Generac Power Systems 005221 0 Users Manual Cover026 Rev0 9 05
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2015-02-09
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QT 3.9L 40kW Model: 005221-0 Serial Number STANDBY GENERATOR OWNER'S MANUAL A new standard of reliability —CAUTION— ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! This manual should remain with the unit. Cover026 Rev. 0 09/05 Part No. 0F7924 Standby Generator Sets Table of Contents 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 SECTION 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 Service Facilities .....................................................10-1 EQUIPMENT DESCRIPTION ...................................3-1 Equipment Description ................................................3-1 Engine Oil Requirements .............................................3-1 Coolant Recommendations...........................................3-1 ENGINE PROTECTIVE DEVICES ............................4-1 High Coolant Temperature Switch ............................4-1 Low Coolant Level Sensor.........................................4-1 Low Oil Pressure Switch ...........................................4-1 Overcrank Shutdown ................................................4-1 Overspeed Shutdown ................................................4-1 RPM Sensor Loss Shutdown.....................................4-1 DC Fuse ....................................................................4-1 FUEL SYSTEMS .....................................................5-1 Fuel Requirements ....................................................5-1 Natural Gas Fuel System ..........................................5-1 Propane Vapor Withdrawal Fuel System....................5-1 LP Fuel System .........................................................5-1 SPECIFICATIONS ...................................................6-1 Generator .................................................................6-1 Engine.......................................................................6-1 Cooling System .........................................................6-1 Fuel System ..............................................................6-1 Electrical System ......................................................6-1 Cold Weather Kit .......................................................6-2 GENERAL INFORMATION.......................................7-1 Generator AC Lead Connections ..................................7-1 Four-lead, Single-phase Stator ..................................7-1 Alternator Power Winding Connections ........................7-1 3-phase Alternators ..................................................7-1 INSTALLATION.......................................................8-1 Installation ...................................................................8-1 Preparation Before Start-up .........................................8-1 Prior to Initial Start-up .............................................8-1 Cooling System ..........................................................10-1 Checking Fluid Levels ................................................10-1 Check Engine Oil ....................................................10-1 Battery Fluid ...........................................................10-1 Engine Coolant .......................................................10-1 Maintenance Owner/Operator Can Perform ................10-2 Check Engine Oil Level ...........................................10-2 Check Battery .........................................................10-2 Exercise System ......................................................10-2 Inspect Cooling System ...........................................10-2 Check Engine Coolant Level....................................10-2 Perform Visual Inspection .......................................10-2 Inspect Exhaust System ..........................................10-2 Check Fan Belt........................................................10-2 Inspect Engine Governor ........................................10-2 Changing Engine Oil ...............................................10-2 Changing the Engine Air Cleaner ............................10-3 Spark Plugs ............................................................10-3 Coolant Change .......................................................10-3 Miscellaneous Maintenance ........................................10-3 Cleaning the Generator ...........................................10-3 Battery ....................................................................10-3 Battery Maintenance ...............................................10-4 Battery Replacement ...............................................10-4 SERVICE SCHEDULE ...........................................11-1 30 kW - 150 kW Standby Gas Engine Driven Generator Sets ............................................11-1 TROUBLESHOOTING ...........................................12-1 Troubleshooting Guide...............................................12-1 NOTES EXPLODED VIEWS & PARTS LISTS WIRING DIAGRAMS & SCHEMATICS WARRANTY Initial Inspection for QT Genset Start-up .....................8-1 Start-up Inspection ...................................................8-2 Content001 Rev. 0 08/05 Standby Generator Sets Important Safety Instructions WARNING: GENERAL HAZARDS • For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by an Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations. • Installation, operation, servicing and repair of this (and related) equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations. • The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided. Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people, animals, etc., will not be harmed. This exhaust system must be installed properly, in strict compliance with applicable codes and standards. • Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating. • Adequate, unobstructed flow of cooling and ventilating air is critical in any room or building housing the generator to prevent buildup of explosive gases and to ensure correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator. • Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous. • When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued. • Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. WARNING: This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions. The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all inclusive. If a procedure, work method or operating technique is used that the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the generator unsafe. DANGER the safe design of this generator, Despite operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate or maintain this equipment. lethal voltages are generated by Potentially these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator. of the generator are rotating and/or hot Parts during operation. Exercise care near running generators. 1-1 Safety 001 Rev. 0 08/05 SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. Standby Generator Sets Important Safety Instructions • Generators installed with an automatic transfer switch will crank and start automatically when normal (utility) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, disable the generator’s automatic start circuit (battery cables, etc.) before working on or around the unit. Then, place a “Do Not Operate” tag on the generator control panel and on the transfer switch. • In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help. • Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury. • Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last. • Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc. ELECTRICAL HAZARDS • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the standby generator. Avoid contact with bare wires, terminals, connections, etc., on the generator as well as the transfer switch, if applicable. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard. • Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT. • If personnel must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats. • The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static electricity. Never disconnect the ground wire. • Wire gauge sizes of electrical wiring, cables and cord sets must be adequate to handle the maximum electrical current (ampacity) to which they will be subjected. • Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are positively turned off at their source. Failure to do so will result in hazardous and possibly fatal electrical shock. • Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating. Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy. FIRE HAZARDS • Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department. EXPLOSION HAZARDS • Properly ventilate any room or building housing the generator to prevent build-up of explosive gas. • Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris. • These generator sets may operate using one of several types of fuels. All fuel types are potentially FLAMMABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the unit’s fuel system frequently and correct any leaks immediately. Fuel supply lines must be properly installed, purged and leak tested according to applicable fuel-gas codes before placing this equipment into service. • Diesel fuels are highly FLAMMABLE. Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air; install leak detectors accordingly. 1-2 Safety 001 Rev. 0 08/05 Standby Generator Sets Important Safety Instructions INTRODUCTION This symbol points out potential fire hazard. symbol points out potential electrical shock This hazard. Thank you for purchasing this model of the standby generator set product line. Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice. The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recommends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency. READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing procedures. OPERATION AND MAINTENANCE It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by an Authorized Service Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service. Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows: DANGER After this heading, read instructions that, if not strictly complied with, will result in personal injury or property damage. Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum. See an Authorized Service Dealer for service aids and accessories. Operating instructions presented in this manual assume that the standby electric system has been installed by an Authorized Service Dealer or other competent, qualified contractor. Installation of this equipment is not a “do-it-yourself” project. After this heading, read instructions that, if not strictly complied with, may result in personal injury or property damage. HOW TO OBTAIN SERVICE After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property. NOTE: When the generator requires servicing or repairs, simply contact an Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs. After this heading, read explanatory statements that require special emphasis. When contacting an Authorized Service Dealer or the factory about parts and service, always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit. These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents. Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows: To locate the nearest AUTHORIZED SERVICE DEALER, please call this number: This symbol points out important safety information that, if not followed, could endanger personal safety and/or property of others. 1-800-333-1322 symbol points out potential explosion This hazard. or locate us on the web at: www.generac.com 1-3 Safety 001 Rev. 0 08/05 AUTHORIZED SERVICE DEALER LOCATION Standby Generator Sets General Information IDENTIFICATION RECORD NOTE: For actual information related to this particular model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data label affixed to the unit. DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator. The data label, which can be found attached to the generator’s lower connection box, lists the unit’s serial number and its rated voltage, amps, wattage capacity, phase, frequency, rpm, power factor, etc. Generator Model and Serial Number This number is the key to numerous engineering and manufacturing details pertaining to your unit. Always supply this number when requesting service, ordering parts or seeking information. Data Label GENERATOR SET DATA MADE IN USA SERIAL MODEL RATED KVA RATED KW RATED AMPS RATED VOLTAGE POWER FACTOR PHASE HERTZ ALT RPM PRODUCTION DATE ENGINE RPM ALTERNATOR SUBTRANSIENT REACTANCE ALTERNATOR TRANSIENT REACTANCE ROTOR STATOR WINDING INSULATION AT 25°C AMBIENT GENERAC POWER SYSTEMS, INC. WAUKESHA, WI 2-1 Identy 002 Rev. A 12/05 CLASS Standby Generator Sets Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers. The unit comes complete with a sound attenuated enclosure, internally mounted muffler, control console, mainline circuit breaker, battery charger, and protective alarms as explained in the following paragraph. Use a mixture of half low silicate ethylene glycol base anti-freeze and deionized water. Cooling system capacity is listed in the specifications. Use only deionized water and only low silicate anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture. not use any chromate base rust inhibitor Do with ethylene glycol base anti-freeze or chro- All AC connections, including the power leads from the alternator, 120 volt battery charger input and control connections to the transfer switch are available in the main connection box. mium hydroxide (“green slime”) forms and will cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high silicate anti-freeze boosters or additives will also cause overheating. The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment. The generator incorporates the following generator features: • Rotor and Stator insulation is Class H rated as defined by NEMA MG1-32.6, NEMA MG1-1.66. The generator is self ventilated and drip-proof constructed. • The voltage waveform deviation, total harmonic content of the AC waveform and telephone influence factor have been evaluated and are acceptable according to NEMA MG1-32. DANGER not remove the radiator pressure cap while Do the engine is hot or serious burns from boiling liquid or steam could result. glycol base antifreeze is poisonous. Ethylene Do not use mouth to siphon coolant from the ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W-40 engine oil at the factory. Use a high-quality detergent oil classified “For Service CC, SD, SE, SF.” Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change: Temperature Above 80° F (27° C) 32° to 80° F (0° to 27° C) Below 32° F (0° C) radiator, recovery bottle or any container. Wash hands thoroughly after handling. Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them. Oil Grade (Recommended) SAE 30W or 15W-40 SAE 20W-20 or 15W-40 See Note attempt to crank or start the engine before Any it has been properly serviced with the recommended oil may result in an engine failure. NOTE: For temperatures below 32° F, it is strongly recommended to use the optional Cold Weather Start Kit (part number listed in the Specification Section). The oil grade for temperatures below 32° F is 5W30 synthetic oil. Equip001 Rev. 0 08/05 3-1 Standby Generator Sets Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low, the coolant temperature is too high, the coolant level is too low, or the engine is running too fast. After a prespecified duration of cranking, this function ends the cranking if the engine has failed to start. The overcrank LED will turn ON. Turn OFF the AUTO/OFF/MANUAL switch, then turn switch back to AUTO to reset the generator control board. NOTE: If the fault is not corrected, the overcrank feature will continue to activate. NOTE: Approximate Crank Cycle Times Engine protective switches and sensors are mentioned here for the reader’s convenience. Also refer to the applicable control panel manual for additional automatic engine shutdown information. • • • • • HIGH COOLANT TEMPERATURE SWITCH This switches contacts close if the temperature should exceed approximately 140° C (284° F), initiating an engine shutdown. The generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level. 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total. OVERSPEED SHUTDOWN A speed circuit controls engine cranking, start-up, operation and shutdown. Engine speed signals are delivered to the circuit board whenever the unit is running. Should the engine overspeed above a safe, preset value, the circuit board initiates an automatic engine shutdown. Contact the nearest Authorized Dealer if this failure occurs. LOW COOLANT LEVEL SENSOR Should the engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shutdown. To prevent such overheating, the engine has a low coolant level sensor. If the level of engine coolant drops below the level of the low coolant level sensor, the engine automatically shuts down. RPM SENSOR LOSS SHUTDOWN If the speed signal to the control panel is lost, engine shutdown will occur. DC FUSE LOW OIL PRESSURE SWITCH This fuse is located inside of the control panel. It protects the panel wiring and components from damaging overload. Always remove this fuse before commencing work on the generator. The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rating. (See the exploded views and parts lists at the end of this manual for replacement part number.) 4-1 EngProt001 Rev. 0 08/05 This switch has normally closed contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure drop below the 8 psi range, switch contacts close, and the engine shuts down. The unit should not be restarted until oil is added, and the AUTO/OFF/MANUAL switch must be turned to OFF and then back to AUTO. Standby Generator Sets Fuel Systems 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 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state. The vapor withdrawal system is generally best suited for smaller engines that require less fuel. The installer should be aware of the following: The standby generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (PV) fuel system The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the unit. • The natural gas and LP gas systems are similar. However, the natural gas system delivers gas at a pressure of approximately five inches water column to the carburetor. • When ambient temperatures are low and engine fuel consumption is high, the vapor withdrawal system may not function efficiently. • Ambient temperatures around the supply tank must be high enough to sustain adequate vaporization, or the system will not deliver the needed fuel volume. • In addition to the cooling effects of ambient air, the vaporization process itself provides an additional cooling effect. Recommended fuels should have a Btu content of at least 1,000 Btus per cubic foot for natural gas; or at least 2,520 Btus per cubic foot for LP gas. Ask the fuel supplier for the Btu content of the fuel. Required fuel pressure for natural gas is 5 inches to 14 inches water column (0.18 to 0.5 psi); and for liquid propane, 5 inches to 14 inches of water column (0.18 to 0.5 psi). NOTE: Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below five inches water column for natural gas or 5 inches water column for propane vapor for all load ranges. LP FUEL SYSTEM LP is supplied as a liquid in pressure tanks. It is usually made up of propane, butane, or a mixture of the two gases. Propane tends to vaporize readily even at temperatures as low as -20° F (-29° C). However, butane reverts to its liquid state when temperatures drop below 32° F (0° C). NOTE: It is the responsibility of the installer to make sure that only the correct recommended fuel is supplied to the generator fuel system. Thereafter, the owner/operator must make certain that only the proper fuel is supplied. LP in a liquid withdrawal system must be converted to its gaseous state before it is introduced into the engine carburetor. A vaporizer-converter is generally used to accomplish this. In such a converter, heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state. NATURAL GAS FUEL SYSTEM Natural gas is supplied in its vapor state. In most cases, the gas distribution company provides piping from the main gas distribution line to the standby generator site. The following information applies to natural gas fuel systems. • Gas pressure in a building is usually regulated by national, state and local codes. • To reduce gas pressure to a safe level before the gas enters a building, a primary regulator is needed. The natural gas supplier may or may not supply such a regulator. • It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator. • Gas pressure at the inlet to the fuel shutoff solenoid 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). FuelSys001 Rev. 0 08/05 5-1 Standby Generator Sets Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ...................................................................... Gear Oil Filter ............................................... Full Flow Spin-on, Cartridge Crankcase Oil Capacity ....................................................4 U.S. qts. GENERATOR Type ............................................................................. Synchronous Rotor Insulation ................................................................... Class H Stator Insulation .................................................................. Class H Total Harmonic Distortion ......................................................< 3.5% Telephone Interference Factor (TIF) ..........................................< 50 Alternator Output Leads 3-phase ........................................... 4-wire Bearings .........................................................................Sealed Ball Coupling .......................................................................Flexible Disc Load Capacity (Standby Rating) ............................................40kW* * NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349, COOLING SYSTEM Type ...................................................Pressurized Closed Recovery Water Pump.................................................................... Belt Driven Fan Speed .........................................................................2060 rpm Fan Diameter .....................................................................22 inches Fan Mode ..............................................................................Pusher Air Flow (inlet air including alternator and combustion air) .......................................................... 2725 ft3/min. Coolant Capacity ........................................................ (3.0 U.S. gal.) Heat Rejection to Coolant ..........................................154,000 Btu/h Maximum Operating Air Temp. on Radiator ..............60° C (150° F) Maximum Ambient Temperature................................50° C (140° F) ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural gas. Excitation System ....................................................................Direct Generator Output Voltage/kW - 60 Hz kW Amp CB Size 120/240V, 1-phase, 1.0 pf (LP) 40 167 175 120/240V, 1-phase, 1.0 pf (NG) 37 154 175 120/208V, 3-phase, 0.8 pf (LP) 40 139 150 277/480V, 3-phase, 0.8 pf (LP) 40 60 70 Generator Locked Rotor KVA Available @ Voltage Dip of 35% Single-phase or 208V, 3-phase .......................................... 80 KVA 480V, 3-phase .................................................................... 90 KVA FUEL SYSTEM Type of Fuel .........................................Natural Gas, Propane Vapor Carburetor ...................................................................... Down Draft Secondary Fuel Regulator .................................................Standard Fuel Shut-off Solenoid ........................................................Standard Operating Fuel Pressure ...................... 5 in. - 14 in. Water Column ENGINE Fuel Consumption - ft3/hr (Natural Gas/LPV) Exercise 25% 50% 75% 100% Cycle Load Load Load Load 82/33 148/59 285/114 397/160 550/221 Make ................................................................................... Generac Model ...................................................................................... V-type Cylinders and Arrangement............................................................ 6 Displacement ....................................................................... 3.9 Liter Bore ...................................................................................... 3.91 in. Stroke ................................................................................... 3.31 in. Compression Ratio ...............................................................9.1-to-1 Air Intake System ...............................................Naturally Aspirated Valve Seats........................................................... Precision Ground Lifter Type ......................Overhead Valve Push Rod/Hydraulic Lifter ELECTRICAL SYSTEM Battery Charge Alternator ............................................12V, 30 Amp Static Battery Charger ............................................................2 Amp Recommended Battery................................................ 24F 525CCA System Voltage .....................................................................12 Volts Voltage Regulator Type .................................................................................. Electronic Sensing........................................................................ Single-phase Regulation ................................................................................± 1% Features .................................................V/F Adjustable, Adjustable Voltage and Gain LED Indicators Engine Parameters Rated Synchronous RPM ..............................................60 Hz, 1800 HP at rated kW (LP/NG)...............................................60 Hz, 64/59 Exhaust System Exhaust Flow at Rated Output 60 Hz.................................. 318 cfm Exhaust Temperature at Rated Output .................................. 938° F Power Adjustment for Ambient Conditions Temperature Deration 3% for every 10° C above °C ..................................................... 25 1.65% for every 10° above °F .................................................... 77 Altitude Deration 1% for every 100 m above m ................................................... 183 3% for every 1000 ft. above ft. ................................................. 600 Combustion Air Requirements (Natural Gas) Flow at rated power, 60 Hz ................................................. 118 cfm Governor Type .................................................................................. Electronic Frequency Regulation ...................................................Isochronous Steady State Regulation......................................................± 0.25% Controller .................................................R-100 GenSpec001 Rev. D 11/05 6-1 Standby Generator Sets Specifications Figure 1 — Interconnections COLD WEATHER KIT 10. Reverse the procedure to convert back to natural gas. 11. The Dip switch inside the control panel must be in the LP or NG position when switching to different fuels. For cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes: • Battery Warmer • 4” Junction Box with hardware • 6 qt. pack 5W-30 synthetic oil (engine) Figure 6.2 — Reconfigure the Fuel System Port 2 Port 1 RECONFIGURING THE FUEL SYSTEM NOTE: PLUG All models are configured for natural gas or LP vapor from the factory. FUEL HOSE FUEL HOSE BRASS HOSE FITTING OUT PORT 1 BRASS HOSE FITTING PLUG OUT PORT 2 HOUSING PORTS HOUSING PORTS 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). 3. Remove the brass hose fitting from the outlet port (Port 1) of the demand regulator. 4. Remove pipe plug from Port 2. 5. Install brass hose fitting into Port 2. 6. Install pipe plug into Port 1. 7. Connect carburetor gas hose to brass fitting. 8. Tighten all clamps and plugs. 9. Make sure fuel supply is of the proper pressure and type for configuration. NG FUEL SYSTEM LP FUEL SYSTEM NOTE: Port 1 is for NG only and Port 2 is for LP vapor only. No provision for dual fuel has been made. NOTE: For LP vapor application substitue LPG fuel inlet decal P/N 050280 for NG fuel inlet decal P/N 050279. 6-2 GenSpec001 Rev. D 11/05 Standby Generator Sets General Information GENERATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING CONNECTIONS See “Voltage Codes”. This generator may be rated at any one of three voltages, either single-phase or three-phase. The electrical wires in the unit’s AC connection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. If there are any questions regarding lead connection, refer to the wiring diagrams at the back of this manual. 3-PHASE ALTERNATORS The generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory to the main circuit breaker with a “Y” configuration as shown in Figures 7.2 and 7.3. Voltage codes apply to the type of stator assembly installed on a particular generator. The rated voltage between circuit breaker terminals E1-E2, E1-E3 and E2-E3 is either 480V or 208V depending on the model. FOUR-LEAD, SINGLE-PHASE STATOR The rated voltage between each circuit breaker terminal and the neutral point 00 is either 277V or 120V depending on the model. Four-lead generators (see Figure 7.1) are designed to supply electrical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical power is produced in the stator power windings. These windings were connected at the factory to the main circuit breaker as shown in Figure 7.1. Figure 7.2 — Stator Power Winding Connections - 3-phase, 277/480V (6 Lead) The rated voltage between each circuit breaker terminal is 240V. The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V. S1 E1 Figure 7.1 — Four-lead, Single-phase Stator INTERNAL CONNECTIONS L-L S6 S4 NEUTRAL S5 E3 S3 S2 E2 L-N Figure 7.3 — Stator Power Winding Connections - 3-phase, 120/208V (6 Lead) E1 S1 S1 S6 S3 E3 L-L S4 S4 S5 00 (NEUTRAL) S2 S6 S5 S3 S2 E2 L-N ACConn001 Rev. 0 08/05 7-1 Standby Generator Sets Installation PRIOR TO INITIAL START-UP INSTALLATION Refer to the separate “Installation Guide QT Product Line” supplied with the unit. to initially starting the generator, it must Prior be properly prepared for use. Any attempt to PREPARATION BEFORE START-UP The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor. Be sure to read the “Safety Rules”, as well as all other safety information in this manual, before attempting to operate this (and related) equipment. crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure. ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See “Specifications” and “Coolant” sections. Before starting the generator for the first time, the installer must complete the following procedures. For follow-up maintenance information and/or service intervals, please refer to the “Maintenance” section and the “Service Schedule”. BELT TENSION TRANSFER SWITCH Check-the engine-fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of approximately 22 pounds (10 kg), applied midway between pulleys, deflects the belt about 3/8- to 5/8inch (10 to 16 mm). If this generator is used to supply power to any electrical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (For additional information, see the applicable transfer switch manual for this unit.) The transfer switch, as well as the generator and other standby components, must be properly located and mounted in strict compliance with applicable codes, standards and regulations. ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground. Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use. FUEL SYSTEM Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear of any moving generator set components. Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and (b) is properly purged and leak tested according to code. No fuel leakage is permitted. See “Specifications” for more information. INITIAL INSPECTION FOR QT GENSET STARTUP GENERATOR SET LUBRICATION Inspect for the following. • • • • • NOTE: This engine is shipped from the manufacturer with “break-in” oil. This oil should be changed after 30 hours of operation. • • Check the oil level in the generator gearbox (if so equipped) prior to initial use and at the intervals indicated by the “Service Schedule.” The recommended oil is SAE 90 gear lubricant. • • Also, if the engine is equipped with a mechanical governor, make sure the governor is properly lubricated with clean engine oil. • 8-1 Freight Damage. Manuals present. Fluid Levels ( Oil, coolant, battery, Gear Drive). Correct fuel piping. Correct muffler installation for QT50, QT70, QT100 - QT150. Adequate air flow, clearances and ventilation per installation drawings and applicable codes. Correct AC and DC wire size, connections and grounding. Control and communication wiring to/ from the transfer switch must be run in a separate conduit from the AC power leads. Battery charger connection to 120 VAC. Communication wires connected between transfer switch and generator (HTS only). Unit secured to pad. Install001 Rev. A 11/05 Check the engine crankcase oil level before operating and add oil to the proper level – the dipstick “FULL” mark. Never operate the engine with the oil level below the dipstick “ADD” mark. See “Specifications” and “Engine Oil Recommendations”. Standby Generator Sets Installation START-UP CHECKLIST • Check voltage at the generator terminals. • For 3-phase units, check phase rotation at the transfer switch terminals. The generator phase rotation must match the utility phase rotation. • Check for coolant, fuel, oil, and exhaust leaks. • Close the generators main line circuit breaker. • Turn the generator set off. • Connect the UTILITY supply to the transfer switch. • Set the AUTO/OFF/MANUAL switch to AUTO. • Disconnect utility power before the transfer switch. Engine should start, transfer to load. Run at least 15 minutes on generator power. Make certain all 3-phase loads are functioning correctly (correct phase rotation). • Reconnect Utility power Transfer switch will transfer back to Utility and engine will shut down within the given time parameters set up for the specific transfer switch and controller. • Install all covers, access plates and door panels. • Put the Owners Manual in a safe and accessible place. • Make certain the AUTO/OFF/MANUAL switch is in the AUTO position. working on the generator, ensure the fol Before lowing: • The AUTO/OFF/MANUAL switch is in the OFF position. • The 120VAC supply to the battery charger is switched OFF. PREPARATION FOR START-UP • Ensure that the 120VAC circuit breaker to the battery charger is open. • Remove the fuse from the the control panel. For the H-100 and R-100: Open the front door of the control box and remove the 15 Amp ATO fuse in the lower left-hand corner of the control box. • Connect the battery cables to the battery. Attach negative battery cable last. • Close the 120VAC circuit breaker to the battery charger. • Measure the voltage at the battery before and after the charger is turned on. • Verify all AC electrical connections are tight at the circuit breaker and transfer switch. • Visually inspect entire area looking for loose paper, plastic wrappings, leaves, etc. • Check all hoses clamps fittings for leaks or damage. • Check all electrical plugs throughout the generator. Ensure each plug is seated correctly and fully inserted into its receptacle. • Verify the AUTO/OFF/MANUAL switch is in OFF position. • Open the valve to the engine fuel line. • Bleed the fuel system of air. (necessary for long fuel lines). • Open the generator main line circuit breaker. • Connect a manometer to the gas line and record the static pressure. It must be as listed in the Specifications. • Insert the fuse into the control panel. • Move the AUTO/OFF/MANUAL switch to the MANUAL position. The engine should now crank and start. START-UP INSPECTION When a start-up is performed by an Authorized Service Dealer, a standard three-part form titled “Start-up Inspection for Standby Power Systems” (part no. 067377), should be completed by the installation technician or engineer. See page 1-3 for information on locating the nearest Authorized Service Dealer. The installer should complete the form and disseminate copies as follows: • White copy: Mail to Generac Warranty Department, P.O. Box 340, 211 Murphy Dr., Eagle, WI 531192062. • Pink Copy: For service file of installing dealer. • Yellow Copy: For the customer’s records. 8-2 Install001 Rev. A 11/05 Standby Generator Sets Operation GENERATOR CONTROL AND OPERATION not crank the engine continuously for longer Do than 30 seconds, or the heat may Refer to the appropriate control panel operator’s manual for this unit. • • OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the generator was installed in conjunction with a transfer switch capable of manual operation only, the following procedure applies. A manually operated transfer switch is one that will not provide automatic start-up and does not include an intelligence circuit. • • ENGINE START-UP AND TRANSFER damage the starter motor. Let engine stabilize and warm up. Check all applicable instrument and gauge readings. When certain that all readings are correct, move the transfer switch manual handle to its STANDBY (GENERATOR) position, i.e., load circuits supplied by the generator. Set the standby generator’s main line circuit breaker to its ON (or CLOSED) position. Load circuits are now powered by the standby generator. RETRANSFER AND SHUTDOWN For additional information, refer to the applicable control panel manual for this unit, as well as any literature pertaining to the specific transfer switch. For additional information, refer to the applicable control panel manual for this unit, as well as any literature pertaining to the specific transfer switch. DANGER To transfer the load back to the utility power source and shut down the generator, follow these directions: Maintenance Disconnect Switch and the The AUTO/OFF/MANUAL switches (if so equipped) must be set properly, or the generator will crank and start as soon as the utility power to the transfer switch is turned off. Refer to applicable control panel and transfer switch manuals for more information. • Set the standby generator’s main line circuit breaker to its OFF (or OPEN) position. • Manually move the transfer switch handle to its UTILITY (NORMAL) position, i.e., load circuits connected to the utility. • Turn ON the utility power supply to the transfer switch, using the means provided (such as the utility power source main line circuit breaker). • Let the generator run at no-load for a few minutes to stabilize internal temperatures. • Shut down the generator. not proceed until certain that utility source Do voltage is available to the transfer switch and the transfer switch main contacts are set to UTILITY. not attempt manual operation until all power Do supplies to the transfer switch have been positively turned off, or extremely dangerous - possibly lethal - electrical shock will result. OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH Transfer switch enclosure doors should be kept closed and locked. Only authorized personnel should be allowed access to the transfer switch interior. Extremely high and dangerous voltages are present in the transfer switch. In order to transfer load from the utility source to the generator, follow these directions: If the generator has been installed with an automatic transfer switch, such as an RTS, HTS, or GTS-type transfer switch, the engine may be started and stopped automatically or manually. NOTE: Refer to the applicable manual for your transfer switch and to “Transfer Switch Start Signal Connections”. In addition, please note the dangers under “Engine Start-up and Transfer.” 9-1 Oper001 Rev. 0 08/05 • Turn OFF or disconnect the utility power circuit to the transfer switch, using the means provided (such as the utility source main line circuit breaker). • Set the transfer handle to its UTILITY (NORMAL) position with load circuits connected to the utility power supply. • Set the standby generator’s main line circuit breaker to its OFF (or OPEN) position. • Start the generator. Standby Generator Sets Maintenance MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES exhaust system parts from this product get The extremely hot and remain hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system. working on the generator, ensure the fol Before lowing: • The AUTO/OFF/MANUAL switch is in the OFF position. • The 15A fuse has been removed from the control box. • The 120VAC supply to the battery charger is switched OFF. CHECKING FLUID LEVELS CHECK ENGINE OIL Check engine crankcase oil level (Figure 10.1) at least every 20 hours of operation, or prior to use. EVERY THREE MONTHS 1. 2. 3. 4. 5. 6. • Remove oil dipstick and wipe dry with a clean, lintfree cloth. • Install oil dipstick, then remove again. • Oil should be between FULL and ADD marks. • If oil level is below the dipstick ADD mark, remove oil fill cap. Add the recommended oil to bring oil level up to the FULL mark. DO NOT FILL ABOVE THE “FULL” MARK. See “Engine Oil Recommendations” for recommended oils. Check battery state of charge and condition. Inspect and test fuel system. Check transfer switch. Inspect exhaust system. Check engine ignition system. Check fan belts. ONCE EVERY SIX MONTHS Figure 10.1 - Oil Dipstick and Oil Fill Cap 1. Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature). Oil Dipstick ONCE ANNUALLY Oil Fill 1. Test engine governor. Adjust or repair, if needed. 2. Clean, inspect generator. 3. Flush cooling system. FIRST 100 OPERATING HOURS 1. Change engine oil and oil filter. (After initial change, service engine oil and filter at 150 operating hours or 6 months, whichever comes first.) Oil Filter EVERY 500 OPERATING HOURS BATTERY FLUID 1. Service air cleaner. 2. Check starter. 3. Check engine DC alternator. Check battery electrolyte fluid at least once weekly. Fluid should cover separators in all battery cells. If fluid level is low, add distilled water to cover tops of separators. DO NOT USE TAP WATER IN BATTERY. COOLING SYSTEM Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow. Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. Maint002 Rev. 0 08/05 10-1 Standby Generator Sets Maintenance ENGINE COOLANT CHECK FAN BELT Check coolant level in coolant recovery bottle. See the “Specifications” section. • Inspect fan belts every three months. Replace any damaged, deteriorated, worn or otherwise defective belt. • Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 inch. Adjust belt tension as required. • Add recommended coolant mixture as necessary. • Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact an Authorized Service Dealer. Inspect cooling system and coolant recovery system for leaks. INSPECT ENGINE GOVERNOR Visually inspect electronic governor. DANGER not attempt to adjust the governor. Only Do qualified service facilities should adjust the MAINTENANCE OWNER/ OPERATOR CAN PERFORM governor. Excessively high operating speeds are dangerous and increase the risk of personal injury. Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life. Correct rated frequency and voltage are supplied only at the proper governed speed. Some connected electrical load devices may be damaged by incorrect frequency and/or voltage. Only qualified service technicians should adjust the governed speed. CHECK ENGINE OIL LEVEL Refer to the “Checking Fluid Levels” section. CHECK BATTERY • Check battery fluid level each week as outlined under “Check Fluid Levels”. • Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as necessary. CHANGING ENGINE OIL EXERCISE SYSTEM Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies. Start the generator engine at least once every seven days and let it run at least 20 minutes. See the “Weekly Exercise Cycle” section. Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down and drain immediately as follows: INSPECT COOLING SYSTEM 1. Remove OIL DRAIN HOSE from its retaining clip. 2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container. 3. When all oil has drained, install and tighten OIL DRAIN HOSE CAP, and re-install into its retaining clip. 4. Turn OIL FILTER (Figure 10.2) counterclockwise and remove. Dispose of old filter. 5. Apply light coating of new engine oil to seal of new oil filter.-Install FILTER and tighten by hand only. DO NOT OVERTIGHTEN. 6. Remove OIL FILL CAP. Add recommended oil (see SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK “FULL” MARK. Crankcase oil capacity is 4.0 U.S. quarts (3.8 liters). • Inspect engine cooling system at least once each month. • Check hoses for damage, deterioration, leaks, etc. Correct any discrepancies found. • Check hose clamps for tightness. CHECK ENGINE COOLANT LEVEL See the “Checking Fluid Levels” section. PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks. INSPECT EXHAUST SYSTEM refilling the crankcase with oil, always After check oil level on dipstick. NEVER OPERATE Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage. ENGINE WITH OIL BELOW THE DIPSTICK “ADD” MARK. 10-2 Maint002 Rev. 0 08/05 Standby Generator Sets Maintenance COOLANT CHANGE 7. Start engine and check for oil leaks. Every year, have an Authorized Service Facility drain, flush and refill the cooling system. See the “Specifications” section for cooling system recommendations. Figure 10.2 - Oil Filter MISCELLANEOUS MAINTENANCE CLEANING THE GENERATOR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance. Oil Filter Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dry, low pressure air to remove any accumulations of dirt. The generator is housed inside an all-weather enclosure, clean the enclosure with a soft, damp cloth or sponge and water. CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner, (part number 0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover. Once each year, have the generator cleaned and inspected by an Authorized Service Dealer. That dealer will use dry, low pressure air to clean internal windings. Parts inside the control console should be cleaned and inspected at this time as well. See the “Service Schedule” section for air cleaner maintenance. Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low, the generator may require drying. SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary. BATTERY 1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean. 2. Remove the spark plugs and check the condition. Replace the spark plugs if worn or if reuse is questionable. See the “Service Schedule” section for recommended inspection. 3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 1.01 mm (0.040 inch) by carefully bending the ground electrode (Figure 10.3). All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery. If such information is not available, observe the following precautions when handling a battery: • DO NOT use jumper cables and a booster battery to crank or start the generator engine. • DO NOT recharge a weak battery while it is installed in the generator. Remove battery from generator and recharge in a well-ventilated area, away from fuel vapors, sparks, heat or flames. • Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns. DO NOT permit fluid to contact eyes, skin, clothing, painted surfaces, wiring insulation, etc. If any battery 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, causing blindness or other serious injury. SET PLUG GAP AT 1.01 mm (0.040 inch) 10-3 Maint002 Rev. 0 08/05 Figure 10.3 – Setting the Spark Plug Gap Standby Generator Sets Maintenance BATTERY MAINTENANCE The battery should be inspected per the “Service Schedule” section. The following procedure should be followed for inspection: sure the AUTO/OFF/MANUAL switch is set to Be the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected. 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. 2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES. 3. Have the state of charge and condition checked. This should be done with an automotive-type battery hydrometer. sure the 120VAC power supply to the battery Be is turned OFF, or sparking may occur at the battery posts as the cables are attached and cause an explosion. BATTERY REPLACEMENT When replacing batteries, use the same number and the type of battery that follows: DANGER batteries give off explosive hydrogen Storage gas. This gas can form an explosive mixture BCI Group No. 24F-6 around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery. CCA 535 @ 0 deg. F NOTE: The BCI number should be located directly on the battery. REPAIR PARTS The latter portion of this manual consists of exploded views, parts lists and electrical data pertaining to this generator set. The parts lists consist of (a) an item number, (b) a part number, (c) the quantity required, and (d) a description of the part. The item number corresponds to an identical number on the exploded view drawing. Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If the fluid is spilled, flush the affected area immediately with clear water. Periodic Replacement Parts not use any jumper cables or booster battery Do to crank and start the generator engine. If the Part Name battery has completely discharged, remove it from the generator for recharging. Oil Filter Radiator Cap Air Cleaner Spark Plug 10-4 Part Number # 0E7415 # 046627 # 0A4637 Champion # RC12LC4 Maint002 Rev. 0 08/05 Standby Generator Sets Service Schedule SERVICE SCHEDULE 30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use calendar time, from the previous maintenance interval to determine the next required maintenance interval. Service Maintenance Interval Information: The various service maintenance intervals are designated by interval numbers as follows: 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas. This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning: To prevent injury, perform the following steps in the order indicated before starting any maintenance: • Disable the generator set from starting and/or connecting to the load by setting the control panel Auto/Off/ Manual switch to the “OFF” position. • Remove the 15 amp control panel fuse. • Turn off the battery charger. • Remove the negative battery cable. The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits. Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required. 2 A wear-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer. 3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed semi-annually or following each 50 hours of operation of the unit. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer. 4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed annually or following each 100 hours of operation of the unit. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer. 5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required, and to identify any potential problem areas. Performed annually or following each 250 hours of operation of the unit. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer. SrvSchd001 Rev. A 09/05 11-1 Standby Generator Sets Service Schedule Maintenance Tasks Level 1 Recommended to be done monthly/ 10 hrs. Level 2 Level 3 Task Required Task Required Comp. to be done Comp. to be done (Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/ 30 hrs. 50 hrs. 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level. Adjust as necessary. 4. Check the engine coolant thermal protection level. Correct as necessary. 5. Check the natural gas delivery system for leaks and correct pressure on gas engine driven units. Tighten connections as necessary. 6. Check the air inlets and outlets for debris. Clean as necessary. 7. Check the battery electrolyte level and specific gravity if accessible. Adjust as necessary. 8. Check the battery posts, cables, and charger for loose connections, corrosion, and proper operation. Correct as necessary. 9. Check the unit wiring for loose connections, corrosion, and damage. Correct as necessary. 11-2 Level 4 Task Comp. (DateInitials) Required to be done Annually/ 100 hrs. Level5 Task Comp. (DateInitials) Required to be done Biannually/ 250 hrs. Task Comp. (DateInitials) SrvSchd001 Rev. A 09/05 Standby Generator Sets Service Schedule Maintenance Tasks Level 1 Recommended to be done monthly/ 10 hrs. Level 2 Level 3 Task Required Task Required Comp. to be done Comp. to be done (Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/ 30 hrs. 50 hrs. Level 4 Task Comp. (DateInitials) Required to be done Annually/ 100 hrs. Level5 Task Comp. (DateInitials) Required to be done Biannually/ 250 hrs. Task Comp. (DateInitials) 10. Check the engine accessory drive belts and fan coupling device if equipped for correct tension, wear, weather cracking, and damage. Replace as necessary. 11. Check the engine valve clearance. Adjust as necessary. 12. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary. 13. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary. 14. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary. 15. Replace the engine accessory drive belts. 16. Check gearbox oil level (if equipped). 17. Change gearbox oil (if equipped). SrvSchd001 Rev. A 09/05 11-3 Standby Generator Sets Service Schedule Maintenance Tasks Level 1 Recommended to be done monthly/ 10 hrs. Level 2 Level 3 Task Required Task Required Comp. to be done Comp. to be done (Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/ 30 hrs. 50 hrs. 18. Start and exercise the unit at full rated load (use a load bank if the site load is not enough) for at least 2 hours looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary. 19. Perform an engine oil analysis (send a sample to a lab for results). Change the engine oil and filters if the analysis results indicate this is required. 20. Change the engine oil. 21. Replace the engine oil filter(s). 22. Replace engine spark plugs. Clean and re-gap or replace as necessary. 23. Replace the engine air filter(s). 24. Perform a 5 minute no-load operational run of the unit looking for any post service problems. 25. Return the unit to standby setup for operation when required. 11-4 Level 4 Task Comp. (DateInitials) Required to be done Annually/ 100 hrs. Level5 Task Comp. (DateInitials) Required to be done Biannually/ 250 hrs. Task Comp. (DateInitials) SrvSchd001 Rev. A 09/05 Standby Generator Sets Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 5 amp fuse blown. 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor.* 4. Replace starter motor.* 5. Remove, change or replace battery. 6. Replace fuse.* Engine cranks but won't start 1. Out of fuel. 2. Fuel solenoid (FS) is defective 3. Open Wire #14A from Engine Control circuit board. 4. Spark plugs defective. 5. Door on tank not closed. 1. Replenish fuel. 2. Replace solenoid.* 3. Reconnect wire. 1. Flame arrestor (air cleaner) plugged or damaged. 2. Plugged fuel line. 3. Defective spark plugs. 4. Fuel pressure incorrect. 1. Clean or replace as needed. Engine starts hard, runs rough. 2. Unclog fuel line. 3. Clean, regap or replace plugs. 4. Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS. Engine starts then shuts down. 1. 2. 3. 4. 5. 6. 7. AUTO/OFF/MANUAL Switch at OFF, engine continues to run 1. Defective AUTO/OFF/MANUAL switch 2. Open/disconnected wire #15A between AUTO/OFF/MANUAL switch and Control Module circuit board. 3. Defective Control Module circuit board 3. Replace board.* 1. 2. 3. 4. 5. 1. 2. 3. 4. 5. Check main line circuit breaker. Check circuit breaker & fuses. Transfer switch set to NORMAL position Generator internal failure. Thermal circuit breaker open. 1. 2. 3. 4. 5. 6. 7. Check oil and add oil as needed. Check cooling system for leaks. Replace switch.* Replace switch.* Replace board.* Repair leak - Add coolant. Replace Switch.* 1. Replace switch.* 2. Reconnect/close wire. Reset to ON or CLOSED. Reset and replace, if necessary. Set to GENERATOR position. * Auto-reset - Wait 5 min. and attempt restart. *Contact the nearest Authorized Dealer for assistance. 12-1 Trblsht001 Rev. 0 08/05 No AC output from generator. Engine oil level is low. Engine is overheated. Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board. Coolant Level is Low. Defective Low Coolant Level Switch 4. Clean, regap or replace plugs. 5. Close door on tank. Standby Generator Sets Notes 1 2 3 4 5 *** 0F3137 0F3188 0F3189 023484N 0F6366B 0F6366A 043180 022264 0C3990 057701 022155 0C2428 0F3824 0A9457 057073 0D5466 0A7822 022237 022241 049226 0C2266 0C2454 022473 022097 0D4698 0F4464 025433 024469 067210A 0D6029 081008 077043J 051713 0F6156 029289 047411 064153B 1 1 1 1 1/2 1 2/4 2/4 2/4 REF 4 4 1 1 2 REF REF 2 2 7 6 8 8 4 REF 1 1 1 1 4 1 1 2 1 1 4 2 0F3328 065469 0D5552 0D5554 0D5556 0D9693 0F0492 048927 023897 022152 022158 0C2454 029289 0F1733 1 1 1 1 4 4 4 4 7 1 1 UL CIRCUIT BREAKER (ED) COVER ED CB SHORT STND DECAL DANGER HIGH VOLTAGE CB 0050A 3P 480V S ED4 LL CB 0070A 3P 480V S ED4 LL CB 0090A 3P 480V S ED4 LL CB 0125A 3P 480V S ED4 LL INSULATOR CB S (ED-3P) SCREW RHM #10-32 X 4-1/2 WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX #10-32 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM (AS REQ’D) DECAL CUSTOMER CONNECT INSIDE D E F G H J K L 0F3138 065469 0D5572 0D5573 0D5574 0D5575 0D5576 0F0199 081320 022473 022097 022127 0C2454 029289 0F1733 1 1 1 1 4 4 4 4 7 1 1 UL CIRCUIT BREAKER (FD) COVER CB CONN BOX DECAL DANGER HIGH VOLTAGE CB 0150A 3P 600V S FD6 LL CB 0175A 3P 600V S FD6 LL CB 0200A 3P 600V S FD6 LL CB 0225A 3P 600V S FD6 LL CB 0250A 3P 600V S FD6 LL INSULATOR CB FD FRAME 30MIL SCREW SHC 1/4-20 X 4.5 G8.8 NZ WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM (AS REQ’D) DECAL CUSTOMER CONNECT INSIDE A 0F3329 1 UL CIRCUIT BREAKER (JD+LD) COVER JD/LD CB SHRT STAND 6 *** 7 *** 8 *** 9* 10 11 12 13 14 15 ** 16 ** 17 18 19 20 21 23 24 26 * 27 28 29 30 31 32 33 34 35 36 37 38 **** 1) A B C D E F G H J K L 2) A B C 3) PAN CB CONN BOX STAND RH CONTROL STAND LH CONTROL BUSHING SNAP SB-2.5-31 XFMR DUAL 120V/16V (FOR 120/240V & 277/480V UNITS) XFMR DUAL 104V/16V (FOR 120/208V UNITS) WASHER FLAT M4 WASHER LOCK #8-M4 SCREW PHTT M4-0.7 X 10 ZYC BLOCK TERM 20A 8 X 6 X 1100V WASHER LOCK #6 SCREW PHTT #6-32 X 1/2 ZYC DECAL UTIL SENSE/CUST CONN DECAL NEUTRAL JUNCTION BLOCK 3/8-16 BUS BAR NEUTRAL BLOCK 390 LUG SLDLSS 600/250-1/0 X 1/4-28 WASHER LOCK 3/8 NUT HEX 3/8-16 STEEL WASHER LOCK M5 SCREW PHTT M5-0.8 X 16 ZYC SCREW THF M6-1 X 16 N WA Z/JS WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 BLOCK TERM 20A 6 X 3 X 1100V DECAL CUST CONN 120V UTILITY LUG SLDLSS #6-14 X 13/64 CU SCREW HHTT #10-32 X 3/8 CZ DECAL GROUND LUG SCREW HHTT M6-1.0 X 16 ZYC GROMMET 1.25 X .25 X .75 CONDUIT FLEX 2.0" ID (36” LG) WASHER FLAT M5 PLATE WIRE SNGL GALV TAPE ELEC 1/2 FOAM (AS REQ’D) SCREW HHC M6-1.0 X 16 G8.8 WIRE JUMPER TRANSFORMER (NOT SHOWN) B C D E F G H J K L 065469 0D5577 0F2353 022770 022473 022097 022127 0C2454 029289 0F1733 1 1 2 4 4 4 4 7 1 1 DECAL DANGER HIGH VOLTAGE CB 0300A 3P 600V S JD6 LL INSULATOR CIRCUIT BR. JD/LD SCREW RHM 1/4-20 X 3 WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL SCREW THF M6-1 X 16 N WA Z/JS TAPE ELEC 1/2 FOAM (AS REQ’D) DECAL CUSTOMER CONNECT INSIDE A B C D E F G H J K 0F8135 065469 0E7283 0E7284 0E3664 074908 0F8140 036261 0C2454 029289 0F1733 1 1 1 2 1 4 7 1 1 UL CIRCUIT BREAKER (QN) COVER QN FRM CB DECAL, DANGER HIGH VOLTAGE CB 0150A 2P 240V S QN2 LL CB 0175A 2P S QN2 LL 240V BASE, QN CIRCUIT BREAKER SCREW HHTT M5-0.8 X 10 BP COVER QN CB DISH RIVET POP .125 X .275 SS SCREW THF M6-1X16 N WA Z/JS TAPE ELEC 1/2 FOAM (AS REQ’D) DECAL CUSTOMER CONNECT INSIDE A B C D E F G H J K L M N P Q 0F8137 065469 0E7994 0F8136 036261 022473 022097 022127 0F8139 0C2454 022237 048527 029289 022770 0F1733 1 1 1 4 2 2 2 1 7 2 2 1 2 1 UL CIRCUIT BREAKER (QJ-2P) COVER QJ 2P FRM CB DECAL, DANGER HIGH VOLTAGE CB 0225A 240V 2P S QJ22 COVER QJ 2P CB DISH RIVET POP .125 X .275 SS WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL INSUL CB 2P QJ SCREW THF M6-1X16 N WA Z/JS WASHER LOCK 3/8 SCREW SHC 3/8-16 X 3/4 G8.8 NZ TAPE ELEC 1/2 FOAM (AS REQ’D) SCREW RHM 1/4-20 X 3 DECAL CUSTOMER CONNECT INSIDE A B C D E F G H J 0D5466 039287 022145 022129 045771 022473 022097 045335 0A7822 2 1 1 1 1 2 2 2 1 NEUTRAL BLOCK 390 / 200-400A BUS BAR NEUTRAL BLOCK 390 SCREW HHC M8-1.25 X 45 G8.8 FT WASHER FLAT 5/16-M8 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 YEL CHR WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 SCREW HHC 1/4-28 X 3/4 G5 LUG SLDLSS 600/250-1/0 X 1/4-28 4) 5) 6) * ITEM INCLUDED WITH HARNESS ** ITEM INCLUDED WITH 0D5464B *** ITEM QTY DOUBLES FOR 277/480V **** ITEM USED WITH 277/480V UNITS ONLY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 * 25 * 0F3438 0F3440 0F6188 0F6190 0F3439 0F3441 0F6189 0F6199 0F6655 0F6656 0C9708 SEE ENGINE EV SEE ENGINE EV 0F5536 0E5706 0F7874 0F6124 0F6123 0E6076 023454 077043F 04576100BU 04576100AQ 052646 043123 051779 0A2601 0A2602 0F3398 046526 0C3993 022264 038150 047248 070892 1 1 1 1 1 1 1 1 1 1 1 REF REF 1 1 1 1 1 1 1 1 4 4 4 4 4 1 1 8 8 4 4 4 1 1 RTR 390 30AD1 CPL RTR 390 40AD2 CPL HI-EF ASSY RTR 390 30KD1 CPL ASSY RTR 390 40KD2 CPL STR 390 30AD1 CPL STR 390 40AD2 CPL STR 390 30GD1 CPL STR 390 40GD2 CPL ASSY STR 390 30KD1 CPL ASSY STR 390 40KD2 CPL INSTR HYPOT TEST ENGINE ADAPTER FLEXPLATE ASSY FLYWHEEL C2 CPL REAR BEARING CARRIER 390/DRCT ASSY BRUSH HOLDER 390/HSB GUARD REAR BEARING CARRIER CPL 3.0L 30KW GUARD REAR BEARING CARRIER CPL 3.9L 40KW REVCOR FAN 12.63 X 2 W/PRESSDISK KEY WOODRUFF #E CONDUIT FLEX 1-1/4" (30” LG) STUD M14-2.0 570 G5 ZINC (30KW) STUD M14-2.0 X 615 G5 ZINC WASHER FLAT M14 WASHER LOCK M14 NUT HEX M14-2.0 G8 YEL CHR SCREW HHC M16-2.0 X 45 G8.8 WASHER FLAT .688 ID X 3.25 OD SCREW SHC M10-1.5 X 16 G10.9 WASHER LOCK M10 SCREW HHTT M4-0.7 X 25 BP WASHER LOCK #8-M4 WASHER FLAT #8 ZINC BALL BEARING-45 MM SLIP RING MACHINED * ROTOR REPLACEMENT PARTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 0F1823A 0F3078 0F2606 036261 043181 052777 0F4245E 0F1262 0F1263 0F1264 0F1725C 067680 0E6875A 055911 0E3161 0F5459 0F5462 0A5062J 029673 048467 0F1958 082573 0E4494 0F3215 0F5886 051713 049226 0F5752F 0F5884 0F5896 0C2265 0C3990 091526 051716 079224 043182 051714 0F3192 0E7403C 0F4416 0F6305 0F6305A COMPONENTS INCLUDED IN 01827E 1 ENCL HSB CONTROL PANEL 1 COVER CONTROL PANEL 1 HINGE CONTINUOUS H-PANEL 6 RIVET POP .125 X .275 SS 4 SCREW PHM M3-0.5 X 10MM 7 WASHER FLAT M3 1 ASSY PCB CPL CTRLR 1800 RPM 4 HOLDER FUSE WICKMANN 178.6150 1 ADPTR RH SIDE WICKMAN 178.6191 1 ADPTR LH SIDE WICKMAN 178.6192 1 ASSY PCB 2AMP 12V UL BATT CHGR 1 ASSY VOLTAGE REGULATOR 60HZ 2 RELAY 12VDC C FORM W/DIODE 1 BLOCK TERM 20A 12 X 6 X 1100V 1 ASSY PCB BOSCH GOV DRIVER 1 DECAL CPL CONTROL PANEL FUSES 1 DECAL CPL 3.9L TB1 4 SPACER 9.5H 3.2 ID 1 DIO BRIDGE 25A 600V 1 CIRCT BRK 7 X 1 ETA 46-500-P 1 PLATE,HARNESS CLAMP 1 SWITCH RKR DPST 125V SPD 1 SWITCH RKR DPDT ON-OFF-ON 1 DECAL CONTROL HSB 3 SCREW HHPM M5-0.8 X 12 12 WASHER FLAT M5 12 WASHER LOCK M5 1 RES WW 15R 5% 25W QK CONN 2 SCREW PHTT M3.5-0.6 X 10 2 SCREW PHTT M3.5-0.6 X 16 4 SCREW PHTT M4-0.7 X 12 ZYC 2 SCREW PHTT M4-0.7 X 10 ZYC 4 SCREW PPHM M5-0.8 X 12 ZNC 9 NUT HEX M5-0.8 G8 CLEAR ZINC 2 SCREW PPHM M5-0.8 X 30 SS 7 WASHER LOCK M3 7 NUT HEX M3-0.5 G8 YEL CHR 1 SUPPORT ANGLE PCB 1 FUSE ATO TYPE 15 AMP (BLUE) 1 HARN 1800RPM R-100 CONTROL PNL (NOT SHOWN) 2 SEAL COVER 3.18 X 12.7 X 382 1 SEAL COVER 3.18 X 12.7 X 283 A B C D E F G H J K 056739 047411 022473 022097 049813 0F6145 0F2627A 049815 049226 023897 COMPONENTS INCLUDED IN 0F7376D 1 RELAY SOLENOID 12VDC PNL MNT 2 SCREW HHC M6-1.0 X 16 G8.8 4 WASHER FLAT 1/4-M6 ZINC 2 WASHER LOCK M6-1/4 2 NUT HEX M6 X 1.0 G8 YEL CHR A/R SEAL WEATHER .45"DIA 1 COVER CONTROL PANEL SIDE 4 SCREW HHC M5-0.8 X 16 G8.8 4 WASHER LOCK M5 4 WASHER FLAT #10 ZINC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 0F3270 052860 052251 052257 052252 052259 052891 0536210410 042909 047411 055414 022447 022097 022473 049813 022261 0F2230 0F5898 036833 022302 022131 065852 045764 022129 022145 026204 045771 051755 022237 1 4 4 4 4 4 4 1 1 1 1 1 1 1 1 1 2 2 4 1 4 1 1 1 1 1 1 1 4 MTG BASE 3.9L 40KW C2 NUT FLANGED HEX M12-1.75 DAMPENER VIBRATION 40 BLUE SPACER .49 X .62 X 1.87 PWDR/ZNC DAMPENER VIBRATION WASHER FLAT M12 SCREW HHC M12-1.75 X 80 G8.8 ASSY WIRE 14.00" SCREW HHC M8-1.25 X 30 G8.8 SCREW HHC M6-1.0 X 16 G8.8 LUG SLDLSS #2-#8 X 17/64 CU WASHER SHAKEPROOF INT 1/4 WASHER LOCK M6-1/4 WASHER FLAT M6-1/4 ZINC NUT HEX M6 -1.0 G8 YEL CHR WASHER SHAKEPROOF INT 3/8 SUPPORT ENGINE 3.9L LH & RH SD PLATE ALT VARMINT SCREW HHC 3/8-16 X 1 G8 WASHER LOCK 7/16 WASHER FLAT 3/8-M10 ZINC SPRING CLIP HOLDER .37-.62 SCREW HHTT M4-0.7 X 8 BP WASHER LOCK M8-5/16 WASHER FLAT 5/16-M8 ZINC WASHER SHAKEPROOF INT 5/16 NUT HEX M8-1.25 G8 CLEAR ZINC SCREW HHC M10-1.5 X 16 G8.8 WASHER LOCK 3/8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0F3408 0F3411 058208 036833 022237 022131 050331A 050331 038805H 038804Y 045771 022129 027482 075763 0C2454 1 1 REF 1 1 1 1 1 1 1 1 1 2 1 6 TRAY BATTERY STRAP BATTERY RETAINMENT BATT 12VDC 24F 625 SCREW HHC 3/8-16 X 1 G8 WASHER LOCK 3/8 WASHER FLAT 3/8-M10 ZINC BATT POST COVER RED + BATT POST COVER BLK CABLE BATT BLK #1 X 23.00 CABLE BATT RED #1 X 35.00 NUT HEX M8-1.25 G8 YEL CHR WASHER LOCK M8-5/16 WASHER SHAKEPROOF EXT 5/16 STL BOOT BATTERY CABLE SCREW THF M6-1 X 16 N WA Z/JS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0E5048A 0F3903A 0F2982 0E6703 0F3795 0E8336 0E7841 0E7254 0E7956 0E7953 047411 0E8615 0E9868A 054455 022097 022473 049721 1 1 1 1 REF REF 2 1 1 1 4 6 1 1 7 10 2 FLEXPLATE HSB 3.9L CHRYSLER (1800RPM) FLEX PLATE 2 POLE 3.9L CHRY (3600RPM) ENG ADAPTER MACH 3.9L HSB NSPS COVER FLYWHEEL ACCESS ENGINE INSERTED VALVE 3.9L (3600 RPM) MAKE 3.9L CHRYSLER ENGINE (1800 RPM) GASKET THERMOSTAT ADAPTOR MACH THERM ADAPTOR 3.9L CHRY BRACKET IGNITION COIL COIL IGNITION 3.9L CHRYSLER SCREW HHC M6-1.0 X 16 G8.8 BOLT 7/16-20 X 7/8 D.C. ALTERNATOR W/OUT PULLEY ADP OIL DRN 1/2-20 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW HHC M6-1.0 X 35 G8.8 BLK 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 049813 036833 022131 022237 0E6729 022129 049821 043790 052677 0F1444A 0E9975 0F5114 0D2244M 0E0992B 0E0992A 0F5806 0E8731 052647 0E7855 0F2694A 0E7952 035606 0A8584 061012 0F1444 050873A 031919 022145 030231 030795 048031J 069860E 0E7954 057824 023645 022403 0E7950 0E7951 0E8445 0E7415 042568 0F3447 0F3446 0F3216C 0F3216 039253 022241 022746 0F3641 3 11 15 19 1 19 3 1 1 1 1 1 1 REF REF 1 1 2 1 1 1 1 1 REF 1 REF REF 15 6 6 REF 1 1 1 5 2 1 1 1 1 1 1 1 1 1 1 1 1 1 0F4272 1 0F3217 0D3488H 022532 0F3844 026925 0F4110 0F5454 0F6027 0F6029 045771 0F5928 087173 0F6480 0F6715 0E0561 059057 057822 057795A 057796 1 1 1 6 1 1 1 2 2 5 6 1 1 2 1 1 1 1 1 NUT HEX M6 X 1.0 G8 YEL CHR SCREW HHC 3/8-16 X 1 G8 WASHER FLAT 3/8-M10 ZINC WASHER LOCK 3/8 STARTER 12V WASHER LOCK M8-5/16 SCREW SHC M8-1.25 X 30 G12.9 BARBED EL 90 3/8 NPT X 3/8 WASHER NYLON .50 X .87 X .06 HEAT SHEILD L/H SIDE CAP VINYL 1/4" ID X 1" DP BLK DECAL REFER TO OWNERS MANUAL ASSY MAGPICKUP (3/8-24 MALE) PLUG EXPANSION 21/32" O.D. (WATER PUMP) (QTY 1) PLUG EXPANSION 14.1 O.D. (INJCTOR HOLE) (QTY 6) SPACER FLEX PLATE 3.9L C4 CPL (3600 RPM) PLATE FLEX DISK SPACER (1800 RPM) SCREW SHC M10-1.5 X 25 G12.9 TENSIONER W/BRACKET PULLEY CRANKSHAFT (3600 RPM) PULLEY CRANKSHAFT 3.9L CRYSLR (1800 RPM) SENSOR HI COOLANT SHUTDOWN SWITCH OIL PRESSURE 10 PSI 2 POL PLUG STD PIPE 1/8 SOCKET HEAD HEAT SHIELD R/H SIDE PLUG PIPE 1/4 CSK W/ VIBRA SL PLUG STD PIPE 3/8 COUNTERSUNK WASHER FLAT 5/16-M8 ZINC SCREW HHC 5/16-18 X 1-1/2 G5 (3600 RPM) SCREW HHC 5/16-18 X 1 G5 (1800 RPM) HOSE CLAMP BAND 5/8" HOSE DRAIN ASSY 28" CABLE IGN COIL 3.9L CHRYSLER CLAMP HOSE #16 .87-1.50 (3600 RPM) SCREW SHC 3/8-16 X 1.25 G8.8 Z SCREW HHC 5/16-18 X 2 G5 TUBE DIPSTICK 3.9L CHRYSLER DIPSTICK OIL LEVEL 3.9L CHRYSLER BRACKET DIPSTICK TUBE OIL FILTER 3.9L CHRYSLER SCREW HHC M6-1.0 X 20 G8.8 BRKT L/H SIDE D.C. ALTERNATOR BRKT R/H SIDE D.C. ALTERNATOR PULLEY 132 OD DC ALTERNATOR (3600 RPM) PULLEY 80 OD DC ALTERNATOR (1800 RPM) SCREW HHC M8-1.25 X 20 G8.8 NUT HEX 3/8-16 STEEL SCREW HHC 3/8-16 X 1-3/4 G5 HARN ENG 3.9L 3600 RPM FLEX PNL (NOT SHOWN)(3600 RPM) HARN ENG 3.9L 1800 RPM FLEX PNL (NOT SHOWN)(1800 RPM) SPACER DC ALTERNATOR PULLEY SERPENTINE BELT (60.5") SCREW HHC 5/16-18 X 2-1/2 G5 WASHER FLAT .45 X 1.00 PLUG STD PIPE 3/8 STEEL SQ HD BYPASS ORIFICE 3.9L CHRYSLER (3600 RPM) PLATE MAG PICK-UP ADAPTOR SHIELD HT RR (C4 3600RPM ONLY) (BOTH SIDES) SHIELD HT FRT (C4 3600RPM ONLY) (BOTH SIDES) NUT HEX M8-1.25 G8 CLEAR ZINC (C4 3600 RPM ONLY) REFLEX WRAP 13MM X 153.3MM (C4 3600 RPM ONLY) SCREW HHC M8-1.25 X 45 G8.8 BRKT L/H SIDE DC ALTERNATOR SPACER .41 X .75 X .18 AL ASSY WATER LEVEL SENSOR C/E PL HOSE 3/4 ID SAE-30R2 (17” LG) CLAMP HOSE #8 .53-1.00 BARBED EL 90 3/4 PLASTIC GROMMET 1 2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 * 40 41 43 44 45 46 0F3203 035685 0F2608 0F4413 0F4414 0E7854 0F2820 051756 046526 022131 0F3312 0C2454 0F8651 022129 022097 0C8566 0E3257 0F3313 080712 076749 048031C 0F4051D 0F4073C 0F3890 0F3890C 0F3072 078115 089961 052250 0F4767 0F8085 0F4765 089514 055596 0C7649 069860E 069811 065852 045764 089685 0F4768 0F8085A 090283 1 4 1 1 1 1 1 4 4 4 1 13 8 8 8 8 4 1 1 1 1 3 1 3 2 10 10 1 2 1 1 1 1 1 1 1 REF. 1 1 1 1 1 1 WELDMENT RAD SUPPORT 3.9L C2 CLAMP HOSE #28 1.32-2.25 RADIATOR 598 X 568 X 49 CPL RH HOSE UPPER RAD CPL C2 3.9L HOSE LOWER RAD CPL C2 3.9L CLUTCH COOLING FAN FAN 22" DIA 10 BLADE SCREW HHC M10-1.5 X 20 G8.8 WASHER LOCK M10 WASHER FLAT 3/8-M10 ZINC DUCT INNER DISCHARGE TOP C2 SCREW THF M6-1 X 16 N WA Z/JS SCREW HHFC M8-1.25 X 20 W/M6 WASHER LOCK M8-5/16 WASHER LOCK M6-1/4 SCREW HHFC M6-1.0 X 20 G8.8 SCREW HWHTF M6-1.0 X 16 DUCT INNER DISCHARGE C2 BRKT COOLANT RECOVERY TANK TANK COOLANT RECOVERY CLAMP HOSE BAND 1/4 INSULATION INNER DUCT INSUL DUCT SIDE OR INNER DUCT RETAINER INSULATION (450) RETAINER INSULATION (220) INSULATION RETAINMENT HANGER WASHER SELF LOCKING DOME FOAM STRIP 3/4" WIDE X 3/16" THK (46” LG) TAPE FOAM 1 X 1 (22.5” LG) TUBE FAN CLUTCH PREHTR UPPR C2 GUARD FAN C2 CPL, BOTTOM FTG CMPN BLKHD 3/8" OD TUBE BRS FTG CMPR 3/8TUBE X 3/8 NPT W/FERL BARBED STR 3/8 NPT X 3/8 CLAMP HOSE .38-.87 HOSE DRAIN ASSY 28" CAP HEX 1/4 NPT BRASS SPRING CLIP HOLDER .37-.62 SCREW HHTT M4-0.7 X 8 BP GROMMET .75 X .12 X .50 TUBE FAN CLUTCH PREHTR LOWR C2 GUARD FAN C2 CPL, TOP CAP RADIATOR 13 PSI * ITEM #39 IS INCLUDED WITH ITEM #38. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 0F6504 0F3127 0F2808B 0F0738 0F2962 0F2830 047411 022097 022473 080762 0D9832 087171 083215 051548 0F3794 0F3794A 0E8816 036797 024114 022129 0F5078 0F3133 1 1 1 1 1 1 2 2 2 1 4 8 4 4 1 1 1 4 8 8 1 1 PIPE R/H SIDE MUFFLER PIPE L/H SIDE 3.9L CPL PIPE EXHAUST MUFFLER OUT MUFFLER 7" X 9"-(2) 2" IN/2.5" OUT MUFFLER STRAP MUFFLER BRACKET STIFFENER SCREW HHC M6-1.0 X 16 G8.8 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC BOLT U 3/8-16 X 2.62 SCREW HHC M12-1.75 X 75 SS WASHER FLAT 1/2 SS WASHER LOCK 1/2 SS NUT HEX M12-1.75 G8 SS EXHAUST BLANKET 549MM LONG (R/H) EXHAUST BLANKET 448MM LONG (L/H) EXHAUST FLANGE 2" PIPE BOLT U 5/16-18 X 2.25 NUT HEX 5/16-24 STEEL WASHER LOCK M8-5/16 PIPE L/H SIDE MUFFLER PIPE R/H SIDE 3.9L CPL 1 2 3 4 5 6 7 8 9 10 0F6322 0F5418 0E6406 0E7702 0F6323 037561 049815 049226 051713 0E6586 1 1 1 1 1 1 4 4 4 1 BOTTOM PLATE, AIR CLEANER 3.9L ELEMENT AIR FILTER HOLDER VENTURI HOLD DOWN AIR CLEANER PLATE, AIR CLEANER TOP 3.9L NUT WING 1/4-20 NYLK SCREW HHC M5-0.8 X 16 G8.8 WASHER LOCK M5 WASHER FLAT M5 GASKET BOSCH 32 & 40 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 * 18 19 20 21 22 23 24 25 26 27 28 29 30 31 33 033212 075580 0F6390 039253 022145 022129 045771 0E8286 026812 0F8379 0F3869 057823 059194 064945 0D1509 050279 050280 0E7839 0E6586 0E4394 040105 0E6382B 0E7121 0E6376B 042561 0E9295 061012 022097 044118 046580 026915 0F6155 4 1 1 2 2 6 2 1 2 1 1 (REF.) 2 1 1 1 1 1 1 1 1 1 1 (REF) 1 (REF) 1 (REF) 2 1 1 4 1 4 2 1 SCREW HHC 5/16-18 X 1-1/4 G5 FLANGE FUEL INLET REGULATOR ASSEMBLY DUAL FUEL SCREW HHC M8-1.25 X 20 G8.8 WASHER FLAT 5/16-M8 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 CLEAR ZINC STREET EL 45 DEG 1/2" NPT BRASS ELBOW 90D 3/4 NPT NIPPLE PIPE 3/4 NPT X 7” SWITCH PRESSURE GAS 5" RISE (INCLUDED WITH I/N 3) CLAMP HOSE #10 .56-1.06 HOSE 5/8 ID LPG & NG (31.5” LG) GASKET CARB ADAPTOR DECAL INLET PRESSURE DECAL FUEL INLET NG (NATURAL GAS APPLICATION) DECAL FUEL INLET LPG (LP VAPOR APPLICATION) MACHINING CARBURETOR ADAPTOR GASKET BOSCH 32 & 40 ACTUATOR BOSCH 40 GOVERNOR HOSE COOL 2IN ID 20R4 (2” LG) VENTURI HOLDER W/40MM ACTUATOR O-RING 47.625 ID X 2.38 WIDTH VENTURI 28 ID THROTTLE W/CHOKE CLAMP HOSE #36 1.88-2.75 ASSY THROTTLE 28MM PLUG STD PIPE 1/8 SOCKET HEAD WASHER LOCK M6-1/4 BARBED STR 1/2 NPT X 5/8 SCREW SHC M6-1.0 X 45 G12.9 NIPPLE CLOSE 3/4 X 1.375 HARNESS CPL FUEL JUMPER NOTES: 1. REGULATOR (I/N 3) AS SHOWN IN ILLUSTRATION IS SET UP FOR NATURAL GAS APPLICATION. 2. TO CONFIGURE REGULATOR FOR LP VAPOR, SWITCH HOSE BARB, HOSE CLAMP (I/N 13) AND HOSE (I/N 14) FROM “OUT-1” TO “OUT-2”. 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 P/N 050280 FOR NG FUEL INLET DECAL P/N 050279 (ITEM17). 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. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 ** 40 * 43 *** 0F5853 (XX) 0C2454 0F5849 (XX) 087233 0E3257 0F5852 (XX) 0F5850 (XX) 0F5851 (XX) 0F3313 0F3312 0F5848 0F2786 0F2785 0F3364 0F4880 0F5049 0C2634A 022473 022097 022127 0F3072 078115 0F4051 0F4051A 0F5048 0E5968 0F3760K 0F3760E 0F4051C 0F3890B 0F4051B 0F3890 0F3890A 0F3760L 042568 0912970094 022447 049813 077992 0F6321 0C3397 1 68 2 2 4 2 2 1 1 (REF.) 1 (REF.) 1 2 1 1 2 2 1 3 1 1 16 48 2 1 2 1 2 2 2 8 2 4 3 1 2 2 2 2 21 1 4 REAR WRAP C2 SCREW THF M6-1 X 16 N WA Z/JS DOOR C2 RIVET POP .1875 X .450 SS SCREW TH-FRM M6 W/CAP SHKPRF W DISCHARGE DUCT,LH & RH SIDE C2 FRONT CORNERS C2 DISCHARGE CENTER DUCT C2 DUCT INNER DISCHARGE C2 DUCT INNER DISCHARGE TOP C2 ROOF C2 ALUM SLITTER C4 SPLITTER LOWER C4 SPLITTER STINGER C2 SUPPORT SPLITTER LH C2 TAB PULL ASSEMBLY COVER ACCESS WASHER FLAT 1/4-M6 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL INSULATION RETAINMENT HANGER WASHER SELF LOCKING DOME INSULATION DOOR C2 INSULATION ROOF TOP LATCH VISE ACTION 5/16HEX SOCK GASKET EXTRUDED TRIM (440.64” LG) INSULATION SPLITTER INSULATION SPLITTER INSULATION DUCT RETAINER INSULATION (820) INSULATION DUCT SIDES RETAINER INSULATION (450) RETAINER INSULATION (740) INSULATION LOWER SPLITTER SCREW HHC M6-1.0 X 20 G8.8 ASSY WIRE 14 AWG 34.8" GRN/YEL WASHER SHAKEPROOF INT 1/4 NUT HEX M6 X 1.0 G8 YEL CHR NUT HEX LOCK M6-1.0 SS NY INS ROOF RAIN DEFLECTOR FASTENER RATCHET OPTIONAL COMPARTMENT MATERIALS: ALL P/N’S WITH AN (XX) SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION. USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER: PART NO. 0XXXXXSN 0XXXXXAN 0XXXXXSG 0XXXXXAG MATERIAL STEEL ALUMINUM STEEL ALUMINUM COLOR TAN TAN GRAY GRAY * 3.9L ONLY ** ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 2 & 5 THREAD FORMING FASTENER AND ITEM 39 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER. *** 3.0L ONLY Standby Generator Sets Warranty 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. • 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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Any unit built/manufactured prior to January 1, 2005. Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up). Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze. 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. 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. 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. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing. 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). Failure due to misapplication, misrepresentation, or bi-fuel conversion. Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses. Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.). Overtime, holiday, or emergency labor. Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal. Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct cause of the problem. 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.
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