6421 SW 64 ST_YELLOW GENERATOR SOUT
City of South Miami
F �
., Planning Department
U City Hall,6130 Sunset Drive,South Miami,Florida 33143
INCORPORATED • Telephone: 305.663.6331 or 6326;Fax: 305.668.7356
1927
ORY9�
Application for Permanent Generator
Address of Subject Property: / Lot(s) � Block I Subdivision i-� r z4
6 l J (/V (7 4 C PB
Property Owner: i711LL>R11,, J�. Zfi 0,1 Aj f d,W Phone: 36-5 — 3 a a V 30J7
c/hoV-r F/ZA-1Z
Mailing Address: 54.a j S w 6 y S ! Fax:
s A L 3�3 A
Applicant: Phone: �cd l— 790.._10 �' S
Address: 0-76 S_ c�a a
�✓ G'A�N- �iCl� F� 3-3
Zoning District
�t7U7 rte
APPLICATION IS HEREBY MADE FOR THE FOLLOWING: SUBMITTED MATERIALS
1/ PLEASE CHECK ALL THAT APPLY:
1) Is the generator certified by Underwriters Laboratory(UL) 7 E S roof of ownership or letter from owner
?owners manual(Generator)
2) Is the generator Internally filled or externally filled? YCurrent survey
_
.-Site ite Plan (11"x17"max. size)
3) What type of fuel does the generator use? A14/—RA L 6A S —quired Fee($50.00)
4) Does the generator exceed 65dB at the minimum setback? -A/b
?OP of- S l" Ia. + 6e A-Cove W(W 9 F—
The undersigned has read this completed application and represents that the information and all submitted materials are true and correct to
the best of the applicant's knowledge and belief.
Applicant's Signature Date
Upon receipt, applications and all submitted materials will be reviewed for compliance with the Land.Development Code(LDC),City of
South Miami,and other applicable regulations. Applications found not in compliance will be rejected and returned to the applicant.
OFFICE USE ONLY:
Date Filed: Approved by Date of Approval:
Method of Payment
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Serial Number QT
2.5L
25kW
Model : 005212-0
STANDBY GENERATOR
OWNER ' S MANUAL
A new standard of reliability
GUARDIAN
by Generac Power Systems,Inc.
- ,�L CAUTION 0 -
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
This manual should remain with the unit.
Zl6Ld0'ONUed 90/60 0'^08 8t0)OAOO
ToFE Standby Generator TAQE.
CONTENTS Table of • CONTENTS
SECTION PAGE OPERATION...........................................................9-1
SAFETY RULES................................................ 1-1 Generator Control and Operation................................9-1
INTRODUCTION.....................................................1-3 Operating Unit with Manual Transfer Switch...............9-1
Read this Manual Thoroughly..................................:1-3 Engine Start-up and Transfer...................................9-1
Operation and Maintenance.......................................1-3 Retransfer and Shutdown.........................................9-1
How to Obtain Service..............................................1-3 Operating Unit with Automatic Transfer Switch...........9-1
IDENTIFICATION RECORD.....................................2-1 MAINTENANCE.....................................................10-1
Data Label ................................................................2-1 Maintenance Performed by Authorized
EQUIPMENT DESCRIPTION 3-1 Service Facilities.....................................................10-1
Equipment Description................................................3-1 Every Three Months ...............................................10-1
Engine Oil Recommendations......................................3-1 Once Every Six Months...........................................10-1
Coolant Recommendations...........................................3-1 Once Annually.........................................................10-1
ENGINE PROTECTIVE DEVICES............................4-1 First 100 Operating Hours......................................10-1
High Coolant Temperature Switch............................4-1 Every 500 Operating Hours....................................10-1
Low Coolant Level Sensor.........................................4-1 Every 800 Operating Hours....................................10-1
Low Oil Pressure Switch...........................................4-1 Exhaust Manifold Procedure......................................10-1
Overcrank Shutdown................................................4-1 Intake Manifold Procedure.........................................10-1
Overspeed Shutdown....................... ...4-1 Cylinder Head Procedure...........................................10-1.
RPM Sensor Loss Shutdown.....................................4-1
Cooling System..........................................................10-2
DC Fuse....................................................................4-1 Overload Protection for Engine DC
Electrical System....................................................10-2
FUELSYSTEMS.....................................................5-1 Checking Fluid Levels................................................10-2
............................
Fuel Requirements....................................................5-1 Check Engine Oil....................................................10-2
Natural Gas Fuel System ..........................................5 1 Battery Fluid...........................................................10-2
Propane Vapor Withdrawal Fuel System....................5-1 Engine Coolant...........................
LP Fuel System.........................................................5-1 Maintenance Owner/Operator Can Perform................10-3
SPECIFICATIONS...................................................6-1 Check Engine Oil Level...........................................10-3
Generator .................................................................6-1 Check Batter 10-3
Engine.......................................................................6-1 Exercise System......................................................10-3
Cooling System.........................................................6-1 Inspect Cooling System.............
Fuel System ..............................................................6-1 Check Engine Coolant Level....................................10-3
Electrical System......................................................6-1 Perform Visual Inspection.......................................10-3
Cold Weather Kit.......................................................6-2 Inspect Exhaust System..........................................10-3
Reconfiguring the Fuel System..................................6-2 Check Fan Belt........................................................10-3
GENERAL INFORMATION.......................................7-1 Inspect Engine Governor 10-3
Generator AC Lead Connections..................................7-1 Changing Engine Oil...............................................10-3
Four-lead, Single-phase Stator..................................7-1 Changing the Engine Air Cleaner............................10-3
Alternator Power Winding Connections........................7-1 Spark Plugs............................................................10-4
3-phase Alternators..................................................7-1 Coolant Change.......................................................10-4
INSTALLATION.......................................................8-1 Miscellaneous Maintenance........................................10-4
Installation...................................................................8-1 Cleaning the Generator...........................................10-4
Preparation Before Start-up.........................................8-1
Battery....................................................................10-4
Transfer Switch........................................................8-1 Battery Maintenance...............................................10-4
Fuel System ..............................................................8-1 Battery Replacement...............................................10-5
Generator Set Lubrication........................................8-1 SERVICE SCHEDULE 11-1
...........................................
Prior to Initial Start-up.............................................8-1 TROUBLESHOOTING 12-1
...........................................
Engine Coolant.........................................................8-1 Troubleshooting Guide...............................................12-1
BeltTension..............................................................8-1 NOTES
Electrical System......................................................8-1 EXPLODED VIEWS &PARTS LISTS
Initial Inspection for QT Genset Start-up.....................8-1 WIRING DIAGRAMS &SCHEMATICS
Start-up Checklist........................................................8-2 WARRANTY
Preparation for Start-up............................................8-2
Start-up Inspection...................................................8-2
90/60 O'Aad b00lu91u00
SAFETY RULES SAFETY RULES
Standby Generator Sets
Important Safety Instructions UAA1
QSAVE THESE INSTRUCTIONS - The manufacturer suggests that these rules for safe Q
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.
a
WARNING: 0 GENERAL HAZARDS 0
The engine exhaust from this product For safety reasons, the manufacturer recommends
contains chemicals known to the state that this equipment be installed, serviced and
of California to cause cancer, birth repaired by an Authorized Service Dealer or other
defects or other reproductive harm. competent, qualified electrician or installation tech-
nician who is familiar with applicable codes, stan-
dards and regulations. The operator also must
comply with all such codes, standards and regula-
This product contains or emits chemicals tions.
known to the state of California to cause Installation, operation, servicing and repair of this
rcancer, birth defects or other reproductive harm. (and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Study these SAFETY RULES carefully before install- Adhere strictly to local, state and national electri-
ing, operating or servicing this equipment. Become cal and building codes. Comply with regulations
familiar with this Owner's Manual and with the unit. the Occupational Safety and Health Administration
The generator can operate safely, efficiently and reli- (OSHA) has established. Also, ensure that the
ably only if it is properly installed, operated and generator is installed, operated and serviced in
maintained. Many accidents are caused by failing to accordance with the manufacturer's instructions
follow simple and fundamental rules or precautions. and recommendations. Following installation, do
nothing that might render the unit unsafe or in
The manufacturer cannot anticipate every possible noncompliance with the aforementioned codes,
circumstance that might involve a hazard. The warn- standards, laws and regulations.
ings in this manual, and on tags and decals affixed The engine exhaust fumes contain carbon monox-
to the unit are, therefore, not all inclusive. If a pro- ide gas,which can be DEADLY.This dangerous gas,
cedure, work method or operating technique is used if breathed in sufficient concentrations, can cause
that the manufacturer does not specifically recom- unconsciousness or even death. For that reason,
mend, ensure that it is safe for others. Also make adequate ventilation must be provided. Exhaust
sure the procedure, work method or operating tech- gases must be piped safely away from any building
nique utilized does not render the generator unsafe. or enclosure that houses the generator to an area
where people, animals, etc., will not be harmed.
A A This exhaust system must be installed properly, in
Despite the safe design of this generator, strict compliance with applicable codes and stan-
operating this equipment imprudently, neglect- dards.
ing its maintenance or being careless can cause • Keep hands, feet, clothing, etc., away from drive
possible injury or death. Permit only responsible belts, fans, and other moving or hot parts. Never
and capable persons to install, operate or main- remove any drive belt or fan guard while the unit
tain this equipment. is operating.
• Adequate, unobstructed flow of cooling and venti-
Q Potentially lethal voltages are generated by lating air is critical in any room or building hous-
these machines. Ensure all steps are taken to ing the generator to prevent buildup of explosive
render the machine safe before attempting to gases and to ensure correct generator operation.
work on the generator. Do not alter the installation or permit even partial
Q Parts of the generator are rotating and/or hot blockage of ventilation provisions, as this can seri-
during operation. Exercise care near running ously affect safe operation of the generator.
generators. • Keep the area around the generator clean and
uncluttered. Remove any materials that could
become hazardous.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Inspect the generator regularly, and promptly
repair or replace all worn, damaged or defective
parts using only factory-approved parts.
1-1 50/80 O'AEd t00 419JES
SAFETY RULES SAFETY RULES
FUNIN Important Instructions. 1 FOUR
• Before performing any maintenance on the gen- Generators installed with an automatic transfer
erator, disconnect its battery cables to prevent switch will crank and start automatically when
accidental start-up. Disconnect the cable from the normal (utility) source voltage is removed or is
battery post indicated by a NEGATIVE, NEG or (-) below an acceptable preset level. To prevent such
first. Reconnect that cable last. automatic start-up and possible injury to person-
• Never use the generator or any of its parts as a nel, disable the generator's automatic start circuit
step. Stepping on the unit can stress and break (battery cables, etc.) before working on or around
parts, and may result in dangerous operating con- the unit. Then, place a "Do Not Operate" tag on
ditions from leaking exhaust gases, fuel leakage, the generator control panel and on the transfer
oil leakage, etc. switch.
• In case of accident caused by electric shock, imme-
QQ ELECTRICAL HAZARDS Qf diately shut down the source of electrical power.
• All generators covered by this manual produce If this is not possible, attempt to free the victim
dangerous electrical voltages and can cause fatal from the live conductor.AVOID DIRECT CONTACT
electrical shock. Utility power delivers extremely WITH THE VICTIM. Use a.nonconducting imple-
high and dangerous voltages to the transfer switch ment, such as a dry rope or board, to free the vic-
as well as the standby generator. Avoid contact tim from the live conductor. If the victim is uncon-
with bare wires, terminals, connections, etc., on scious, apply first aid and get immediate medical
the generator as well as the transfer switch, if help.
applicable. Ensure all appropriate covers, guards • Never wear jewelry when working on this equip-
and barriers are in place before operating the gen- ment. Jewelry can conduct electricity resulting in
erator. If work must be done around an operating electric shock, or may get caught in moving com-
unit, stand on an insulated, dry surface to reduce ponents causing injury.
shock hazard.
• Do not handle any kind of electrical device while AN FIRE HAZARDS
standing in water,while barefoot, or while hands or • Keep a fire extinguisher near the generator at all
feet are wet. DANGEROUS ELECTRICAL SHOCK times. Do NOT use any carbon tetra-chloride type
MAY RESULT. extinguisher. Its fumes are toxic, and the liquid
• If personnel must stand on metal or concrete while can deteriorate wiring insulation. Keep the extin-
installing, operating, servicing, adjusting or repair- guisher properly charged and be familiar with its
ing this equipment, place insulative mats over a use. If there are any questions pertaining to fire
dry wooden platform. Work on the equipment only extinguishers, consult the local fire department.
while standing on such insulative mats.
• The National Electrical Code (NEC) requires the EXPLOSION HAZARDS
frame and external electrically conductive parts . properly ventilate any room or building housing
of the generator to be connected to an approved
earth ground. This grounding will help prevent the generator to prevent build-up of explosive gas.
dangerous electrical shock that might be caused • Do not smoke around the generator. Wipe up any
by a ground fault condition in the generator set or fuel or oil spills immediately. Ensure that no com-
bustible materials are generator com-
left in the
by static electricity. Never disconnect the ground g
wire. partment, or on or near the generator, as FIRE or
• Wire gauge sizes of electrical wiring, cables and EXPLOSION may result. Keep the area surround-
cord sets must be adequate to handle the maxi- ing the generator clean and free from debris.
mum electrical current (ampacity) to which they • These generator sets may operate using one of
will be subjected. several types of fuels. All fuel types are potentially
• Before installing or servicing this (and related) FLAMMABLE and/or EXPLOSIVE and should be
equipment, make sure that all power voltage handled with care. Comply with all laws regulat-
supplies are positively turned off at their source. ing the storage and handling of fuels. Inspect the
Failure to do so will result in hazardous and pos- unit's fuel system frequently and correct any leaks
sibly fatal electrical shock. immediately. Fuel supply lines must be prop-
erly installed, purged and leak tested according to
• Connecting this unit to an electrical system nor- applicable fuel-gas codes before placing this equip-
mally supplied by an electric utility shall be by ment into service.
means of a transfer switch so as to isolate the . Diesel fuels are highly FLAMMABLE. Gaseous
generator electric system from the electric utility fluids such as. natural gas and liquid propane
distribution system when the generator is operat- (LP) gas are extremely EXPLOSIVE. Natural gas
ing. Failure to isolate the two electric system power is lighter than air, and LP gas is heavier than air;
sources from each other by such means will result install leak detectors accordingly.
in damage to the generator and may also result
in injury or death to utility power workers due to
backfeed of electrical energy.
50/90 O MH t00/1aleS 1-2
SAFETY�RU SAQ
Standby Generator
Important Safety Instructions INTRODUCTION ® This symbol points out potential fire hazard.
Thank you for purchasing this model of the standby
generator set product line. Q This symbol points out potential electrical shock
Every effort was expended to make sure that the hazard.
information and instructions in this manual were The operator is responsible for proper and safe use
both accurate and current at the time the manual was of the equipment. The manufacturer strongly recom-
written. However, the manufacturer reserves the right mends that the operator read this Owner's Manual
to change, alter or otherwise improve this product(s) and thoroughly understand all instructions before
at any time without prior notice. using this equipment. The manufacturer also strong-
ly recommends instructing other users to properly
♦ READ THIS MANUAL THOROUGHLY start and operate the unit. This prepares them if they
need to operate the equipment in an emergency.
If any portion of this manual is not understood, con-
tact the nearest Authorized Service Dealer for start- OPERATION AND MAINTENANCE
MAINTENANCE
ing, operating and servicing procedures.
Throughout this publication, and on tags and It is the operator's responsibility to perform all safety
decals affixed to the generator, DANGER, WARNING, checks, to make sure that all maintenance for safe
CAUTION and NOTE blocks are used to alert person- operation is performed promptly, and to have the
nel to special instructions about a particular service equipment checked periodically by an Authorized
or operation that may be hazardous if performed Service Dealer. Normal maintenance service and
incorrectly or carelessly. Observe their carefully. replacement of parts are the responsibility of the
Their definitions are as follows: owner/operator and, as such, are not considered
defects in materials or workmanship within the terms
AA of the warranty. Individual operating habits and usage
contribute to the need for maintenance service.
After this heading, read instructions that, if not Proper maintenance and care of the generator ensure
strictly complied with, will result in personal injury a minimum number of problems,and keep operating
or property damage. expenses at a minimum. See an Authorized Service
AWARNING A- Dealer for service aids and accessories.
Operating instructions presented in this manual
After this heading, read instructions that, if not assume that the standby electric system has been
strictly complied with, may result in personal installed by an Authorized Service Dealer or other
injury or property damage. competent, qualified contractor. Installation of this
equipment is not a "do-it-yourself" project.
A CAUTION A
After this heading, read instructions that, if not ♦ HOW TO OBTAIN SERVICE
strictly complied with, could result in damage to When the generator requires servicing or repairs,
equipment and/or property. simply contact an Authorized Service Dealer for
NOTE: assistance. Service technicians are factory-trained
After this heading, read explanatory statements and are capable of handling all service needs.
that require special emphasis. When contacting an Authorized Service Dealer or the
These safety warnings cannot eliminate the hazards factory about parts and service, always supply the
that they indicate. Common sense and strict compli- complete model number of the unit as given on the
ance with the special instructions while performing front cover of this manual or on the DATA LABEL
the service are essential to preventing accidents. affixed to the unit.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type AUTHORIZED SERVICE DEALER LOCATION
of information each indicates is as follows:
To locate the nearest AUTHORIZED
Qj This symbol points out important safety infor- SERVICE DEALER,please call this number:
mation that, if not followed, could endanger
personal safety and/or property of others. 1-800-333-1322
A This symbol points out potential explosion or locate us on the web at:
hazard. www.generac.com
1-3 90/80 0'ABU loo AlajeS
GENERAL Standby GENERAL
INFORMATION information
INFORMATION
IDENTIFICATION RECORD NOTE:
For actual information related to this particular
♦ DATA LABEL model, please refer to the Manual Drawing Listing
Every generator set has a DATA LABEL that contains located at the end of this manual, or to the data
important information pertinent to the generator. The label affixed to the unit.
data label, which can be found attached to the gen- ♦ Generator Model and Serial Number
erator's lower connection box, lists the unit's serial
number and its rated voltage, amps,wattage capacity, This number is the key to numerous engineering and
phase, frequency, rpm, power factor, etc. manufacturing details pertaining to your unit.Always
supply this number when requesting service, order-
ing parts or seeking information.
Data Label
GENERATOR SET DATA MADE IN USA
MODEL SERIAL
RATED KW RATED KVA PHASE
RATED VOLTAGE I RATED AMPS
POWER FACTOR HERTZ ALT RPM
ENGINE RPM I PRODUCTION DATE
ALTERNATOR SUBTRANSIENT REACTANCE
ALTERNATOR TRANSIENT REACTANCE
CLASS ❑ ROTOR F] STATOR WINDING INSULATION AT 25°C AMBIENT
GENERAC POWER SYSTEMS, INC.
WAUKESHA, WI
c
2-1 90131 V'A98 ZOO AIUaPI
GENERAL GENERAL
INFORMATION Standby Description
Generator Sets
, , INFORMATION
EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS
This equipment is a revolving field, alternating cur- Use a mixture of half low silicate ethylene glycol
rent generator set. It is powered by a gaseous fueled base anti-freeze and deionized water. Cooling system
engine operating at 1800 rpm for 4-pole direct drive capacity is listed in the specifications. Use only deion-
units, 3600 rpm for 2-pole direct drive units and ized water and only low silicate anti-freeze. If desired,
2300 - 3000 rpm for quiet drive gear units. See the add a high quality rust inhibitor to the recommended
Specifications section for exact numbers. The unit coolant mixture. When adding coolant, always add
comes complete with a sound attenuated enclosure, the recommended 50-50 mixture.
internally mounted muffler, control console, main-
line circuit breaker, battery charger, and protective A CAUTION A
alarms as explained in the following paragraph.
the power leads from 0 w not use any chromate base rust inhibitor
All AC connections, including p wi th ethylene glycol base anti-freeze or chro-
the alternator, 120 volt battery charger input and mium hydroxide ("green slime")forms and will
control connections to the transfer switch are avail- cause overheating. Engines that have been oper-
able in the main connection box. ated with a chromate base rust inhibitor must
The generator incorporates the following generator be chemically cleaned before adding ethylene
features: glycol base anti-freeze. Using any high silicate
• Rotor and Stator insulation is Class H rated as anti-freeze boosters or additives will also cause
defined by NEMA MG1-32.6, NEMA MG1-1.66. overheating. The manufacturer also recommends
The generator is self ventilated and drip-proof con- that any soluble oil inhibitor is NOT used for this
equipment.
structed.
• The voltage waveform deviation, total harmonic A A
content of the AC waveform and telephone influ-
ence factor have been evaluated and are acceptable 0 Do not remove the radiator pressure cap while
according to NEMA MG1-32. the engine is hot or serious burns from boiling
liquid or steam could result.
ENGINE OIL RECOMMENDATIONS A Ethylene glycol base antifreeze is poisonous.
The unit has been filled with 15W-40 engine oil at Do not use mouth to siphon coolant from the
the factory. Use a high-quality detergent oil classified radiator, recovery bottle or any container. Wash
"For Service CC, SD, SE, SF." Detergent oils keep the hands thoroughly after handling. Never store
engine cleaner and reduce carbon deposits. Use oil used antifreeze in an open container because
having the following SAE viscosity rating, based on animals are attracted to the smell and taste of
the ambient temperature range anticipated before the antifreeze even though it is poisonous to them.
next oil change:
Temperature Oil Grade Recommended
Above 80° F 27°C SAE 30W or 15W-40
320 to 80°F 00 to 27°C SAE 20W-20 or 15W-40
Below 32°F(0°C) See Note
-A CAUTION A
0 Any attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
NOTE:
For temperatures below 32°F, it is strongly recom-
mended to use the optional Cold Weather Start Kit
(part number listed in the Specification Section).
The oil grade for temperatures below 32° F is 5W-
30 synthetic oil.
3-1 50(80 o'Aau loodinb3
GENERAL GENERAL
Standby Generator Sets
INFORMATION Protective Devices INFORMATION
ENGINE PROTECTIVE DEVICES ♦ OVERCRANK SHUTDOWN
The standby generator may be required to operate for After a prespecified duration of cranking, this func-
long periods of time without an operator on hand to tion ends the cranking if the engine has failed to
monitor such engine conditions as coolant tempera- start. The overcrank LED will turn ON. Turn OFF the
ture, oil pressure or rpm. For that reason, the engine AUTO/OFF/MANUAL switch, then turn switch back to
has several devices designed to protect it against AUTO to reset the generator control board.
potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too NOTE:
low, the coolant temperature is too high, the coolant If the fault is not corrected, the overcrank feature
level is too low, or the engine is running too fast. will continue to activate.
NOTE:
Engine protective switches and sensors are men- Approximate Crank Cycle Times
tion'ed here for the reader's convenience. Also • 15 seconds ON
refer to the applicable control panel manual for • 7 seconds OFF
additional automatic engine shutdown informa- • 7 seconds ON
tion. • 7 seconds OFF
• Repeat for 45 seconds
HIGH COOLANT TEMPERATURE SWITCH Approximately 90 seconds total.
This switches contacts close if the temperature should ♦ OVERSPEED SHUTDOWN
exceed approximately 140° C (284° F), initiating an
engine shutdown. The generator will automatically A speed circuit controls engine cranking, start-up,
restart and the LED will reset once the temperature operation and shutdown. Engine speed signals are
has returned to a safe operating level. delivered to the circuit board whenever the unit is
running. Should the engine overspeed above a safe,
LOW COOLANT LEVEL SENSOR preset value, the circuit board initiates an automatic
engine shutdown. Contact the nearest Authorized
Should the engine coolant level drop below the level Dealer if this failure occurs.
of the high coolant temperature switch, it is possible
for the engine to overheat without automatic shut- ♦ RPM SENSOR LOSS SHUTDOWN
down. To prevent such overheating, the engine has a
low coolant level sensor. If the level of engine coolant If the speed signal to the control panel is lost, engine
drops below the level of the low coolant level sensor, shutdown will occur.
the engine automatically shuts down.
♦ DC FUSE
LOW OIL PRESSURE SWITCH This fuse is located inside of the control panel. It
This switch has normally closed contacts that are . protects the panel wiring and components from
held open by engine oil pressure during cranking and damaging overload. Always remove this fuse before
operating. Should oil pressure drop below the 8 psi commencing work on the generator. The unit will
range, switch contacts close, and the engine shuts not start or crank if the fuse is blown. Replace the
down. The unit should not be restarted until oil is fuse with one of the same size, type, and rating. (See
added, and the AUTO/OFF/MANUAL switch must be the exploded views and parts lists at the end of this
turned to OFF and then back to AUTO. manual for replacement part number.)
4-1 90/90 O MH 10010Jd0U3
GENERAL Standby GENERAL
Fuel Systems
INFORMATION INFORMATION
FUEL SYSTEM ♦ PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
♦ FUEL REQUIREMENTS This type of system utilizes the vapors formed above
the liquid fuel in the supply tank. Approximately 10
The standby generator may be equipped with one of to 20 percent of the tank capacity is needed for fuel
the following fuel systems: expansion from the liquid to the vapor state. The
vapor withdrawal system is generally best suited for
• Natural gas fuel system smaller engines that require less fuel. The installer
• Propane vapor (PV) fuel system should be aware of the following:
The Manual Drawing Listing that is affixed to the . The natural gas and LP gas systems are similar.
unit includes the "Identification Code,"which may be However, the natural gas system delivers gas at a
used to identify the type of fuel system installed on pressure of approximately five inches water col-
the unit.
umn to the carburetor.
Recommended fuels should have a Btu content of at • When ambient temperatures are low and engine
least 1,000 Btus per cubic foot for natural gas; or at fuel consumption is high, the vapor withdrawal
least 2,520 Btus per cubic foot for LP gas. Ask the system may not function efficiently.
fuel supplier for the Btu content of the fuel. • Ambient temperatures around the supply tank
Required fuel pressure for natural gas is 5 inches must be high enough to sustain adequate vaporiza-
to 14 inches water column (0.18 to 0.5 psi); and tion, or the system will not deliver the needed fuel
for liquid propane, 5 inches to 14 inches of water volume.
column (0.18 to 0.5 psi). • In addition to the cooling effects of ambient air, the
NOTE: vaporization process itself provides an additional
Any piping used to connect the generator to the cooling effect.
fuel supply should be of adequate size to ensure ♦ LP FUEL SYSTEM
the fuel pressure NEVER drops below five inches
water column for natural gas or 5 inches water LP is supplied as a liquid in pressure tanks. It is
column for propane vapor for all load ranges. usually made up of propane, butane, or a mixture of
NOTE: the two gases. Propane tends to vaporize readily even
at temperatures as low as -20° F (-29° Q. However,
It is the responsibility of the installer to make sure butane reverts to its liquid state when temperatures
that only the correct recommended fuel is sup- drop below 32° F (0° Q.
plied to the generator fuel system. Thereafter, the
owner/operator must make certain that only the LP in a liquid withdrawal system must be converted
proper fuel is supplied. to its gaseous state before it is introduced into the
engine carburetor. A vaporizer-converter is generally
used to accomplish this. In such a converter, heated
♦ NATURAL GAS FUEL SYSTEM engine coolant is ported through the converter to
Natural gas is supplied in its vapor state. In most provide the necessary heat for conversion of the fuel
cases, the gas distribution company provides piping from a liquid to a gaseous state.
from the main gas distribution line to the standby
generator site. The following information applies to
natural gas fuel systems.
• Gas pressure in a building is usually regulated by
national, state and local codes.
• To reduce gas pressure to a safe level before
the gas enters a building, a primary regulator is
needed. The natural gas supplier may or may not
supply such a regulator.
• It is the responsibility of the gas supplier to make
sure sufficient gas pressure is available to operate
the primary regulator.
• Gas pressure at the inlet to the fuel shutoff sole-
noid should not exceed approximately 14 inches
water column (0.5 psi). Optimum pressure at the
fuel shutoff solenoid is 11 inches water column
(0.4 psi).
5-1 90/80 0'A88 100shsland
GENERAL Standby GENERAL
INFORMATION INFORMATION
Specifications
SPECIFICATIONS ♦ COOLING SYSTEM
GENERATOR Type...................................................Pressurized Closed Recovery
WaterPump....................................................................Belt Driven
Type.............................................................................Synchronous Fan Speed.........................................................................2090 rpm
Rotor Insulation...................................................................Class H Fan Diameter.....................................................................16 inches
Stator Insulation..................................................................Class H Fan Mode..............................................................................Pusher
Total Harmonic Distortion......................................................<3.5% Air Flow(inlet air including alternator and
Telephone Interference Factor(TIF)..........................................<50 combustion air)...........................................................1438 ft3/min.
Alternator Output Leads 3-phase...........................................4-wire Coolant Capacity........................................................(3.0 U.S.gal.)
Bearings.........................................................................Sealed Ball Heat Rejection to Coolant............................................95,000 Btu/h
Coupling.......................................................................Flexible Disc Maximum Operating Air Temp.on Radiator..............60°C(150°F)
Load Capacity(Standby Rating)...........................................25kW* Maximum Ambient Temperature.................................50°C(140°F)
*NOTE:Generator rating and performance in accordance with IS08528-5,BS5514,SAE J1349,
IS03046 and DIN 6271 Standards.KW rating is based on LPG fuel and may derate with natural ♦ FUEL SYSTEM
gas.
Excitation System....................................................................Direct Type of Fuel.........................................Natural Gas, Propane Vapor
Generator Output Voltage/kW-60 Hz kW Amp CB Size Carburetor......................................................................Down Draft
120/240V, 1-phase, 1.0 pf 25 104 125 Secondary Fuel Regulator.................................................Standard
120/208V,3-phase,0.8 pf 25 85 100 Fuel Shut-off Solenoid........................................................Standard
Generator Locked Rotor KVA Available @ Voltage Dip of 35% Operating Fuel Pressure ......................5 in.- 14 in.Water Column
Single-phase or 208 3-phase.............................................38 KVA
Puel Consumption - ft3/hr (Natural Gas/LPV)
♦ ENGINE Exercise 25% 50% 75% 100%
Make..................... .............Generac Cycle Load Load Load Load
•••••""•...... "' "' " '' 60/24 140/56 220/87 300/119 380/151
Model...................:.................................................................In Line
Cylinders and Arrangement............................................................4 ♦ ELECTRICAL SYSTEM
Displacement.......................................................................2.5 Liter
Bore......................................................................................3.78 in. Battery Charge Alternator............................................12V,30 Amp
Stroke.....................................................................................3.4 in. Static Battery Charger............................................................2 Amp
Compression Ratio...............................................................9.4-to-1 Recommended Battery......................................Group 26,525CCA
Air Intake System...............................................Naturally Aspirated System Voltage.....................................................................12 Volts
Valve Seats...................................................................Replaceable
Lifter Type....................Overhead Cam Rocker Arm/Hydraulic Lifter Voltage Regulator.
Type..................................................................................Electronic
Engine Parameters Sensing........................................................................Single-phase
Rated Synchronous RPM..............................................60 Hz, 1800 Regulation................................................................................± 1%
HPat rated kW..................................................................60 Hz,40 Features.................................................V/F Adjustable,Adjustable
Voltage and Gain LED Indicators
Exhaust System
Exhaust Flow at Rated Output 60 Hz..................................227 cfm Power Adjustment for Ambient Conditions
Exhaust Temperature at Rated Output—.............................1000°F Temperature Deration
3%for every 10°C above°C.....................................................25
Combustion Air Requirements (Natural Gas) 1.65%for every 100 above OF....................................................77
Flow at rated power,60 Hz................................................67.5 cfm Altitude Deration
1%for every 100 m above m...................................................183
Governor 3%for every 1000 ft.above ft..................................................600
Type..................................................................................Electronic
Frequency Regulation...................................................Isochronous Controller.................................................R-100
Steady State Regulation......................................................t 0.25%
Engine Lubrication System
Typeof Oil Pump......................................................................Gear
Oil Filter...............................................Full Flow Spin-on,Cartridge
Crankcase Oil Capacity....................................................4 U.S.qts.
6-1 90/1l O'A08 Zto3adgua0
i
GENERAL Standby Generator GENERAL
INFORMATION INFORMATION
Specifications
Figure 1 —Interconnections
000000 Utility In
Transfer Switch
CONTROLPANEL ®®
NEUtRA
TO
ALTERNATOR
Gen o
N2 0 0 0 �RAL o¢
GENERATOR 194 s.
CONNECTION 4-#14 GA Load
BOX 183EAKeR WIRES TO ne out
178 ® ® ® GENERATOR
CONNECTION
BOX
Ipd cR°uu°
TO GENERATOR
CONNECTION BOX
To Generator Control Panel
i FRAHE RAIL'
CIRCUIT BREAKER SIZE
KW VOLTS / AMPS LUG SIZE
25 240 1 0 125 #4 to 1/0
Ground Level STUB-UP AREA
Concrete Slab See Install Dwg for
Dimensions
♦ COLD WEATHER KIT 10. Reverse the procedure to convert back to natural
gas.
For ;cold climates, optional cold weather kit (part 11. The Dip switch inside the control panel must be
number OF6148) is recommended. The kit includes: in the LP or NG position when switching to differ-
* Battery Warmer ent fuels.
• 4 Junction Box with hardware
• 6 qt. pack 5W-30 synthetic oil (engine) Figure 6.2 —Reconfigure the Fuel System
RECONFIGURING THE FUEL SYSTEM P°'" - Po 2
-FUEL HOSE FUEL HGSE� 1
NOTE: —aNA�s F,GGE BRASGHGSE, JIII ��R UG
R.UG� F,I'ING RIII ING ee
_— —OUT GUl'._.....,, — E
All models are configured for natural gas or LP -- PGFTI+ HGRT 2 —�
SfN
HOUSING
.�
vapor from the factory. i; -HAS PGR,S
To reconfigure the fuel system from NG to LP follow
these steps:
1. Turn the main gas supply off. °
2. Remove the carburetor fuel hose from the outlet•
port (Port 1) of the demand regulator (Figure,/,�
6.2).
M.
3. Remove the brass hose fitting from the outlet port NG FUEL SYSTE LP FUEL SYSTEM
(Port 1) of the demand regulator. NOTE:
4. Remove pipe plug from Port 2.
5.. Install brass hose fitting into Port 2. Port 1 is for NG only and Port 2 is for LP vapor
6. Install pipe plug into Port 1. only. No provision for dual fuel has been made.
7. Connect carburetor gas hose to brass fitting. A A-
8. Tighten all clamps and plugs.
9. Make sure fuel supply is of the proper pressure 0 Serious injury or damage may occur if not con-
and type for configuration. figured properly. Please consult an Authorized
.Service Dealer with any questions.
g0/Il (]:Aga z[ooedguaD 6-2
GENERAL GENERAL
Standby Generator Sets
INFORMATION Information
INFORMATION
GENERATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING
See "Voltage Codes". This generator may be rated CONNECTIONS
at any one of three voltages, either single-phase or
three-phase. The electrical wires in the unit's AC con- 13-PHASE ALTERNATORS
nection (lower)panel should be installed according to
the number of leads and the voltage/phase required The generator is designed to supply 3-phase electri-
for the application. If there are any questions regard- cal loads. Electric power is produced in the alterna-
ing lead connection, refer to the wiring diagrams at for power windings. These windings were connected
the back of this manual. at the factory to the main circuit breaker with a "Y"
Voltage codes apply to the type of stator assembly configuration as shown in Figures 7.2 and 7.3.
installed on a particular generator. The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is either 480V or 208V
FOUR-LEAD, SINGLE-PHASE STATOR depending on the model.
Four-lead generators (see Figure 7.1) are designed to The rated voltage between each circuit breaker termi-
supply electrical loads with voltage code A (240V, nal and the neutral point 00 is either 277V or 120V
1-phase, 60 Hz). Electrical power is produced in the depending on the model.
stator power windings. These windings were con-
nected at the factory to the main circuit breaker as Figure 7.2—Stator Power Winding
shown in Figure 7.1. Connections - 3-phase, 2771480V(6 Lead)
The rated voltage between each circuit breaker ter-
minal is 240V. The rated voltage between each circuit S1 E1
breaker terminal and the neutral point 00 is 120V.
C
Figure 7.1 — Four-lead, Single-phase Stator INTERNAL
CONNECTIONS
44 - - , E3 L-L
I I � S4
120 S6 NEUTRAL
I VOLTS
33 I I S5
22 I VOLTS
I NEUTRAL .N
I E3 S3 jS2 E2
I 120
1 I VOLTS L N
I
11 ' I E1 Figure 7.3—Stator Power Winding
L - - - Connections - 3-phase, 1201208V(6 Lead)
CIRCUIT BREAKER
E1
S1 < S1
S4 <S4 L-L
00(NEUTRAL)
S6 S5
S3,-T S6 S5� S2
E3 S3 V lS2 E2
—L-N-1
7-1 50/80 0'AGH 1000U000V
INSTALLATION INSTALLATION
Standby
Installation
_�-
INSTALLATION ♦ PRIOR TO INITIAL START-UP
Refer to the separate "Installation Guide QT Product
Line" supplied with the unit. A CAUTION A
PREPARATION BEFORE START-UP Q Prior to initially starting the generator, it must
be properly prepared for use. Any attempt to
The instructions in this section assume that the crank or start the engine before it has been
standby generator has been properly installed, ser- properly serviced with the recommended types
vieed, tested, adjusted and otherwise prepared for and quantities of engine fluids(oil, coolant, fuel,
use by a competent, qualified installation contractor. etc.) may result in an engine failure.
Be sure to read the "Safety Rules", as well as all other
safety information in this manual, before attempting ♦ ENGINE COOLANT
to operate this (and related) equipment.
Have the engine cooling system properly filled with
Before starting the generator for the first time, the the recommended coolant mixture. Check the system
installer must complete the following procedures. For for leaks and other problems. See "Specifications"
follow-up maintenance information and/or service and "Coolant" sections.
intervals, please refer to the "Maintenance" section
and the "Service Schedule". ♦ BELT TENSION
TRANSFER SWITCH Check-the engine-fan belt tension and condition prior
to placing the unit into service and at recommended
If this generator is used to supply power to any elec- intervals. Belt tension is correct when a force of
trical system normally powered by an electric utility, approximately 22 pounds (10 kg), applied midway
the National Electrical Code requires that a transfer deflects the belt about 3/8- to 5/8-
de
,ys
between pulleys,switch be installed.The transfer switch prevents elec- inch (10 to le s, de
trical backfeed between two different electrical sys-
tems. (For additional information, see the applicable ♦ ELECTRICAL SYSTEM
transfer switch manual for this unit.) The transfer
switch, as well as the generator and other standby Make sure the generator is properly connected to an
components, must be properly located and mounted approved earth ground.
in strict compliance with applicable codes, standards Make sure the generator battery is fully charged,
and regulations. properly installed and interconnected, and ready for
FUEL SYSTEM use.
Make sure the fuel supply system to the genera- Check to ensure that there are no loose electrical con-
tor (a) delivers the correct fuel at the correct pres- nections. Restrain any loose wires to keep them clear
sure and (b) is properly purged and leak tested of any moving generator set components.
according to code. No fuel leakage is permitted. See INITIAL INSPECTION FOR QT GENSET
"Specifications" for more information.
GENERATOR SET LUBRICATION STARTUP
Inspect for the following.
Check the engine crankcase oil level before operating
and add oil to the proper level - the dipstick "FULL' • Freight Damage.
mark. Never operate the engine with the oil level • Manuals present.
below the dipstick `ADD" mark. See "Specifications" • Fluid Levels ( Oil, coolant, battery, Gear Drive).
and "Engine Oil Recommendations". • Correct fuel piping.
NOTE: • Correct snuffler installation for QT50, QT70,
QT 100 - QT 150.
This engine is shipped from the manufacturer • Adequate air flow, clearances and ventilation per
with "break-in" oil. This oil should be changed installation drawings and applicable codes.
after 30 hours of operation. • Correct AC and DC wire size, connections and
Check the oil level in the generator gearbox (if so grounding. Control and communication wiring to/
equipped) prior to initial use and at the intervals from the transfer switch must be run in a separate
indicated by the "Service Schedule." The recom- conduit from the AC power leads.
mended oil is SAE 90 gear lubricant. • Battery charger connection to 120 VAC.
Also, if the engine is equipped with a mechanical gov- • Communication wires connected between transfer
ernor, make sure the governor is properly lubricated switch and generator (HTS only).
with clean engine oil. • Unit secured to pad.
s-� 90/tt V'AOH t0011e)SUI
INSTALLATION INSTALLATION
Standby Generator
installation
START-UP CHECKLIST • Check voltage at the generator terminals.
• For 3-phase units, check phase rotation at the
AWARNING A transfer switch terminals. The generator phase
rotation must match the utility phase rotation.
Di Before working on the generator, ensure the fol- • Check for coolant, fuel, oil, and exhaust leaks.
lowing: • Close the generators main line circuit breaker.
• The AUTO/OFF/MANUAL switch is in the OFF • Turn the generator set off.
position. • Connect the UTILITY supply to the transfer
• The 120VAC supply to the battery charger is switch.
switched OFF. • Set the AUTO/OFF/MANUAL switch to AUTO.
PREPARATION FOR START-UP • Disconnect utility power before the transfer
switch.
• Ensure that the 120VAC circuit breaker to the bat- Engine should start, transfer to load.
tery charger is open. Run at least 15 minutes on generator power.
• Remove the fuse from the the control panel. For Make certain all 3-phase loads are functioning
the H-100 and R-100: Open the front door of the correctly (correct phase rotation).
control box and remove the 15 Amp ATO fuse in Reconnect Utility power
the lower left-hand corner of the control box. Transfer switch will transfer back to Utility and
• Connect the battery cables to the battery. Attach engine will shut down within the given time
negative battery cable last. parameters set up for the specific transfer switch
• Close the 120VAC circuit breaker to the battery and controller.
charger. • Install all covers, access plates and door panels.
• Measure the voltage at the battery before and after • Put the Owners Manual in a safe and accessible
the charger is turned on. place.
• Verify all AC electrical connections are tight at the • Make certain the AUTO/OFF/MANUAL switch is in
circuit breaker and transfer switch. the AUTO position.
• Visually inspect entire area looking for loose paper,
plastic wrappings, leaves, etc. ♦ START-UP INSPECTION
• Check all hoses clamps fittings for leaks or dam- When a start-up is performed by an Authorized
age. Service Dealer, a standard three-part form titled
• Check all. electrical plugs throughout the genera- "Start-up Inspection for Standby Power Systems"
tor. Ensure each plug is seated correctly and fully (part no. 067377), should be completed by the instal-
inserted into its receptacle. lation technician or engineer. See page 1-3 for infor-
• Verify the AUTO/OFF/MANUAL switch is in OFF mation on locating the nearest Authorized Service
position. Dealer. The installer should complete the form and
• Open the valve to the engine fuel line. disseminate copies as follows:
• Bleed the fuel system of air. (necessary for long fuel White copy: Mail to Generac Warranty Department,
lines). P.O. Box 340, 211 Murphy Dr., Eagle, WI 53119-
• Open the generator main line circuit breaker. 2062.
• Connect a manometer to the gas line and record Pink Copy: For service file of installing dealer.
the static pressure. It must be as listed in the Yellow Copy: For the customer's records.
Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the MAN-
UAL position. The engine should now crank and
start.
90/11 V,98 10011e;su1 8-2
4
OPERATION 1111IF PERATION
Operation
C
GENERATOR CONTROL AND A CAUTION A
OPERATION
Refer to the appropriate control panel operator's Q Do not crank the engine continuously for longer
manual for this unit. than 30 seconds, or the heat may
damage the starter motor.
OPERATING UNIT WITH MANUAL ' Lei engine stabilize and warm up.
• Check all applicable instrument and gauge read-
TRANSFER SWITCH ings. when certain that all readings are correct,
If the generator was installed in conjunction with a move the transfer switch manual handle to its
transfer switch capable of manual operation only, the STANDBY (GENERATOR) position, i.e., load cir-
following procedure applies. A manually operated cuits supplied by the generator.
transfer switch is one that will not provide automatic • Set the standby generator's main line circuit break-
start-up and does not include an intelligence circuit. er to its ON (or CLOSED) position.
• Load circuits are now powered by the standby
♦ ENGINE START-UP AND TRANSFER generator.
For additional information, refer to the applicable ♦ RETRANSFER AND SHUTDOWN
control panel manual for this unit, as well as any lit- For additional information, refer to the applicable
erature pertaining to the specific transfer switch. control panel manual for this unit, as well as any lit-
AA erature pertaining to the specific transfer switch.
To transfer the load back to the utility power source
Q The Maintenance Disconnect Switch and the and shut down the generator, follow these diree-
AUTO/OFF/MANUAL switches(if so equipped) tions:
must be set properly, or the generator will crank
and start as soon as the utility power to the • Set the standby generator's main line circuit break-
transfer switch is turned off. Refer to applicable er to its OFF (or OPEN) position.
control panel and transfer switch manuals for - Manually move the transfer switch handle to its
more information. UTILITY (NORMAL) position, i.e., load circuits
connected to the utility.
voltage o not proceed until certain that utility source e Turn ON the utility power supply to the transfer
voltage is available to the transfer switch and switch, using the means provided (such as the util-
the transfer switch main contacts are set to ity power source main line circuit breaker).
UTILITY. • Let the generator run at no-load for a few minutes
Q Do not attempt manual operation until all power to stabilize internal temperatures.
supplies to the transfer switch have been posi- • Shut down the generator.
tively turned off, or extremely dangerous- pos-
sibly lethal -electrical shock will result. OPERATING UNIT WITH AUTOMATIC
Q Transfer switch enclosure doors should be kept TRANSFER SWITCH
closed and locked. Only authorized personnel
should be allowed access to the transfer switch If the generator has been installed with an automatic
interior. Extremely high and dangerous voltages transfer switch, such as an RTS, HTS, or GTS-type
are present in the transfer switch. transfer switch, the engine may be started and
stopped automatically or manually.
In order to transfer load from the utility source to the
generator, follow these directions: NOTE:
• Turn OFF or disconnect the utility power circuit Refer to the applicable manual for your trans-
to the transfer switch, using the means provided fer switch and to "Transfer Switch Start Signal
(such as the utility source main line circuit break- Connections". In addition, please note the dangers
er). under "Engine Start-up and Transfer."
• Set the transfer handle to its UTILITY (NORMAL)
position with load circuits connected to the utility
power supply.
• Set the standby generator's main line circuit break-
er to its OFF (or OPEN) position.
• Start the generator.
B-'1 5o/so o'nad looiado
C
MAINTENANCE MAINTENANCE
Standby Generator Sets
Maintenance
MAINTENANCE PERFORMED BY EXHAUST MANIFOLD PROCEDURE
AUTHORIZED SERVICE FACILITIES 1. If necessary, clean gasket surfaces on exhaust
manifold and cylinder head.
A WARNING A- 2. Install exhaust manifold and exhaust manifold
gasket.
0 Before working on the generator, ensure the fol- 3. Install fasteners.
lowing: NOTE:
• The AUTO/OFF/MANUAL switch is in the OFF Exhaust manifold fasteners must be tightened in
position.
• The 15A fuse has been removed from the con-
trol box. 4. Tighten fasteners to 20-30 N-m (15-22 lb-ft) dur-
• The 120VAC supply to the battery charger is ing the first stage.
switched OFF. 5. Retighten fasteners to 60-80 N-m (44-59 lb-ft)
during the second stage.
EVERY THREE MONTHS
1. Check battery condition. INTAKE MANIFOLD PROCEDURE.
2. Inspect and test fuel system. 1. Clean and inspect the mounting surfaces of the
3. Check transfer switch. intake manifold and the cylinder head. Both sur-
faces must be clean and flat (Figure 10.1).
4. Inspect exhaust system. 2. Clean and lightly oil the manifold bolt/stud
5. Check engine ignition system. threads.
6. Check fan belts. 3. Install a new lower intake manifold gasket.
ONCE EVERY SIX MONTHS 4. Position the lower intake manifold to the cylinder
head.
1. Test Engine Safety Devices (low oil pressure, low 5. Install retaining bolts/studs finger tight.
coolant level, high coolant temperature). 6. Tighten all bolts/studs to specifications in the
♦ ONCE ANNUALLY tightening sequence shown:
• First pass = 7=10 N-m (5-7 lb-ft).
1. Test engine governor; adjust or repair, if needed. • Final pass = 26-38 N-m (19-28 lb-ft).
2. Clean, inspect generator.
3. Flush cooling system. Figure 90.1 -Intake Manifold Installation
♦ FIRST 100 OPERATING HOURS �8 rA
1. Change engine oil and oil filter. After initial G --
change, service engine oil and filter at 150 operat-
ing hours or six months, whichever comes first. ° ,Il --;t ��c cJ I! �� {
2. Retorque cylinder head. •��'°' � �,=1
3. Retorque intake and exhaust manifold.
`6) (,2) 3: `✓
EVERY 500 OPERATING HOURS
1. Service air cleaner. FASTENER TORQUE SEQUENCE
FPP00283
2. Check starter.
3. Check engine DC alternator. CYLINDER HEAD PROCEDURE
EVERY 800 OPERATING HOURS 1. Position head gasket on the block (Figure 10.2).
1. Retorque cylinder head. 2. Position cylinder head to cylinder block.
2. Retorque intake and exhaust manifold. 3. Install 10 cylinder head bolts in numerical
sequence.Tighten to 70 N-m(521b-ft)in sequence.
3. Check engine compression. Retighten to 70 N-m (52 lb-ft) in sequence. Then
4. Check valve clearance. turn all head bolts an additional 90- 100 degrees
in sequence.
��� S0/90 O'Aad S00JU!0W
Cam '
MAINTENANCE Standby Generator Sets
MAINTENANCE
Maintenance
Figure 10.2— Cylinder Head installation CHECKING FLUID LEVELS
CYLINDER
HEAD ♦ CHECK ENGINE OIL
11 2 ;'�.� Check engine crankcase oil level (Figure 10.3) at least
e 5 ,, ,° �1 every 20 hours of operation, or prior to use.
Remove oil dipstick and wipe dry with a clean, lint-
a i � ; = i free cloth.
Install oil dipstick, then remove again.
GASKET •
Oil should be between FULL and ADD marks.
• If oil level is below the dipstick ADD mark, remove
u oil fill cap. Add the recommended oil to bring oil
CYLINDER level up to the FULL mark. DO NOT FILL ABOVE
HEAD THE "FULL' MARK. See "Engine Oil Recommen-
dations" for recommended oils.
DOWEL Figure 10.3 - Oil Dipstick and Oil Fill Cap
- 6� ;
Engine
r Oil Fill Cap Air Cleaner
FPPOW24
COOLING SYSTEM >��;.< °` � j;n s Oil Dipstick
r. \ �;
Air intake and outlet openings in the generator com-
partment must be open and unobstructed for contin-
ued proper operation. This includes such obstrue- ' `�� Oil
tions as high grass, weeds, brush, leaves and snow. �F. '� ""
, ; Filter
Without sufficient cooling and ventilating air flow, the � '�'�`` ;:_,
lfi "X
engine/generator quickly overheats, which causes it
to shut down. (See the installation diagram.)
A WARNING ® �
® The exhaust system parts from this product get ♦ BATTERY FLUID
extremely hot and remains hot after shutdown. Check battery electrolyte fluid based on the
High grass,weeds, brush, leaves, etc. must Maintenance Schedule. Fluid should cover separa-
remain clear of the exhaust. Such materials may tors in all battery cells. If fluid level is low, add dis-
ignite and burn from the heat of the exhaust tilled water to cover tops of separators. DO NOT USE
system. TAP WATER IN BATTERY.
OVERLOAD PROTECTION FOR ENGINE ♦ ENGINE COOLANT
DC ELECTRICAL SYSTEM Check coolant level in coolant recovery bottle. See
Engine cranking, start up and running are controlled Specifications.
by a solid state Engine Controller circuit board.
Battery voltage is delivered to that circuit board via ' Add recommended coolant mixture as necessary.
a 15 amp fuse. These overcurrent protection devices • Periodically remove radiator pressure cap (only
will open if the circuit is overloaded. when engine has cooled down) to make sure the
coolant recovery system is functioning properly.
—A CAUTION A Coolant should be at bottom of radiator filler neck.
If coolant level is low, inspect gasket in radiator
pj if a circuit breaker opens or a fuse element pressure cap. Replace cap, if necessary. To have
melts, find the cause of the overload before pressure cap tested, contact an Authorized Service
resetting the circuit breaker or replacing the Dealer. Inspect cooling system and coolant recov-
fuse. ery system for leaks.
SO/80 O'A98 GoojU! N 10-2
Cam—=
MAINTENANCE MAINTENANCE
Standby Generator Sets
Maintenance
MAINTENANCE OWNER/ A A
OPERATOR CAN PERFORM
Qi Do not attempt to adjust the governor. Only
CHECK ENGINE OIL LEVEL qualified service facilities should adjust the
governor. Excessively high operating speeds
Refer to "Checking Fluid Levels". are dangerous and increase the risk of personal
injury. Low speeds impose a heavy load on the
♦ CHECK BATTERY engine when adequate engine power is not
available and may shorten engine life. Correct
• See "Checking Fluid Levels". rated frequency and voltage are supplied only
• Check battery cables for condition, tightness, cor- at the proper governed speed. Some connected
rosion or damage. Clean, tighten or replace as electrical load devices may be damaged by incor-
necessary. rect frequency and/or voltage. Only qualified
service technicians should adjust the governed
♦ EXERCISE SYSTEM speed.
Start the generator engine at least once every seven
days and let it run at least 20 minutes. See "Weekly ♦ CHANGING ENGINE OIL
Exercise Cycle". Refer to maintenance performed by authorized ser-
vice facilities for engine oil and filter change frequen-
INSPECT COOLING SYSTEM cies.
• Inspect engine cooling system. See "Maintenance Drain the oil while the engine is still warm from run-
Schedule". ning. This means warm up the engine, shut it down
• Check hoses for damage, deterioration, leaks, etc. and drain immediately as follows:
Correct any discrepancies found. 1. Remove OIL DRAIN HOSE from its retaining
• Check hose clamps for tightness. clip.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain
CHECK ENGINE COOLANT LEVEL oil completely into suitable container.
See "Checking Fluid Levels". 3. When all oil has drained, install and tighten OIL
DRAIN HOSE CAP and re-install into its retaining
♦ PERFORM VISUAL INSPECTION clip.
4. Turn OIL FILTER (Figure 10.3) counterclockwise
Complete a thorough visual inspection of the entire and remove. Properly dispose of old filter.
engine-generator monthly. Look for obvious damage, 5. Apply light coating of new engine oil to seal of new
loose, missing or corroded nuts, bolts and other fas- oil filter.-Install FILTER and tighten by hand only.
teners. Look for fuel, oil or coolant leaks. DO NOT OVER TIGHTEN.
6. Remove OIL FILL CAP.Add recommended oil (see
INSPECT EXHAUST SYSTEM SPECIFICATIONS). DO NOT FILL ABOVE THE
DIPSTICK "FULL' MARK. Crankcase oil capacity
Inspect the exhaust system at least once every three is 4.0 U.S. quarts (3.8 liters).
months. Check all exhaust system pipes, mufflers,
clamps, etc. for condition, tightness, leaks, security, A CAUTION A
damage.
Qi After refilling the crankcase with oil, always
CHECK FAN BELT check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK"ADD"
• Inspect fan belts every three months. Replace any MARK.
damaged, deteriorated, worn or otherwise defec- 7. Start engine and check for oil leaks.
tive belt.
• Check fan belt tension. Thumb pressure, exerted ♦ CHANGING THE ENGINE AIR CLEANER
midway between pulleys, should deflect about 3/8
to 5/8 of an inch. Adjust belt tension as required. To replace the engine air cleaner, (part number
059402), simply remove the air cleaner cover and
INSPECT ENGINE GOVERNOR replace the air filter making sure it is positioned
properly before reattaching the cover (Figure 10.3).
Visually inspect electronic governor.
See the "Service Schedule," for air cleaner mainte-
nance.
10-3 . 90180 0'A88 9001weW
Cam= Standby Generator Sets Cv__
Maintenance
MAINTENANCE MAINTENANCE
♦ SPARK PLUGS Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
Reset the spark plug gap or replace the spark plugs excessively low, the generator may require drying.
as necessary (Figure 10.4).
1. Clean the area around the base of the spark plugs ♦ BATTERY
to keep dirt and debris out of the engine. Clean All lead-acid storage batteries discharge when not in
by scraping or washing using a wire brush and use. Refer to specific instructions and warnings that
commercial solvent. Do not blast the spark plugs accompany the battery. If such information is.not
to clean. available, observe the following precautions when
2. Remove the spark plugs and check the condition. handling a battery:
Replace the spark plugs if worn or if reuse is
questionable. See the "Service Schedule,"Section DO NOT use jumper cables and a booster battery
6, for recommended inspection. to crank or start the generator engine.
3. Check the spark plug gap using a wire feeler DO NOT recharge a weak battery while it is
gauge. Adjust the gap to 1.07-1.17 mm (0.042- installed in the generator. Remove battery from
0.046 inch) by carefully bending the ground elec- generator and recharge in a well-ventilated area,
trode (Figure 10.4). away from fuel vapors, sparks, heat or flames.
• Battery electrolyte fluid is an extremely caustic
Figure 10.4 —Setting the Spark Plug Gap sulfuric solution that can cause severe burns. DO
SET PLUG GAP AT 1.07- 1.17 mm NOT permit fluid to contact eyes, skin, clothing,
(0.042-0.046 inch) painted surfaces, wiring insulation, etc. If any bat-
tery fluid is spilled, flush the affected area with
clear water immediately.
• Always wear safety glasses, rubber apron and
gloves when handling a battery.
• Batteries give off explosive hydrogen gas while
charging. The gas can form an explosive mixture
around the battery for several hours after charging.
�\ Any spark, heat or flames can ignite the gas and
cause an explosion which can shatter the battery,
COOLANT CHANGE causing blindness or other serious injury.
Every year, have an Authorized Service Facility drain, ♦ BATTERY MAINTENANCE
flush and refill the cooling system.See"Specifications" The battery should be inspected per Section 4.7,
for cooling system recommendations. Scheduled Maintenance. The following procedure
should be followed for inspection:
MISCELLANEOUS MAINTENANCE 1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
♦ CLEANING THE GENERATOR 2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with DISTILLED WATER
Keep the generator as clean and as dry as possible. ONLY. DO NOT USE TAP WATER IN BATTER-
Dirt and moisture that accumulates on internal gen- IES.
erator windings have an adverse effect on insulation 3. Have the state of charge and condition checked.
resistance. This should be done with an automotive-type bat-
Periodically clean generator exterior surfaces. A soft tery hydrometer.
brush may be used to loosen caked on dirt. Use a A MM A
vacuum system or dry, low pressure air to remove
any accumulations of dirt. The generator is housed A Storage batteries give off explosive hydrogen
inside an all-weather enclosure, clean the enclosure gas. This gas can form an explosive mixture
with a soft, damp cloth or sponge and water. around the battery for several hours after charg-
Once each year have the generator cleaned and ing. The slightest spark can ignite the gas and
inspected by an Authorized Service Dealer. That cause an explosion. Such an explosion can shat-
dealer will use dry, low pressure air to clean internal ter the battery and cause blindness or other
windings. Parts inside the control console should be injury. Any area that houses a storage battery
cleaned and inspected at this time as well. must be properly ventilated. Do not allow smok-
ing, open flame, sparks or any spark producing
tools or equipment near the battery.
40/80 O'AgH 4001weW 10-4
C r�
MAINTENANCE Standby Generator Sets
MAINTENANCE
Maintenance
A Battery electrolyte fluid is an extremely corro-
♦ BATTERY REPLACEMENT
sive sulfuric acid solution that can cause severe When replacing batteries, use the same number and
burns. Do not permit fluid to contact eyes, skin, the type of battery that follows:
clothing, painted surfaces, etc. Wear protective BCI Group No. CCA
goggles, protective clothing and gloves when 26 525 @ 0 deg.F
handling a battery. If fluid is spilled, flush the
affected area immediately with clear water. NOTE:
Qi Do not use any jumper cables or booster battery The BCI number should be located directly
to crank and start the generator engine. If the on the battery.
battery has completely discharged, remove it
from the generator for recharging. PERIODIC REPLACEMENT PARTS
A WARNING A
Part Name Part Number
A Be sure the AUTO/OFF/MANUAL switch is set to Oil Filter Motorcraft FL-400-S(supplied with engine)
the OFF position, before connecting the battery Radiator Cap #046627
cables. If the switch is set to AUTO or MANUAL, Air Cleaner #059402
the generator can crank and start as soon as the S ark Plua Motorcraft AWSF-52-C(supplied with engine)
battery cables are connected. Battery #077483
A Be sure the 120VAC power supply to the battery
is turned OFF, or sparking may occur at the bat-
tery posts as the cables are attached and cause
an explosion.
10-5 So/90 0-H SOOIWuW
i
Cam' Standby Generator Cam'
Service MAINTENANCE MAINTENANCE
Schedule
SERVICE SCHEDULE
The!following is a recommended maintenance schedule for small standby and residential generator sets. The
established intervals in the schedule are the maximum recommended when the unit is used in an average service
application. They will need to be decreased (performed more frequently) if the unit is used in a severe applica-
tion. Use calendar time or accumulated run time, from the previous maintenance interval to determine the next
required maintenance interval.
i
Service Maintenance Interval Information:.
The various service maintenance intervals are designated by interval numbers as follows:
1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten-
tial problem areas.
Performed monthly this requires approximately .5 man-hours per unit to complete.
This inspection may be performed by the end user providing the following safety steps are taken to prevent
the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
• Disable the generator set from starting and/or connecting to the load by setting the control panel
AUTO/OFF/MANUAL switch to the OFF position.
• Remove the 5 amp and 15 amp control panel fuses.
• Turn off the battery charger(turn OFF utility supply to ATS).
• Remove the negative battery cable.
The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition
from burning out sensitive control panel components and circuits.
Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal
operation when required.
2 A,break-in service inspection of the generator set to insure it is ready to operate and carry the load when
required, and to identify any potential problem areas.
Performed ONLY ONCE following the first three months, or 30 run time hours of operation after purchase of
the unit and requires approximately 2.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed semi-annually this requires approximately I.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
4 A'mid-level inspection of the generator set to insure it is ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed annually this requires approximately 4.0 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
i
i
i
-� 5021 9'A9d d00P40SAJS
C) Standby Generator
Service MAINTENANCE ��MAINTE��NANCjjE��,,
Schedule
Maintenance Level Level Level Level
Tasks Recom- Task Required Task Required Task Task
mended Comp. to be done Comp. to be done Comp. Required Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date-
monthly Initials) Break-in Initials) annually Initials) Annually Initials)
10 Hrs. 30 Hrs. 50 Hrs. 100 Hrs.
1. Disable the unit from
operating per the first page n C7 <
warning.
2. Check the engine oil level. 0 <=> 0 0
Adjust as necessary.
3. Check the engine coolant
level.Adjust as necessary.
4. Check the engine coolant
thermal protection level. D
Correct as necessary,
5. Check the natural gas
delivery system on gas
engine driven units. D O CD
Tighten connections as
necessary,
6. Check the air inlets and
outlets for debris.Clean as D O D O
necessary.
7. Check the battery
electrolyte level if E�
accessible.Adjust as
necessary,
8. Check the battery posts,
cables, and charger for
loose connections,
corrosion, and proper 0 n
operation.Correct as
necessary.
9. Check the unit wiring for
loose connections, 0
corrosion, and damage.
Correct as necessary,
10.Check the engine
accessory drive belts for
wear,weather cracking, <
and damage.Replace as
necessary.
11.Visually inspect the unit
looking for leaks, wear or
damage, loose connections C7 <=> 0
or components, and
corrosion.Correct as
necessary.
12.Test the engine and
transfer switch safety
devices.Correct and/or
adjust as necessar .
501ZL 8'A98 ZOOPgDSNS 11-2
StandbyC
Service MAINTENANCE �MjA�INTE-NANC�E
Schedule C�
Maintenance Level Level Level Level
Tasks Recom- Task Required Task Required Task Task
mended Comp. to be done Comp. to be done Comp. Required Comp.
to be done (Date- 3 months/ (Date- Semi- (Date to be done (Date-
monthly In itials) Break-in Initials) annually Initials) Annually Initials)
10 Hrs. 30 Hrs. 50 Hrs. 100 Hrs.
13.Initiate an automatic start
and transfer of the unit to
site load and exercise it for
at least 1 hour looking for
leaks, loose connections
or components, and
abnormal operating
conditions.Correct as
necessary.
14.Start and exercise the unit
at full rated load (use a
load bank if the site load is
not enough)for at least 2
hours looking for leaks, D
loose connections or
components,and abnormal
operating conditions.
Correct as necessar .
15.Change the engine oil.
16.Replace the engine oil
filter(s).
17.Replace the engine air
filter(s).
18.Replace the engine fuel
filter(s) on diesel engine
driven units and re-prime C�
the fuels stem.
19.Check the engine spark
plugs on gas engine driven
units.Clean and re-gap or
replace as necessary,
20.Perform a 5 minute no-load
operational run of the unit
looking for any post service
problems.
21.Return the unit to standby
setup for operation when <=> V 0 CD
required.
11-3 5021 9"Aaa ZOOPgDSAJS
TROUBLESHOOTING RI Standby Generator T mlf HOOTNG
Troubleshooting
♦ I
TROUBLESHOOTING GUIDE
PROBLEM CAUSE CORRECTION
Engine won't crank. 1. 15 amp fuse blown. 1. Replace fuse.
2. Loose or corroded or defective 2. Tighten,clean or replace
battery cables. battery cables as necessary.
3. Defective starter contactor. 3. Replace contactor:*
4. Defective starter motor. 4. Replace starter motor.*
5. Dead or Defective Battery. 5. Remove,change or replace battery.
6. 5 amp fuse blown. 6. Replace fuse.*
Engine cranks but won't start 1. Out of fuel. 1. Replenish fuel.
2. Fuel solenoid(FS)is defective 2. Replace solenoid.*
3. Open Wire#14A from Engine Control 3: Reconnect wire.
circuit board.
4. Spark plugs defective. 4. Clean, regap or replace plugs.
5. Door on tank not closed. 5. Close door on tank.
Engine starts hard, runs rough. 1. Flame arrestor(air cleaner)plugged or 1. Clean or replace as needed.
damaged.
2. Plugged fuel line. 2. Unclog fuel line.
3. Defective spark plugs. 3. Clean, regap or replace plugs.
4. Fuel pressure incorrect. 4. Confirm fuel pressure to regulator is as
recommended in SPECIFICATIONS.
Engine starts then shuts down. 1. Engine oil level is low. 1. Check oil and add oil as needed.
2. Engine is overheated. 2. Check cooling system for leaks.
3. Defective Low Oil Pressure Switch 3. Replace switch.*
4. Defective Coolant Temperature Switch 4. Replace switch.*
5. Defective Control Module circuit board. 5. Replace board.*
6. Coolant Level is Low. 6. Repair leak-Add coolant.
7. Defective Low Coolant Level Switch 7. Replace Switch.*
AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch 1. Replace switch.*
engine continues to run 2. Open/disconnected wire#15A between 2. Reconnect/close wire.
AUTO/OFF/MANUAL switch and Control
Module circuit board.
3. Defective Control Module circuit board 3. Replace board.*
No AC output from generator. 1. Check main line circuit breaker. 1. Reset to ON or CLOSED.
2. Check circuit breaker&fuses. 2. Reset and replace,if necessary.
3. Transfer switch set to NORMAL position 3. Set to GENERATOR position.
4. Generator internal failure. 4. *
5. Thermal circuit breaker open. 5. Auto-reset-Wait 5 min.and
attempt restart.
*Contact the nearest Authorized Dealer for assistance.
12-1 4080 O'naH 1O014SIQjl
NOTES Standby Generator jj NOTES
Notes
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EXPLODED VIEW:CONNECTION BOX SPL PARTS
DRAWING#: OF7352 GROUP A
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
1 OF7135 1 BREAKER TRAY BACK/BOTTOM
2 OF7022 1 SUPPORT CONTROL PANEL SIDE RH
3 OF7021 1 SUPPORT CONTROL PANEL SIDE LH
4 OF7260 1 COVER CIRCUIT BREAKER 2P
OF7136 1 COVER CIRCUIT BREAKER 3P
5 OF6156 1 PLATE WIRE SNGL GALV
6 OF4464 1 DECAL CUST CONN 120V UTILITY
7 OD4698 REF BLOCK TERM 20A 6 X 3 X 1100V
8 OF3824 1 DECAL UTIL SENSEICUST CONN
9 057701 REF BLOCK TERM 20A 8 X 6 X 1100V
10 OF6146 1 HANG TAG 2 WIRE START(NOT SHOWN)
12 081008 1 GROMMET 1.25 X.25 X.75
13 OC2267 2 SCREW HHTT M5.0.8 X 12 BP
14 049226 2 WASHER LOCK M5
15 051713 2 WASHER FLAT M5
16 OC2212 11 SCREW PHTT M4.0.7 X 16 ZYC
17 022264 11 WASHER LOCK#8-M4
18 OF6366A 1 XFMR DUAL 104VI16V(1 PHASE)
OF6366B 1 XFMR DUAL 120V116V(3 PHASE)
19 022241 1 NUT HEX 318.16 STEEL
20 022237 1 WASHER LOCK 318
21 057329 1 LUG SLDLSS 35046 X 13132 AL/CU
22 057073 1 JUNCTION BLOCK 318.16
23 023484J 1 BUSHING SNAP SB-2000.26
24 OE3257 15 SCREW HWHTF M6.1.0 X 16
25 OE7890 REF BRKT CB MTG BACK 2P
OE6002 REF MTG TRACK BQ SIEMENS CB 3P
26 OD5544 REF CB 0100A 2P 240V S B02 LL(1.51-2 POLE)
062812 REF CB 0080A 3P 240V S BQ3 LL(1.51-3 POLE)
OA2077 REF CB 0125A 2P 240V S B02 LL(2.51-2 POLE)
040532 REF CB 0100A 3P 240V S BQ3 LL(2.51-3 POLE)
27 052619 REF SCREW HHC M5.0.8 X 20 G8.8(NOT SHOWN)
28 023897 REF WASHER FLAT#10 ZINC(NOT SHOWN)
29 049226 REF WASHER LOCK M5(NOT SHOWN)
30 051716 REF NUT HEX M5.0.8 G8 CLEAR ZINC(NOT SHOWN)
31 025433 1 LUG SLDLSS#6.14 X 13164 CU
32* OA1354A REF REGULATOR-DC ALT
33* 042568 REF SCREW HHC M6.1.0 X 20 G8.8
34* 022473 REF WASHER FLAT 114-M6 ZINC
35* 022097 REF WASHER LOCK M6.114
36* 049813 REF NUT HEX M6 X 1.0 G8 YEL CHR
37* OF7194 REF BRACKET PANEL SUPPORT 1.51-Cl
38 057593 1 CABLE TIE MOUNT BLACK
39 OF1733 1 DECAL CUSTOMER CONNECT INSIDE
*USED ON 1.51-ONLY.
REVISION: G-6772-E
DATE: 11/2/05 PAGE 2 OF 2
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EXPLODED VIEW:CPL ALTERNATOR DIRECT EXCITATION
DRAWING#: OF7491
GROUP A
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
1 OF7489 1 ROTOR 30KW DIRECT 390 4P 1800
OF7490 1 ROTOR 25KW 3PH DIRECT 3901800
2 OF7458A 1 STR 390 30AD1 HSB TECUM
OF7459 1 ASSY STR 390 25 GD1 CPL
3 OC9708 REF INSTR HYPOT TEST(NOT SHOWN)
4 SEE ENGINE EV REF ENGINE ADAPTER
5 SEE ENGINE EV REF FLEXPLATE
6 OF7364B 1 ASSY FLYWHEEL CPL W125MM FAN B
7 OE5706 1 REAR BEARING CARRIER 3901DRCT
8 OF7874 1 ASSY BRUSH HOLDER 3901HSB
9* 070892 1 SLIP RING MACHINED
10* 047248 1 BALL BEARING-45 MM
11 023454 1 KEY WOODRUFF#E
12 077043E 1 CONDUIT FLEX 1.0"ID(20"LG)
13 04576100BK 4 STUD M14-2.0 X 490 G5 ZINC
14 052646 4 WASHER FLAT M14
15 043123 4 WASHER LOCK M14
16 051779 4 NUT HEX M14-2.0 G8 YEL CHR
17 OA2601 1 SCREW HHC M16.2.0 X 45 G8.8
18 OA2602 1 WASHER FLAT.6881D X 3.250D
19 OF8408 4 SCREW HHC M10.1.50 X 16 G10.9
20 046526 4 WASHER LOCK M10
21 OC3993 4 SCREW HHTT M4.0.7 X 25 BP
22 022264 4 WASHER LOCK#8-M4
23 038150 4 WASHER FLAT#8 ZINC
24 077043B 1 CONDUIT FLEX.50"ID(16"LG)
*ROTOR REPLACEMENT PARTS
REVISION: G-6376-C
DATE: 9/6/05 PAGE 2 OF 2
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EXPLODED VIEW:COOLING SYSTEM 2.51-Cl
DRAWING#: OF7363 GROUP C
APPLICABLE TO:
i
TTEM PART# QTY. DESCRIPTION
1 OF7074 1 SUPPORT RADIATOR LH SIDE
2 OF7076 1 VENTURI 16"DIA.FAN
3 OF7075 1 SUPPORT RADIATOR RH SIDE
4 OE9837A 1 RADIATOR 2.51-CPL
6 OF0230A 1 FAN COOL 16"DIA 8 BLADE
6 OF7130 1 SPACER FAN 2.51-Cl
7 OE9833 1 HOSE 2.51-FORD LOWER RADIATOR
6 099502 4 CLAMP HOSE#24 61.06.2.00
9 069860C 1 HOSE OIL DRAIN ASSY 21"
10 035461 1 BARBED STR 114 NPT X 318
11 OF0127 1 HOSE UPPER RADIATOR 174MM TAL
12 046627 1 CAP RADIATOR
13 052250 2 TAPE FOAM 1 X 1(20"LG)
14 022473 4 WASHER FLAT 11446 ZINC
15 022097 12 WASHER LOCK M6.114
16 OC8566 8 SCREW HHFC M6.1.0 X 20 G8.8
17 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR
16 OC2454 24 SCREW THE M6.1 X 16 N WA ZIJS
19 040976 8 SCREW SHC M8.1.25 X 20 G12.9
26 022145 4 WASHER FLAT 5116-M8 ZINC
21 022129 4 WASHER LOCK M8.5116
22 OC7649 1 CLAMP HOSE.38-.87
23 076749 1 TANK COOLANT RECOVERY
24 OF1433 1 BRACKET 2.51-FORD WATER BOTTLE
25 048031C 2 CLAMP HOSE BAND 114
26 029032 1 HOSE 9132 ID(40"LG)
27 049814 REF. SCREW HHC M10.1.5 X 25 G8.8
28 046526 REF. WASHER LOCK M10
29 022131 REF. WASHER FLAT 318-MlO ZINC
30 OF7307 1 GUARD FAN RH Cl CPL
31 OF7308 1 GUARD FAN LH Cl CPL
34 029107 1 GROMMET 718 X 3116 X 518
REVISION: G-6474-C
DATE: 9/21/05 PAGE 2 OF 2
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EXPLODED VIEW:MOUNTING BASE 2.51-FORD
DRAWING#: OF7416 GROUP C
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
1 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR
2 022097 1 WASHER LOCK M6.114
3 026850 2 WASHER SHAKEPROOF EXT 114 STL
4 055414 1 LUG SLDLSS#248 X 17164 CU
5 022473 1 WASHER FLAT 114-M6 ZINC
6 047411 1 SCREW HHC M6.1.0 X 16 G8.8
7 052860 4 NUT FLANGED HEX M12-1.75
8 052251 4 DAMPENER VIBRATION 40 BLUE
9 052257 4 SPACER.49 X.62 X 1.87 PWDRIZNC
10 052252 4 DAMPENER VIBRATION
11 052259 4 WASHER FLAT M12
12 052891 4 SCREW HHC M12-1.75 X 80 G8.8
13 0536210261 1 ASSY WIRE#012.00"
14 074906 1 SCREW HHTT M6-1.0 X 20 BP
15 025507 REF WASHER SHAKEPROOF EXT 7116 STL
16 OF6935 1 MTG BASE,2.51-FORD Cl CPL _
19 046526 REF WASHER LOCK M10
20 049814 REF SCREW HHC M10-1.5 X 25 G8.8
21 022131 REF WASHER FLAT 318-M10 ZINC
REVISION: G-6148-A
DATE: 8/10/05 PAGE 2 OF 2
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EXPLODED VIEW:BATTERY Cl CPL
DRAWING#: OF7422 GROUP C
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
1 OF3408B 1 BATTERY TRAY Cl CPL
2 OF3411 1 STRAP BATTERY RETAINMENT
3 025507 REF WASHER SHAKEPROOF EXT 7116 STL
4 052647 REF SCREW SHC M10.1.5 X 25 G12.9
5 046526 REF WASHER LOCK M10
6 022131 REF WASHER FLAT 318-M10 ZINC
7 050331A REF BATT POST COVER RED+
8 050331 REF BATT POST COVER BLK-
9 038805J 1 CABLE BATTERY BLK#1 X 30.00
10 0388040 1 CABLE BATTERY RED#1 X 28.00
11 045771 REF NUT HEX M8.1.25 G8 YEL CHR
12 022129 REF WASHER LOCK M8.5116
13 027482 REF WASHER SHAKEPROOF EXT 5116 STL
14 OF3976 3 BOOT CONTACTOR CABLES
15 OC2454 4 SCREW THE M6.1 X 16 N WA ZIJS
16 022145 REF WASHER FLAT 5116-M8 ZINC
17 077483 REF BATTERY 12VDC 75-AH 26
18 0742600131 1 ASSY WIRE#16 RED 1.6
REVISION: G-6517-D
DATE: 9/23/05 PAGE 2 OF 2
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EXPLODED VIEW: ENGINE COMMON PARTS 2.51-
DRAWING#: OF7423 GROUP D
APPLICABLE TO: 2.5L FORD
ITEM PART# QTY. DESCREMON ITEM PART# QTY. DESCRIPTION
1 OE9909 REF ENGINE 2.51.FORD 16 022097 7 WASHER LOCK M6.114
2 OE 73 1 PULLEY 2.51.FORD WATER PUMP 17 022129 10 WASHER LOCK M8.5116
3 049814 7 SCREW HHC M10.1.5 X 25 G8.8 18 043107 10 SCREW HHC M8.1.25 X 25 G8.8
5 OD3488B 1 SERPENTINE BELT-40.85"LENGTH 19 022131 13 WASHER FLAT 318-MlO ZINC
6 OA8584 1 SWITCH OIL PRESSURE 1OPSI 2POL 20 046526 23 WASHER LOCK M10
7 OE0561 1 ASSY WATER LEVEL SENSOR CIE PL 21 052625 2 SCREW SHC M10.1.5 X 35 G12.9
8 OA6751 1 SW-TMP 245 DEG 318 NPT 22 OE9708 2 ENGINE FOOT 2.51-FORD
9 035579 1 BUSHING REDUCER 114 TO 118 23 OE9738 1 DIPSTICK 2.51-FORD
10 026925 1 PLUG STD PIPE 318 STEEL SQ HD 24 OE9929 1 BRACKET DIPSTICK TUBE
11 OE9611 1 MANIFOLD INTAKE(MACHINED)(STEPPER MOTOR) 25 042568 1 SCREW HHC M6.1.0 X 20 G8.8
12 OE9681 1 GASKET 2.51-FORD INTAKE MAN. 26 OF7428 1 HARNESS ENGINE 2.5L R-100 CPL(NOT SHOWN)
13 025507 3 WASHER SHAKEPROOF EXT 7116 STL 27 OD5417 6 SCREW HHC M10.1.0 X 25 G10.9
14 077043A 1 CONDUIT FLEX.38"ID(6"LG) 28 OF3903B 1 FLEX PLATE 2 POLE 2.51-FORD
15 022145 2 WASHER FLAT 5116-M8 ZINC 29 OE9655 1 ADAPT CASTING MACH 2.51-FORD
30 057192 4 SCREW SHC M10.1.5 X 30 G12.9
31 060619 .2 SCREW SHC M10.1.50 X 40 G12.9
32 OE8940 1 SPACER FLEXPLATE HSB
33 OE9680 1 GASKET 2.51-FORD EXHAUST MAN.
34 OE9609 1 MANIFOLD EXHAUST(MACHINED)
35 OE9930 1 HEAT SHIELD EXHAUST MANIFOLD
36 049821 3 SCREW SHC M8.1.25 X 30 G12.9
37 OE9747 1 STARTER 12 VOLT
38 047411 4 SCREW HHC M6.1.0 X 16 G8.8
39 022473 8 WASHER FLAT 11446 ZINC
40 045772 2 NUT HEX M10.1.5 G8 YEL CHR
41 064416 2 SCREW HHC M10.1.5X 45 G8.8
42 OF0252 1 SPRING BUSHING
43 OE9868 1 ALTERNATOR D.0
44 OF0035 1 BRKT D.C.ALTERNATOR(MACHINED)
45 026082 1 SCREW HHC 318.16 X 2.114 G5
46 OE9928 1 TENSIONER D.C.ALTERNATOR
47 OF0383 1 HOSE 2.51-FORD COOLANT BY-PASS
48 035473 2 CLAMP HOSE#12.50.1.25
49 OE9737 1 LOWER HOSE ADAPTER 2.51-FORD
50 OF0393 1 0-RING 1.3116 X 1.7116 X 118
51 045757 2 SCREW HHC M6.1.0 X 25 G8.8
52 069860C 1 HOSE OIL DRAIN ASSY 21"
53 048031) 1 HOSE CLAMP BAND 518"
54 043790 1 BARBED EL 90 318 NPT X 318
55 077456 1 ADAPTER M12.1.75318 NPT
56 052677 1 WASHER NYLON.50 X.87 X.06
57 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR
58 OE9738A 1 DIPSTICK TUBE 2.51-FORD
59 OF1132 1 COVER RIH SIDE ENGINE ADAPTOR
60 OF1133 1 COVER LIH SIDE ENGINE ADAPTOR
61' 059355 8 SCREW SHC M10.1.50 X 50 G12.9
62 085296 3 SCREW HHC 11420 X 112 SS
63 083896 3 WASHER LOCK 114M6 SS
64 084929 3 WASHER FLAT 114 SS
65 027482 1 WASHER SHAKEPROOF EXT 5116 STL
66 045771 REF NUT HEX M8-1.25 G8 CLEAR ZINC
67 021991 1 EARTH STRAP
68 022129 REF WASHER LOCK M8.5116
69 052647 1 SCREW SHC M10.1.5 X 25 G12.9
70 OF4604 REF FILTER 2.51.FORD OIL
'NOTE:TORQUE TO 44 FTILBS.
REVISION: G-6531-C
DATE: 9/28/05 PAGE 2 OF 2
GROUP D
ENGINE - - - - -
CONTROL PANEL COMPARTMENT THE ITEMS INSIDE THE DASHED RECTANGLE
WTS REPLACE WATER LEVEL SENSOR PART NUMBER A WLS B
OE0561
I
P/N OE2507�/
5
TYPICAL -85
CONTROL -85 I 21 Z 85 INTERFACE 573 I
PANEL I MODULE
CONNECTION 0 1 � - - P/N OF9483 573A - - - -
WIRING DIAGRAM FOR NEW COOLANT LEVEL SENSOR
MECHANICAL DIAGRAM FOR NEW COOLANT LEVEL SENSOR INSTALATION
TO „ B„ a T❑ „ A„
P/N OE2507
P/N OF9483
P/N OF6749
SEALANT MUST BE APPLIED T❑
THREAD PRIOR TO INSTALATI❑N
(WHERE APPLICABLE)
" A" = EXISTING COOLANT LEVEL SENSOR LOCATION ON UNIT
" B" = EXISTING COOLANT LEVEL SENSOR WIRE HARNESS CONNECTOR
EXPLODED VIEW:
REVISION: ERRATA SHEET FOR OE0561
DATE: 12/7/05 PAGE 1 OF 2 DRAWING#: OF9502
GROUP D
. BLA NK
PAGE
EXPLODED VIEW:
REVISION: ERRATA SHEET FOR OE0561
DATE: 12/7/05 PAGE 2 OF 2 DRAWING#: OF9502
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EXPLODED VIEW:NATURAL GAS FUEL OR LPV
DRAWING#: OF7440
GROUP E
APPLICABLE TO: 2.51-FORD
TTEM PART# QTY. DESCRIPTION
1 OE8456 1 BRACKET FUEL REGULATOR
2 075580 1 FLANGE FUEL INLET
3 OF6364 1 FUEL REG.2.51-FORD REWORK
4 039253 4 SCREW HHC M8.1.25 X 20 G8.8
5 022145 2 WASHER FLAT 5116 ZINC
6 022129 6 WASHER LOCK M8.5116
7 045771 2 NUT HEX M8.1.25 G8 YEL CHR
8* OF1570 1 BODY CARBURETOR ASSEMBLY
9 OA6344 1 BARBED EL 90118 NPT X 318
10 OF3994 REF. PCV VALVE 2.51-FORD
11 026582 1 NIPPLE PIPE 314 NPT X 4"LG BI
12 OF0397 1 HOSE CRANKCASE BREATHER
13 OA5547 1 COVER AIR CLEANER
14 OC7649 1 CLAMP HOSE.38-.87
15 OD1509 1 DECAL INLET PRESSURE
16* OE0591 1 ADAPTER CARB.TO AIR CLNR
17 059402 1 FILTER ELEMENT
18 037561 1 NUT WING 114-20 NYLK
19 OE1028B 1 CARBURETOR ASSY.2.51-FORD
20 059401 1 CARBURETOR GASKET
21* 091526 4 SCREW PPHM M5.0.8 X 12 ZNC
22* 049226 4 WASHER LOCK M5
23 026915 2 NIPPLE CLOSE 314 X 1.375
24 062522 1 STUD TH 114.20 X 3 G2 ZNC FULL
25 022127 1 NUT HEX 114.20 STEEL
26 022259 2 NUT HEX 5116.18 STEEL
27** 050279 1 DECAL FUEL INLET NG
050280 1 DECAL FUEL INLET LPG
28 OA6125 2 STUD 5116.18 X 1.25 F THR
29 OC2454 3 SCREW TH-FRM M6.1 X 16 N WA ZIJS
30* OE1104 1 GASKET AIR CLEANER ADAPTER
31* OE0668 1 0-RING 2-028 1.38 X 1.50 X.06
32* OE0590A 1 VENTURI20MM
33* 005133 1 0-RING 29.82 X 2.62
34* OE0665 1 SCREW THROTTLE PIN STOP
35* OE1108A 1 THROTTLE ARM REWORK 2.51-FORD
36* 033138 1 SCREW HHM#10-32 X 518
37* 022152 1 WASHER LOCK#10
38* OE0645 1 LEVER,THROTTLE STOP
39* 034339 . 1 BARBED EL 90 318 NPT X 518
40 059194 1 HOSE 518 ID LPG&NG(24"LG)
41 057823 2 CLAMP HOSE#10.56.1.06 .
42 OF0382 1 HOSE 318"90 DEG 2.51-PVC
43* 089617 1 BARBED STR 114NPT X 114 MALE
44 030340 1 HOSE 114 ID SAE 30R7(24"LG)
45 040173 2 CLAMP HOSE#5.5.62-.62
46 OF6155 1 HARNESS FUEL JUMPER SINGLE REG
47 026812 2 ELBOW 90D 314 NPT
*INCLUDED IN ITEM 19(CARBURETOR ASSY)
NOTES:
1. REGULATOR(IIN 3)AS SHOWN IN ILLUSTRATION IS SET UP FOR
NATURAL GAS APPLICATION.
2. TO CONFIGURE REGULATOR FOR LP VAPOR,SWITCH HOSE BARB,
HOSE CLAMP([IN 41)AND HOSE(IIN 40)FROM"OUT-1"TO"OUT-29'.
REPLACE PIPE PLUG FROM"OUT-2"TO"OUT-1".USE PIPE SEALANT
ON HOSE BARB AND PIPE PLUG.MAKE SURE TO KEEP PORTS FREE
FROM DEBRIS DURING RECONFIGURATION PROCESS.
3.** FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL INLET DECAL PIN
050280 FOR NG FUEL INLET DECAL PIN 050279(ITEM 27).
4. WHEN SWITCHING FUEL TYPES,THE PROPER DIP SWITCH SITTINGS
MUST BE MADE TO THE CONTROL PANEL.SEE OWNERS MANUAL,FUEL
SECTION FOR MORE DETAILS.
DATE: 6/15/05 PAGE 2 OF 2
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EXPLODED VIEW:ENCLOSURE Cl CPL
DRAWING#: OF7356 GROUP F
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
1 OF7003(XX) 1 ROOF Cl CPL
2 OF7004(XX) 1 CORNER POST LH SIDE Cl CPL
3 OF7008(XX) 1 DOOR REAR Cl CPL
4 OF7005(XX) 1 CORNER POST RH SIDE Cl CPL
5 OF7007(XX) 2 DOOR LH 8 RH SIDE Cl CPL
6 OF7006(XX) 1 DUCT FRONT DISCHARGE Cl CPL
7 OC2634A 1 ASSEMBLY COVER ACCESS
8 0912970091 1 ASSY WIRE 14AWG 13.8"GRNIYEL
9 0912970090 2 ASSY WIRE 14AWG 33.5"GRNIYEL
10 OE5968 1 GASKET EXTRUDED TRIM(356"LG)
11 OE3257 6 SCREW HWHTF M6.1.0 X 16
12- 077992 18 NUT HEX LOCK M6.1.0 SS NY INS
13 OF5049 3 TAB PULL d
14 OF5048 3 LATCH VISE ACTION 5116 HEX SKT
15 022473 1 WASHER FLAT 114-M6 ZINC
16 022097 1 WASHER LOCK M6.114
17 022127 1 NUT HEX 114.20 STEEL
18 OC2454 24 SCREW THE M6-1 X 16 N WA ZIJS
19 078115 20 WASHER SELF LOCKING DOME
20 OF3890B 2 RETAINER INSULATION(820)
21 OF3890 4 RETAINER INSULATION(450)
22 OF7365 2 INSULATION SIDE DOOR Cl
23 OF7365B 1 INSULATION REAR DOOR Cl CPL
24 OF7365A 1 INSULATION ROOF Cl CPL
OPTIONAL COMPARTMENT MATERIALS:
ALL PIN'S WITH AN(XX)SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION.
USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER:
PART NO. MATERIAL COLOR
OXXXXXSN STEEL TAN
OXXXXXAN ALUMINUM TAN
OXXXXXSG STEEL GRAY
OXXXXXAG ALUMINUM GRAY
"ALUMINUM ENCLOSURE NOTE:ALL ENCLOSURE PANELS THAT FASTEN TO
THE BASE FRAME MUST BE SECURED USING ITEM 18 811 THREAD FORMING
FASTENER AND ITEM 12 LOCK NUT.LOCK NUT IS TO BE INSTALLED AFTER THREAD
FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN
ENCLOSURE PANELS.ALL ROOF PANELS ARE TO BE SECURED IN THE SAME
MANNER.
DATE: 6/13/05 PAGE 2 OF 2
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EXPLODED VIEW:EXHAUST SYSTEM 2.5L Cl
DRAWING#: OF7385 GROUP F
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
1 OF7366 1 MUFFLER Cl
2 OF7647 1 MUFFLER SADDLE
3 OF8095 1 PIPE EXHAUST OUTLET
4 OF7172 1 PIPE EXH INLET MFLR SIDE 2.51
5 OE3257 4 SCREW HWHTF M6.1.0 X 16
6 OF7382 1 PIPE EXH INLET MANIFLD SIDE 2.5
7 OC6119 1 BOLT U 5116-18 X 2-114
8 036434 2 BOLT U 5116.18 X 2.09
9 036449 2 SADDLE 21NCH
10 022129 6 WASHER LOCK M8.5116
11 022259 4 NUT HEX 5116.18 STEEL
12 038750 3 SCREW HHC M6.1.0 X 30 G8.8
13 044149 1 GASKET EXHAUST RING
14 OE0170A 1 EXHAUST BLANKET 988MM
15 OE8816 1 FLANGE EXHAUST 2"PIPE
16 022131 2 WASHER FLAT 318-M10 ZINC
17 085917 2 WASHER LOCK 318 SS
18 OD2611 2 SCREW HHC 318.16 X 1.314 SS
19 OF7644 2 MUFFLER STRAP
20 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR
21 022473 6 WASHER FLAT 114-M6 ZINC
22 022097 1 WASHER LOCK M6-114
REVISION: G-6457-A
DATE: 9/15/05 PAGE 2 OF 2
GROUP G
rF--------- -------------------------------------------------
CONTROL PANEL LEGEND
AVR - AUTOMATIC VOLTAGE REGULATOR 1
I BCH - BATTERY CHARGER CUSTOMER CONNECTION I
BRI - DIODE (FIELD BOOST)
CB2 - CIRCUIT BREAKER.(EXCITATION) & ALTERNATOR LEGEND,
FI - FUSE, BAT. POWER (15A ATO TYPE) BA - BRUSH ASSEMBLY (GENERATOR)
'J2 - CONNECTOR 2 (ON PCB) ICT - INTERCONNECT TERMINAL BLOCK I
I J3 - CONNECTOR 3 (ON PCB) MCB - MAINLINE CIRCUIT BREAKER I
R4 - FIELD BOOST RESISTOR, 15 OHM NB - NEUTRAL BLOCK I
RLI - RELAY I (START RELAY) UCT - UTILITY CONNECT TERMINAL BLOCK
RL2 - (RELAY 2 (ENGINE RUN>
I SW1 - AUTO/OFF/MANUAL SWITCH I
I SW2 - SET EXERCISER SWITCH NOTE, ALL WIRES ARE I
TB_ - TERMINAL BLOCK 18 AWG UL LISTED UNLESS
TRI - TRANSFORMER 1 OTHERWISE NOTED AS SHOWNi
I (AWG) I
rim I F1 1 UCT j_7
1 13 �is Is SW1 I
I 15 SW2 Lo'Uln Ll I® Ll
1mr o I I
15E v N ' 2� N SUPPLY
u uo
-PCB J3 23 a GND 3� GND
I 61REP* 3—W' 194 � — —
N-o 4—W2 CUSTOMER CONNECTIONS R4
I Yurt-q 5—W3 I
9mm 6—W4
13 s a l 2 1a c-> BR1 29 a I
0
OO
ANALOG INP RET ICB J 224 TR1 j
START RELAY 2-56A 49 49•I
FUEL(RUN) RELAY 3—14A
2 WIRE START(1) 4-183
I MOMENT. OPEN 5 1215E I
I 2 WIRE'START(2) 6—178 z N I
MAN/AUTO INPUTiB-15A AVR `rj62B2
16 ALA M RELAY> 8—224 N1
I ALARM RELAY�9— N2 [544
1 1
XFER RELAY 10-23 14
MAN. INPUT ill 1-239 62
16VAC SENSE(2) 12-225 TB1 11 1 ANALOG INP A B 15 GND-B 14� 0 0 6 I
0 1 0
I I
1 2 1
4
I 4 3 4 I
2 4 2
6 5 6 I
11/Si 6 11
I I.
I Z 44/S 7 44
114 13 13 8 13 I
I �z 15A ISA 14 14 9 1415
I z 15 15 15A 1 15A l5 I
_W a 97. 6 IS 1 15 I
1 J 56 �1 15
I u 15A I
I w I
1 601 6011
I 11/111 11/SI 56 561
44/S3 44/S3 SINGLE-PHASE STATOR SHOWN. 0 I
1 FOR 3-PHASE SEE DWG. OF6839.
1 CB1 1
I 0 0 l FS2 1
I 2 I
,I CT 601
IUTILITY FROM T/SW N1 I 6 I
IUTILITY FROM T/SW N2 11 0 I
ITRANSFER RELAY COIL 23 44 BA FS I
ITRANSFER RELAY COIL M19
TT22 141
REMOTE START 8 33
I
REMOTE START 17 NB I
STATOR LFP O I
I I I
L------------CONNECCTIONS —
WIRING-DIAGRAM
REVISION:* 2.5L COMMERCIAL PROD LINE
DATE:05/23/05 PAGE 1 OF 2 DRAWING#: OF7104
GROUP G
--------------------------------------------------------------�
ENGINE WIRING LEGEND 1
AFS - AIR/FUEL SOLENOID
I STM ALT - D.C. CHARGE ALTERNATOR
I 2 BAT - 12VDC BATTERY I
I
3—WI CP - COIL PACK
CS - CRANK SENSOR
4—W2-- FS - FUEL SOLENOID
CB 5—W3- FS2 - AUX, FUEL SOLENOID I
DEG +12V 1,4 1— 6—W4 GND- GROUND I
OX INP RET 2-805' HCT - HIGH COOLANT TEMP SWITCH
DEG GND 3— e J1 - CONNECTOR I (ON PCB)
COOLANT SENSORS —85 LFP - LOW FUEL PRESSURE SWITCH
DEG OV T5— LOS - LOW OIL PRESSURE SWITCH I
I DEG +5V 6— I 02 - OXYGEN SENSOR I
DISTRIBUTOR 12V-7— SC - STARTED CONTACTOR
AFS OUT 8—808 SM - STARTER MOTOR
CRANK SENSOR IN-9—79 STM - STEPPER MOTOR
CRANK SENSE RET. 10— WLS - COOLANT LEVEL SWITCH
LFP IN--11-601 - WIRE SPLICE
I DEG FDBK 12— I
OX INP 13-804
COIL (+)--I — 5R
COIL (A-)-15M25A
DISTRIBUTOR RET.1-16— I CS
DISTR. INPUT-17— 1 2 I
I DEG PWM�18—
DEG ENABLE-19—
LOW OIL PRESS. 20—86 `Z
I
CRANK SHIELD 21—SHL
COIL (C-) 22—
COIL (B-) 23M25B I
I
I I
I I
I 4 — — I
AFS 2sA cP j
808 I 25B
I 15 OPTIONAL I
II EMISSION CONTROL
I
�1-15 I FRONT �
I D ° I
I a eoa I
A
�I 02
II 14 49 / � I
I / I
I � I
0
i
0 0 ALT/
IGND
o I
0
601 14 0 13 0
56 56 13 SC
1601 Ir 13 I
56 56 0 L-13
BE LOS BA13 I
I ° 5 85 HCT j
1a
° RED WLS 0 Sm � I
I I
I I
I"0 I
I
114 I
I I
I
I
I
L--------------------------------------------------------------J
WIRING-DIAGRAM
REVISION:* 2.5L COMMERCIAL PROD LINE
DATE:05/23/05 PAGE 2 OF 2 . DRAWING#: OF7104
GROUP G
---------------------------------------------------------------
1 CONTROL PANEL LEGEND
AVR - AUTOMATIC VOLTAGE REGULATOR 1
BCH - BATTERY CHARGER
BR1 - BRIDGE RECTIFIER
1 CB2 - CIRCUIT BREAKER (EXCITATION) I
F1 - FUSE, BAT POWER (15A ATO TYPE) 1
CB J3 J2 - CONNECTOR 2 (ON PCB) I
NOT USED--I J3 - CONNECTOR 3 (ON PCB)
1 NOT USED--2 R4 - FIELD BOOST RESISTOR
BLACK-WI--3-WI RLI - RELAY 1 (START RELAY) 1
I
RED-W24-W2- RL2 - RELAY 2 (ENGINE RUN) I
WHITE-W3--5-W3- SW1 - AUTO/OFF/MANUAL SWITCH I
GREEN-W4 6-W4 SW2 - SET EXERCISER SWITCH.
TR1 - TRANSFORMER 1 (6VA 240/16 VAC)
I I
I I
I I
Fl I
I 15 13 I
I 2 I
2 I
I TR1 1
I �J1 I
I NI I
I N2 I
I ANALOG IN P RET 1 CB J2 15A
I START RELAY 2-56A 15 I
I FUEL(RUN) RELAY 3-14A SW2 SW1 I
2 WIRE START(1) 4-183
MOMENT. OPEN 5-15E 15E .-1-15 0-I SA
12 WIRE START(2) 6-178 239 19�I 1941
I MAN/AUTO INPUT 7-15A
1 16VAC SENSEQ)18-224 R4
I ALARM RELAY 9- 4 I
1 XFER RELAY Ul 1 MAN. INPUT 1 CB2 16VAC SENSE(2) 2 162��-2
ANALOG INP GND-B 4 BR1 3 11
1 4-j
5 44 1
I 6 6 I
I I
I
71 , -CT-1 L1 NFTE B 14 CT-2 N 4 CT-3 GND CB1
�14 �Y„ x-11 44 11 15 -44 11 6 2 CT-1/UTILITY FROM T/SW -E 5 55�
I
I � 15 PICT-2/UTILITY FROM T/SW 22
56A 3- ICT-3/TRANSFER COIL RELAY 33 1
9�ICT-4/TRANSFER COIL RELAY NB TATO I
I X56 83tICT-5/REMOTE START I
I. L15 78--ICT-6/REMOTE START - -
15A CUSTOMER CONNECTION & ALTERNATOR LEGEND I
I BA - BRUSH ASSEMBLY (GENERATOR) I
I CB1 - MAINLINE CIRCUIT BREAKER 1
I 240V OUTPUT TO TRANSFER SWITCH I
ICT - INTERCONNECT TERMINAL BLOCK 1
NB - NEUTRAL BLOCK
1 UCT - UTILITY CONNECT TERMINAL BLOCK
I I
I I
I I
I I
NOTE 11
1 WIRING SHOWN FOR CB1, NB, BA AND 1
I STATOR IS TYPICAL FOR SINGLE PHASE. I
I FOR 3-PHASE, SEE DWG. OF6839. I
I
I I
I I
I I
I I
I I
L-------------------------------------------------------------- 1
SCHEMATIC-DIAGRAM
REVISION:* 2.5L COMM PROD LINE
DATE:08/04/05 PAGE 1017 2 DRAWING#: OF7420
GROUP G
---------------------------------------------------------
ENGINE WIRING LEGEND
AFS - AIR/FUEL SOLENOID
j CB J STM ALT - D.C. CHARGE ALTERNATOR
1 BAT - 12VDC BATTERY
I DEG +12V .1- 2 CP - COIL PACK I
OX INP RET 2-805 3-W1 CS - CRANK SENSOR I
DEG GND 3- 4-W2 FS - FUEL SOLENOID
COOLANT SENSORS 4-85 5-W3 FS2 - AUX. FUEL SOLENOID
I
DEG 5 6-W4- HCT - HIGH COOLANT TEMP SWITC
DE +SV- - H
J1 - CONNECTOR 1 (ON PCB)
DISTRIBUTOR 12V-7- e LFP - LOW FUEL PRESSURE SWITCH I
AFS OUT 8-808 LOS - LOW OIL PRESSURE SWITCH I
( CRANK SENSOR IN-9 79 02 - OXYGEN SENSOR
CRANK SENSE RET. 10-0 SC - STARTER CONTACTOR
LFP INP I1-601 SM - STARTER MOTOR
I DEG FDBK 12- STM - STEPPER MOTOR
I OX INP 13-804 WLS - COOLANT LEVEL SWITCH I
COIL (+) 14-15
COIL (A-)-15-25A-
DISTRIBUTOR RET.116-
DISTR. INPUT-17-
I DEG PWM�18- I
I DEG ENABLE-19- I
LOW OIL PRESS. 20-86
CRANK SHIELD 21-SHLD
COIL (C-) 22-
COIL (B-) 23-25B
I - 79 I
N.C.
I I
CS I
I CP I
808 25A 25A -
I I5R I5R I
I 15 25B 25B I
02 804
3
14 I
LOS FRONT
I
805 86
I EEMISSSI N HCT
PT I I CONTROL TT
85-• O— X11
I
I WLS 1 I
85-2—+>—m%,-4>-0-1I1- I
I
A*49 13
I
566 Il�oC}56 I
I Il�o
I 13 16 I
II14JSC
4
13
I 13 I
LFP c+'
6011 —0= <—TBAT ® SM
I L
I
I I
I
I I
I I
I � I
I � I
I
I I
I I
I I
I
I I
I I
--------------------------------------------------------------�
SCHEMATIC-DIAGRAM
REVISION:* 2.5L COMM PROD LINE
DATE:08/04/05 PAGE 2 OF 2 DRAWING#: OF7420
EXPLODED VIEW: INSTALL DWG 1.5L 20KW AND 2.5L 25KW
DRAWING#: OF7555 GROUP G
APPLICABLE TO:
WEIGHT DATA
1. 5L 20KW - 289KG [774. 51b]
2. 5L 25KW - 389KG [10431 b]
WOODEN SHIPPING SKIDS INCREASE
OVERALL WEIGHT - T. B. D.
NOTES'
1) MINIMUM RECOMMENDED CONCRETE PAD SIZE, 1346 (53. 0') WIDE X 2413
(95. 0') LONG. REFERENCE INSTALLATION GUIDE P/N OF5298 FOR CONCRETE
PAD REINFORCEMENT AND PAD DEPTH GUIDELINES.
2) GENERATOR MUST BE LOCATED A MINIMUM DISTANCE OF 5 FEET FROM A WALL OR
FENCE. ALLOW A 5 FOOT MINIMUM PERIMETER OF OPEN SPACE AROUND THE ENTIRE
GENERATOR. REFERENCE INSTALLATION GUIDE P/N OF5298 FOR OUTDOOR ROOF
MOUNTED APPLICATIONS.
3) CIRCUIT BREAKER INFORMATION
SEE SPECIFICATION SHEET WITHIN OWNERS MANUAL
4) INSIDE STUB-UP AREA FOR AC LOAD LEAD CONDUIT CONNECTION, NEUTRAL
CONNECTION, BATTERY CHARGER 120 VOLT AC (. 5 AMP MAX. ) CONNECTION, AND
ACCESS TO TRANSFER SWITCH CONTROL WIRES. REMOVE FRONT COVER FOR ACCESS.
4A) FIELD CUT HOLE IS ONLY REQUIRED FOR MOUNTING OF GENERATOR ON AN
EXISTING PAD.
5> REFERENCE OWNERS MANUAL FOR LIFTING WARNINGS,
6) REMOVE LIFT-OFF ENCLOSURE TO ACCESS EXHAUST MUFFLER.
EXHAUST AND AIR DISCHARGE
LOUVERS - FRONT AND SIDES
305 305
13.5 (.53') DIA. MOUNTING 112 12
HOLE (4) PLACES, 12.7 (1/2') MIN. ® MINI
DIA. MASONRY ANCHOR
BOLTS RECOMMENDED
CONCRETE MOUNTING PAD
SEE NOTE 1
FRONT VIEW
REVISION:
DATE: 9/8/05 PAGE 1 OF 2
EXPLODED VIEW: INSTALL DWG 1.5L 20KW AND 2.5L 25KW
DRAWING#: OF7555 GROUP G
APPLICABLE TO:
SERVICE ITEM .ACCESSIBILITY CHART
CENTER OF GRAVITY SERVICE ITEM 1. 5L 20KW 2. 5L 25KW
REMOVE COVER FOR 870 134.25'] 1.5L 20KW 90 OIL FILL CAP EITHER DDOR EITHER DOOR
ACCESS TO RADIATOR 794 131,25'1 2,5L,25KW 146.5 13.54'] OIL DIP STICK THRU LEFT DOUR THRU LEFT DOOR
FILL CAP [5,77'] OIL FILTER THRU RIGHT DOOR THRU LEFT DOOR
STUB-UP AREA .OIL DRAIN HOSE THRU RIGHT D00RIGHT R THRU RI DOOR
°I eu SEE NOTE 4
RADIATOR DRAIN HOSE THRU LEFT DOOR THRU LEFT DOOR
708 AIR CLEANER ELEMENT THRU RIGHT DOOR THRU LEFT DOOR
127 87'7 388.5 SPARK PLUGS THRU LEFT DDDR THRU LEFT MDR
TYP ® [15.3'] MUFFLERS SEE NOTE 6 SEE NOTE 6
0 o FAN BELT EITHER DOOR EITHER DOOR
(z su BATTERY THRU RIGHT DOOR THRU LEFT DOOR
173.25 REFERENCE OWNERS MANUAL FOR PERIODIC
BATTERY 12 VOLT 6.82'1 REPLACEMENT PART LISTINGS
24F 625 COLD
100 CRANKING AMPS 13.5 (.53') DIA, MOUNTING
13.94'] 1603 163.11'7 TYP HOLE (4) PLACES LOCATED
TYP ON BOTTOM OF GENERATOR
TOP VIEW MOUNTING FRAME
VISE ACTION LATCH,
ONE PER DOOR, ONE LIFT-OFF
DOOR PER SIDE OF GENERATOR
1803 170,989
CONTROL PANEL R100 TYPE
928 136,54'7 BATTERY CHARGER IS
DOOR TYP ENCLOSED WITHIN 736 128.98'7 —{
AIR INLET
EXHAUST MUFFLERS LOUVERS AL
ENCLOSED WITHIN, 733.5 ���
SEE NOTE 6 128.88']
® DOOR FRONT COVER
TYP 906 SEE NOTE 4
305 305 [35.67']
12 12
MIN. MIN. CIRCUIT BREAKER
SEE NOTE 3
n o
]J r 636 125,04'7 837 [32,95']
TYP (RIGHTHAND (LEFTHAND LIFTING PROVISION
SIDE) 1.5L SIDE) 2,5L (4) PLACES, SEE NOTE 5 AND REAR VIEW
CENTER OF GRAVITY DIMENSIONS
FUEL LINE CONNECTION FIELD CUT HOLE FOR OUTSIDE CONDUIT
3/4' NPT FEMALE COUPLING LEFT SIDE VIEW CONNECTION ONLY, SEE NOTE 4A
REVISION:
DATE: 9/8/05 PAGE 2 OF 2
Standby
Warranty
WARRANir WARRANn
GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR
HOME STANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELOW
For a period of two(2)years from the date of sale,or start-up by Authorized/Certified Generac Power Systems Dealer,or branch thereof,Generac
Power Systems, Inc.will,at its option,repair or replace any part(s)which,upon examination,inspection,and testing by Generac Power Systems or
an Authorized/Certified Generac Power Systems Dealer,or branch thereof, is found to be defective under normal use and service,in accordance with
the warranty schedule set forth below.Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/
Certified Generac Power Systems Dealer,or branch thereof.This warranty applies only to Generac Power Systems Generators used in"Standby"
applications,as Generac Power Systems, Inc.has defined Standby,provided said generator has been properly installed and inspected on-site by
appropriate personnel.Scheduled maintenance,as outlined by the generator owner's manual,is highly recommended.This should be performed by
an Authorized/Certified Generac Power Systems Dealer,or branch thereof.This will verify service has been performed on the unit throughout the
warranty period.
WARRANTY SCHEDULE
YEARS ONE and TWO—Limited comprehensive coverage on mileage,labor,and parts listed.
•-ALL COMPONENTS
'Start-up and/or On-line Registration,or Registration Card,along with Proof of Purchase,must be performed and/or sent in.
Guidelines:
• Any and all warranty repairs and/or concerns,must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer,or
branch thereof.
• A Generac Power Systems, Inc.Transfer Switch is highly recommended to be used in conjunction with the genset.If a Non-Generac Power
Systems, Inc.Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty,Policies,and Procedures Flat Rate Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty,as this Warranty is not transferable.
• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision. l
• Use of Non-Generac replacement part(s)will void the warranty in its entirety.
• Engine coolant heaters(block-heaters),heater controls and circulating pumps are only covered during the first year of the warranty provision(If
applicable).
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1. Any unit built/manufactured prior to January 1,2005.
2. Costs of normal maintenance(i.e.tune-ups,associated part(s),adjustments,loose/leaking clamps, installation and start-up).
3. Any failure caused by contaminated fuels,oils,coolants/antifreeze or lack of proper fuels,oils or coolants/antifreeze.
4. Units sold, rated or used for"Prime Power",'Trailer Mounted"or"Rental Unit'applications as Generac Power Systems have defined Prime Power,
Trailer Mounted or Rental Unit.Contact a Generac Power Systems Distributor for Prime Power,Trailer Mounted or Rental Unit definition and warranty.
5. Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not
normally exist.
6. Failures caused by any external cause or act of God such as,but not limited to,collision,fire,theft,freezing,vandalism, riot or wars,lightning,
earthquake,windstorm,hail,volcanic eruption,water or flood,tornado,hurricane,terrorist acts or nuclear holocaust.
7. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
8. Failures due,but not limited to,normal wear and tear,accident,misuse,abuse,negligence,or improper installation or sizing.
9. Any incidental,consequential or indirect damages caused by defects in materials or workmanship,or any delay in repair or replacement of the
defective part(s).
10. Failure due to misapplication,misrepresentation,or bi-fuel conversion.
11. Telephone,facsimile,cell phone,satellite, internet,or any other communication expenses.
12. Rental equipment used while warranty repairs are being performed(i.e.rental generators,cranes,etc.).
13. Overtime,holiday,or emergency labor.
14. Planes,ferries, railroad,busses,helicopters,snowmobiles,snow-cats,off-road vehicle or any other mode of transportation deemed abnormal.
15. Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct
cause of the problem.
16. Starting batteries,fuses,light bulbs,engine fluids,and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES,EXPRESSED OR IMPLIED,SPECIFICALLY,GENERAC POWER SYSTEMS
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.Some states do not allow
limitations on how long an implied warranty lasts,so the above limitation may not apply to purchaser/owner.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S)AS STATED ABOVE.IN NO EVENT
SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC POWER SYSTEMS, INC.NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages,so the above limitations may not apply to purchaser/
owner.Purchaser/owner agrees to make no claims against Generac Power Systems, Inc.based on negligence.This warranty gives purchaser/owner
specific legal rights.Purchaser/owner also may have other rights that vary from state to state.
Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187
Ph: (262) 544-4811 • Fax: (262) 544-4851
Bulletin 0171360SVE/Printed in U.S.A. 7.05
Printed in U.S.A.
Property Information Map Page 1 of 1
My Home
Miami-Dade County, Florida
MIAMI•DADE
Property Information Map
}- Summary Details:
Folio No.: 09-4025-039-1630
� �
Property: 6421 SW 64 ST
Mailing WILLIAM R LAPANE&W
Address: CINDY J FRANZ
6421 SW 64 ST MIAMI FL
_ 33143-3268
Property Information:
Primary 0800 SINGLE FAMILY
Zone: RESIDENCE
63RD TER 0001 RESIDENTIAL-SINGLE
CLUC FAMILY
Beds/Baths: 3/2
Floors: 1
Livinq Units:11
dj Sq 1,796
Footage:
rt 64Tt1 �,.
Lot Size: 10,000 SQ FT
SW ST
Year Built: 1956
cn TWIN LAKES MANOR SUB
PB 57-82 LOT 11 BLK 16
Legal LOT SIZE 100.000 X 100 OR
Description: 15136-2912 0891 1 COC
22186-4024 03 2004 4
Sale Information:
s q, _ Sale O/R: 15136-2912
M Sale Date: 8/1991
Sale Amount: 1$79,900
Assessment Information:
ear: 2005 2004
Land Value: $159,494 $113,870
Digital Orthophotography-2005 0 11 ft Building Value: $134,044 $125,316
Market Value: $293,538 $239,186
This map was created on 8/9/2006 11:57=50 AM for referencB purposes only. Assessed Value: $122,210 $118,650
Wet,Site(9 2002 Miami-Dade County.AI rights reserved. Homestead $25,000 $25,000
Exemption:
otal Exemptions: $25,000 $25,000
[Taxable Value: $97,210 $93,650
http://gisims2.miamidade.gov/m-home/printmap.asp?mapurl=http://gis-ms2.miamidade.gov... 8/9/2006