Generac Power Systems 20 Users Manual Cover113 RevB 09 07

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1.6L
20/25/30 kW
Models

Serial Number

STANDBY GENERATOR

OWNER'S MANUAL

A new standard of reliability

Not intended for use in critical life support applications. 
—CAUTION—
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
Cover113 Rev. B 09/07

Catalog Number OMASPEA025-2

Part No. 0G5244

Standby Generator Sets
Table of Contents

SECTION
PAGE
SAFETY RULES ................................................ 1-1

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

INTRODUCTION .....................................................1-3
Read this Manual Thoroughly ...................................1-3
Operation and Maintenance ......................................1-3
How to Obtain Service ..............................................1-3
IDENTIFICATION RECORD .....................................2-1
Data Label ................................................................2-1
EQUIPMENT DESCRIPTION ...................................3-1
Equipment Description ................................................3-1
Engine Oil Recommendations ......................................3-1
Coolant Recommendations...........................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
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
Reconfiguring the Fuel System ..................................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
Transfer Switch ........................................................8-1
Fuel System ..............................................................8-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Engine Coolant .........................................................8-1
Belt Tension ..............................................................8-1
Electrical System ......................................................8-1
Initial Inspection for Genset Start-up ...........................8-1
Start-up Checklist ........................................................8-2
Preparation for Start-up............................................8-2

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

Generator Control and Operation ................................9-1
Engine Start-up and Transfer ...................................9-1
Retransfer and Shutdown .........................................9-1
Operating Unit with Automatic Transfer Switch ...........9-1
MAINTENANCE.....................................................10-1
Maintenance Performed by Service Facilities ..............10-1
Every Three Months ...............................................10-1
Once Every Six Months ...........................................10-1
Once Annually.........................................................10-1
First 30 Operating Hours ........................................10-1
First 100 Operating Hours ......................................10-1
Every 500 Operating Hours ....................................10-1
Every 800 Operating Hours ....................................10-1
Cooling System ..........................................................10-1
Overload Protection for Engine DC
Electrical System ....................................................10-1
Checking Fluid Levels ................................................10-1
Check Engine Oil ....................................................10-1
Battery Fluid ...........................................................10-2
Engine Coolant .......................................................10-2
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 ...............................................10-3
Changing the Engine Air Cleaner ............................10-3
Spark Plugs ............................................................10-3
Coolant Change .......................................................10-3
Miscellaneous Maintenance ........................................10-4
Cleaning the Generator ...........................................10-4
Battery ....................................................................10-4
Battery Maintenance ...............................................10-4
Battery Replacement ...............................................10-4
Repair Parts ............................................................10-4
SERVICE SCHEDULE ...........................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
Content014 Rev. A 04/07

Standby Generator Sets
Important Safety Instructions





WARNING:

 GENERAL HAZARDS 

The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.



WARNING:



• For safety reasons, the manufacturer recommends
that this equipment be installed, serviced and
repaired by a Service Dealer or other competent,
qualified electrician or installation technician who
is familiar with applicable codes, standards and
regulations. The operator also must comply with
all such codes, standards and regulations.
• 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.
This should be considered prior to installing the
generator. The unit should be positioned to direct
exhaust gasses safely away from any building
where people, animals, etc., will not be harmed.
Any exhaust stacks that ship loose with the unit
must be installed properly per the manufacturer's
instruction, and in strict 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.



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

Safety004 Rev. B 08/07



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

Safety004 Rev. B 08/07

Standby Generator Sets
Important Safety Instructions

INTRODUCTION

symbol points out potential explosion
 This
hazard.

Thank you for purchasing this model of the standby
generator set product line.

 This symbol points out potential fire hazard.
symbol points out potential electrical shock
 This
hazard.

Every effort was expended to make sure that the
information and instructions in this manual were
both accurate and current at the time the manual was
written. However, the manufacturer reserves the right
to change, alter or otherwise improve this product(s)
at any time without prior notice.

The operator is responsible for proper and safe use
of the 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 Service Dealer for starting, operating
and servicing procedures.
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:

‹ OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by a Service Dealer.
Normal maintenance service and replacement of parts
are the responsibility of the owner/operator and, as
such, are not considered defects in materials or workmanship within the terms of the warranty. Individual
operating habits and usage contribute to the need for
maintenance service.

DANGER
After this heading, read instructions that, if not
strictly complied with, will result in serious personal injury, including death, or property damage.

Proper maintenance and care of the generator ensure
a minimum number of problems and keep operating
expenses at a minimum. See a Service Dealer for service aids and accessories.

After this heading, read instructions that, if not
strictly complied with, may result in personal
injury or property damage.

Operating instructions presented in this manual
assume that the standby electric system has been
installed by a Service Dealer or other competent,
qualified contractor. Installation of this equipment is
not a “do-it-yourself” project.

After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:

‹ HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
simply contact a Service Dealer for assistance.
Service technicians are factory-trained and are capable of handling all service needs.

After this heading, read explanatory statements
that require special emphasis.
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.

When contacting a Service Dealer 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.

Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:
symbol points out important safety infor This
mation that, if not followed, could endanger
personal safety and/or property of others.

Safety004 Rev. B 08/07

1-3

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

MANUFACTURING INFORMATION

Identy 005 Rev. A 03/07

2-1

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 F rated as
defined by NEMA MG1-32.6, NEMA MG1-1.66.
The generator is self ventilated and drip-proof constructed.
• The voltage waveform deviation, total harmonic
content of the AC waveform and telephone influence factor have been 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 5W-30 engine oil at the
factory. Use a high-quality detergent oil classified “For
Service SJ or SH.” Detergent oils keep the engine
cleaner and reduce carbon deposits. When changing
the engine oil, be sure to use 5W-30 engine oil (synthetic oil is recommended).

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.

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.

Equip007 Rev. A 04/07

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

‹ GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ....................................................................Class F
Stator Insulation ...................................................................Class F
Total Harmonic Distortion .........................................................< 5%
Alternator Output Leads 3-phase ........................................... 4-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) ................................ 20/25/30 kW*

‹ COOLING SYSTEM
Type .......................................................................................Closed
Water Pump.................................................................... Belt Driven
Fan Speed ................................................................................ 2450
Fan Diameter ..................................................................17.7 inches
Fan Mode ..............................................................................Pusher
Air Flow (inlet air including alternator and
combustion air) ........................................................... 2490 ft3/min.
Coolant Capacity ...........................................................2.0 U.S. gal.
Heat Rejection to Coolant ..........................................117,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature................................50° C (140° F)

* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural
gas.

Excitation System ....................................................................Direct
Generator Output Voltage/kW - 60 Hz
kW
Amp
CB Size
120/240V, 1-phase, 1.0 pf 20/25/30 83/104/125 100/125/150
120/208V, 3-phase, 0.8 pf 20/25/30
69/87/104 80/100/125
277/480V, 3-phase, 0.8 pf 20/25/30
30/38/45
35/45/50

‹ 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

Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208 3-phase:
20kW
25kW
30kW
34 KVA 38 KVA 56 KVA

‹ ENGINE
Make ................................................................................... Generac
Model ..................................................................................... In Line
Cylinders and Arrangement............................................................ 4
Displacement ....................................................................... 1.6 Liter
Bore ...................................................................................... 3.15 in.
Stroke ................................................................................... 3.13 in.
Compression Ratio .............................................................9.75-to-1
Air Intake System ...............................................Naturally Aspirated
Valve Seats................................................................... Replaceable
Lifter Type .......................................................................... Hydraulic

Fuel Consumption - ft3/hr
Exercise
25%
Cycle
Load
20kW
56/24
124/49
25kW
56/24
161/64
30kW
56/24
209/82

(Natural Gas/LPV)
50%
75%
100%
Load
Load
Load
188/75
250/99 315/125
253/101 345/138 430/175
281/117 360/147 437/185

‹ ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 15 Amp
Static Battery Charger ............................................................2 Amp
Recommended Battery...................................... Group 26, 525CCA
System Voltage .....................................................................12 Volts

Engine Parameters
Rated Synchronous RPM ..............................................60 Hz, 3600
HP at rated:
20kW
25kW
30kW
35 HP
45 HP
48 HP

Voltage Regulator
Type .................................................................................. Electronic
Sensing........................................................................ Single-phase
Regulation ................................................................................± 1%
Features ................................................. V/F Adjustable, Adjustable
Voltage and Gain LED Indicators

Exhaust System
Exhaust Flow at Rated Output 60 Hz: 20kW
25kW
30kW
209 cfm 235 cfm 240 cfm
Exhaust Temp. at Rated Output:
910°F 1015°F 1022°F

Power Adjustment for Ambient Conditions
Temperature Deration:
3% for every 10° C above °C
20kW
25kW
40
40
1.65% for every 10° above °F
104
104
Altitude Deration:
1% for every 100 m above m
20kW
25kW
1220
915
3% for every 1000 ft. above ft.
4000
3000

Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz:
20kW
25kW
30kW
80 cfm 90 cfm 92 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation........................................................± .25%
Adjustments:
Speed ............................................................................ Selectable

30kW
25
77
30kW
182
600

Controller .................................................R-200
GenSpec037 Rev. A 04/07

6-1

Standby Generator Sets
Specifications

Figure 6.1 — Interconnections

Utility In
Transfer Switch

CONTROL PANEL

NEUTRAL

TO
ALTERNATOR

Gen

N1
N2
23
194

GENERATOR
CONNECTION
BOX

183
178

NEUTRAL

N1
N2
23
194

4- # 14 GA
WIRES TO
GENERATOR
CONNECTION
BOX

CIRCUIT
BREAKER

Battery
Charger
Input

186
178

Load
Out
TO GENERATOR
CONNECTION BOX

GROUND

120 Volt +
Neutral
Grd

To Generator Control Panel
FRAME RAIL

Ground Level
Concrete Slab

KW
25
25

STUB-UP AREA
See Install Dwg for
Dimensions

‹ COLD WEATHER KIT

CIRCUIT BREAKER SIZE
VOLTS / AMPS
LUG SIZE
240 1 Ø
125
#4 to 1/0
208 3 Ø
100
#4 to 1/0

NOTE:

For cold climates, optional cold weather kit (part
number 0F6148) is recommended. The kit includes:

The jet sizes are stamped on the individual jets.
The larger jet size is used for running on NG.

• Battery Warmer
• 4” Junction Box with hardware
• 6 qt. pack 5W-30 synthetic oil (engine)

8. Install the previously removed NG jet into the jet
keeper port on the side of the regulator housing.
9. Install the previously removed black pipe onto
the outlet port of the demand regulator.
10. Reverse steps 1-4 in this procedure to reactivate
the demand regulator.

‹ RECONFIGURING THE FUEL SYSTEM
NOTE:

Figure 6.2 — Reconfigure the Fuel System

All models are configured to run on natural gas
from the factory.
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 of the demand regulator (see Figure 6.2).
3. Disconnect the power wires from the fuel solenoid located on top of the regulator assembly.
4. Loosen the spring clamp on the small fuel enrichment line and remove the hose from the hose
barb.
5. Remove the black pipe assembly from the outlet
port of the demand regulator.
6. Remove the NG fuel jet (loosen counter clockwise) from the outlet port.
7. Remove the LP fuel jet (loosen counter clockwise)
from the jet keeper port on the side of the regulator housing. Install this jet into the outlet port in
the regulator casting.

DANGER
injury or damage may occur if not con Serious
figured properly. Please consult an Authorized
Dealer with any questions.
6-2

GenSpec037 Rev. A 04/07

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” 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

NOTE:

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.

Battery charger must be connected to 120 VAC, 15
amp circuit to operate.
Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear
of any moving generator set components.

‹ GENERATOR SET LUBRICATION

INITIAL INSPECTION FOR GENSET
STARTUP

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”.

Inspect for the following.
•
•
•
•
•

Freight Damage.
Manuals present.
Fluid Levels (Oil, coolant, battery, Gear Drive).
Correct fuel piping.
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.

This engine is shipped from the manufacturer
with “break-in” oil. This oil should be changed
after 30 hours of operation.

8-1

Install002 Rev. C 01/07

NOTE:

Standby Generator Sets
Installation

• 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.
• 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.

• Battery charger connection to 120 VAC.
• Communication wires connected between transfer
switch and generator (HTS only).
• Unit secured to pad.

START-UP CHECKLIST
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. 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.

8-2

Install002 Rev. C 01/07

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
SERVICE FACILITIES

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.

working on the generator, ensure the fol Before
lowing:

Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to shut down. (See the installation diagram.)

• 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.

exhaust system parts from this product get
 The
extremely hot and remains hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.

‹ EVERY THREE MONTHS
1.
2.
3.
4.
5.
6.

Check battery condition.
Inspect and test fuel system.
Check transfer switch.
Inspect exhaust system.
Check engine ignition system.
Check fan belts.

OVERLOAD PROTECTION FOR ENGINE
DC ELECTRICAL SYSTEM
Engine cranking, start up and running are controlled
by a solid state Engine Controller circuit board.
Battery voltage is delivered to that circuit board via
a 15 amp fuse. These overcurrent protection devices
will open if the circuit is overloaded.

‹ ONCE EVERY SIX MONTHS
1. Test Engine Safety Devices (low oil pressure, low
coolant level, high coolant temperature).

‹ ONCE ANNUALLY

a circuit breaker opens or a fuse element
 Ifmelts,
find the cause of the overload before

1. Test engine governor; adjust or repair, if needed.
2. Clean, inspect generator.
3. Flush cooling system.

resetting the circuit breaker or replacing the
fuse.

‹ FIRST 30 OPERATING HOURS

CHECKING FLUID LEVELS

1. Change engine "break-in" oil and filter.

‹ CHECK ENGINE OIL

‹ FIRST 100 OPERATING HOURS

Check engine crankcase oil level (Figure 10.1) at least
every 20 hours of operation, or prior to use.

1. Change engine oil and oil filter. After initial
change, service engine oil and filter at 100 operating hours or six months, whichever comes first.
2. Retorque cylinder head.
3. Retorque intake and exhaust manifold.

• 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.

‹ EVERY 500 OPERATING HOURS
1. Service air cleaner.
2. Check starter.
3. Check engine DC alternator.

‹ EVERY 800 OPERATING HOURS
Retorque cylinder head.
Retorque intake and exhaust manifold.
Check engine compression.
Check valve clearance.
10-1

Maint011 Rev. D 06/07

1.
2.
3.
4.

Standby Generator Sets
Maintenance

‹ EXERCISE SYSTEM

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Start the generator engine at least once every seven
days and let it run at least 20 minutes. For more
detailed exercise information, see the respective sections in the Control Panel Technical Manual that is
supplied with the unit.

OIL FILL CAP

‹ INSPECT COOLING SYSTEM
• Inspect engine cooling system. See “Maintenance
Schedule”.
• Check hoses for damage, deterioration, leaks, etc.
Correct any discrepancies found.
• Check hose clamps for tightness.

OIL
DIPSTICK

‹ CHECK ENGINE COOLANT LEVEL
See “Checking Fluid Levels”.

‹ 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.

‹ BATTERY FLUID
Check battery electrolyte fluid based on the
Maintenance Schedule. Fluid should cover separators in all battery cells. If fluid level is low, add distilled water to cover tops of separators. DO NOT USE
TAP WATER IN BATTERY.

‹ INSPECT EXHAUST SYSTEM
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 COOLANT
Check coolant level in coolant recovery bottle. See
Specifications.

‹ CHECK FAN BELT

• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap (only
when engine has cooled down) to make sure the
coolant recovery system is functioning properly.
Coolant should be at bottom of radiator filler neck.
If coolant level is low, inspect gasket in radiator
pressure cap. Replace cap, if necessary. To have
pressure cap tested, contact a Service Dealer.
Inspect cooling system and coolant recovery system for leaks.

• 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 of an inch. Adjust belt tension as required.

‹ INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.

DANGER

MAINTENANCE OWNER/OPERATOR
CAN PERFORM

not attempt to adjust the governor. Only
 Do
qualified service facilities should adjust the
governor. Excessively high operating speeds
are dangerous and increase the risk of personal
injury. Low speeds impose a heavy load on the
engine when adequate engine power is not
available and may shorten engine life. Correct
rated frequency and voltage are supplied only
at the proper governed speed. Some connected
electrical load devices may be damaged by incorrect frequency and/or voltage. Only qualified
service technicians should adjust the governed
speed.

‹ CHECK ENGINE OIL LEVEL
Refer to “Checking Fluid Levels”.

‹ CHECK BATTERY
• See “Checking Fluid Levels”.
• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as
necessary.
10-2

Maint011 Rev. D 06/07

Standby Generator Sets
Maintenance

‹ CHANGING ENGINE OIL

Figure 10.3 – Engine Air Cleaner

Refer to maintenance performed by service facilities
for engine oil and filter change frequencies.

Air Cleaner

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:
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. Properly dispose of old filter.
(Doors Removed for Clarity)

Figure 10.2 – Oil Filter

‹ SPARK PLUGS
Reset the spark plug gap or replace the spark plugs
as necessary (Figure 10.4).

OIL
DIPSTICK

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 0.76 mm (0.030 inch)
by carefully bending the ground electrode (Figure
10.4).

OIL
FILTER
5. Apply light coating of new engine oil to seal of new
oil filter.-Install FILTER and tighten by hand only.
DO NOT OVER TIGHTEN.
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).

Figure 10.4 – Setting the Spark Plug Gap
SET PLUG GAP AT 0.76 mm
(0.030 inch)

refilling the crankcase with oil, always
 After
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
7. Start engine and check for oil leaks.

‹ CHANGING THE ENGINE AIR CLEANER

‹ COOLANT CHANGE

To replace the engine air cleaner, simply remove the
air cleaner cover and replace the air filter making
sure it is positioned properly before reattaching the
cover (Figure 10.3).

Every year, have a service facility drain, flush and
refill the cooling system. See “Specifications” for cooling system recommendations.

See the “Service Schedule,” for air cleaner maintenance.
Maint011 Rev. D 06/07

10-3

Standby Generator Sets
Maintenance

MISCELLANEOUS MAINTENANCE

3. Have the state of charge and condition checked.
This should be done with an automotive-type battery hydrometer.

‹ CLEANING THE GENERATOR

DANGER

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.
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.
Once each year have the generator cleaned and
inspected by a Service Dealer. That dealer will use
dry, low pressure air to clean internal windings. Parts
inside the control console should be cleaned and
inspected at this time as well.

batteries give off explosive hydrogen
 Storage
gas. This gas can form an explosive mixture



Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
excessively low, the generator may require drying.



‹ BATTERY
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.

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.
Battery electrolyte fluid is an extremely corrosive sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If fluid is spilled, flush the
affected area immediately with clear water.
Do not use any jumper cables or booster battery
to crank and start the generator engine. If the
battery has completely discharged, remove it
from the generator for recharging.

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.
Be sure the 120VAC power supply to the battery
is turned OFF, or sparking may occur at the battery posts as the cables are attached and cause
an explosion.

‹ BATTERY REPLACEMENT
NOTE:
Unit DOES NOT include battery.
When supplying or replacing the battery, the recommended number and type of battery is listed in the
Specifications Section.
NOTE:
The BCI number should be located directly on the
battery.

‹ BATTERY MAINTENANCE

‹ REPAIR PARTS

The battery should be inspected per the Scheduled
Maintenance section. The following procedure should
be followed for inspection:
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.

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.
10-4

Maint011 Rev. D 06/07

Standby Generator Sets
Service Schedule

SERVICE SCHEDULE
The following is a recommended maintenance schedule for small standby and residential generator sets. The
established intervals in the schedule are the maximum recommended when the unit is used in an average service
application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use calendar time or accumulated run 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.
Performed monthly this requires approximately .5 man-hours per unit to complete.
This inspection may be performed by the end user providing the following safety steps are taken to prevent
the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
•
•
•
•

Disable the generator set from starting and/or connecting to the load by setting the control panel
AUTO/OFF/MANUAL switch to the OFF position.
Remove the 5 amp and 15 amp control panel fuses.
Turn off the battery charger (turn OFF utility supply to ATS).
Remove the negative battery cable.

The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition
from burning out sensitive control panel components and circuits.
Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal
operation when required.
2 A break-in service inspection of the generator set to insure it is ready to operate and carry the load when
required, and to identify any potential problem areas.
Performed ONLY ONCE following the first three months, or 30 run time hours of operation after purchase of
the unit and requires approximately 2.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by a Service Dealer.
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed semi-annually this requires approximately 1.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by a Service Dealer.
4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed annually this requires approximately 4.0 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by a Service Dealer.

SrvSchd002 Rev. C 05/06

11-1

Standby Generator Sets
Service Schedule

Maintenance
Tasks

Level 1
Recommended
to be done
monthly
10 Hrs.

Level 2
Task
Comp.
(DateInitials)

Required
to be done
3 months/
Break-in
30 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 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 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.
10. Check the engine
accessory drive belts for
wear, weather cracking,
and damage. Replace as
necessary.
11. Visually inspect the unit
looking for leaks, wear or
damage, loose connections
or components, and
corrosion. Correct as
necessary.
12. Test the engine and
transfer switch safety
devices. Correct and/or
adjust as necessary.

11-2

Level 3
Task
Comp.
(DateInitials)

Required
to be done
Semiannually
50 Hrs.

Level 4
Task
Comp.
(DateInitials)

Required
to be done
Annually
100 Hrs.

Task
Comp.
(DateInitials)

SrvSchd002 Rev. C 05/06

Standby Generator Sets
Service Schedule

Maintenance
Tasks

Level 1
RecomTask
mended
Comp.
to be done (Datemonthly
In itials)
10 Hrs.

Level 2
Required
to be done
3 months/
Break-in
30 Hrs.

Level 3
Task
Comp.
(DateInitials)

Required
to be done
Semiannually
50 Hrs.

Level 4
Task
Comp.
(DateInitials)

Required
to be done
Annually
100 Hrs.

Task
Comp.
(DateInitials)

13. Initiate an automatic start
and transfer of the unit to
site load and exercise it for
at least 1 hour looking for
leaks, loose connections
or components, and
abnormal operating
conditions. Correct as
necessary.
14. Start and exercise the unit
at full rated load (use a
load bank if the site load is
not enough) for at least 2
hours looking for leaks,
loose connections or
components, and abnormal
operating conditions.
Correct as necessary.
15. Change the engine oil.
16. Replace the engine oil
filter(s).
17. Replace the engine air
filter(s).
18. Replace the engine fuel
filter(s) on diesel engine
driven units and re-prime
the fuel system.
19. Check the engine spark
plugs on gas engine driven
units. Clean and re-gap or
replace as necessary.
20. Perform a 5 minute no-load
operational run of the unit
looking for any post service
problems.
21. Return the unit to standby
setup for operation when
required.

SrvSchd002 Rev. C 05/06

11-3

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 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.

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

2. Unclog fuel line.
3. Clean, regap or replace plugs.
4. Confirm fuel pressure to regulator is as
recommended in SPECIFICATIONS.

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 Dealer for assistance.

12-1

Trblsht002 Rev. 0 09/05

Engine starts hard, runs rough.

4. Clean, regap or replace plugs.
5. Close door on tank.

Standby Generator Sets
Notes

Standby Generator Sets
Notes

Standby Generator Sets
Notes

Standby Generator Sets
Notes

1

2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18
19
20
21
22
(1) 23
24
25
26
27
28

0G4827
0G2927
0G2827
0G3451C
0G0820A
0G4452
020746
049226
051713
022129
0G4825
0G4826
0G2926
0G3682
0G5584
0G3685
0G2826
0G3683
0G6573
0G3686
0G3452C
0G3684
0G3687
0G5909
0G6103
0A5382A
075591
051787
0A5601A
075554B
075554E
0A9375
022152
0G4196
042558
049814
0G0965B
053607
051769
023365
0F3353
072578
0G3787
0A8830
077043E
0G2070

1
1
1
1
1
1
4
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
4
1
4
4
4
4
1
1
4
1
1
1
4
6
1
10
4
1
1

ASSY RTR 104 KD1 HI EFF (18KW)
RTR-102-20.0AD1 CPL (2006) (20KW)
ASSY RTR 25KW 2P (2006) (25KW)
RTR 102 30KD2 (2006) CPL CHI (30KW)
HOUSING BLOWER LG PILOT
BLOWER HOUSING SCREEN
SCREW PPHM M5-0.8 X 8 ZINC
WASHER LOCK M5
WASHER FLAT M5
WASHER LOCK M8-5/16
ASSY STR 104-18AD1 HI EFF (18KW)
ASSY STR 104 18GD1 HI EFF (18KW)
STR-102-20.0AD1 CPL (2006) (20KW)
STR-102-20.0GD1 CPL (2006) (20KW)
STR-102-20.0JD1 CPL (2006) (20KW)
STR-102-20.0KD1 CPL (2006) (20KW)
ASSY STR 102 25AD1 (2006) (25KW)
STR-102-25.0GD1 CPL (2006) (25KW)
STR-102-25.0-JD1 CPL (2006) (25KW)
STR-102-25.0KD1 CPL (2006) (25KW)
STR 102 30AD2 (2006) CPL CHI (30KW)
STR-102-30.0GD2 CPL (30KW)
STR-102-30.0KD2 CPL (30KW)
ASSY STR 102 30AD2 10" (30KW)
STR-102-30.0JD2
BEARING CARRIER REAR LG PILOT
ASSY HOLDER BRUSH
SCREW HHC M4-0.7 X 16 G8.8
COVER REAR BEARING
BOLT STATOR X 16" LG (20KW & 25KW)
SCREW HHC M8-1.25 X 463 G5 ZP (30KW)
SCREW RHM #10-24 X 2
WASHER LOCK #10
FLYWHEEL & RINGGEAR ASSY 1.6L
KEY SQ 3/8 X 1 STEEL
SCREW HHC M10-1.5 X 25 G8.8
PLATE FLEX 1.6L R12.7
SCREW HHC M12-1.75 X 35 G8.8
WASHER LOCK M12
WASHER SHAKEPROOF INT #8
SCREW HHC M10-1.0 X 20 G10.9
SPACER ROTOR SHAFT
WASHER .41 ID .94 OD .12 THK
WASHER FLAT .34 ID X .75 OD
FLEX CONDUIT 1" BLACK (NOT SHOWN)
PLATE SPACER 14GA 1.6L

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

1
A

B
C
D
E
F
G
H
J
K
L
2
A

B
C
D
E
F
G
H
J
K
L

N/A
0D5543
0D5544
0A2077
0G4499
0C2265
0C2264
0E7890
0G4497
052619
023897
049226
051716
0E3257

N/A
1
1
1
1
2
2
1
1
2
4
2
2
7

UL BREAKER BQ2
CB 0090A 2P 240V S BQ2 LL
CB 0100A 2P 240V S BQ2 LL
CB 0125A 2P 240V S BQ2 LL
CB COVER 20-25K 1P (BQ2)
SCREW PHTT M4-0.7 X 12 ZYC
WASHER LOCK #8-M4
BRKT CB MTG BACK
CIRCUIT BREAKER SUPPORT (BQ)
SCREW HHC M5-0.8 X 20 G8.8
WASHER FLAT #10 ZINC
WASHER LOCK M5
NUT HEX M5-0.8 G8 CLEAR ZINC
SCREW HWHTF M6-1.0 X 16

N/A
049135
062812
040532
0G4500
0C2265
0C2264
0E6002
0G4497
052619
023897
049226
051716
0E3257

N/A
1
1
1
1
2
2
1
1
3
6
3
3
7

UL BREAKER BQ3
CB 0070A 3P 240V S BQ3 LL
CB 0080A 3P 240V S BQ3 LL
CB 0100A 3P 240V S BQ3 LL
CB COVER 20-25K 3P (BQ3)
SCREW PHTT M4-0.7 X 12 ZYC
WASHER LOCK #8-M4
BRKT CB MTG BACK
CIRCUIT BREAKER SUPPORT (BQ)
SCREW HHC M5-0.8 X 20 G8.8
WASHER FLAT #10 ZINC
WASHER LOCK M5
NUT HEX M5-0.8 G8 CLEAR ZINC
SCREW HWHTF M6-1.0 X 16

3
A

B
C
D
E
F
G
H
J
K
L

N/A
0D5548
0D5549
0D5551
0D5552
0D5556
0D5557
0D9693
0G4502
066715
038150
022264
022471
0A8278
022097
0D5621
0G4498
0E3257

N/A
1
1
1
1
1
1
1
1
4
4
4
4
3
3
3
1
7

UL BREAKER ED
CB 0030A 3P 480V S ED4 LL
CB 0035A 3P 480V S ED4 LL
CB 0045A 3P 480V S ED4 LL
CB 0050A 3P 480V S ED4 LL
CB 0090A 3P 480V S ED4 LL
CB 0100A 3P 480V S ED4 LL
CB 0125A 3P 480V S ED4 LL
CB COVER 20-30K 3P (ED)
SCREW RHM #8-32 X 4-1/2
WASHER FLAT #8 ZINC
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
SCREW SHC 1/4-28 X 3/4 G8.8 NZ
WASHER LOCK M6-1/4
WASHER-STEP 1/2ODX9/32ID BRASS
CIRCUIT BREAKER SUPPORT (ED)
SCREW HWHTF M6-1.0 X 16

4
A
B
C
D
E
F

N/A
0E7283
0G3474
074908
0E3257
0E3664
0G4112

N/A
1
1
2
7
1
1

UL BREAKER QN
CB 0150A 2P 240V S QN2 LL
CONBOX FRONT COVER 1.6L QN 2P
SCREW HHTT M5-0.8 X 10 BP
SCREW HWHTF M6-1.0 X 16
BASE, QN CIRCUIT BREAKER
BREAKER SUPPORT BRACKET 30KW

5
6
7

26
27
28

0A1354A
0G3473
0F6366A
0F6366B
0G3524
057701
0F3824
057073
057329
0D4698
0F4464
025433
0G3472
0E3257
0C2212
022264
022241
022237
0C2265
023762
0A9457
0G4577E
0G4578E
047411
022097
049813

1
1
1
1
1
1
1
1
1
1
1
1
1
22
4
9
1
1
5
1
1
REF
REF
1
1
1

REGULATOR - DC ALT
CONBOX TOP PANEL SUPPORT
XFMR 208 TO 16V 6VA (208V. ONLY)
XFMR 240 TO 16V 6VA (240 / 480V.)
COVER BELL HOUSING CONBOX
BLOCK TERM 20A 8 X 6 X 1100V
DECAL UTIL SENSE/CUST CONN
JUNCTION BLOCK 3/8-16
LUG SLDLSS 350-#6X13/32 AL/CU
BLOCK TERM 20A 6 X 3 X 1100V
DECAL CUST CONN 120V UTILITY
LUG SLDLSS #6-14 X 13/64 CU
CONBOX BACK & SIDES 1.6L
SCREW HWHTF M6-1.0 X 16
SCREW PHTT M4-0.7 X 16 ZYC
WASHER LOCK #8-M4
NUT HEX 3/8-16 STEEL
WASHER LOCK 3/8
SCREW PHTT M4-0.7 X 12 ZYC
WASHER SHAKEPROOF EXT #10 STL
DECAL NEUTRAL
ASSY R-200 3600 1.6L
ASSY R-200 1800 1.6L
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR

5
A
*
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R

N/A
0G5249
W/CB
0G5735
053640
038150
022264
022471
0F8432A
0G5734
0E3257
049897
022129
022145
058306
045771
0F8451
0F8843

N/A
1
2
1
2
2
2
2
1
1
8
4
4
6
2
2
2
2

UL BREAKER
CB 150A 2 POLE 240V 225AF
TERMINAL COVER CB
CB COVER 30K G 225AF
SCREW RHM #8-32 X 3-1/4
WASHER FLAT #8 ZINC
WASHER LOCK #8-M4
NUT HEX #8-32 STEEL
INSULATOR CB 2P 225AF
CIRCUIT BREAKER SPPRT G 225AF
SCREW HWHTF M6-1.0 X 16
SCREW SHC M8-1.25 X 20 G8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
SCREW SHC M8-1.25 X 25 G12.9
NUT HEX M8-1.25 G8 CLEAR ZINC
LUG SLDLSS 300 MCM-6 AL/CU
BUS BAR 200A LUG ADAPTOR

8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
43
44
45
46
47
48

0F1823A
0F3078
0F2606
036261
0E7358
052777
0G3958D
0F1262
0F1263
0F1264
0F1725C
067680
0E6875A
055911
0F5459
0F5462
0A5062J
029673
049350
0F1958
082573
0E4494
0F3215
0F6305
0F6305A
0F5886
051713
049226
0F5752F
0F5884
0F5896
0C2265
0C3990
091526
051716
043182
051714
0F3192
0E7403C
0G4583
0F2627

COMPONENTS INCLUDED IN 0G4577E
1
ENCL HSB CONTROL PANEL
1
COVER CONTROL PANEL
1
HINGE CONTINUOUS H-PANEL
6
RIVET POP .125 X .275 SS
4
SCREW PPPH HI-LO #4-24 X 3/8
3
WASHER FLAT M3
1
ASSY PCB R-200A CNTRL 3600
REF
HOLDER FUSE WICKMANN 178.6150
REF
ADPTR RH SIDE WICKMAN 178.6191
REF
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
REF
BLOCK TERM 20A 12 X 6 X 1100V
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 4 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
2
SEAL COVER 3.18 X 12.7 X 382
1
SEAL COVER 3.18 X 12.7 X 283
3
SCREW HHPM M5-0.8 X 12
14
WASHER FLAT M5
14
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
8
SCREW PPHM M5-0.8 X 12 ZNC
7
NUT HEX M5-0.8 G8 CLEAR ZINC
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 CTRL PNL R-200 LOW KW (NOT SHOWN)
1
PLATE COVER H PANEL

A
B
C
D
E
F
G

056739
022287
022473
022097
022127
0F6145
0G3545

COMPONENTS INSTALLED PER THIS DRAWING
1
RELAY SOLENOID 12VDC PNL MNT
2
SCREW HHC 1/4-20 X 3/4 G5
4
WASHER FLAT 1/4-M6 ZINC
2
WASHER LOCK M6-1/4
2
NUT HEX 1/4-20 STEEL
A/R
SEAL WEATHER .45"DIA
1
DANGER HIGH VOLTAGE (SPANISH)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
23
24
25
26
27
28
29
30
31
32
33
34
35
(1) 36
37
38
39

0G3418
0G3421
0G3419
0E9837B
0G3553
0E3257
0G4080
099502
0G4070
0G4072
0G4071
046627
052250
022473
022097
0C8566
045771
0C2454A
042568
0G3573
0G3574
0G3420
080713
076749
048031C
029032
0G4451
055934N
0F9504
0G0568
0G3433
0E2507
0A2628
029333A
042907
027482
022129
039253

1
1
1
1
1
2
1
6
1
1
1
1
2
8
8
4
4
28
4
1
1
1
1
1
2
1
REF
2
1
1
1
1
1
1
4
4
4
4

RADIATOR SUPPORT LH SIDE 1.6L
VENTURI 1.6L
RADIATOR SUPPORT RH SIDE 1.6L
RADIATOR 1.6L CHY
FAN COOL 450MM DIA 7 BLADE
SCREW HWHTF M6-1.0 X 16
HOSE LOWER RADIATOR 1.6L
CLAMP HOSE #24 B1.06-2.00
HOSE REAR COOLANT 1.6L
TUBE ENGINE COOLANT 1.6L
HOSE UPPER RADIATOR 1.6L
CAP RADIATOR
TAPE FOAM 1 X 1 (24” LG)
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
SCREW HHFC M6-1.0 X 20 G8.8
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW THF M6-1 X 12 N WA Z/JS
SCREW HHC M6-1.0 X 20 G8.8
GUARD FAN LH C1
GUARD FAN RH C1
RADIATOR BLOCK-OFF
BRACKET COOLANT TANK
TANK COOLANT RECOVERY
CLAMP HOSE BAND 1/4
HOSE 9/32 ID (43” LG)
BRACKET STEPPER MOTOR COOLANT
CLAMP VINYL 1.31 X .281 Z
GROMMET 5/8"X 1 1/8"X 5/16"
ASSY FAN BEARING SUPPORT
BRACKET FAN ALT ADAPTER 1.6L
PROBE COOLANT LEVEL 3/8 NPTF
PULLEY - FAN 95 DIA
TIE WRAP UL 7.4" X .19" BLK
SCREW HHC M8-1.25 X 16 G8.8
WASHER SHAKEPROOF EXT 5/16 STL
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 20 G8.8

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

1
2
3
4
5
6
7
8
9
10
11
13
14
15
16
17
18

0G3343
027482
070936
070936C
039253
022145
022129
045771
071956
051730
021991
026850
049813
055414
047411
022097
022473

1
2
2
2
8
12
12
4
4
4
1
1
1
1
1
1
5

MOUNTING BASE 1.6L 2007 C1
WASHER SHAKEPROOF EXT 5/16 STL
DAMPENER VIBRATION
VIB. ISO. 70-75 DURO
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
WASHER FLAT M8
SCREW HHC M8-1.25 X 60 G8.8
EARTH STRAP
WASHER SHAKEPROOF EXT 1/4 STL
NUT HEX M6 X 1.0 G8 YEL CHR
LUG SLDLSS #2-#8 X 17/64 CU
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

0F3408C
0F3411
025507
059980
046526
077483
050331A
050331
038805J
038804M
045771
022131
027482
0F3976
0C2454
022145

1
1
1
1
1
REF
REF
REF
1
1
REF
1
1
1
4
REF

BATTERY TRAY, C1 & C2
STRAP BATTERY RETAINMENT
WASHER SHAKEPROOF EXT 7/16 STL
SCREW HHC M10-1.5 X 25 G10.9
WASHER LOCK M10
BATTERY 12VDC 75-AH 26
BATTERY POST COVER RED +
BATTERY POST COVER BLK CABLE BATTERY BLACK #1 X 30.00
CABLE BATTERY RED #1 X 21.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER FLAT 3/8-M10 ZINC
WASHER SHAKEPROOF EXT 5/16 STL
BOOT CONTACTOR CABLES
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FLAT 5/16-M8 ZINC

NOTE: WHEN INSTALLING BATTERY, TUCK BATTERY’S LIFTING STRAP ALONG
THE LEFT SIDE OF BATTERY ( SIDE OPPOSITE RADIATOR) BEFORE
CONNECTING THE BATTERY CABLES.

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
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62

0G0207
0G0834
0G0820
0E9747
0G0839
0G0781
0G0722
0G4059
0G4604
0G3424
0G4863
0G0786
0G4605
0F9617A
0A1354B
0G0823
0G4949
0G3900
0D2244M
036710
0C5479
059980
046526
022131
0G3922
0G0464
0G0465
052858
051735
0G3920
0A7387
039414
022129
022145
029333A
057821
045771
022507
022097
022473
090388
0A5768
0A6751
035579
0A8584
0C1852
070928
069860C
069811
0G38580ST03
025065
027738A
0E3257
0A8830
0G4582
0G4581
0G02070100
077043H
0G38620ST03
055596
0C7649
0C5210
051756
0G3433
049541

REF
1
REF
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
7
22
18
9
1
1
14
1
4
4
1
4
3
1
3
3
2
2
5
3
5
1
1
1
1
1
1
1
1
1
1
3
29
1
1
1
1
1
1
2
1
6
REF
1

ENGINE GENERAC 1.6L NG
ENGINE PLATE 1.6L
HOUSING BLOWER MACHINED 1.6L
STARTER 12 VOLT
ENGINE MOUNTING FOOT STAMPING
EXHAUST MANIFOLD 1.6L MACHINED
INTAKE MANIFOLD MACHINED 1.6L
SHIELD 1.6L EXHAUST HEAT
DC ALTERNATOR ADAPTER MACHINED
PULLEY CRANKSHAFT MACHINED (3600RPM)
PULLEY CRANKSHAFT CASTING (1800RPM)
WASHER PULLEY
BRACKET TENSIONER DC ALT
SPACER ALTERNATOR
DC ALTERNATR HAN-KOK
V-BELT 3/8 X 30.6 (3600RPM)
V-BELT 3/8 X 31.6 (1800RPM)
CAP, 1.5" HOLE SHALLOW
ASSY MAGPICKUP(3/8-24 MALE)
PIN SPRING 1/4 X 3/4
SCREW HHC M12-1.5 X 40 G10.9
SCREW HHC M10-1.5 X 25 G10.9
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
NUT HEX M10-1.5 CLASS 10 ZINC
GASKET INTAKE MANIFOLD 1.6L
GASKET EXHAUST MANIFOLD 1.6L
NUT TOP LOCK FL M8-1.25
SCREW HHC M10-1.5 X 70 G8.8
SCREW HHC M10-1.5 X 110 G10.9
SCREW HHC M10-1.5 X 40 G10.9
SCREW HHC M8-1.25 X 35 G8.8
WASHER LOCK M8-5/16
WASHER FLAT 5/16-M8 ZINC
TIE WRAP UL 7.4" X .19" BLK
SCREW HHC M8-1.25 X 40 G8.8
NUT HEX M8-1.25 G8 CLEAR ZINC
SCREW HHC 1/4-20 X 1/2 G5
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW HHTT M6-1.0 X 12 ZINC
WASHER FLAT M10 HEAVY DUTY
SWITCH HI-TEMP 245 D X 3/8 NPT
BSHG RDCR HEX 1/4 TO 1/8
SWITCH OIL PRESSURE 10PSI 2POL
ADAPTER DRAIN OIL
CLAMP HOSE - OIL DRAIN
HOSE OIL DRAIN ASSY 21"
CAP HEX 1/4 NPT BRASS
STRUT LH 1.6L ENG ADAPT PLATE
NIPPLE PIPE 3/8 NPT X 1-1/2
PIPE TEE 3/8 NPT
SCREW HWHTF M6-1.0 X 16
WASHER FLAT .34 ID X .75 OD
HARN ENG 1.6L R200 3600RPM G11 (NOT SHOWN) (3600RPM)
HARN ENG 1.6L R200 1800RPM G11 (NOT SHOWN) (1800RPM)
OIL FILTER 1.6L
CONDUIT FLEX .25"ID (6” LG)
STRUT RH 1.6L ENG ADAPT PLATE
BARBED STR 3/8 NPT X 3/8
CLAMP HOSE .38-.87
HOSE 3/8 ID LOW PRES OIL/WATER (11” LG)
SCREW HHC M10-1.5 X 20 G8.8
BRACKET FAN ALT ADAPTER 1.6L
SCREW HHC M10-1.5 X 35 G8.8

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

098290
098941A
098958A
098942A
098225
043146
022097
084543A
098783
037398
0E1326
0G4451
064526
029333A
022507
0E1694

1
1
REF
1
2
3
5
1
1
2
1
1
1
10
2
1

ASM MOTOR STEPPER
HOUSING GOVERNOR CONNECTOR
CONNECTOR INTERFACE ASSEMBLY
COVER CONNECTOR HOUSING
SCREW FHM #2 X 5/8 SELF TAP
SCREW HHC M6-1.0 X 10 G8.8
WASHER LOCK M6-1/4
SCREW PHM M3-0.5 X 12MM
LEVER STEPPER MOTOR
NUT LOCK HEX #10-32 NYL INS
ASSY. CARBURETOR LINKAGE ROD
BRACKET STEPPER MOTOR COOLANT
SCREW TAP HWH #6-25 X 3/8 ZINC
TIE WRAP 7.4"X.19" BLK UL
SCREW HHC 1/4-20 X 1/2 G5
SPRING ANTI LASH

1
2
3
4
5
6
7
(1) 8
9
10
11
12
13
14
15

026812
075580
0G1397A
0G1397B
039253
022145
022129
045771
0F1570
0A6344
0C5210
025424
0C5210
0A5547
0G3178
0D1509

2
1
1
1
2
2
4
2
1
1
1
1
1
1
1
1

ELBOW 90D 3/4 NPT
FLANGE FUEL INLET
FUEL REG. REWORK 1.6L 3600 '07 (3600RPM)
FUEL REG. REWORK 1.6L 1800 '07 (1800RPM)
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
BODY CARBURETOR ASSEMBLY
BARBED EL 90 1/8 NPT X 3/8
HOSE 3/8 ID LOW PRES OIL/WATER (16” LG)
NIPPLE PIPE 3/4 NPT X 6
HOSE 3/8 ID LOW PRES OIL/WATER (12” LG)
COVER AIR CLEANER
HOSE BREATHER 1.6L
DECAL INLET PRESSURE

(1) 16
17
18
19
20
(1) 21
(1) 22
23
24
25
(1) 26
(3) 27
28
29
(1) 30
(1) 31
(1) 32
(1) 33
(1) 34
(1) 35
(1) 36
(1) 37
(1) 38
(1) 39
40
41
42
43
44
46
47
(1) 49
(1) 50
(1)(2) 51
(1) 52
53

0E0591
059402
037561
0E1028F
0E1028E
059401
091526
049226
026915
062522
022127
0E1339
050279
050280
030795
0F6155
0E1104
0E0668
0E0590A
0E0590
0C5133
0E0665
0E1108
033138
022152
0E0645
034339
059194
057823
026073A
048031L
048031J
0G1985
0F3994
0E0568
0E0527
025105
0E0991
048031P

1
1
1
1
1
1
4
4
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
4
4
1
1
1
1
1
1
1

ADAPTER CARB. TO AIR CLNR
FILTER ELEMENT
NUT WING 1/4-20 NYLK
ASSY CARBURETOR 1.6L 3600RPM
ASSY CARBURETOR 1.6L 1800RPM
CARBURETOR GASKET
SCREW PPHM M5-0.8 X 12 ZNC
WASHER LOCK M5
NIPPLE CLOSE 3/4 X 1.375
STUD TH 1/4-20 X 3 G2 ZNC FULL
NUT HEX 1/4-20 STEEL
PIN SPRING 3/16 X 5/8
DECAL FUEL INLET NG
DECAL FUEL INLET LPG
SCREW HHC 5/16-18 X 1 G5
HARNESS FUEL JUMPER SINGLE REG
GASKET AIR CLEANER ADAPTER
O-RING 2-028 1.38 X 1.50 X .06
VENTURI 20MM (3600RPM)
VENTURI 18MM (1800RPM)
O-RING 29.82 X 2.62
SCREW THROTTLE PIN STOP
THROTTLE ARM REWORK
SCREW HHM #10-32 X 5/8
WASHER LOCK #10
LEVER THROTTLE STOP
BARBED EL 90 3/8 NPT X 5/8
HOSE 5/8 ID LPG & NG (12” LG)
CLAMP HOSE #10 .56 - 1.06
PLUG STD PIPE 1/4 STEEL SQ HD
CLAMP HOSE BAND 1.0"
CLAMP HOSE BAND .63
HOSE BARB REDUCR TEE 3/4"-3/8"
PCV VALVE 2.5L FORD
SHAFT THROTTLE 1.5L
THROTTLE VALVE PLATE 27MM
SCREW RHMS 6-32 X 1/4 ZINC
SEAL SHAFT COVER
CLAMP HOSE BAND .88"

(1) INCLUDED IN ITEM 19 (CARBURETOR ASSY )
(2) APPLY LOCTITE TO I/N 51 BEFORE THREADING INTO
I/N 49.
(3) FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL
INLET DECAL P/N 050280 FOR NG FUEL INLET DECAL P/N
050279 (ITEM 27).

NOTES:
1. REGULATOR (I/N 3) AS SHOWN IN ILLUSTRATION IS SET
UP FOR NATURAL GAS APPLICATION.
2. TO CONFIGURE REGULATOR FOR LP VAPOR, REFER
TO THE “RECONFIGURING THE FUEL SYSTEM” SECTION
OF THIS MANUAL.

(1) 1
(1) 2
(2) 3
(1) 4
(1) 5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

0G3337
0G3336
077992
0G3341
0G3335
0F4487A
022127
022097
022473
0C2454
0F5048D
0F5049
0F8869D
089961
078115
0G4029
0G4029A
0F3890
0E3257
0912970090
0G4029B
0F3890B

1
1
16
2
1
1
1
1
1
16
2
2
1
1
18
2
1
5
4
2
1
4

ROOF 1.6L C1
REAR INTAKE WRAP 1.6L C1
NUT HEX LOCK M6-1.0 SS NY INS
RIGHT SIDE DOOR 1.6L C1
FRONT DISCHARGE WRAP 1.6L C1
ASSY ACCESS COVER
NUT HEX 1/4-20 STEEL
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
SCREW THF M6-1 X 16 N WA Z/JS
VISE-ACTION LATCH, SLOTTED CIR
TAB PULL
KEY VISE-ACTION LATCH,SLOT CIR
FOAM STRIP 3/4"WIDE X 3/16"THK (294”LG)
WASHER SELF LOCKING DOME
INSULATION SIDE DOOR C1
INSULATION ROOF C1
RETAINER INSULATION (450)
SCREW HWHTF M6-1.0 X 16
ASSY WIRE 14AWG GRN/YEL (32.25”LG)
INSULATION REAR C1
RETAINER INSULATION (820)

(1) REFER TO CHART BELOW FOR COLOR AND MATERIAL TYPE
(2) ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO
THE BASE FRAME MUST BE SECURED USING ITEM 10 & 19 THREAD FORMING
FASTENER AND ITEM 3 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.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

0F7366
0F7647
0F8095
0G3576
0E3257
0F7644
0C6119
036434
036449
022129
022259
038750
0G3575
0F3794A
022097
049813
022473

1
1
1
1
4
2
1
3
3
6
6
1
1
1
1
1
6

MUFFLER C1
MUFFLER SADDLE
PIPE EXHAUST OUTLET
EXHAUST PIPE LOWER 1.6L
SCREW HWHTF M6-1.0 X 16
MUFFLER STRAP
BOLT U 5/16-18 X 2-1/4
BOLT U 5/16-18 X 2.09
SADDLE 2 INCH
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
SCREW HHC M6-1.0 X 30 G8.8
EXHAUST PIPE UPPER 1.6L SS
EXHAUST BLANKET 500MM LONG
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
WASHER FLAT 1/4-M6 ZINC

BackPg001 Rev. A 04/07



---

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