Generac Power Systems 13694330200, SD100 Owner's Manual

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

GENERAC®

Model: 13694330200

Type:

SDI00

Engine: D6.

7.1

Owner's

Manual

Stationary

Emergency

Generator

c@us

LISTED

This

manual

should

remain

with

the

unit.

Table of Contents

Safety

Rules

2

Introduction

1

Read

This

Manual

Thoroughly

1

Operation

and

Maintenance

1

HowtoObtain

Service

1

Authorized

Service

Dealer

Locator

Number

..'

...

1

Warranty

29

Notes

27

Maintenance

17

SERVICE

SCHEDULE..............

.

17

Authorized

Operator

Maintenance

Functions

17

Authorized

Service

Technician

Maintenance

Functions

.

17

PERIODIC

MAINTENANCE

18

Test

Stationary

Emergency

Generator

System

Operation

and

Components..

.. ..

.

18

Inspect

Battery...

..

18

Check

Fluids.

..

19

Inspect

Exhaust

System..

.

19

Inspect/Test

Fuel

Supply

System..

19

REPAIR

PARTS........

.

19

HowtoOrder

Parts..

. . 19

500

I\VV

TO

600

I\VV

STATIONARY

EMERGENCY

DIESEL

ENGINE

DRIVEN

GENERATOR

SETS..

.

..

20

SERVICE

MAINTENANCE

INTERVAL

INFORMATION

..

,,20

Operation

16

GENERATOR

CONTROL

AND

OPERATION

16

OPERATING

UNIT

WITH

MANUAL

TRANSFER

SWITCH

...16

Start-up

and

Transfer...

16

Retransfer

and

Shutdown..

.,..17

OPERATING

UNIT

WITH

AUTOMATIC

TRANSFER

SWITCH

....

17

Installation

13

STATIONARY

EMERGENCY

GENERATOR

INSTALLATION

.13

NFPA

Standards...

.

13

Other

Published

Standards..

...13

BASIC

STATIONARY

EMERGENCY

ELECTRIC

SYSTEM..

.

13

EMERGENCY

CIRCUIT

ISOLATION

METHOD

..

14

TOTAL

CIRCUIT

ISOLATION

METHOD

...14

GROUNDING

THE

GENERATOR...

.

14

GENERATORACNEUTRAL

CONNECTIONS..............

..14

TRANSFER

SWITCH

START

SIGNAL

CONNECTIONS.

.

14

BATTERY

INSTALLATION.....

. .

14

Vented

Batteries.....

.

.15

PREPARATION

BEFORE

START-UP

..

..

15

PriortoInitial

Start-up..

...15

Start-up

Inspection

..

16

. 5

ENGINE

PROTECTIVE

DEViCES..

5

Coolant

Temperature

Sender

5

Low

Coolant

Level

Sensor...

. 5

Oil

Pressure

Sender

0

Overs

peed

Shutdown

;)

Overcrank

Shutdown

5

RPM

Sensor

Loss

Shutdown...

. 5

DC

FUSES..

5

FUEL

SYSTEM

6

Diesel

Fuel

System...

. 6

SPECIFICATIONS

6

Generator

6

Engine

Oil

Recommendations

6
Coolant. 6
Gearbox

Lubrication..

. 6

Fuel

System

Requirements

and

Recommendations.....

. 7

BATTERY

INSTALLATION..

. 7

THE

BATTERY...

8

GENERATORACLEAD

CONNECTIONS

8
Four-lead,

Single-phase

Stator..

. 8

12-lead,

Broad

Range

Stators

9

Six-lead,

600

VAC,

Three-phase

Stator

.....

10

FIELD

WIRING

CONNECTIONS

REQUIREMENTS

10

Field

Wiring

ConnectionstoBuss

Bars..

.

11

GENERATOR

AND

LOAD

COMPATIBILITY

11

STARTING

AIDS

.

11

Engine

Coolant

Heaters..

..

.

11

Engine

Oil

Heater

(Optional)

..

.

11

Battery

Warmers

(Optional)..

.

12

Battery

Chargers..

. .

12

Generallnformation

4

IDENTIFICATION

RECORD

.4

Data

Label

...

Generator

Set

XPL

Label

.

EQUIPMENT

DESCRIPTION

;)

Standard

Generator

Features

.

INTRODUCTION

Thank

you

for

purchasing

this

modelofthe

stationary

emergency

generator

set

product

linebyGenerac

Power

Systems,

Inc"

Every

effort

was

expendedtomake

sure

that

the

information

and

instructionsinthis

manual

were

both

accurate

and

currentatthe

time

the

manual

was

written.

However,

the

manufacturer

reserves

the

righttochange,

alterorotherwise

improve

this

product(s)

at

any

time

without

prior

notice.

READ

THIS

MANUAL

THOROUGHLY

If

any

portionofthis

manualisnot

understood,

contact

the

near-

est

Authorized

Service

Dealer

for

starting,

operating

and

servicing

procedures.
Throughout

this

publication,

andontags

and

decals

affixedtothe

generator,

DANGER,

WARNING,

CAUTION

and

NOTE

blocks

are

usedtoalert

personneltospecial

instructions

aboutaparticular

serviceoroperation

that

maybehazardousifperformed

incor-

rectlyorcarelessly.

Observe

them

carefully.

Their

definitions

are

as

follows:

~

INDICATESAHAZARDOUS

SITUATIONORACTION

WHICH,

IF

NOT

AVOIDED,

WILL

RESULTINDEATHORSERIOUS

INJURY.

IAWARNING!I

Indicatesahazardous

situationoraction

which,ifnot

avoided,

could

resultindeathorserious

injury.

ACAUTIONI

Indicatesahazardous

situationoraction

which,ifnot

avoided,

could

resultinminorormoderate

injury.

NOTE:

Notes

contain

additional

information

importanttoa

procedure

and

willbefound

within

the

regular

text

bodyofthis

manual.

These

safety

warnings

cannot

eliminate

the

hazards

that

they

indicate.

Common

sense

and

strict

compliance

with

the

special

instructions

while

performing

the

actionorservice

are

essential

to

preventing

accidents.

Four

commonly

used

safety

symbols

accompany

the

DANGER,

WARNING

and

CAUTION

blocks.

The

typeofinformation

each

indicatesisas

follows:

A

This

symbol

points

out

important

safety

information

that,

....ifnot

followed,

could

endanger

personal

safety

and/or

propertyofothers.

A

This

symbol

points

out

potential

explosion

hazard.

£

This

symbol

points

out

potential

fire

hazard.

Lh

This

symbol

points

out

potential

electrical

shock

hazard.

Introduction

The

operatorisresponsible

for

proper

and

safe

useofthe

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

userstoproperly

start

and

operate

the

unit.

This

prepares

themifthey

needtooperate

the

equipment

inanemergency.

OPERATION

AND

MAINTENANCE

Itisthe

operator's

responsibilitytoperform

all

safety

checks,

to

make

sure

that

all

maintenance

for

safe

operationisperformed

promptly,

andtohave

the

equipment

checked

periodically

by

an

Authorized

Service

Dealer.

Normal

maintenance

service

and

replacementofparts

are

the

responsibilityofthe

owner/operator

and,assuch,

are

not

considered

defectsinmaterialsorworkman-

ship

within

the

termsofthe

warranty.

Individual

operating

habits

and

usage

contributetothe

need

for

maintenance

service.

Proper

maintenance

and

careofthe

generator

ensureaminimum

numberofproblems

and

keep

operating

expensesata

minimum.

SeeanAuthorized

Service

Dealer

for

service

aids

and

acces-

sories.

Operating

instructions

presentedinthis

manual

assume

that

the

stationary

emergency

electric

system

has

been

installedbyan

Authorized

Service

Dealerorother

competent,

qualified

contractor.

Installationofthis

equipmentisnota"do-it-yourself"

project.

HOWTOOBTAIN

SERVICE

When

the

generator

requires

servicingorrepairs,

contact

an

Authorized

Service

Dealer

for

assistance.

Service

technicians

are

factory-trained

and

are

capableofhandling

all

service

needs.

When

contactinganAuthorized

Service

Dealer

about

parts

and

service,

always

supply

the

complete

model

numberofthe

unit

as

givenonthe

front

coverofthis

manualoron

the

DATA

LABEL

affixedtothe

unit.

AUTHORIZED

SERVICE

DEALER

LOCATION

To

locate

the

nearest

AUTHORIZED

SERVICE

DEALER,

please

call

this

number:

1·800·333·1322

DEALER

LOCATION

INFORMATION

CANBEOBTAINEDATTHIS

NUMBER

or

visit

the

website

at

www.generac.com.

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

"'durlng

Installation and maintenance of the generator and batteries.

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

onlyifitisproperly

installed,

operated

and

maintained.

Many

accidents

are

causedbyfailingtofollow

simple

and

fundamental

rulesorprecautions.

The

manufacturer

cannot

anticipate

every

possible

circumstance

that

might

involveahazard.

The

warningsinthis

and

on

tags

and

decals

affixedtothe

unit

are,

therefore,

not

all-inclusive.

If

usingaprocedure,

work

methodoroperating

technique

that

the

manufacturer

does

not

specifically

recommend,

ensure

thatitis

safe

for

others.

Also

make

sure

the

procedure,

work

method

or

operating

technique

utilized

does

not

render

the

generator

unsafe.

~

It..

Despite the safe design of this genera·

...

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.

~

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.

It..

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

equipmentbeinstalled,

serviced

and

repairedbyan

Authorized

Service

Dealerorother

competent,

qualified

electrician

or

installation

technician

whoisfamiliar

with

applicable

codes,

standards

and

regulations.

The

operator

also

must

comply

with

all

such

codes,

standards

and

regulations.

•

Installation,

operation,

servicing

and

of

this

(and

related)

equipment

must

always

comply

with

applicable

codes,

stan-

dards,

laws

and

regulat'lons.

Adhere

strictlytolocal,

state

and

national

electrical

and

building

codes.

Comply

with

regulations

the

Occupational

Safety

and

Health

Administration

(OSHA)

has

established.

Also,

ensure

that

the

generatorisinstalled,

operat-

ed

and

servicedinaccordance

with

the

manufacturer's

instruc-

tions

and

recommendations.

Following

installation,donothing

that

might

render

the

unit

unsafeorin

noncompliance

with

the

aforementioned

codes,

standards,

laws

and

regulations.

2

•

The

engine

exhaust

fumes

contain

carbon

monoxide

gas,

which

canbeDEADLY.

This

dangerous

gas,ifbreathed

in

sufficient

concentrations,

can

cause

unconsciousnessoreven

death.

For

that

reason,

adequate

ventilation

mustbeprovided.

Exhaust

gases

mustbepiped

safely

away

from

any

building

or

enclosure

that

houses

the

generatortoan

area

where

people,

animals,

etc.,

will

notbeharmed.

This

exhaust

system

must

be

installed

properly,instrict

compliance

with

applicable

codes

and

standards.

•

Keep

hands,

feet,

clothing,

etc,

away

from

drive

belts,

fans,

and

other

movingorhot

parts.

Never

remove

any

drive

belt

or

fan

guard

while

the

unitisoperating.

•

Adequate,

unobstructed

flowofcooling

and

ventilating

air

is

criticalinany

roomorbuilding

housing

the

generatortoprevent

buildupofexplosive

gases

andtoensure

correct

generator

operation.Donot

alter

the

installationorpermit

even

partial

blockageofventilation

provisions,asthis

can

seriously

affect

safe

operationofthe

generator.

•

Keep

the

area

around

the

generator

clean

and

uncluttered.

Remove

any

materials

that

could

become

hazardous.

•

When

workingonthis

equipment,

remain

alertatall

times.

Never

workonthe

equipment

when

physicallyormentally

fatigued.

•

Inspect

the

generator

regularly,

and

promptly

repairorreplace

all

worn,

damagedordefective

parts

using

only

factory-

approved

parts.

•

Before

performing

any

maintenanceonthe

generator,

discon-

nect

its

battery

cablestoprevent

accidental

start-up.

Disconnect

the

cable

from

the

battery

post

indicatedbya

NEGATIVE,

NEG

or

first.

Reconnect

that

cable

last.

•

Never

use

the

generatororanyofits

partsasa

step.

Stepping

on

the

unit

can

stress

and

break

parts,

and

may

resultindan-

gerous

operating

conditions

from

leaking

exhaust

gases,

fuel

leakage,

oil

leakage,

etc.

ELECTRICAL

HAZARDS

•

All

generators

coveredbythis

manual

produce

dangerous

elec-

trical

voltages

and

can

cause

fatal

electrical

shock.

Utility

power

delivers

extremely

high

and

dangerous

voltagestothe

transfer

switchaswellasthe

stationary

emergency

generator.

Avoid

contact

with

bare

Wires,

terminals,

connections,

etc.,onthe

generatoraswellasthe

transfer

switch,ifapplicable.

Ensure

all

appropriate

covers,

guards

and

barriers

areinplace

before

oper-

ating

the

generator.Ifwork

mustbedone

aroundanoperating

unit,

standonan

insulated,

dry

surfacetoreduce

shock

hazard.

•

Do

not

handle

any

kindofelectrical

device

while

stand-

inginwater,

while

barefoot,orwhile

handsorfeet

are

wet.

DANGEROUS

ELECTRICAL

SHOCK

MAY

RESULT.

•Ifpeople

must

standonmetalorconcrete

while

installing,

operating,

servicing,

adjustingorrepairing

this

equipment,

place

insulative

mats

overadry

wooden

platform.

Workonthe

equipment

only while

standingonsuch

insulative

mats.

•

The

generator

set

mustbegroundedinaccordance

with

the

National

Electrical

Code

and

any

stateorlocal

requirements.

•

Wire

gauge

sizesofelectrical

wiring,

cables

and

cord

sets

mustbeadequatetohandle

the

maximum

electrical

current

(ampacity)towhich

they

willbesubjected.

See

the

Field

Wiring

Requirements

Table.

•

Before

installingorservicing

this

(and

related)

equipment,

make

sure

that

all

power

voltage

supplies

are

positively

turned

off

at

their

source.

Failuretodosowill

resultinhazardous

and

pos-

sibly

fatal

electrical

shock.

•

Connecting

this

unittoan

electrical

system

normally

supplied

byanelectric

utility

shallbeby

meansofa

transfer

switchsoas

to

isolate

the

generator

electric

system

from

the

electric

utility

distribution

system

when

the

generatorisoperating.

Failure

to

isolate

the

two

electric

system

power

sources

from

each

other

by

such

means

will

resultindamagetothe

generator

and

may

also

resultininjuryordeathtoutility

power

workers

due

to

backfeedofelectrical

energy.

•

Generators

installed

withanautomatic

transfer

switch

will

crank

and

start

automatically

when

NORMAL

(UTILITY)

source

voltageisremovedoris

belowanacceptable

preset

level.

To

prevent

such

automatic

start-up

and

possible

injurytoperson-

nel,

disable

the

generator's

automatic

start

circuit

(battery

cables,

etc.)

before

workingonor

around

the

unit.

Then,

place

a

"Do

Not

Operate"

tagonthe

generator

control

panel

and

on

the

transfer

switch.

•Incaseofaccident

causedbyelectric

shock,

immediately

shut

down

the

sourceofelectrical

power.Ifthisisnot

pos-

sible,

attempttofree

the

victim

from

the

live

conductor.

AVOID

DIRECT

CONTACT

WITH

THE

VICTIM.

Useanonconducting

implement,

suchasa

dry

ropeorboard,tofree

the

victim

from

the

live

conductor.Ifthe

victimisunconscious,

apply

first

aid

and

get

immediate

medical

help.

•

Never

wear

jewelry

when

workingonthis

equipment.

Jewelry

can

conduct

electricity

resultinginelectric

shock,ormay

get

caughtinmoving

components

causing

injury.

Safety Rules

FIRE

HAZARDS

•

Keepafire

extinguisher

near

the

generatoratall

times,DoNOT

use

any

carbon

tetra-chloride

type

extingUisher,

Its

fumes

are

toxic,

and

the

liquid

can

deteriorate

wiring

insulation.

Keep

the

extinguisher

properly

charged

andbefamiliar

with

its

use.

If

there

are

any

questions

pertainingtofire

extinguishers,

consult

the

local

fire

department.

EXPLOSION

HAZARDS

•

Properly

ventilate

any

roomorbuilding

housing

the

generator

to

prevent

bUild-Upofexplosive

gas,

•

Do

not

smoke

around

the

generator,

Wipeupany

fueloroil

spills

immediately.

Ensure

thatnocombustible

materials

are

left

in

the

generator

compartment,oronornear

the

generator,

as

FIREorEXPLOSION

may

result.

Keep

the

area

surrounding

the

generator

clean

and

free

from

debris.

•

All

fuel

types

are

potentially

FLAMMABLE

and/or

EXPLOSIVE

and

shOUldbehandled

with

care,

Comply

with

all

laws

regulat-

ing

the

storage

and

handlingoffuels,

Inspect

the

unit's

fuel

system

frequently

and

correct

any

leaks

immediately,

Fuel

supply

lines

mustbeproperly

installed,

purged

and

leak

tested

accordingtoapplicable

fuel-gas

codes

before

placing

this

equipment

into

service,

•

Diesel

fuels

are

highly

FLAMMABLE.

CALIFORNIA

PROPOSITION65WARNING

Engine

exhaust

and

someofits

constituents

are

known

to

the

StateofCaliforniatocause

cancer,

birth

defects

and

other

reproductive

harm.

CALIFORNIA

PROPOSITION65WARNING

This

product

containsoremits

chemicals

knowntothe

StateofCaliforniatocause

cancer,

birth

defects

and

other

reproductive

harm

3

General

Information

IDENTIFICATION

RECORD

DATA

LABEL

Figure

1.2

-

XPL

Label

GENERAC

POWER

SYSTEMS

WHEN

ORDERING

REPAIR

PARTS,

ALWAYS

GIVE

THE

ABOVE

INFORMATION

NOTE:

The

aboveisa

generic

representationofan

XPllabel.

For

actu-

al

information

relatedtothis

particular

model,

please

refer

to

the

"construction

document"

locatedatthe

endofthis

manual,

ortothe

data

cards

affixedtothe

unit.

Every

generator

set

hasaDATA

LABEL

that

contains

important

information

pertinenttothe

generator

(Figure

1,1),

The

data

label,

which

canbefound

attachedtothe

generator's

lower

connection

box,

lists

the

unit's

serial

number

and

its

rated

voltage,

amps,

watt-

age

capacity,

phase,

frequency,

rpm,

power

factor,

etc

Figure

1.1

-

Data

Label

MODELNOOOA

00000

S

GROUP

DESCRIPTION

A

Generator

B

Control

Panel

C

Mounting

Base

D

Engine&Accy,

E

Fuel

Systems

F

Compartments

G

Wiring

Diagrams

H

Kits

DATE

00/00/05

ASSEMBLY

NUMBERS

00000 00000
00000 00000

00000
00000 00000 00000
00000 00000
00000
00000 00000
00000

00000 00000

00000

00000

NOTE:

The

aboveisa

generic

representationofa

data

label.

For

actual

information

relatedtothis

particular

model,

please

refertothe

"construction

document"

locatedatthe

endofthis

manual,

or

to

the

data

labels

affixedtothe

unit.

GENERATOR

SET

XPL

LABEL

Every

generator

set

hasaXPL

LABEL

affixedtothe

lower

con-

nection

box

(Figure

1,2),

Additionally,aprinted

CONSTRUCTION

DOCUMENT

containing

identical

information

canbefoundatthe

endofthis

manual.

When

requesting

information,

ordering

replacement

parts,

asking

for

service,

etc"

oneormoreofthe

following

maybeneeded:

•

Generator

Model

Number

•

DateofManufacture

•

Generator

Identification

Code

•

Generator

Assembly

Groups

Generator

Model

Number

This

numberisthe

keytonumerous

engineering

and

manufactur-

ing

details

pertainingtothe

unit

Always

supply

this

number

when

requesting

service,

ordering

partsorseeking

information,

4

Identification

Code

Use

this

codetoobtain

important

information

about

the

generator,

For

example,ifthe

codeis'"

SO

0100A617

4.5018

HBYY3

-

identify

the

generatorasfollows:

•

SO-Stationary

emergency

diesel

generator

("58"

indicates

a

stationary

emergency

gaseous

fuel

unit),

•

0100-Rated

outputis100,000

watts

(100

kW),

• A-

Voltage

code

(see

"Voltage

Codes"),

•

G17

-Indicates

engine

MFG

(for

Generac

use).

•

4,5-Engineis4,5

liter.

• 0 -

Unit

has

diesel

fuel

system

("N"

indicates

natural

gas;

'T'

indicatesLPLiquid

Withdrawal;

"v"

indicatesLPVapor

Withdrawal),

•18-

Alternator

rpm

rating

(1,800

rpm);

"36"

indicates

3,600

rpm.

• H-

Unit

hasanoption

"H"

control

panel

("G"

panels

are

also

availableonsome

units).

• B-

Indicatesabrushless

unit

("P"

indicatesapermanent

mag-

net

excitation).

• Y-

Unitisequipped

withastandard

enclosure

("N"

indicates

no

enclosure;

"5'

indicates

Level1sound

attenuation;

"L"

indi-

cates

Level2sound

attenuation),

•

"Y"

indicatesamuffler

has

been

mounted;N-Unit

does

not

haveanexhaust

muffler;

"L:'

indicatesamuffler

has

been

shipped

loose

with

the

unit),

• 3-

Emission

designation

(for

factory

use),

Groups

and

Assembly

Numbers

The

XPL

label

lists

the

groups

and

corresponding

assembly

numbers

for

each

unit.

The

assembly

numbers

refertoexploded

view

drawing

numbers

that

are

applicabletothe

specific

gen-

erator

model.

These

drawings

are

locatedinthe

back

halfofthis

manual.

Voltage

Codes

The

identification

code

letter

following

the

unit's

kilowatt

rating

is

the

generator's

"voltage

code."

Anyoneofthe

following

voltage

codes

maybelisted.

A -

120/240

volts,

single-phase,

four-lead,60Hz

o -

120/240

volts,

single-

and

three-phase,

12-lead,60Hz

G -

120/208

volts,

three-phase,

12-lead,60Hz

Broad

Range

J

120/240

volts,

three-phase,

12-lead,60Hz

Broad

Range

K -

277/480

volts,

three-phase,

12-lead,60Hz

Broad

Range

L

346/600

volts,

three-phase,

six-lead,60Hz

M -

110/220

volts,

single-phase,

four-lead,50Hz

N -

115/200

volts,

three-phase,

12-lead,50Hz

Broad

Range

P -

100/200

volts,

three-phase,

12-lead,50Hz

Broad

Range

R -

231/400

volts,

three-phase,

12-lead,50Hz

Broad

Range

S

277/480

volts,

three-phase,

six-lead,50Hz

EQUIPMENT

DESCRIPTION

This

equipmentisa

revolving

field,

alternating

current

generator

set.

The

generator

was

designedtosupply

electrical

power

for

the

operationofcompatible

electrical

loads-when

the

UTILITY

power

supplyisnot

availableorhas

droppedtoan

unacceptable

level.

The

generator's

revolving

fieldisdirectly

connectedtoand

driven

byanenginebymeansofflexible

discs.

Generators

withafour-

pole

rotor

are

drivenatrated

speedsof1,800

rpmtosupply

a

frequencyof60

Hertz.

Refertothe

data

labelonthis

specific

generatororto

the

data

label

affixedtothe

unit

for

ratedACvoltage,

wattage,

amperage,

number

of

phases,

etc.

See

"Identification

Code"

foranexplanationofthe

waytoidentify

the

unit's

features.

STANDARD

GENERATOR

FEATURES

This

generator

incorporates

the

following

generator

features:

•

The

rotor

insulation

systemisClass

"H"

rated,

and

the

stator

insulationisClass

"H"

ratedasdefinedbyNEMA

MG1-22.4

and

NEMA

MG1-1.65.

•

The

generatorisself

-ventilated

and

drip-proof

constructed.

•

The

voltage

waveform

deviation,

total

harmonic

content

of

theACwaveform

and

"telephone

influence

factor"

have

been

evaluated

and

are

acceptable

accordingtoNEMA

MG1-22.

•

All

prototype

tested

models

have

passed

three-phase

sym-

metrical

short

circuit

testtoensure

system

protection

and

reliability.

General Information

ENGINE

PROTECTIVE

DEVICES

The

stationary

emergency

generator

mayberequiredtooperate

for

long

periodsoftime

withoutanoperatoronhandtomonitor

such

engine

conditionsascoolant

temperature,

oil

pressure

or

rpm.

For

that

reason,

the

engine

has

several

devices

designed

to

protectitagainst

potentially

damaging

conditionsbyautomatically

shutting

down

the

unit

when

the

oil

pressureistoo

low,

the

coolant

temperatureistoo

high,

the

coolant

levelistoo

low,orthe

engine

is

running

too

fast.

NOTE:

Engine

protective

switches

and

sensors

are

mentioned

here

for

the

reader's

convenience.

Also

refertothe

applicable

control

panel

manual

for

additional

automatic

engine

shutdown

infor-

mation.

COOLANT

TEMPERATURE

SENDER

This

sender

automatically

shuts

down

the

engineifthe

engine

coolant

temperature

rises

aboveasafe

level.

LOW

COOLANT

LEVEL

SENSOR

Should

the

engine

coolant

level

drop

below

the

levelofthe

high

coolant

temperature

switch,itis

possible

for

the

enginetooverheat

without

automatic

shutdown.Toprevent

such

overheating,

the

engine

hasalow

coolant

level

sensor.Ifthe

levelofengine

coolant

drops

below

the

levelofthe

low

coolant

level

sensor,

the

engine

automatically

shuts

down.

OIL

PRESSURE

SENDER

This

sender

monitors

oil

pressureinthe

engine.Ifoil

pressure

drops

belowasafe

level,

the

control

system

automatically

shuts

down

the

engine.

OVERSPEED

SHUTDOWN

A

speed

circuit

controls

engine

cranking,

start-up,

operation

and

shutdown.

Engine

speed

signals

are

deliveredtothe

circuit

board

whenever

the

unitisrunning.

Should

the

engine

overspeed

above

a

safe,

preset

value,

the

circuit

board

initiatesanautomatic

engine

shutdown.

OVERCRANK

SHUTOOWN

Afteraprespecified

durationofcranking,

this

function

ends

the

crankingifthe

engine

has

failedtostart.

RPM

SENSOR

LOSS

SHUTDOWN

If

the

speed

signaltothe

control

panelislost,

engine

shutdown

will

occur.

DC

FUSES

These

fuses

are

located

inside

the

front

panelofthe

control

sys-

tem.

They

protect

the

panel

wiring

and

components

from

damag-

ing

overload.

5

General Information

FUEL

SYSTEM

DIESR

FUEL

SYSTEM

Diesel

fuelissuppliedtothe

generator

set

fromabase-mounted

fuel

tankorexternal

source.

Diesel

fuels

are

less

volatile

than

gaseous

fuels,

however,

careless

installation

can

leadtosafety

hazards

and/or

serious

problems

with

engine/generator

performance

and

reliability.

NOTE:

Appropriate

care

shouldbetakeninapplications

where

extremely

low

ambient

temperatures

are

possibletoensure

the

temperatureofthe

diesel

fuelisnot

allowedtofall

below

levels

where

"gelling"

could

occur.

SPECIFICATIONS

GENERATOR

Refertothe

data

plateonthe

generator

for

rated

watts,

amperes,

frequency,

voltage,

phase

and

other

pertinent

information.

Refer

to

the

drawingsinthe

backofthis

manual

for

engine,

cooling

system,

and

exhaust

system

specifications.

ENGINE

OIL

RECOMMENDATIONS

The

unit

has

been

filled

with

15W-40

engine

oilatthe

factory.

Use

a

high-quality

detergent

oil

classified

"For

ServiceSJand

CG/CH".

Detergent

oils

keep

the

engine

cleaner

and

reduce

carbon

deposits.

Use

oil

having

the

following

SAE

viscosity

rating,

basedonthe

ambient

temperature

range

anticipated

before

the

next

oil

change

(Figure

1.3).

COOLANT

Use

only

de-ionized

water

and

Ethylene

glycol

antifreeze

(Propylene

glycol

can

alsobeused

but

should

notbemixed

with

Ethylene

gly-

col-see

DANGER

below).

When

adding

coolant,

always

add

the

recommended

50-50

mixture.

~

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.

Never

store used antifreeze

in an open container
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

011

Inhibitor Is

NOT USED for this equipment.

GEARBOX

LUBBICATION

If

the

generator

setisequipped

withagearbox,

the

appropriate

lubricantisSAE90gear

oil.

Figure

1.3

-

Engine

Oil

Recommendations

-35

-30

-25

-20

-15

-10

·5

15

20

25

30

35

40

45

50'C

SAE

lOW

I

I

SAE

20W

SAE

30

I I

SAE

40

SAE1OW

-30

SAE

lOW

-40

SAE

10W

·60

SAE

l5W

-40

mineral

base

SAE

15W

-40

semisynthetic

base

SAE

20W

·60

semisynthetic

base

SAE5W-30

synthetic

base

SAEOW·30

synthetic

base

6

-31

-22 -13

14

23

32

41

50

59

68

77

86

95

104

113 122

'F

General

Information

BLACK

___________

RED

LEAD

(FROM

STARTER

CONTACTOR)

BLACK

LEAD

~

(FROM

FRAME)

---<~~

+

BATTERY

4.

Connect

the

red

battery

cable

(from

starter

contactor)tothe

battery

post

indicatedbya

positive,

pas

or

(+).

5.

Connect

the

black

battery

cable

(from

frame

ground)tothe

battery

post

indicatedbya

negative,

NEGor(-).

NOTE:

Damage

will

resultifbattery

connections

are

madeinreverse.

NOTE:

The

generatorisequipped

withabattery

trickle

charger

that

is

active

when

the

unitissetupfor

automatic

operation.

With

the

battery

installed

and

utility

power

source

voltage

available,

the

battery

receivesatrickle

charge

while

the

engineisnot

run-

ning,toprevent

self-discharge.

The

trickle

chargerisdesigned

to

help

extend

the

lifeofthe

batterybymaintaining

the

battery

when

the

unitisnot

running.

The

trickle

charge

feature

cannot

be

usedtorechargeadischarged

battery.

Before

installing

and

connecting

the

battery,

complete

the

follow-

ing

steps:

1.

Set

the

generator's

AUTO/OFF/MANUAL

switchtoOFF.

2.

Turn

off

utility

power

supplytothe

transfer

switch.

3.

Remove

the

10A

and

15A

fuses

from

the

generator

control

panel.

Battery

cables

were

factory

connectedatthe

generator

(Figure

1.4).

Connect

cablestobattery

postsasfollows:

Figure

1.4

-

Battery

Cable

Connections

Diesel

Engine

Battery

Size

Minimum

CCA

2.4L

3.4L

GRP27or

GRP

31

650or925

4.5L

GRP31or

GRP

925

31E

6.7L

(100,

130Kw)1or2XGRP

31

925

6.7L

(150,

175Kw)

2X

GRP

31

925

8.7L

10.3L

12.9L

13.0L

2x

GRP31or

2x

16.0L

GRP

80

925or1155

18.0L

22.0L

Fill

the

battery

with

the

proper

electrolyte

fluidifnecessary

and

have

the

battery

fUlly

charged

before

installing

it.

BATTERY

INSTALLATION

Whenaunitissupplied

with

outabatteryorduring

replacement

use

the

following

tabletoproperly

select

the

battery

size

and

mini-

mum

Cold

Cranking

Ampere

required

foraparticular

unit.

FUEL

SYSTEM

REDUIREMENTS

AND

RECOMMENDATIONS

Diesel

Fuel

System:

See

Chapter8of

Engine-Generator

Stationary

Emergency

Electric

Power

Systems

Installer's

Guide

and

Reference

Manual

(part

no.

046622).

1.

Beginning

October1,2007,

owners

and

operators

that

use

diesel

fuel

must

use

diesel

fuel

that

meets:

A.

Sulfur

contentof500

parts

per

million

(ppm)

maximum.

B.

Cetane

indexoraromatic

contentasfollows:

• A

minimum

cetane

indexof40

or;

• A

maximum

aromatic

contentof35

volume

percent.

2.

Beginning

October1,2010,

owners

and

operators

that

use

diesel

fuel

must

use

diesel

fuel

that

meets:

A.

Sulfur

contentof15

parts

per

million

(ppm)

maximum.

B.

Cetane

indexoraromatic

contentasfollows:

• A

minimum

cetane

indexof40

or;

• A

maximum

aromatic

contentof35

volume

percent.

7

General Information

THE

BATTERY

~

A Do

not

disposeofthe

battery

In a

fire.

The

tAbattery

Is

capableofexploding.

/r\ A

battery

presentsariskofelectrical

shock

illand

high

short

circuit

current.

The

following

precautions

aretobe

observed

when

work-

ingonbatteries:

• Remove

the

10A

and

15A

fuses

from

the

gen-

erator

control

panel.

• Remove

watches,

ringsorother

metal

objects;

• Use

tools

with

Insulated

handles;

• Wear

rubber

gloves

and

boots;

• Do

not

lay

toolsormetal

parts

on

topofthe

battery;

and

• Disconnect

charging

source

priortoconnecting

or

disconnecting

battery

terminals.

IA

WARNING!1

Jt..

Do

not

openormutilate

the

battery.

Released

....

electrolyte

has

been

knowntobe

harmful

to

the

skin

and

eyes,

andtobe

toxic.

A The

electrolyteIsa

dilute

sulfuric

acid

that

Is

....

harmfultothe

skin

and

eyes.Itis

electrically

conductive

and

corrosive.

The

following

procedures

aretobe

observed:

• Wear

full

eye

protection

and

protective

clothing;

•

Where

electrolyte

contacts

the

skin,

washItoff

Immediately

with

water;

•

Where

electrolyte

contacts

the

eyes,

flush

thoroughly

and

Immediately

with

water

and

seek

medical

attention;

and

•

Spilled

electrolyteIstobewashed

down

with

an

acid

neutralizing

agent.Acommon

practice

Istouseasolutionof1

pound

(500

grams)

bicarbonateofsodato1

gallon(4liters)

of

water. The

bicarbonateofsoda

solutionisto

be

added

until

the

evidenceofreaction

(foam-

ing)

has

ceased.

The

resulting

liquidIsto

be

flushed

with

water

and

the

area

dried.

&.

lead-acid

batteries

presentariskoffire

Lmbecause

they

generate

hydrogen

gas.

The

following

procedures

aretobe

followed:

• DO NOT SMOKE

when

near

the

battery;

• DO NOT

cause

flameorsparkinbattery

area;

and

•

Discharge

static

electricity

from

body

before

touching

the

batterybyfirst

touchingaground-

ed

metal

surface.

A Be

sure

the

AUTO/OFF/MANUAL

switchisset

....

to

the

OFF

position

before

connecting

the

battery

cables.Ifthe

switchissettoAUTO

or

MANUAL,

the

generator

can

crank

and

startassoonasthe

battery

cables

are

con-

nected.

8

A Be

sure

the

utility

power

supplyisturned

off

tAand

the

10A

and

15A

fuses

are

removed

from

the

generator

control

panel,orsparking

may

occuratthe

battery

postsasthe

cables

are

attached

and

causeanexplosion.

Servicingofthe

batteryistobeperformedorsupervisedbyper-

sonnel

knowledgeableofbatteries

and

the

required

precautions.

Keep

unauthorized

personnel

away

from

batteries.

A

negative

ground

systemisused.

Battery

connections

are

shown

on

the

wiring

diagrams.

Make

sure

the

batteryiscorrectly

con-

nected

and

terminals

are

tight.

Observe

battery

polarity

when

con-

necting

the

batterytothe

generator

set.

GENERATOR

AC

LEAD

CONNECTIONS

See

"Voltage

Codes".

This

generator

mayberatedatanyone

of

several

voltages,

either

single-phaseorthree-phase.

The

electrical

wiresinthe

unit'sAGconnection

(lower)

panel

shouldbeinstalled

accordingtothe

numberofleads

and

the

voltage/phase

required

for

the

application.Ifthereisany

question

regarding

lead

connec-

tion,

refertoFigures

1.4

through

1.9

.

Voltage

codes

applytothe

typeofstator

assembly

installedona

particular

generator

.

fOUR-LEAD,

SINGLE-PHASE

STATOR

Four-lead

generators

are

dual

voltage

coilsorwindings

(Figure

1.5).

Units

maybeassigned

anyofthe

following

voltage

codes:

•

"{:>:.'

units

are

rated

120/240

VAG,

single-phase,60Hertz.

•

"M"

units

are

rated

110/220

VAG,

single-phase,50Hertz.

Each

stator

windinginthis

case

deliversa110

VAGor120

VAG

output;

connecting

the

two

windings

series

resultsina

220

VAG

or

240

VAC

output.

The

neutral

lineisformedbya

junctionofstator

leads22and

33.

Therefore,

connectionof120

VAG

(60

Hertz)or110

VAC

(50

Hertz)

loads

across

leads11and

neutral,oracross

leads44and

neutral

canbemade.

Figure

1.5

-

Four-lead,

Single-phase

Stator

E

44~EJ

I I
I

II

110/120

I

VOLTS

JJ ] I :

00

b20h40

I I

NEUTRAL:lloLTS

E

22

I
I :

110/120

I

VOLTS

I I

I

11~E1

l _

CIRCUIT

BREAKER

General Information

Figure

1.9

-

Single-/Three-phase

Delta

Stator

Connection

Figure

1.10-Six-lead

Stator

Connection

240V

SII

E2

240V

S6

I

S3~

--

240V

----J

51

1 1

277V

50HZ

480V50HZ

346V60HZ

600V60HZ

!

S2

SIX-LEAD.

600

VAG,

THREE-PHASE

STATOR

This

typeofstator

has

three

coils

and

six

leads

(Figure

1.10).

Units

maybeassigned

anyofthe

following

voltage

codes:

•

"1.:'

units

are

rated

346/600

VAG,

three-phase,60Hertz.

•

"5"

units

are

rated

277/480

VAG,

three-phase,50Hertz.

FIELD

WIRING

CONNECTIONS

REQUIREMENTS

The

table

shouldbeusedasa

reference

for:

wire

type,

temperature

rating,

and

size

rangeofoutput

wirestobe

connectedtothe

circuit

breakers.

Wire

sizes

shouldbein

accordance

with

table

310.16

of

the

National

Electric

Gode

(NEG).

FIELD

WIRING

REQUIREMENTS

TABLE

Circuit

Breaker

Breaker

Frame

Gircuit

Breaker

Range

Wire

Type

Wire

Temperature

Lug

AWG

Wire

TorquetoWire

(A)

Rating

Range/(Number

of

Gonductors)

SeriesG-JG

Frame

20-250

Cu

75cC

4-350

kemil

(1)

180

in-Ib

SeriesG-LG

Frame

160-600

Cu/AI

75CC

2-500

kemil

(2)

3751n-lb

(#14-10)35In-Ib

15-100

Cu/AI

75cC

14-1/0

(1)

(#8)40In-Ib

Series

C- F

Frame

(#6-4)45in-Ib

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

60-200

CulAl

75cC

4-4/0

(1)

120

in-Ib

100-225

Cu/AI

75°C

6-300

kemll

(1)

120

in-Ib

Series

C-J

Frame

250

Cu

75°C

4-350

kemll

(1)

275

in-Ib

225

CulAl

75°C

3-350

kemll

(1)

275

in-Ib

Series

C- K

Frame

300

CulAl

75DC

250-500

kemll

(1)

375

In-Ib

350-400

Cu/AI

75DC

3/0-250

kemil

(2)

2751n-lb

450-500

Cu/AI

75°C

3/0-350

kemil

(2)

275

in-Ib

Series

C- L

Frame

600

Cu/AI

75°C

400-550

kemll

(2)

275

in-Ib

Series

C- M

Frame

700-800

Cu/AI

WC

3/0-400

kemll

(3)

3751n-lb

900-1000

Cu/AI

75°C

4/0-500

kemll

(4)

375

In-Ib

Series

C- N

Frame

1200

Cu/AI

WC

500-750

kemil

(3)

450

In-Ib

Series

C- R

Frame

1400-1600

Cu/AI

75°C

500-1000

kemil

(4)

550

in-Ib

NOTE:

All

field

installations

must

meet

the

National

Electric

Code

for

wire

size

and

bending

space

requirements.

10

General

Information

FIELD

WIRING

CONNECTIONSTOBUSS

BARS

ENGINE

COOLANT

HEATERS

500Kw

Volvo

and

500/600Kw

Doosan

powered

units

supplied

with

Series

C- R

Frame

Breakers

rated

1400,

1600,

2000

and

2500A

have

Buss

Bars

suppliedinthe

connection

Module

for

the

connectionofthe

Field

Conductors.

The

following

information

shouldbefollowedinordertoobtainasuitable

electrical

connec-

tiontothe

Buss

Bars.

•

Conductor

Lugs

-

The

Buss

Bars

have

been

configured

to

accept

Aluminum

Compression

Lugs

suitable

for

copper

or

aluminum

stranded

wire

.

•

Suggested

Manufacturer

-

PENN

UNION

CORP

•

Manufacturers

Part

No.

-

BLUA060D2

•

Type

-

Dual

Rated

(Al/CU),

Two

Studs

spaced13/4"

Apart

•

Wire

Size

-

600

kcmil

Required

Hardware

Belowisthe

recommended

hardware

requiredtoattach

the

Lugs

to

the

Buss

Bars,

•

M12x65mm

Grade

8,8

Hex

Head

Cap

Screw,

M12

Flat

Washers,

Lock

Washer

and

Nut

or

If

the

unitisequipped

withanengine

coolant

(block)

heater

(Figure

1.11),itis

poweredbya

circuit

normally

fedbythe

utility

power

supply.

This

heats

the

engine

coolant

when

the

unitisnot

operat-

ing,

This

action

keeps

the

engine

warm

evenincold

weather,

helpingtoensure

quicker

starts,

Heated

coolantinthe

engine

rises

continuously

drawing

cold

coolant

into

the

heater,

creating

a

constant

flowofwarm

coolant

through

the

engine

.

Figure

1.11-

Typical

Engine

Coolant

Heaters

OUTLET

TYPE

A

Lubed58FHbs
Lubed65FHbs

STARTING

AIDS

The

stationary

emergency

generator

maybeequipped

with

one

or

more

starting

aids

that

servetoprovide

quicker,

easier

starts

under

varying

climactic

conditions.

This

generator

may

have

been

mounted

with

(a)anengine

coolant

heater,

(b)anengine

oil

heater,

(c)abattery

warmeror(d)abat-

tery

charger.

These

aids

are

poweredbya

normal

(utility)

power

source

during

nonoperating

periods.

GENERATOR

AND

LOAD

COMPATIBILITY

The

generator

mustbefully

compatible

with

the

rated

voltage,

phase

and

frequencyofthe

connected

electrical

loads.

The

gen-

erator,

connected

electrical

devices,orboth,

canbedamaged

if

voltage,

phase

and

frequency

are

not

compatible,

NOTE:

This

manual

assumes

that

the

stationary

emergency

generator

has

been

properly

selected,

installed

and

interconnectedbya

competent,

qualified

electricianorinstallation

contractor.

Once

the

installationiscomplete,donothing

that

may

resultinnon-

compatibility

between

the

generator

and

connected

electrical

loads.

TYPES

The

engine

oil

heaterisdesigned

for

installations

where

the

engine

oil

mustbekept

near

operating

temperatureatall

times.Ifincluded

with

this

unit,alow-watt

density

heater

and

thermostat

are

mount-

edinthe

engine's

oil

sumporon

the

sump

pan

(Figure

1.12).

The

heater

and

thermostatdonot

require

maintenance.

1.

Disconnect

battery

cablestoprevent

accidental

start-up.

Disconnect

the

negative

battery

cable

first

from

the

battery

post

indicatedby(-)orNEG,

2.

Make

sure

powerisoff

from

the

appropriate

power

source.

3.

To

connect

the

wires,

hold

the

bare

metal

leads

together

and

placeawire

nut

over

them,

then

twist

clockwise

until

tight.

For

all

these

connections,

use

the

wire

nuts

provided.

4.

Connect

the

ground

wire

from

120V

power

sourcetothe

ground

wire

from

oil

heater,

5.

Using

wire

nuts

provided

connect

the

white

wire

and

black

wire

from

the

oil

heaterasfollows:

•

The

white

(common)

power

wire

from

120V

power

source

to1st

wire

from

the

oil

heater.

•

The

wire

from

load

sideofthermostatto2nd

wire

from

the

oil

heater.

ENGINE

OIL

HEATER

(OPTIONAL)

Flat

•

1/2"-20x2.5"

Grade

SAE5Hex

Head

Cap

Screw,

Washers,

Lock

Washer

and

Nut

Required

Torque

-

Tighten

fasteners

to:

M12

Dry75Ft-Lbs

1/2"

Dry85FHbs

11

Lubed58Ft-Lbs
Lubed65Ft-Lbs

-------_.

__

_--_

..

_-------

FIELD

WIRING

CONNECTIONSTOBUSS

BARS

Units

supplied

with

Series

C- R

Frame

Breakers

rated

1600,

2000

and

2500A

have

Buss

Bars

suppledinthe

connection

Module

for

the

connectionofthe

Field

Conductors.

The

following

information

shouldbefollowedinordertoobtainasuitable

electrical

connec-

tiontothe

Buss

Bars.

•

Conductor

lugs

-

The

Buss

Bars

have

been

configured

to

accept

Aluminum

Compression

Lugs

suitable

for

copper

or

aluminum

stranded

wire.

•

Suggested

Manufacturer

-

PENN

UNION

CORP

•

Manufacturers

Part

No.

-

BLUA060D2

•

Type

-

Dual

Rated

(AL/CU),

Two

1/2"

Studs

spaced13/4"

Apart

•

Wire

Size

-

600

kcmil

Required

Hardware

Belowisthe

recommended

hardware

requiredtoattach

the

Lugs

to

the

Buss

Bars.

•

M12x65mm

Grade

8.8

Hex

Head

Cap

Screw,

M12

Flat

Washers,

Lock

Washer

and

Nut

or

•

1/2"-20x2.5"

Grade

SAE5Hex

Head

Cap

Screw,

1/2"

Flat

Washers,

Lock

Washer

and

Nut

Required

Torque

-

Tighten

fasteners

to:

M12

Dry75Ft-Lbs

1/2"

Dry85Ft-Lbs

GENERATOR

AND

LOAD

COMPATIBILITY

The

generator

mustbefully

compatible

with

the

rated

voltage,

phase

and

frequencyofthe

connected

electrical

loads.

The

gen-

erator,

connected

electrical

devices,orboth,

canbedamaged

if

voltage,

phase

and

frequency

are

not

compatible.

NOTE:

This

manual

assumes

that

the

stationary

emergency

generator

has

been

properly

selected,

installed

and

interconnectedbya

competent,

qualified

electricianorinstallation

contractor.

Once

the

installationiscomplete,donothing

that

may

resultinnon-

compatibility

between

the

generator

and

connected

electrical

loads.

STARTING

AIDS

The

stationary

emergency

generator

maybeequipped

with

one

or

more

starting

aids

that

servetoprovide

quicker,

easier

starts

under

varying

climactic

conditions.

This

generator

may

have

been

mounted

with

(a)anengine

coolant

heater,

(b)anengine

oil

heater,

(c)abattery

warmeror(d)abat-

tery

charger.

These

aids

are

poweredbya

normal

(utility)

power

source

during

nonoperating

periods.

General

Information

ENGINE

COOLANT

HEATERS

If

the

unitisequipped

withanengine

coolant

(block)

heater

(Figure

1.11),itis

poweredbya

circuit

normally

fedbythe

utility

power

supply.

This

heats

the

engine

coolant

when

the

unitisnot

operat-

ing.

This

action

keeps

the

engine

warm

evenincold

weather,

helpingtoensure

quicker

starts.

Heated

coolantinthe

engine

rises

continuously

drawing

cold

coolant

into

the

heater,

creating

a

constant

flowofwarm

coolant

through

the

engine.

Figure

1.11-

Typical

Engine

Coolanl

Healers

OUTLET

TYPE

A

1~'_KE

__

~

TYPEB

ENGINE

OIL

HEATER

(OPTIONALl

The

engine

oil

heaterisdesigned

for

installations

where

the

engine

oil

mustbekept

near

operating

temperatureatall

times.Ifincluded

with

this

unit,alow-watt

density

heater

and

thermostat

are

mount-

edinthe

engine's

oil

sumporon

the

sump

pan

(Figure

1.12).

The

heater

and

thermostatdonot

require

maintenance.

1.

Disconnect

battery

cablestoprevent

accidental

start-up.

Disconnect

the

negative

battery

cable

first

from

the

battery

post

indicatedby(-)orNEG.

2.

Make

sure

powerisoff

from

the

appropriate

power

source.

3.

To

connect

the

wires,

hold

the

bare

metal

leads

together

and

placeawire

nut

over

them,

then

twist

clockwise

until

tight.

For

all

these

connections,

use

the

wire

nuts

provided.

4.

Connect

the

ground

wire

from

120V

power

sourcetothe

ground

wire

from

oil

heater.

5.

Using

wire

nuts

provided

connect

the

white

wire

and

black

wire

from

the

oil

heaterasfollows:

•

The

white

(common)

power

wire

from

120V

power

source

to1st

wire

from

the

oil

heater.

•

The

wire

from

load

sideofthermostatto2nd

wire

from

the

oil

heater.

11

General Information

ACAUTIONI

A.

Be

surenobare wire or wire strands are vis-

~Ible

after making connections.

6.

Push

all

wires

and

wire

nuts

into

junction

box.

7.

Assemble

junction

box

covertojunction

box

8.

Reconnect

battery

cablestobattery

posts.

Connect

the

posi-

tive

cable

firsttothe

battery

post

indicated

by

(+)

or

POS.

Figure

1.12

-

Oil

Heater

Kit

BATTERY

WARMERS

(OPTIONAL)

When

usedinconjunction

withacoolant

(block)

heater,

battery

warmers

(Figure

1.13)

aidinensuring

that

the

engine

will

reach

maximum

cranking

speed.

1,

Disconnect

battery

cablestoprevent

accidental

start-up.

Disconnect

the

negative

battery

cable

first

from

the

battery

post

indicatedby(-)orNEG,

2.

Make

sure

powerisoff

from

the

appropriate

power

source,

3,

To

connect

the

wires,

hold

the

bare

metal

leads

together

and

placeawire

nut

over

them,

then

twist

clockwise

until

tight.

For

all

these

connections,

use

the

wire

nuts

provided.

4,

Connect

the

ground

wire

from

120V

power

sourcetothe

ground

wire

from

battery

heater.

5,

Using

wire

nuts

provided

connect

the

white

wire

and

black

wire

from

the

battery

heaterasfollows:

•

The

white

(common)

power

wire

from

120V

power

source

to1st

wire

from

the

battery

heater,

•

The

wire

from

load

sideofthermostatto2nd

wire

from

the

battery

heater,

12

ACAUTIONI

A.

Be

surenobare wire or wire strands are vis-

~

Ible after making connections.

6.

Push

all

wires

and

wire

nuts

into

junction

box,

7.

Assemble

junction

box

covertojunction

box,

8,

Reconnect

battery

cablestobattery

posts,

Connect

the

posi-

tive

cable

firsttothe

battery

post

indicated

by

(+)

or

POS,

Figure

1.13

-

Battery

Warmer

Kit

BATTERY

CHARGERS

There

are

two

typesofbattery

chargers

available:

2,5-amp

and

10-amp

(nine-amp

UL)

rated,

The

2,5-amp

chargeris12

VDC

only.

The1Q-ampisavailableas12

VDCor24

VDC,asappropri-

ate

for

the

engine'sDCsystem

voltage,

These

chargers

are

UL

component

recognized

for

useonthese

generator

sets.

Bothofthe

chargers

are

fully

automatic

float

types

and

are

fully

fuse

protected

(input

and

output),

They

have

automatic

current

limitingtoreduce

riskofovercharging,

and

have

automatic

main-

tenanceofcharge

voltage.

Therefore,

they

canbeconnectedtothe

batteries

continuously,

The

chargers

require

the

connectionofa

batteryinordertoturn

on,

The

battery

provides

boost

voltage

for

the

charger,soa

com-

pletely

dead

battery

will

not

allow

the

chargertooperate.

The

boost

requiredisapproximately

nineto11

volts

fora12

VDC

system

and18to22volts

fora24

VDC

system,Ifthe

batteryisbelow

the

boost

voltage,itneedstobe

replaced.

They

are

not

water

resistant,sothey

mustbeinstalled

withinarain

resistant

enclosure.

Installation

STATIONARY

EMERGENCY

GENERATOR

INSTALLATION

~

k..

Connecting this generator to an electrical

illsystem

normally supplied by an electric util-

ity shall

be

by means of a transfer switch

(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.

ACAUTIONI

t

If

an open bottom is used, the engine-gener-

Lmator

is to be installed over non-combustible
materials and should be located such that
combustible materials are not capable of
accumulating under the generator set.

Only

qualified,

competent

installation

contractorsorelectricians

thoroughly

familiar

with

applicable

codes,

standards

and

regula-

tions

should

install

this

stationary

emergency

electric

power

sys-

tem.

The

installation

must

comply

strictly

with

all

codes,

standards

and

regulations

pertainingtothe

installation.

This

genset

mustbeinstalledona

level

surface.

The

base

frame

mustbelevel

within

two

(2)

inches

all

around.

ACAUTIONI

A After the system has been installed, do noth-

.....

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

NOTE:

For

more

information

about

the

installationofa

stationary

emergency

system,

order

Engine-Generator

Stationary

emer-

gency

Electric

Power

Systems

Installer's

Guide

and

Reference

Manual

(part

#046622)

fromanAuthorized

Service

Dealer.

•

NFPA

No.

30,

FLAMMABLE

AND

COMBUSTIBLE

LIQUIDS

CODE.

•

NFPA

No.

10,

INSTALLATION,

MAINTENANCE

AND

USE

OF

PORTABLE

FIRE

EXTINGUISHERS.

OTHER

PUBLISHED

STANDARDS

In

additiontoNFPA

standards,

the

following

information

pertain-

ingtothe

installation

and

useofstationary

emergency

electric

systemsisavailable:

•

ArticleX,NATIONAL

BUILDING

CODE,

available

from

the

American

Insurance

Association,85John

Street,

New

York,

NY

10038,

o

AGRICULTURAL

WIRING

HANDBOOK,

obtainable

from

the

Food

and

Energy

Council,

909

University

Avenue,

Columbia,

MO,

65201.

•

ASAE

EP-364.2,

INSTALLATION

AND

MAINTENANCEOFFARM

STANDBY

ELECTRIC

POWER,

available

from

the

American

SocietyofAgricultural

Engineers,

2950

Niles

Road,

St.

Joseph,

M149085.

•

A52.1,

AMERICAN

NATIONAL

STANDARD

FOR

CHIMNEYS,

FIREPLACES

AND

VENTING

SYSTEMS,

available

from

the

American

National

Standard

Institute,

1430

Broadway,

New

York,

N.Y

10018.

BASIC

STATIONARY

EMERGENCY

ELECTRIC

SYSTEM

Figure

2.1

showsaschematic

diagramofa

basic

stationary

emergency

electric

system.

Both

the

UTILITY

power

supply

and

the

STANDBY

(GENERATOR)

output

are

connectedtoan

approved

transfer

switch.

The

transfer

switchisrequiredbyelectrical

code

and

serves

the

following

functions:

o

Permits

the

LOAD

circuitstobe

connectedtoonly

one

power

supplyata

time

.

o

Prevents

electrical

backfeed

between

the

generator

and

the

UTILITY

power

circuits.

Notice

that

both

the

STANDBY

and

the

UTILITY

power

supplies

to

the

transfer

switch

are

protected

against

overloadbya

main

line

circuit

breaker.

Figure

2.1

-

Basic

Stationary

Emergency

Electric

System

MAIN

UNE

CIRCUIT

BREAKER

TRANSFER

r---+-~

SWITCH

UTIUTY

POWER

--t-/

SUPPLY

'- - - -

--

STANDBY

---

--

GENERATOR

--~'

,..;.-'

--1

OUTPUT

,

~

MAIN

UNE

CIRCUIT

BREAKER

TO

LOAD

c--f---CIRCUITS

I-

I

,

. _ J

,

,

'-

-

NFPA

STANDARDS

The

following

published

standards

booklets

pertainingtostation-

ary

emergency

electric

systems

are

available

from

the

National

Fire

Protection

Association

(NFPA),

Batterymarch

Park,

Quincy,

MA

02269orwww.nfpa.org.

o

NFPA

No.

37,

STATIONARY

COMBUSTION

ENGINES

AND

GAS

TURBINES.

o

NFPA

No.

76A,

ESSENTIAL

ELECTRICAL

SYSTEMS

FOR

HEALTH

CARE

FACILITIES.

o

NFPA

No.

220,

STANDARD

TYPESOFBUILDING

CONSTRUCTION

o

NFPA

No.

68,

GUIDE

FOR

EXPLOSION

VENTING

o

NFPA

No.

70,

NATIONAL

ELECTRICAL

CODE.

13

Installation

EMERGENCY

CIRCUIT

ISOLATION

METHOD

This

prevents

overloading

the

generatorbykeeping

electrical

loads

below

the

wattage/amperage

capacityofthe

generator,

If

the

generatorispowering

only

critical

loads,

within

the

wattage/

amperage

capacity,

during

utility

power

outages,

consider

using

the

emergency

circuit

isolation

method,

Critical

electrical

loads

are

grouped

together

and

wired

intoasepa-

rate

"Emergency

Distribution

Panel."

Load

circuits

poweredbythat

panel

are

within

the

wattage/amperage

capacityofthe

generator

set.

When

this

methodisused,itis

difficulttooverload

the

gen-

erator,

The

transfer

switch

must

meet

the

requirements:

•Itmust

haveanampere

rating

equaltothe

total

amperage

rating

of

the

emergency

distribution

panel

circuit.

•

Haveitinstalled

between

the

building's

main

distribution

panel

and

the

emergency

distribution

panel.

TOTAL

CIRCUIT

ISOLATION

METHOD

Whenagenerator

capableofpowering

all

electrical

loadsinthe

circuitistobeinstalled,

use

the

"Total

Circuit

Isolation

Method,"

It

is

possible

for

the

generatortobe

overloaded

when

this

isolation

methodisemployed,

The

following

applytothe

transfer

switch

in

this

typeofsystem,

•

Ampere

ratingofthe

transfer

switch

must

the

ampere

ratingofthe

normal

incoming

utility

service,

•

The

transfer

switchisinstalled

between

the

utility

service

entrance

and

the

building

distribution

panel.

GROUNDING

THE

GENERATOR

The

generator

set

mustbegroundedinaccordance

with

the

National

Electrical

Code

and

any

stateorlocal

requirements,

~

A Do not connect the ground wire to any pipe

~that

carries a flammable or explosive sub-

stance - FIRE or an EXPLOSION may result.

Figure

2.2 -

Grounding

Electrode

Terminal

(typical)

Base

Frame

Grounding

Electrode

Terminal

14

GENERATOR

AC

NEUTRAL

CONNECTIONS

Groundingisrecommended

onlyatone

pointinthe

system,

Consult

local

building

codes

for

proper

neutral

grounding

require-

ments,

TRANSFER

SWITCH

START

SIGNAL

CONNECTIONS

If

the

generatoristobeinstalled

withastandard

automatic

transfer

switch,

suchasa

GTS

type

switch,itwillbenecessarytoconnect

the

two-wire

start

control

system,

Connect

the

two-wire

start

signal

from

the

automatic

transfer

switchtothe

automatic

start

connection,

whichislocatedinthe

lower

rearoftheACconnection

panel.

Match

wires

178

(0)

and

183Inthe

transfer

SWitchto178

(0)

and

183onthe

terminal

strip

In

the

connection

box,

The

conductors

for

the

two-wire

start

circuit

mustbein

their

own

conduit.

If

the

generatoristobeinstalled

withanHTS-type

transfer

switch

a

different

connection

methodisneeded,

Use

shielded

2-wir~

communications

cable

(suchaBelden

#9460)tomake

the

con-

nection

from

the

HTS

transfer

switchtothe

engine

generator

connection

panel.

This

cableistoberoutedina

separate

conduit

between

the

HTS

transfer

switch

and

the

generator,

The

cableisto

be

connectedasfollows:

HTS

transfer

switch-4position

terminal

block,inthe

bottomofthe

transfer

switch

enclosure

(labeled

"comm,

Ports"),

Engine

generator-terminal

strip

locatedinthe

lower

rearofthe

AC

connection

panel.

Connect

the

RS485+

and

RS485-tothe

respective

terminalsinswitch

and

generator.Donot

connect

the

shieldatthe

transfer

switch

end.

BATTERY

INSTALLATION

~

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 per-

sonnel, 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 an explosion. Such an explo­sion

can shatter the battery and cause blind-

ness

or

other injury. Any area that houses a
storage battery mustbeproperly ventilated.
Do not allow smoking, open flame, sparks or
any spark producing tools or equipment near
the battery.

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 harm-

ful to the skin and eyes.

Ir\

The battery represents a risk of high short

illcircuit

current. When working on the battery,
always remove watches, rings or other metal
objects, and only use tools that have insu-

lated handles.

VENTED

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 pro­cedures 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

water

and

seek

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.

A Lead acid batteries present a risk of fire

~because

they generate hydrogen gas. The

following procedure are to be followed:

o DO NOT SMOKE when

near

batteries,

o DO

NOT

cause flame or spark in battery area,

and

o Discharge static electricity from body before

touching batteries by first touching a grounded
metal surface.

Operation

Servicingofbatteriesistobeperformedorsupervisedbyperson­nel

knowledgeableofbatteries

and

the

required

precautions,

Keep

unauthorized

personnel

away

from

batteries.

For

recommended

batteries,

see

"Specifications,"

All

batteries

mustbeat100

percent

state-of

-charge

before

they

are

installed

on

the

generator.

When

using

maintenance-free

batteries,itis

not

necessary

to

check

the

specific

gravityorelectrolyte

level.

Have

these

procedures

performedatthe

intervals

specifiedinSection

4,

"Maintenance,"Anegative

ground

systemisused.

Battery

con-

nections

are

shownonthe

wiring

diagrams,

Make

sure

all

batteries

are

correctly

connected

and

terminals

are

tight.

Observe

battery

polarity

when

connecting

batteriestothe

generator

set.

NOTE:

Damage

will

resultifthe

battery

connections

are

made

in

reverse.

PREPARATION

BEFORE

START-UP

The

instructionsinthis

section

assume

that

the

stationary

emer-

gency

generator

has

been

properly

installed,

serviced,

tested,

adjusted

and

otherwise

prepared

for

usebya

competent,

qualified

installation

contractor.Besuretoread

the"

Safety

Rules"onPages

2

and3,as

wellasall

other

safety

informationinthis

manual,

before

attemptingtooperate

this

(and

related)

equipment.

PRIORTOINITIAL

START-UP

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.)

may

result in an

engine failure.

Before

starting

the

generator

for

the

first

time,

the

installer

must

complete

the

following

procedures.

For

follow-up

maintenance

information

and/or

service

intervals,

please

refertoSection

4,

"Maintenance,"

and

the

"Service

Schedule",

Transfer

Switch

If

this

generatorisusedtosupply

powertoany

electrical

system

normally

poweredbyan

electric

utility,

the

National

Electrical

Code

requires

thatatransfer

switchbeinstalled,

The

transfer

switch

pre-

vents

electrical

backfeed

between

two

different

electrical

systems.

(For

additional

information,

see

the

applicable

transfer

switch

manual

for

this

unit.)

The

transfer

switch,aswellasthe

genera-

tor

and

other

standby

components,

mustbeproperly

located

and

mountedinstrict

compliance

with

applicable

codes,

standards

and

regulations,

15

Operation

Fuel

System

Make

sure

the

fuel

supply

systemtothe

generator

(a)

delivers

the

correct

fuelatthe

correct

pressure

and

(b)isproperly

purged

and

leak

tested

accordingtocode.Nofuel

leakageispermitted.

See

"Specifications"

for

more

information

If

the

unit

has

been

idle

foralong

periodoftime,orif

the

fuel

lines

or

system

components

have

been

removed

and

reinstalled,

the

fuel

system

may

require

bleedingtoremove

air

from

the

system.

Air

in

the

fuel

system

causes

hard

starting

and

rough

operation.

All

fuel

system

lines

mustbeinstalled

and

mustbetight A

loose

line

may

shownosignofleakage,

but

may

draw

air

into

the

system.

Rodent

Protection

Make

sure

the

four,

3-inch

diameter

cap

plugs

are

properly

installedinthe

tie-down

holesinthe

side

railsofthe

unit's

base

frame

(Figure

2.3).

The

cap

plugs

are

shippedina

plastic

bag

locatedinthe

lower

connection

box.

These

plugs

are

needed

to

prevent

rodents

from

accessing

the

interiorofthe

generator

set

On

acoustic

units,

cap

plugs

also

are

neededtostay

within

noise

specification

limits.

Figure

2.3

-

Base

Frame

Cap

Plugs

ACAUTIONI

GENERATOR

CONTROL

AND

OPERATION

Refertothe

appropriate

control

panel

operator's

manual

for

this

unit

OPERATING

UNIT

WITH

MANUAL

TRANSFER

SWITCH

If

the

generator

was

installedinconjunction

withatransfer

switch

capableofmanual

operation

only,

the

following

procedure

applies.

A

manually

operated

transfer

switchisone

that

will

not

provide

automatic

start-up

and

does

not

includeanintelligence

circuit

A

standard

form

titled

"Start-up

Inspection

for

Stationary

Emergency

Power

Systems"

(part

no.

067377)

shouldbecompletedbythe

installation

technicianorengineer.Asstatedonthe

form,

inspec-

tions

aretobe

accomplished

onlybyfactory-trained

personnel.

The

technician

performing

the

install

should

then

scan

and

e-mail

the

completed

[e-mail].

The

form

can

also

be

filled

outata

dealer's

Generac

website.

3-INCH CIA.

PLUG

BASE

FRAME

STA8r-UP

INSPECTION

Belt

Tension

Check

the

engine

fan

belt

tension

and

condition

priortoplacing

the

unit

into

service

andatrecommended

intervals.

Belt

tension

is

correct

whenaforceofapproximately22pounds

(10

kg),

applied

midway

between

pulleys,

deflects

the

belt

about

3/8-to5/8-inch

(10to16

mm).

This

does

not

applytoautomatic

belt

tensioning

systems.

Electrical

System

Make

sure

the

generatorisproperly

connectedtoan

approved

earth

ground.

Make

sure

the

generator

batteryisfUlly

charged,

properly

installed

and

interconnected,

and

ready

for

use.

Checktoensure

that

there

arenoloose

electrical

connections,

Restrain

any

loose

wirestokeep

them

clearofany

moving

genera-

tor

set

components.

Engine

Coolant

Have

the

engine

cooling

system

properly

filled

with

the

recom-

mended

coolant

mixture.

Check

the

system

for

leaks

and

other

problems.

See

"Specifications"

and

"Coolant"

A Use a suitable container to catch the fuel

....

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

Generator

Set

Lubrication

Check

the

engine

crankcase

oil

level

befol'e

operating

and add

oiltothe

proper

level-the

dipstick

"FULL'

mark.

Never

operate

the

engine

with

the

oil

level

below

the

dipstick

"ADD"

mark.

See

"Specifications"

and

"Engine

Oil

Recommendations"

Check

the

oil

levelinthe

generator

gearbox

(ifsoequipped)

prior

to

initial

use

andatthe

intervals

indicatedbythe"

Service

Schedule."

The

recommended

oilisSAE90gear

lubricant

Also,ifthe

engineisequipped

withamechanical

governor,

make

sure

the

governorisproperly

lubricated

with

clean

engine

oil.

ENGINE

STA8T-UP

AND

TRANSFE8

For

additional

information,

refertothe

applicable

control

panel

manual

for

this

unit,aswellasany

literature

pertainingtothe

transfer

switch.

16

~

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 infor­mation.

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

supplies to the transfer switch have

been positively turned off,

or

extremely dan­gerous - possibly lethal - electrical shock
will result.

/i).

Transfer switch enclosure doors should be

~kept

closed and locked. Only authorized
personnel should be allowed access to the
transfer switch Interior. Extremely high and
dangerous voltages are present in the trans­fer switch.

In

ordertomanually

transfer

load

from

the

utility

sourcetothe

generator,

follow

these

directions:

•

Turn

OFFordisconnect

the

utility

power

circuittothe

transfer

switch,

using

the

means

provided

(suchasthe

utility

source

main

line

circuit

breaker).

•

Set

the

transfer

handletoits

UTILITY

(NORMAL)

position

with

load

circuits

connectedtothe

utility

power

supply.

•

Set

the

stationary

emergency

generator's

main

line

circuit

breakertoits

OFF

(or

OPEN)

position.

•

Start

the

generator.

•

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

handletoits

STANDBY

(GENERATOR)

position,

i.e,

load

circuits

suppliedbythe

generator.

•

Set

the

stationary

emergency

generator's

main

line

circuit

breakertoitsON(or

CLOSED)

position.

•

Load

circuits

are

now

poweredbythe

stationary

emergency

generator.

RETRANSFER

AND

SHUTDOWN

For

additional

information,

refertothe

applicable

control

panel

manual

for

this

unit,aswellasany

literature

pertainingtothe

transfer

switch.

To

manually

transfer

the

load

backtothe

utility

power

source

and

shut

down

the

generator,

follow

these

directions:

•

Set

the

stationary

emergency

generator's

main

line

circuit

breakertoits

OFF

(or

OPEN)

position.

•

Manually

move

the

transfer

switch

handletoits

UTILITY

(NOR-

MAL)

position,

i.e.,

load

cirCUits

connectedtothe

utility.

Maintenance

•

TurnONthe

utility

power

supplytothe

transfer

switch,

using

the

means

provided

(suchasthe

utility

power

source

main

line

circuit

breaker)

.

•

Let

the

generator

runatno-load

forafew

minutestostabilize

internal

temperatures.

•

Shut

down

the

generator.

OPERATING

UNIT

WITH

AUTOMATIC

TRANSFER

SWITCH

If

the

generator

has

been

installed

along

withanautomatic

transfer

switch,

suchasa

GTS-type

switch,

the

engine

maybestarted

and

stopped

automaticallyormanually.

NOTE:

Refertothe

applicable

manual

for

the

transfer

switch

and

to

"Transfer

Switch

Start

Signal

Connections".Inaddition,

please

note

the

dangers

under

"Engine

Start-up

and

Transfer."

SERVICE

SCHEDULE

AUTHORIZED

OPERATOR

MAINTENANCE

FUNCTIONS

Every

Monthor100Hours

(whichever

comes

first)

•

Test

stationary

emergency

generator

system.

•

Inspect

battery

(batteries)

and

cables.

•

Check

engine

oil

level.

•

Check

gearbox

oil

level

(ifsoequipped).

•

Check

engine

coolant

level.

•

Check

generator

ground

connections.

•

Test/inspect

starting

aids.

Every

Three

MonthsorEvery

120

Hours

(whichever

comes

first)

•

Inspect

and

test

fuel

system

and

connections.

•

Inspect

exhaust

system.

•

Inspect/test

fuel

supply

system.

AUTHORIZED

SERVICE

TECHNICIAN

MAINTENANCE

FUNCTIONS

After

First30HoursofOperation

•

Inspect

Wiring.

•

Change

engine

crankcase

oil

and

oil

filter.

•

Inspect

engine

fan

belts.

•

Inspect

battery

(batteries)

and

cables.

Every

Six

MonthsorEvery

200

Hours

(whichever

comes

first)

•

Lubricate

engine

controls.

•

Service

engine

air

cleaner.

•

Service

engine

fuel

filter.

•

InspectACgenerator.

•

Test

engine

safety

controls.

•

Inspect

fan

belts.

•

Check

engine

coolant

level.

•

Inspect

engine

cooling

system

hoses.

17

Maintenance

•

Check

optional

starting

aids.

•

Check

battery

(batteries).

•

Check

engine

compression.

•

Check

electrical

connections.

•

Check/test

annunciator

panel.

•

Perform

operational

test

AnnuallyorEvery

600

Hours

(whichever

comes

first)

•

Change

engine

oil

and

filter.

•

Inspect

all

wiring.

•

Test

engine

starter

operation.

•

Drain

water

from

fuel

tank.

•

Retorque

fan

bolts.

•

Drain

and

refill

gearbox

(ifsoequipped).

Every

Two

Years

•

Replace

all

rubber

hoses.

•

Replace

engine

fan

belts.

•

Inspect

the

Stationary

Emergency

Generator

System.

•

Drain,

flush,

refill

cooling

system.

Every

1,000

Operating

Hours

•

Inspect

engineDCalternator.

•

Inspect

engine

starter.

•

Retorque

engine

mounting

brackets.

•

Remove/test

fuel

injection

pump.

•

Remove/test

cooling

system

thermostat.

As

Required

•

Bleed

engine

fuel

system.

PERIODIC

MAINTENANCE

A

rigorous

programofscheduled

periodic

maintenance

should

be

established

and

maintained.

Suchaprogram,ifadhered

to

diligently,

will

provide

added

assurance

that

the

power

system

functions

properly

whenitis

needed.

Keepinga"Maintenance

Log"ishighly

recommended.

Such

a

log

shouldbea

continuous

recordofrepairs,

parts

replacements,

gauge

and

instrument

readings

during

operational

tests,

etc.

The

manufacturer

requires

thata"Scheduled

Maintenance

Plan"

be

established

between

the

userofthis

equipment

and

the

install-

ing

Authorized

Service

Dealer.

Under

this

agreement,

(Part

No.

053263),anAuthorized

Service

Technician

performs

prestart

and

engine

running

tests

and

checksatsix-month

and

one-year

inter-

vals.

AskanAuthorized

Service

Dealer

about

this

agreement

The

tasks

listedinthe

"Service

Schedule"

cover

the

minimum

recommended

maintenance

requirements

for

this

equipment.

Note

that

manyofthe

tests

and

checks

listedinthe

schedule

are

tobeperformed

onlybyan

Authorized

Service

Technician.

Fluid

capacities

and

recommendations,aswellasother

applicable

specifications,

are

listedin"Specifications".

18

TEST

STATIONARY

EMERGENCY

GENERATOR

SYSTEM

OPERATION

AND

COMPONENTS

An

authorized

operator

should

test

the

operationofthe

station-

ary

emergency

generator

system

and

inspect

its

components

monthly

(or

100

hours).

This

should

include

inspecting

the

trans-

fer

switch

for

evidenceofarcing,

and

pittedorburned

contacts;

inspecting

wiring

and

grounding

connections

(see

"Grounding

the

Generator");

and

ensuring

that

starting

devices

are

operational.

During

this

operational

test,

all

instrument

and

gauge

readings

shouldberecordedina

"Maintenance

Log."

The

transfer

system

also

shouldbetestedatthis

time;

the

engine

shouldberunatleast

30

minutes

and

any

discrepancies

corrected

immediately.

Every

six

months

(or

200

hours),anAuthorized

Service

Technician

should

performasystem

operational

test

INSPECT

BAUERY

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

an

explosion. Suchanexplo­sion can shatter the battery and cause blind­ness 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.

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 batteryIna 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.

/;\

The battery represents a risk of high short

illcircuit

current. When working on the battery,
always remove watches, rings or other metal
objects, and only use tools that have insulated
handles.

An

authorized

operator

should

inspect

the

engine

battery

system

monthly

(or

100

hours).Atthis

time,

the

battery

fluid

level

should

be

checked

and

distilled

water

addedifneeded.

Battery

cables

and

connections

also

shouldbeinspected

for

cleanliness

and

corrosion.
Once

every

six

months

(or

200

hours),anAuthorized

Service

Technician

'should

inspect

the

battery

system.Atthis

time

the

battery

condition

and

stateofcharge

shouldbechecked

using

a

battery

hydrometer.

The

battery

shouldberechargeorreplaced

as

required.

CHECK

FLUIDS

An

authorized

operator

should

check

the

levelsofengine

oil,

and

engine

coolant

monthly

(or

100

hours).

The

oil

level

should

be

maintained

between

the

"FULl:'

and

"ADD"

marksonthe

engine

dipstick.

Recommended

fluids

are

listed

areinthe

"Specifications"

section.
Once

annually

(oratevery

600

hour

intervals),anauthorized

ser-

vice

technician

should

completely

drain

and

refill

the

gearbox

(if

so

equipped)

using

the

following

procedure

(Figure

4.1):

1.

Remove

panel

fuse

and

negative

battery

cable.

2.

Remove

the

oil

filler/Vent

cap.

3.

Remove

the

drain

plug

and

drain

the

oil

intoanappropriate

container.

Disposeofor

recycle

the

oil

properly.

4.

Reinstall

the

oil

drain

plug.

5.

To

add

oiltothe

gearbox,

remove

the

oil

level

check

plug.

Figure

4.1-Gearbox

Oil

Servicing

Points

OIL

FILLERNENT

CAP

OIL

LEVEL

CHECK

PLUG

Maintenance

6.

Add

the

recommended

oil

untilitjust

startstoflow

from

the

oil

level

check

plug

opening.

7.

Finally,

install

and

tighten

the

oil

filler/Vent

cap

and

oil

level

check

plug.

8.

Re-install

negative

battery

cable

and

panel

fuse.

Start

unit

and

check

for

leaks.

INSPECT

EXHAUST

SYSTEM

Every

three

months

(or

120

hours),anauthorized

operator

should

inspect

the

entire

exhaust

system.

Abnormal

noise

levels

heard

during

each

operational

test

may

indicateadefective

exhaust

pipe

or

muffler.

Any

defectiveorleaking

component

shouldberepaired

or

replaced

immediatelybyan

Authorized

Service

Technician.

INSPECT/TEST

FUEL

SUPPLY

SYSTEM

Every

three

months

(or

120

hours),anauthorized

operator

should

inspect

and

test

the

fuel

supply

system,aswellasall

fuel

system

connections.

All

connections

mustbetight

andingood

condition.

A

loose

fuel

system

line

may

shownosignsofleakage,

but

may

draw

air

into

the

system

causing

rough

operation

and

starting

dif-

ficulties.

Any

defectiveorleaking

component

shouldberepaired

or

replaced

immediatelybyan

Authorized

Service

Technician.

REPAIR

PARTS

The

latter

portionofthis

manual

consistofexploded

views,

parts

lists

and

electrical

data

pertainingtothis

generator

set.

The

parts

lists

consistof(a)anitem

number,

(b)apart

number,

(c)

the

quantity

required,

and

(d)adescriptionofthe

part.

The

item

number

correspondstoan

identical

numberonthe

exploded

view

drawing.

HOWTOORDER

PARTS

To

orderareplacement

part,

locate

the

partinthe

applicable

exploded

view.

ContactanAuthorized

Service

Dealer

(call

800-

333-1322tolocate

oneinthe

area)

and

provide

the

following

information:

•

The

generator

model

number.

•

The

generator

identification

code,

which

indicates

the

specific

generator

assembly

for

each

unit.

•

The

part

number

and

corresponding

description

from

the

appli-

cable

parts

listinthis

manual.

•

The

applicable

exploded

view

"Group"

letter

(A-H)

and

draw-

ing

number

(five-digit

number),

which

canbefoundonthe

exploded

view

drawing.

NOTE:

In

most

cases,

repair

parts

canbeobtainedbyproviding

the

Authorized

Service

Dealer

with

the

data

label

information

and

a

descriptionofthe

required

part.Ifunabletolocate

either

the

data

labelorthe

construction

document,

describe

the

part

needed

and

provide

the

unit's

model

number.

This

number

can

be

foundonthe

DATA

LABEL

attachedtothe

generator's

lower

connection

box.

19

Maintenance

500

KW

TO

600

KW

STATIONARY

EMERGENCY

DIESEL

ENGINE

DRIVEN

GENERATOR

SETS

FollowingIsa

recommended

maintenance

schedule

for

stationary

emergency

diesel

engine

driven

generator

sets

from

500kWto

600kWin

size.

The

established

intervalsinthe

schedule

are

the

maximum

required

when

the

unitisusedinan

average

service

application.

They

will

need

tobedecreased

(performed

more

frequently)ifthe

unitisusedina

severe

application.

Use

the

unit

hour

meterorcalendar

time,

whichever

occurs

first,

from

the

previous

maintenance

intervaltodetermine

the

next

required

maintenance

interval.

NOTE:

Add

20%toall

times

noted

for12cylinderorlarger

engines.

14

WARNINGll

A

To

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

~

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

over
current condition from burning out sensitive control panel components and circuits. Following all
maintenance,

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

when required.

SERVICE

MAINTENANCE

INTERVAL

INFORMATION

The

various

service

maintenance

intervals

are

designatedbyinterval

numbersasfollows:

1.

An

early

inspectionofthe

generator

settoinsureitis

readytooperate

when

required

andtoidentify

any

potential

problem

areas.

Performed

monthlyorfollowing

each10hoursofoperationofthe

unit

and

requires

approximately.5man-hours

per

unittocomplete.

1A.A

break-in

service

inspectionofthe

generator

settoinsureitis

readytooperate,

transfer

to,

and

carry

the

load

when

required,

and

to

identify

any

potential

problem

areas.

Performed

ONLY

ONCE

following

the

first

six

monthsorthe

first50hoursofoperation

after

purchase

of

the

unit

and

requires

approximately

2.5

man-hours

per

unittocomplete.

2.

An

operational

inspectionofthe

generator

settoinsureitis

readytooperate

and

carry

the

load

when

required,

andtoidentify

any

potential

problem

areas.

Performed

semi-annuallyorfollowing

each50hoursofoperationofthe

unit

and

requires

approximately

1.5

man-hours

per

unittocomplete.

3.Amid-level

inspectionofthe

generator

settoinsureitis

to

operate

and

carry

the

load

when

required,

andtoidentify

any

potential

problem

areas.

Performed

annually

or

each

100

hoursofoperationofthe

unit

and

requires

approximately

4.aman-hours

per

unittocomplete.

4.Acomprehensive

inspectionofthe

generator

settoinsureitis

properly

serviced

and

readytooperate

and

carry

the

load

when

required,

andtoidentify

any

potential

problem

areas.

Performed

biannuallyorfollowing

each

250

hoursofoperationofthe

unit

and

requires

approximately

8.0

man-hours

per

unittocomplete.

20

Maintenance

Maint

Maintenance

Maintenance

Tasks

Task

Completed

level

Interval

Date/Initials

1.

Disable

the

unit

from

operating

per

the

first

page

warning.

2.

Check

the

engine

oil

level.

Adjustasnecessary.

3.

Check

the

engine

coolant

level.

Adjustasnecessary.

Every

month

or

10

hours

of

operation.

4.

Check

the

battery

electrolyte

levelifaccessible.

Adjustasnecessary.

1

(Requires

5.

Check

the

diesel

fuel

supply

level.

Adjustasnecessary.

approximately

0.5

man

hours

per

unit)

6.

Check

the

air

inlets

and

outlets

for

debris.

Cleanasnecessary.

7.

Visually

inspect

the

unit

looking

for

leaks,

wearordamage,

loose

connectionsorcomponents,

and

corrosion.

Correctasnecessary.

8.

Return

the

unittooperational

condition.

Technician's

Signature

Date

Inspection

Completed

Unit

Hour

Meter

ReadingatCompletionofthe

Inspection

21

Maintenance

Maint

Maintenance

Maintenance

Tasks

Task

Completed

Level

Interval

Date/lnitials

1.

Disable

the

unit

from

operating

per

the

first

page

warning.

2.

Check

the

engine

oil

level.

Adjustasnecessary.

3,

Check

the

engine

coolant

level.

Adjustasnecessary,

4,

Check

the

battery

electrolyte

levelifaccessible,

Adjustasnecessary,

5,

Check

the

diesel

fuel

supply

level.

Adjustasnecessary.

First6months

6,

Drain

water

and

sediment

from

the

diesel

fuel

tank.

or

50

hours

of

operation

7.

Drain

water

from

the

diesel

fuel

line

water

separatorifunitisequipped

ONLY

with

one,

1A

8,

Check

the

air

inlets

and

outlets

for

debris,

Cleanasnecessary,

(Requires

approximately

2,5

man

hours

g,

Visually

inspect

the

unit

looking

for

leaks,

wearordamage,

loose

per

unit)

connectionsorcomponents,

and

corrosion,

Correctasnecessary,

1O,

Initiateanautomatic

start

and

transfertoloadofthe

unit,

and

exercise

it

foratleast1hour

looking

for

leaks,

loose

connectionsorcomponents,

and

abnormal

operating

conditions,

Correctasnecessary,

11,

Change

the

engine

oil.

12,

Replace

the

engine

oil

13.

Replace

the

engine

fuel

filter(s),

14,

Return

the

unittostand-by

setup

for

operation

when

required,

Technician's

Signature

Date

Inspection

Completed

Unit

Hour

Meter

ReadingatCompletionofthe

Inspection

22

Maintenance

Maint

Maintenance

Maintenance

Tasks

Task

Completed

Level

Interval

Date/Initials

1.

Disable

the

unit

from

operating

per

the

first

page

warning.

2.

Check

the

engine

oil

level.

Adjustasnecessary.

3.

Check

the

engine

coolant

level.

Adjustasnecessary.

4.

Check

the

battery

electrolyte

levelifaccessible.

Adjust

as

necessary.

Every6months

or

5.

Check

the

diesel

fuel

supply

level.

Adjustasnecessary.

50

hours

of

operation

2

6.

Drain

water

and

sediment

from

the

diesel

fuel

tank.

(Requires

approximately

7.

Drain

water

from

the

diesel

fuel

line

water

separatorifunitisequipped

1.5

man

hours

with

one.

per

unit)

8.

Check

the

air

inlets

and

outlets

for

debris.

Cleanasnecessary.

9.

Visually

inspect

the

unit

looking

for

leaks,

wearordamage,

loose

con-

nectionsorcomponents,

and

corrosion.

Correctasnecessary.

10.

Initiateanautomatic

start

and

transfertoloadofthe

unit,

and

exer-

ciseitforatleast1hour

looking

for

leaks,

loose

connectionsorcom-

ponents,

and

abnormal

operating

conditions.

Correctasnecessary.

11.

Return

the

unittostandby

setup

for

operation

when

required.

Technician's

Signature

Date

Inspection

Completed

Unit

Hour

Meter

ReadingatCompletionofthe

Inspection

23

Maintenance

Maint

Maintenance

Maintenance

Tasks

Task

Completed

level

Interval

Date/lnitials

1.

Disable

the

unit

from

operating

per

the

first

page

warning.

2.

Check

the

engine

oil

level.

Adjustasnecessary.

3.

Check

the

engine

coolant

level.

Adjustasnecessary.

4.

Check

the

engine

coolant

thermal

protection

level.

Correctasneces-

sary.

5.

Check

the

diesel

fuel

supply

level.

Adjustasnecessary.

6.

Drain

water

and

sediment

from

the

diesel

fuel

tank.

Every12months

or

7.

Drain

water

from

the

diesel

fuel

line

water

separatorifunitisequipped

100

hours

of

with

one.

operation

8.

Check

the

air

inlets

and

outlets

for

debris.

Cleanasnecessary.

3

(Requires

9.

Check

the

battery

electrolyte

levelifaccessible.

Adjust

as

approximately

necessary.

4,0

man

hours

10.

Check

the

battery

posts,

cables,

and

charger

for

loose

connections,

per

unit)

corrosion,

and

proper

operation.

Correctasnecessary.

11.

Check

the

unit

wiring

for

loose

connections,

corrosion,

and

damage.

Correctasnecessary.

12.

Check

the

engine

accessory

drive

belts

for

wear,

weather

cracking,

and

damage.

Replaceasnecessary.

13.

Test

the

unit

safety

devices

(alarms,

shutdowns,

etc.)

for

proper

operation.

Correct

and/or

adjustasnecessary.

14.

Performanoil

analysis

(sendasampletoa

lab

for

results).

Change

the

engine

oil

and

filtersifthe

analysis

results

indicate

thisisrequired.

15.

Visually

inspect

the

unit

looking

for

leaks,

wearordamage,

loose

connectionsorcomponents,

and

corrosion.

Correctasnecessary.

16.

Start

and

exercise

the

unit

under

full

rated

load

foratleast2hours

look-

ing

for

leaks,

loose

connectionsorcomponents,

and

abnormal

operating

conditions.

Correctasnecessary.

17.

Return

the

unittostandby

setup

for

operation

when

required.

Technician's

Signature

Date

Inspection

Completed

Unit

Hour

Meter

ReadingatCompletionofthe

Inspection

24

Maintenance

Maint

Maintenance

Maintenance

Tasks

Task

Completed

level

Interval

Datellnitials

1.

Disable

the

unit

from

operating

per

the

first

page

warning.

2.

Check

the

engine

oil

level.

Adjustasnecessary.

3.

Check

the

engine

coolant

level.

Adjustasnecessary.

4.

Check

the

engine

coolant

thermal

protection

level.

Correctasnecessary.

5.

Check

the

diesel

fuel

supply

level.

Adjustasnecessary.

6.

Drain

water

and

sediment

from

the

diesel

fuel

tank.

Every24months

or

7.

Drain

water

from

the

diesel

fuel

line

water

separatorifunitisequipped

250

hours

of

with

one.

operation

8.

Check

the

air

inlets

and

outlets

for

debris.

Cleanasnecessary.

4

(Requires

9.

Check

the

battery

electrolyte

levelifaccessible.

Adjustasnecessary.

approximately

8.0

man

hours

10.

Check

the

battery

posts,

cables,

and

charger

for

loose

connections,

per

unit)

corrosion,

and

proper

operation.

Correctasnecessary.

11.

Check

the

unit

wiring

for

loose

connections,

corrosion,

and

damage.

Correctasnecessary.

12.

Check

the

engine

accessory

drive

belts

for

wear,

weather

cracking,

and

damage.

Replaceasnecessary.

13.

Check

the

engine

valve

clearance.

Adjustasnecessary.

14.

Visually

inspect

the

unit

looking

for

leaks,

wearordamage,

loose

con-

nectionsorcomponents,

and

corrosion.

Correctasnecessary.

15.

Start

and

exercise

the

unit

under

full

rated

load

foratleast2hours

look-

ing

for

leaks,

loose

connectionsorcomponents,

and

abnormal

operating

conditions.

CorrectasnecessalY

16.

Change

the

engine

oil.

17.

Replace

the

engine

oil

filter(s).

Maintenance

Level4continuedonnext

page.

25

Maintenance

Maint

Maintenance

Maintenance

Tasks

Task

Completed

Level

Interval

Date/lnitials

18.

Replace

the

engine

fuel

filter(s).

19.

Replace

the

air

filter(

s).

Every24months

or

20.

Replace

Engine

Coolant.

250

hours

of

operation

4

21

Replace

Coolant

Hoses.

(Requires

approximately

22.

Visibly

inspect

flexible

fuel

lines

and

flexible

air

lines,ifapplicable,

on

8.0

man

hours

this

unit.

Replace

themifthey

seem

worn,

spongyorbrittle.

per

unit)

23.

Start

the

unit

and

exerciseitforatleast15minutes

looking

for

leaks,

loose

connectionsorcomponents,

and

abnormal

operating

conditions.

Correctasnecessary.

24.

Return

the

unittostandby

setup

for

operation

when

required.

Technician's

Signature

Date

Inspection

Completed

Unit

Hour

Meter

ReadingatCompletionofthe

Inspection

26

Warranty

EPA EMISSION-RELATED CI GENERATOR MODEL WARRANTY

Effective

01/01/2011,

applicabletoCI

generator

models

equaltoand

larger

than

SD80

Effective

01/01/2012,

applicabletoCI

generator

models

equaltoand

larger

than

SD35.

Effective

01/01/2013,

applicabletoallCIgenerator

models.

Your

emission-related

warranty

covers

only

components

whose

failure

would

increaseanengine's

emissionsofany

regulated

pollutant

where

they

are

designed,

built,

and

equippedtobe

free

from

defectsinmaterials

and

workmanship

under

applicable

regulationsofsection

213ofthe

clean

air

act.Toreceive

informa-

tion

about

howtomakeanemission-related

warranty

claim,

and

howtomake

arrangements

for

authorized

repairs

call

1-800-333-1322orwwwgenerac.com.

Emission-related

warranty

claims

maybedenied

without

proofofproper

maintenanceoruse,

accidents

beyond

the

controlofthe

manufacturer,oractsofGod.

Proper

maintenanceisspecifiedinthe

owners

manual.

Usageislimitedtostationary

emergency

operations

and

100

hours

per

year

for

maintenance

and

readi-

ness

testing.

The

warranty

period

begins

when

the

engineisplaced

into

service.

Warranty

periods:

Compression

ignition

engines

rated>25HPis5

years.

27

Warranty

Effective

01/01/2011,

applicabletoCI

generator

models

eguilila

ilnd

smilllQ[

than

S060.

Effective

01/01/2012,

applicabletoCI

generator

models

eguiliia

and

smallQr

than

S030.

Effective

01/01/2013,

not

applicabletoCI

generator

models.

NOTE: This Emission Control Warranty Statement applies only to mobile (trallerlzed) non-road diesel engine powered
generators (model year 2000) as follows: The

EPA

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

this statement pertains to this product only IF the generator

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

CALIFORNIA

AND

FEDERAL

EMISSION

CONTROL

WARRANTY

STATEMENT

YOUR

WARRANTY

RIGHTS

AND

OBLIGATIONS

The

California

Air

Resources

Board

(CARB)and

the

United

States

Environmental

Protection

Agency

(EPA),

together

with

Generac

Power

Systems,

Inc.

(Generac),

are

pleasedtoexplain

the

Emission

Control

System

Warrantyonyour

new

non-road

diesel

engine.*

New

non-road

diesel

engines

must

be

designed,

built

and

equippedtomeet

stringent

anti-smog

standards

for

the

stateofCalifornia

and

the

federal

government.

Generac

will

warrant

the

emission

control

systemonyour

non-road

diesel

engine

for

the

periodsoftime

listed

below

provided

there

has

beennoabuse,

neglect,

unapproved

modification

or

improper

maintenanceofyour

non-road

diesel

engine.

Your

emission

control

system

may

include

such

partsasthe

fuel

injection

system

and

the

air

induction

system.

Also

included

maybehoses,

belts,

con-

nectors

and

other

emission-related

assemblies

Generac

will

repair

your

non-road

diesel

enginealno

costtoyou

for

diagnosis,

replacement

paris

and

labor,

shouldawarrantable

condition

occur.

MANUFACTURER'S

EMISSION

CONTROL

SYSTEM

WARRANTY

COVERAGE:

Emission

control

systemson1996

and

later

model

year

non-road

diesel

engines

are

warranted

for

five

years,or3,000

hoursofuse,

whichever

occurs

first.Inthe

absenceofan

hourmeter,

the

said

coverageisfive

years

If,

during

said

warranty

period,

any

emission-related

componentorsystemonyour

engineisfoundtobe

defectiveinmaterialsorworkmanship,

repairsorreplacement

willbeperformedbya

Generac

Authorized

Warranty

Service

Facility.

PURCHASER'S/OWNER'S

WARRANTY

RESPONSIBILITIES:

As

the

non-road

diesel

engine

purchaser/owner,

you

are

responsible

for

the

completionofall

required

maintenanceaslistedinyour

factory

supplied

Owner's

Manual.

For

warranty

purposes,

Generac

recommends

that

you

retain

all

receipts

covering

maintenanceofyour

non-road

diesel

engine.

However,

Generac

cannot

deny

warranty

solely

duetolackofreceiptsorfor

your

failuretoensure

the

completionofall

scheduled

maintenance.

As

the

non-road

diesel

engine

purchaser/owner,

you

should,

however,beaware

that

Generac

may

deny

any

and/or

all

warranty

coverageorresponsibility

if

your

non-road

diesel

engine,ora

parVcomponent

has

failed

duetoabuse,

neglect,

improper

maintenanceorunapproved

modifications.,orthe

useofcounterfeit

and/or

"grey

market"

parts

not

made,

suppliedorapprovedbyGenerac.

Your

engineisdesignedtooperateondiesel

fuel

only

Useofany

other

fuel

may

resultinyour

enginenolonger

operatingincompliance

with

federal

or

California

emission

requirements.

You

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

The

warranty

repairs

shouldbecompletedina

reasonable

amountoftime,

nottoexceed30days.

Warranty

service

canbearrangedbycontacting

either

your

selling

dealerora

Generac

Authorized

Warranty

Service

Facility.Tolocate

the

Generac

Authorized

Warranty

Service

Facility

nearest

you,

call

our

toll-free

number:

1·800·333·1322

IMPORTANT NOTE:

This

statement

explains

your

rights

and

obligations

under

the

Emission

Control

System

Warranty

(ECS

Warranty),

whichisprovidedtoyoubyGenerac

pursuanttofederal

and

California

law.

See

also

the

"Generac

Limited

Warranties

for

Generac

Power

Systems,

Inc.,"

whichisenclosed

herewithona

separate

sheet,

also

providedtoyoubyGenerac.

The

ECS

Warranty

applies

only

to

the

emission

control

systemofyour

new

non-road

diesel

engine.Ifthereisany

conflictinterms

between

the

ECS

Warranty

and

the

Generac

Warranty,

the

ECS

Warranty

shall

apply

except

in

circumstances

where

the

Generac

Warranty

may

providealonger

warranty

period.

Both

the

ECS

Warranty

and

the

Generac

describe

important

I'ights

and

obligations

with

respecttoyour

new

non-road

diesel

engine

Warranty

service

canbeperformed

onlybya

Generac

Authorized

Warranty

Service

Facility.

When

requesting

warranty

service,

evidence

mustbepresented

showing

the

dateofsaletothe

original

purchaser/owner.

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

following address:

ATTENTION

WARRANTY

DEPARTMENT

GENERAC

POWER

SYSTEMS,

INC.

211

MURPHY

DRIVE

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