE: The battery charger must be turned oft BEFORE removing the battery cable to prevent an current condition from burning out sensitive control panel components and circuits. Following all maintenance, when required.

recommended

established

first,

from

Add

20%toall

prevent injury, disable the generator set from starting and/or connecting to the load by setting the

SERVICE

SETS

maintenance

intervalsinthe

(performed

the

more

frequently)ifthe

times

noted

reverse these steps to insure the unit Is returned to standby setup for normal operation

MAINTENANCE

schedule

for12cylinderorlarger

for

stationary

are

the

maximum

unitisusedina

intervaltodetermine

INTERVAL

emergency

required

severe

the

14

WARNINGll

when

the

application.

required

diesel

INFORMATION

engine

driven

unitisusedinan

Use

the

maintenance

generator

average

unit

hour

interval.

sets

from

500kWto

service

application.

meterorcalendar

They

time,

600kWin

will

need

whichever

over

The

various

service

maintenance

1.

An

early

inspectionofthe

monthlyorfollowing

1A.A

break-in

identify

of

the

2.

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per

3.Amid-level problem

unittocomplete.

4.Acomprehensive andtoidentify

approximately

service

any

potential

unit

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unittocomplete.

inspectionofthe

areas.

Performed

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any

8.0

intervals

generator

each10hoursofoperationofthe

inspectionofthe

problem

approximately

semi-annuallyorfollowing

generator

annually

inspectionofthe

potential

man-hours

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are

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generator

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designatedbyinterval

man-hours

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Performed

numbersasfollows:

readytooperate

unit

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per

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readytooperate

each50hoursofoperationofthe

each

100

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biannuallyorfollowing

when

requires

readytooperate,

the

to

operate

properly

serviced

required

approximately.5man-hours

first

and

six

monthsorthe

and

carry

and

each

andtoidentify transfer

to,

and

the

load

when

unit

and

the

load

when

unit

and

requires

readytooperate

250

hoursofoperationofthe

any

carry

first50hoursofoperation

required,

requires

required,

potential

per

problem

unittocomplete.

the

load

andtoidentify

approximately

andtoidentify

approximately

and

carry

the

areas.

when

required,

after

any

1.5 any

4.aman-hours

load

when

unit

and

Performed

and

to

purchase

potential

man-hours

potential

per

required,

requires

20

Maintenance

Maint level

1

Maintenance

Interval

Every

month

or

10

hours

of

operation.

(Requires

approximately

0.5

man

hours

per

unit)

1.

2.

3.

4.

5.

6.

Disable

Check

the

unit

engine

battery

diesel

air

inlets

from

operating

oil

level.

coolant

electrolyte

fuel

supply

and

Maintenance

Adjustasnecessary.

level.

levelifaccessible.

level.

outlets

for

Tasks

per

the

first

Adjustasnecessary.

debris.

page

warning.

Adjustasnecessary.

Cleanasnecessary.

Task

Completed

Date/Initials

Technician's

Unit

Hour

Meter

7.

Visually

connectionsorcomponents,

8.

Return

Signature

ReadingatCompletionofthe

inspect

the

unit

the

unittooperational

Inspection

looking

and

condition.

for

leaks,

corrosion.

wearordamage,

Correctasnecessary.

loose

Date

Inspection

Completed

21

Maintenance

Maint

Level

Maintenance

Interval

1.

2.

3,

4,

5,

Disable

Check

the

unit

engine

battery

diesel

from

operating

oil

level.

coolant

electrolyte

fuel

supply

Maintenance

Adjustasnecessary.

level.

levelifaccessible,

level.

Tasks

per

the

first

page

Adjustasnecessary,

Adjustasnecessary.

warning.

Adjustasnecessary,

Task

Completed

Date/lnitials

1A

First6months

or

50

hours

of

operation

ONLY

(Requires

approximately

2,5

man

hours

per

unit)

6,

Drain

water

and

sediment

Drain

water

from

7. with

one,

8,

Check

the

g,

Visually

connectionsorcomponents,

1O,

11,

12,

13.

14,

inspect

Initiateanautomatic foratleast1hour and

abnormal

Change

Replace

Return

the

air

inlets

and

the

unit

looking

operating

the

engine

the

engine

the

engine

unittostand-by

diesel

outlets

looking

start

oil.

oil

fuel

from

the

diesel

fuel

line

water

for

debris,

for

leaks,

and

corrosion,

and

transfertoloadofthe

for

leaks,

loose

conditions,

filter(s),

setup

Correctasnecessary,

for

fuel

tank.

separatorifunitisequipped

Cleanasnecessary,

wearordamage,

Correctasnecessary,

connectionsorcomponents,

operation

when

loose

unit,

and

required,

exercise

it

Technician's

Unit

Hour

22

Signature

Meter

ReadingatCompletionofthe

Inspection

Date

Inspection

Completed

Maint Level

2

Maintenance

Interval

Every6months

or

50

hours

of

operation

(Requires

approximately

1.5

man

hours

per

unit)

1.

Disable

2.

Check

3.

Check

4.

Check necessary.

5.

Check

6.

Drain

7.

Drain with

8.

Check

the

water

one.

the

unit

from

engine

battery

diesel

and

from

air

inlets

operating

oil

level.

coolant

electrolyte

fuel

supply

sediment

the

diesel

and

outlets

Maintenance

Adjustasnecessary.

level.

levelifaccessible.

level.

from

fuel

Tasks

per

the

first

Adjustasnecessary.

the

diesel

line

water

for

debris.

page

warning.

Adjust

as

fuel

tank.

separatorifunitisequipped

Cleanasnecessary.

Maintenance

Task

Completed

Date/Initials

Technician's

Unit

Hour

Meter

9.

Visually nectionsorcomponents,

10.

11.

Signature

ReadingatCompletionofthe

inspect

the

unit

Initiateanautomatic ciseitforatleast1hour ponents,

Return

and

the

unittostandby

Inspection

start

abnormal

looking

for

leaks,

and

corrosion.

and

transfertoloadofthe

looking

for

operating

setup

conditions.

for

wearordamage,

Correctasnecessary.

unit,

leaks,

loose

connectionsorcom-

Correctasnecessary.

operation

when

required.

loose

and

con-

exer-

Date

Inspection

Completed

23

Maintenance

Maint level

3

Maintenance

Interval

Every12months

or

100

hours

of

operation

(Requires approximately 4,0

man

hours

per

unit)

Disable

1.

Check

2.

3.

Check

4.

Check sary.

Check

5.

Drain

6. Drain

7.

with Check

8.

Check

9.

necessary.

10.

Check corrosion,

the

the the

the

water water

one.

the the

the

engine

engine engine

diesel

air battery

the

unit

from

and from

inlets

battery

and

proper

operating

oil

level.

coolant coolant

fuel

supply

sediment

the

diesel

and

outlets

electrolyte

posts,

operation.

Maintenance

Adjustasnecessary.

level. thermal

level.

from

fuel

levelifaccessible.

cables,

Tasks

per

the

first

Adjustasnecessary.

protection

Adjustasnecessary.

the

diesel

line

water

for

debris.

and

charger

Correctasnecessary.

page

warning.

level.

Correctasneces-

fuel

tank.

separatorifunitisequipped

Cleanasnecessary.

Adjust

as

for

loose

connections,

Task

Completed

Date/lnitials

Technician's

Unit

Hour

Meter

11.

12.

13.

14.

15.

16.

17.

Signature

ReadingatCompletionofthe

Check

the

unit

wiring

for

loose

Correctasnecessary.

Check

the

engine

accessory

and

damage.

Test

the

operation.

Performanoil

engine

Visually

connectionsorcomponents, Start

and

ing

for

conditions. Return

Replaceasnecessary.

unit

safety

devices

Correct

oil

and

inspect

exercise

leaks,

the

unittostandby

Inspection

and/or

analysis

filtersifthe

the

unit

the

unit

loose

connectionsorcomponents,

Correctasnecessary.

adjustasnecessary.

(sendasampletoa

looking

under

setup

connections,

drive

belts

(alarms,

analysis

for

and

corrosion.

full

for

operation

corrosion,

for

wear,

shutdowns,

lab

results

indicate

leaks,

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rated

load

when

and

damage.

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etc.)

for

results).

foratleast2hours

and

abnormal

required.

cracking,

for

proper

Change

thisisrequired.

loose

operating

the

look-

Date

Inspection

Completed

24

Maintenance

Maint level

4

Maintenance

Interval

Every24months

or

250

hours

of

operation

(Requires

approximately

8.0

man

hours

per

unit)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Disable

Check

Drain Drain

with Check

Check

the

water water

one.

the

Check

the

corrosion,

unit

engine

diesel

and from

air

inlets

battery

and

from

operating

oil

level.

coolant

fuel

supply

sediment

the

diesel

and

electrolyte

posts,

proper

Maintenance

per

Adjustasnecessary.

level.

thermal

level.

from

the

fuel

outlets

for

levelifaccessible.

cables,

operation.

Tasks

the

first

Adjustasnecessary.

protection

Adjustasnecessary.

diesel

line

water

debris.

and

charger

Correctasnecessary.

page

warning.

level.

Correctasnecessary.

fuel

tank.

separatorifunitisequipped

Cleanasnecessary.

Adjustasnecessary.

for

loose

connections,

Task

Completed

Datellnitials

11.

Check

the

unit

Correctasnecessary.

12.

Check

the

engine

damage.

13.

Check

14.

Visually nectionsorcomponents,

15.

Start ing conditions.

16.

Change

17.

Replace

Replaceasnecessary.

the

engine

inspect

and

exercise

for

leaks,

loose

CorrectasnecessalY

the

engine

the

engine

wiring

for

loose

connections,

accessory

valve

the

unit

the

connectionsorcomponents,

oil.

oil

drive

clearance.

looking

and

corrosion.

unit

under

filter(s).

belts

Adjustasnecessary.

for

leaks,

full

rated

corrosion,

for

wear,

wearordamage,

Correctasnecessary.

load

foratleast2hours

and

damage.

weather

and

cracking,

loose

abnormal

Maintenance

and

con-

look-

operating

Level4continuedonnext

page.

25

Maintenance

Maint Level

Maintenance

Interval

Maintenance

Tasks

Task

Completed

Date/lnitials

Every24months

4

Technician's

or

250

hours

of

operation

(Requires

approximately

8.0

man

hours

per

unit)

Signature

Replace

18.

Replace

19.

Replace

20.

Replace

21

Visibly

22. this

Start

23. loose Correctasnecessary.

Return

24.

the

Engine

Coolant

inspect

unit.

Replace

the

unit

connectionsorcomponents,

the

unittostandby

engine

fuel

filter(s).

air

filter(

s).

Coolant.

Hoses.

flexible

fuel

lines

and

flexible

themifthey

and

exerciseitforatleast15minutes

seem

setup

worn,

and

for

operation

air

lines,ifapplicable,

spongyorbrittle.

abnormal

operating

when

looking

required.

on

for

leaks,

conditions.

Date

Inspection

Completed

Unit

26

Hour

Meter

ReadingatCompletionofthe

Inspection

Effective

01/01/2011,

Effective

01/01/2012,

Effective

01/01/2013,

Your

emission-related

built,

and

equippedtobe

tion

about

howtomakeanemission-related Emission-related Proper

maintenanceisspecifiedinthe

ness

testing.

The

warranty

EPA EMISSION-RELATED CI GENERATOR MODEL WARRANTY

applicabletoCI applicabletoCI applicabletoallCIgenerator

warranty

free

claims

period

generator generator

covers

only

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owners

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emissionsofany

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the 100

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1-800-333-1322orwwwgenerac.com.

controlofthe

hours

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pollutant

where

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manufacturer,oractsofGod.

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27

Warranty

Effective

01/01/2011,

Effective

01/01/2012,

Effective

01/01/2013,

NOTE: This Emission Control Warranty Statement applies only to mobile (trallerlzed) non-road diesel engine powered generators (model year 2000) as follows: The this statement pertains to this product only IF the generator

applicabletoCI

not

applicabletoCI

generator generator

generator

models models

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portion of this statement pertains to this product; The CARB portion of

size Is (1) 15 kW or below OR (2) 130 kW or greater.

CALIFORNIA

The

California (Generac), designed, control improper

Your

emission nectors labor,

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are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs.

diesel diesel

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PURCHASER'S/OWNER'S

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Useofany

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EMISSION

RIGHTS

Environmental

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for

the

stateofCalifornia

listed

below

injection

repair

years

that

failed

selling

system

your

non-road

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diesel

engines

If,

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WARRANTY

for

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dealerora

number:

CONTROL

AND

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Protection

new

provided

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said

warranty willbeperformedbya

completionofall all

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1·800·333·1322

IMPORTANT NOTE:

whichisprovidedtoyoubyGenerac whichisenclosed new

non-road circumstances obligations

Warranty

showing

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the

following address:

Part 1

28

diesel

where

with

respecttoyour

service

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your

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rights

California

between

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Warranty

ATTENTION

GENERAC

211

EAGLE,WI53119

and

obligations

law.

See

also

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ECS

The

Warranty

period.

Service

WARRANTY

POWER

SYSTEMS,

MURPHY

DRIVE

under

"Generac

Warranty

and

the

ECS

When

the

Limited

Generac

Warranty

requesting

the

ECS

Both

Facility.

DEPARTMENT

INC.

Emission

Warranties

applies

Warranty,

and

warranty

Control

only

the

System for

to

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emission

the

ECS

Generac

service,

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Generac

Warranty

describe

evidence

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Power

control

shall important

Warranty),

Systems,

systemofyour apply

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mustbepresented

Inc.,"

except

and

in

Generac 13694330200 User Manual

Table of Contents

INTRODUCTION

INSTALLATION

Operation

Maintenance

warranty