Generac Power Systems 2 4L Users Manual Cover112 RevA 05 07
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2015-02-09
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Serial Number 2.4L 25kW Models 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. Cover112 Rev. A 05/07 Part No. 0G4159 Standby Generator Sets Table of Contents 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 QT Genset Start-up .....................8-1 Start-up Checklist ........................................................8-2 Preparation for Start-up............................................8-2 Start-up Inspection ...................................................8-2 OPERATION ...........................................................9-1 Generator Control and Operation ................................9-1 Operating Unit with Manual Transfer Switch ...............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 Authorized Service Facilities .....................................................10-1 Every Three Months ...............................................10-1 Once Every Six Months ...........................................10-1 Once Annually.........................................................10-1 First 100 Operating Hours ......................................10-1 Every 500 Operating Hours ....................................10-1 Every 800 Operating Hours ....................................10-1 Exhaust Manifold Procedure ......................................10-1 Intake Manifold Procedure .........................................10-1 Cylinder Head Procedure ...........................................10-1 Cooling System ..........................................................10-2 Overload Protection for Engine DC Electrical System ....................................................10-2 Checking Fluid Levels ................................................10-2 Check Engine Oil ....................................................10-2 Battery Fluid ...........................................................10-2 Engine Coolant .......................................................10-2 Maintenance Owner/Operator Can Perform ................10-3 Check Engine Oil Level ...........................................10-3 Check Battery .........................................................10-3 Exercise System ......................................................10-3 Inspect Cooling System ...........................................10-3 Check Engine Coolant Level....................................10-3 Perform Visual Inspection .......................................10-3 Inspect Exhaust System ..........................................10-3 Check Fan Belt........................................................10-3 Inspect Engine Governor ........................................10-3 Changing Engine Oil ...............................................10-3 Changing the Engine Air Cleaner ............................10-3 Spark Plugs ............................................................10-4 Coolant Change .......................................................10-4 Miscellaneous Maintenance ........................................10-4 Cleaning the Generator ...........................................10-4 Battery ....................................................................10-4 Battery Maintenance ...............................................10-4 Battery Replacement ...............................................10-5 SERVICE SCHEDULE ...........................................11-1 TROUBLESHOOTING ...........................................12-1 Troubleshooting Guide...............................................12-1 NOTES EXPLODED VIEWS & PARTS LISTS WIRING DIAGRAMS & SCHEMATICS Content016 Rev. A 06/07 SECTION PAGE SAFETY RULES ................................................ 1-1 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. 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. 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. A 04/07 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. A 04/07 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 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 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. A 04/07 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 15W-40 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. 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. Equip002 Rev. A 08/06 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 COOLING SYSTEM GENERATOR Type ...................................................Pressurized Closed Recovery Water Pump.................................................................... Belt Driven Fan Speed .........................................................................1000 rpm Fan Diameter .....................................................................22 inches Fan Mode ................................................................................Puller Air Flow (inlet air including alternator and combustion air) ...........................................................1600 ft3/min. Coolant Capacity ........................................................ (3.0 U.S. gal.) Heat Rejection to Coolant ..........................................106,900 Btu/h Maximum Operating Air Temp. on Radiator ..............60° C (150° F) Maximum Ambient Temperature................................50° C (140° F) Type ............................................................................. Synchronous Rotor Insulation ....................................................................Class F Stator Insulation .................................................................. Class H Total Harmonic Distortion ..........................................................<5% Telephone Interference Factor (TIF) ..........................................< 50 Alternator Output Leads 3-phase ........................................... 6-wire Bearings .........................................................................Sealed Ball Coupling .......................................................................Flexible Disc Load Capacity (Standby Rating) ............................................25kW* * NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349, FUEL SYSTEM ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural gas. 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 Excitation System ....................................................................Direct Generator Output Voltage/kW - 60 Hz kW Amp CB Size 120/240V, 1-phase, 1.0 pf 25 104 125 120/208V, 3-phase, 0.8 pf 25 87 100 277/480V, 3-phase, 0.8 pf 25 38 40 Generator Locked Rotor KVA Available @ Voltage Dip of 35% Single-phase ...................................................................... 50 KVA 208V, 3-phase .................................................................... 70 KVA 480V, 3-phase .................................................................... 70 KVA Fuel Consumption - ft3/hr (Natural Gas/LPV) Exercise 25% 50% 75% 100% Cycle Load Load Load Load 42/16 107/41 204/77 293/111 375/142 ENGINE ELECTRICAL SYSTEM Make ................................................................................... Generac Model ..................................................................................... In Line Cylinders and Arrangement............................................................ 4 Displacement ....................................................................... 2.4 Liter Bore ...................................................................................... 3.41 in. Stroke ................................................................................... 3.94 in. Compression Ratio ...............................................................8.5-to-1 Air Intake System ...............................................Naturally Aspirated Valve Seats....................................................................... Hardened Lifter Type .......................................................................... Hydraulic Battery Charge Alternator ............................................12V, 30 Amp Static Battery Charger ............................................................2 Amp Recommended Battery...................................... Group 26, 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 ..................................................................60 Hz, 40 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 Exhaust System Exhaust Flow at Rated Output 60 Hz.................................. 130 cfm Exhaust Temperature at Rated Output .................................. 900° F Combustion Air Requirements (Natural Gas) Flow at rated power, 60 Hz ................................................... 70 cfm Controller .................................................R-200 Governor Type .................................................................................. Electronic Frequency Regulation ...................................................Isochronous Steady State Regulation......................................................± 0.25% Engine Lubrication System Type of Oil Pump ...................................................................... Gear Oil Filter ............................................... Full Flow Spin-on, Cartridge Crankcase Oil Capacity ....................................................4 U.S. qts. GenSpec031 Rev. A 05/07 6-1 Standby Generator Sets Specifications Figure 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 45 45 45 STUB-UP AREA See Install Dwg for Dimensions COLD WEATHER KIT CIRCUIT BREAKER SIZE VOLTS / AMPS LUG SIZE 240 1 Ø 200 #6 to 300 mcm 208 3 Ø 175 #6 to 300 mcm 480 3 Ø 80 #6 to 300 mcm 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 GenSpec031 Rev. A 05/07 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 melts, Iffind the cause of the overload before resetting 1. Test engine governor; adjust or repair, if needed. 2. Clean, inspect generator. 3. Flush cooling system. the circuit breaker or replacing the fuse. CHECKING FLUID LEVELS FIRST 30 OPERATING HOURS 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. Figure 10.1 - Oil Dipstick and Oil Fill Cap Oil Fill Cap EVERY 500 OPERATING HOURS Oil Dipstick 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 Maint012 Rev. D 06/07 1. 2. 3. 4. Standby Generator Sets Maintenance INSPECT COOLING SYSTEM • 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. • Inspect engine cooling system. See “Maintenance Schedule”. • Check hoses for damage, deterioration, leaks, etc. Correct any discrepancies found. • Check hose clamps for tightness. CHECK ENGINE COOLANT LEVEL See “Checking Fluid Levels”. BATTERY FLUID PERFORM VISUAL INSPECTION 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. 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. ENGINE COOLANT INSPECT EXHAUST SYSTEM Check coolant level in coolant recovery bottle. See Specifications. Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage. • 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. CHECK FAN BELT • 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. MAINTENANCE OWNER/ OPERATOR CAN PERFORM INSPECT ENGINE GOVERNOR Visually inspect electronic governor. CHECK ENGINE OIL LEVEL DANGER Refer to “Checking Fluid Levels”. not attempt to adjust the governor. Only Do qualified service facilities should adjust the CHECK BATTERY 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. • See “Checking Fluid Levels”. • Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as necessary. EXERCISE SYSTEM 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. 10-2 Maint012 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). 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 1.07-1.17 mm (0.0420.046 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 1.07 - 1.17 mm (0.042 - 0.046 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, 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. Maint012 Rev. D 06/07 10-3 Standby Generator Sets Maintenance MISCELLANEOUS MAINTENANCE 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. 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. DANGER batteries give off explosive hydrogen Storage gas. This gas can form an explosive mixture 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. 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 The battery should be inspected per the "Scheduled Maintenance" section. The following procedure should be followed for inspection: REPAIR PARTS The later portion of this manuals consists of exploded views, parts lists and electrical data pertaining to this generator set. 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. 10-4 Maint012 Rev. D 06/07 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. B 03/07 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. B 03/07 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/ lash. 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. B 03/07 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. B 03/07 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 Standby Generator Sets Notes 1 2 3 4 5 6 7 8 (1) 9 10 11 12 13 14 (2) 15 (2) 16 17 18 19 20 21 23 24 (1) 26 27 28 29 30 31 32 33 34 35 36 37 (3) 39 (4) 40 (4) 41 (4) 42 (4) 43 (4) 44 1) A C D E F G H J K L 2) A C D E F G H J K L 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 0G0770 0G5952 036943 023897 022152 022158 1 1 1 1 1 1 2 2 2 REF 4 4 1 1 2 REF REF 2 2 4 4 8 8 4 REF 1 1 1 1 4 1 1 2 1 1 4 1 1 2 4 2 2 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 HARNESS, TRANSFORMER ADAPTER ASSY PCB IGN MOD 4.2L SCREW PPHM #10/32 X 2 WASHER FLAT #10 ZINC WASHER LOCK #10 NUT HEX #10-32 STEEL 0F3328 0D5552 0D5554 0D5556 0D9693 0F0492 048927 023897 022152 022158 0C2454 029289 0F1733 UL CIRCUIT BREAKER (ED) 1 COVER ED CB SHORT STND 1 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 1 INSULATOR CB S (ED-3P) 4 SCREW RHM #10-32 X 4-1/2 4 WASHER FLAT #10 ZINC 4 WASHER LOCK #10 4 NUT HEX #10-32 STEEL 7 SCREW THF M6-1 X 16 N WA Z/JS 1 TAPE ELEC 1/2 FOAM (AS REQ’D) 1 DECAL CUSTOMER CONNECT INSIDE 0F3138 0D5572 0D5573 0D5574 0D5575 0D5576 0F0199 081320 022473 022097 022127 0C2454 029289 0F1733 UL CIRCUIT BREAKER (FD) 1 COVER CB CONN BOX 1 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 1 INSULATOR CB FD FRAME 30MIL 4 SCREW SHC 1/4-20 X 4.5 G8.8 NZ 4 WASHER FLAT 1/4-M6 ZINC 4 WASHER LOCK M6-1/4 4 NUT HEX 1/4-20 STEEL 7 SCREW THF M6-1 X 16 N WA Z/JS 1 TAPE ELEC 1/2 FOAM (AS REQ’D) 1 DECAL CUSTOMER CONNECT INSIDE 3) A C D E F G H J K L 4) A C D E F G H J K 0F3329 0D5577 0F2353 022770 022473 022097 022127 0C2454 029289 0F1733 UL CIRCUIT BREAKER (JD+LD) 1 COVER JD/LD CB SHRT STAND 1 CB 0300A 3P 600V S JD6 LL 2 INSULATOR CIRCUIT BR. JD/LD 4 SCREW RHM 1/4-20 X 3 4 WASHER FLAT 1/4-M6 ZINC 4 WASHER LOCK M6-1/4 4 NUT HEX 1/4-20 STEEL 7 SCREW THF M6-1 X 16 N WA Z/JS 1 TAPE ELEC 1/2 FOAM (AS REQ’D) 1 DECAL CUSTOMER CONNECT INSIDE 0F8135 0E7283 0E7284 0E3664 074908 0F8140 036261 0C2454 029289 0F1733 UL CIRCUIT BREAKER (QN) 1 COVER QN FRM CB CB 0150A 2P 240V S QN2 LL CB 0175A 2P S QN2 LL 240V 1 BASE, QN CIRCUIT BREAKER 2 SCREW HHTT M5-0.8 X 10 BP 1 COVER QN CB DISH 4 RIVET POP .125 X .275 SS 7 SCREW THF M6-1X16 N WA Z/JS 1 TAPE ELEC 1/2 FOAM (AS REQ’D) 1 DECAL CUSTOMER CONNECT INSIDE (1) (2) (3) (4) ITEM INCLUDED WITH HARNESS ITEM INCLUDED WITH 0D5464B ITEM USED WITH EARLY MODEL 208V UNITS ONLY ITEMS USED ON 4.2L MODELS ONLY. 5) A C D E F G H J K L M N P Q 0F8137 0E7994 0F8136 036261 022473 022097 022127 0F8139 0C2454 022237 048527 029289 022770 0F1733 UL CIRCUIT BREAKER (QJ-2P) 1 COVER QJ 2P FRM CB CB 0225A 240V 2P S QJ22 1 COVER QJ 2P CB DISH 4 RIVET POP .125 X .275 SS 2 WASHER FLAT 1/4-M6 ZINC 2 WASHER LOCK M6-1/4 2 NUT HEX 1/4-20 STEEL 1 INSUL CB 2P QJ 7 SCREW THF M6-1 X 16 N WA Z/JS 2 WASHER LOCK 3/8 2 SCREW SHC 3/8-16 X 3/4 G8.8 NZ 1 TAPE ELEC 1/2 FOAM (AS REQ’D) 2 SCREW RHM 1/4-20 X 3 1 DECAL CUSTOMER CONNECT INSIDE P (2) R (2) S (2) T (2) U (2) V (1) W X 0F4185 058306 0F4165$ 0F4143 0F4149 0F4151 0G5247$ 0G5250 0G4478 0F4186 0F4186AGS0R 036261 053640 038150 022264 022471 029289 0F1733 022129 0F8432 0F8432A 0C2454 0F8451 049897 022145 045771 0F8843 W/CB 0G3259 UL CIRCUIT BREAKER (225AF) (2P & 3P) 1 COVER CB C2-C4 (225AF) 3 SCREW SHC M8-1.25 X 25 G12.9 REF CIRCUIT BREAKERS 200A FRAME (3P) REF CB 0040A 3P 480V 225AF (3P) REF CB 0150A 3P 480V G 225AF REF CB 0200A 3P 480V G 225AF REF CB 200A FRAME G 240V (2P) REF CB 175A 2 POLE 240V 225AF (2P) REF CB 200A 2 POLE 240V 225AF (2P) 1 COVER CB DISH 225AF (3P) COVER CB DISH 225AF (2P) 4 RIVET POP .125 X .275 SS 2/4 SCREW RHM #8-32 X 3-1/4 2/4 WASHER FLAT #8 ZINC 2/4 WASHER LOCK #8-M4 2/4 NUT HEX #8-32 STEEL 2 TAPE ELEC 1/2 FOAM 1 DECAL CUSTOMER CONNECT INSIDE 6/9 WASHER LOCK M8-5/16 1 INSULATOR CB 225AF (3P) 1 INSULATOR CB 225AF (2P) 7 SCREW THF M6-1 X 16 N WA Z/JS 2/3 LUG SLDLSS 300 MCM-6 AL/CU 4/6 SCREW SHC M8-1.25 X 20 G8 4/6 WASHER FLAT 5/16-M8 ZINC 2/3 NUT HEX M8-1.25 G8 CLEAR ZINC 2/3 BUS BAR 200A LUG ADAPTOR 2 TERMINAL COVER CB 1 DECAL TERMINAL SHOCK HZD BI 7) A C D E F G H J K (2) L (2) M N P (1) S T U V (2) W (2) X Y 0F4187 0F4166$ 0F1733 042419 023897 022152 022158 0C2454 029289 052647 046526 W/CB 0A7822 W/CB 023334 022097 022473 W/CB W/CB 0G3259 UL CIRCUIT BREAKER (400AF) 1 COVER CB C2-C4 400AF REF CIRCUIT BREAKERS 400A FRAME 1 DECAL CUSTOMER CONNECT INSIDE 4 SCREW RHM 10-32 X 4 4 WASHER FLAT #10 ZINC 4 WASHER LOCK #10 4 NUT HEX #10-32 STEEL 7 SCREW THF M6-1 X 16 N WA Z/JS 1 TAPE ELEC 1/2 FOAM 2/3 SCREW SHC M10-1.5 X 25 G12.9 2/3 WASHER LOCK M10 3 BUS BAR CB ADAPTER 225-400 A 3 LUG SLDLSS 600/250-1/0 X 1/4-28 2 TERM COVER CB 6 SCREW HHC 1/4-28 X 1/2 G5 6 WASHER LOCK M6-1/4 6 WASHER FLAT 1/4-M6 ZINC 2/3 SCREW SHC M10-1.5 X 25 G12.9 2/3 WASHER LOCK M10 1 DECAL TERMINAL SHOCK HZD BI 6) A B C D E (2) F (2) G (2) H (2) J K L (2) M N 8) A B C D E F G H 9) A C D E F G H J K L M N 0D5466 039287 022145 022129 045771 045335 083896 0A7822 NEUTRAL BLOCK 390 / 200-400A 2 BUS BAR NEUTRAL BLOCK 390 1 SCREW HHC M8-1.25 X 45 G8.8 FT 1 WASHER FLAT 5/16-M8 ZINC 1 WASHER LOCK M8-5/16 1 NUT HEX M8-1.25 G8 YEL CHR 2 SCREW HHC 1/4-28 X 3/4 G5 2 WASHER LOCK 1/4-M6 SS 1 LUG SLDLSS 600/250-1/0 X 1/4-28 0G1968 0G1970 0A2077 040532 0C3990 0E7890 0E6002 022859 0G0008 023897 022152 022158 0F1733 029289 0C2454 UL CIRCUIT BREAKER (BQ) 1 COVER BQ CIR BREAKER CPL 3P COVER BQ CIR BREAKER CPL 2P 1 CB 0125A 2P 240V S BQ2 LL CB 0100A 3P 240V S BQ3 LL 2 SCREW PHTT M4-0.7 X 10 ZYC 1 BRKT CB MTG BACK MTG TRACK BQ SIEMENS CB 3P 6 SCREW RHM #10-32 X 3/4 1 BRKT BQ CB STANDOFF 6 WASHER FLAT #10 ZINC 6 WASHER LOCK #10 6 NUT HEX #10-32 STEEL 1 DECAL CUSTOMER CONNECT INSIDE 1 TAPE ELEC 1/2 FOAM 7 SCREW THF M6-1 X 16 N WA Z/JS (1) HARDWARE FOR MTG. CB TERMINAL COVERS IS SUPPLIED WITH CIRCUIT BREAKERS. (2) QTY. REQ’D FOR “2POLE / 3POLE” BREAKER 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 0G0056 0G1155 0F9677 0G0959 0G2101 0G1931 0G0057 0F9664 0G0058 0G0184 0G0059 0G0183 0G6104 0G2098 0G2100 0G1932 0G2099 0C9708 SEE ENGINE EV SEE ENGINE EV 0F5767B 0E5706 0F7874 0G0587 038150 023454 077043E 04576100BU 052646 043123 051779 0A2601 0A2602 0F8408 046526 0C3993 022264 047248 070892 0G0588 077043A 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 REF REF REF 1 1 1 1 4 1 1 4 4 4 4 1 1 4 4 4 4 1 1 1 1 ROTOR-2390-35KD1 CPL ROTOR-2390-35KD1 CPL (G2) ROTOR-2390-45KD1 CPL ROTOR-2390-45KD1 CPL (G2) ROTOR 25KW 1PH DIRECT 390 1800 ROTOR 25KW 3PH DIRECT 390 1800 STATOR-2390-35AD1 CPL STATOR-390 45K 2P 1PH DIRECT STATOR-2390-35KD1 CPL STATOR-2309-45-KD1 CPL STATOR-2390-35GD1 CPL STATOR-2309-45KW 2P 3PH 208V STR-2390--45JD1 CPL ASSY STR 390 25AD1 CPL ASSY STR 390 25JD3 CPL ASSY STR 390 25GD3 CPL ASSY STR 390 25KD3 CPL INSTR HYPOT TEST (NOT SHOWN) ENGINE ADAPTER FLEXPLATE ASSY FLYWHEEL CPL W/40MM FAN B REAR BEARING CARRIER 390/DRCT ASSY BRUSH HOLDER 390/HSB GUARD REAR BEARING CARRIER WASHER FLAT #8 ZINC KEY WOODRUFF #E CONDUIT FLEX 1.0" ID (35” LG) STUD M14-2.0 570 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 HHC M10-1.50 X 16 G10.9 WASHER LOCK M10 SCREW HHTT M4-0.7 X 25 BP WASHER LOCK #8-M4 BALL BEARING-45 MM SLIP RING MACHINED GUARD REAR BEARING CARRIER CONDUIT FLEX .38" ID (60”) * ROTOR REPLACEMENT PARTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 43 44 45 46 47 0F1823A 0F3078 0F2606 036261 0E7358 052777 0G1303C 0F1262 0F1263 0F1264 0F1725C 067680 0E6875A 055911 0F5459 0E3161 0F5462 0A5062J 029673 048467 0F1958 082573 0E4494 0F3215 0F6305 0F6305A 0F5886 051713 049226 0F5752F 0F5884 0F5896 0C2265 0C3990 091526 051716 079224 043182 051714 0F3192 0E7403C 0G2281 COMPONENTS INCLUDED IN 0G2283D 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-200 1800 RPM 2.4L 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 DECAL CPL CONTROL PANEL FUSES 1 ASSY PCB BOSCH GOV DRIVER 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 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 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 R-200 CTRL PNL 1800 RPM (NOT SHOWN) A B C D E F G H J K 056739 022287 022473 022097 022127 0F6145 0F2627A 091526 049226 051713 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 COVER CONTROL PANEL SIDE 4 SCREW PPHM M5-0.8 X 12 ZNC 4 WASHER LOCK M5 4 WASHER FLAT M5 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 29 0F9517 052860 052251 052257 052252 052259 052891 0536210410 042909 047411 055414 022447 022097 022473 049813 022261 0F9597A 045764 062963 022302 022131 065852 0F9597 022129 026204 022145 045771 0F9596 0F9596A 1 4 5 5 5 5 5 1 1 1 1 1 1 2 1 1 1 1 4 4 4 1 1 1 1 1 1 1 1 WELDMENT FRAME 2.4L 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 LH ENGINE 2.4L SCREW HHTT M4-0.7 X 8 BP SCREW HHC M10-1.25 X 30 G8.8 WASHER LOCK 7/16 WASHER FLAT 3/8-M10 ZINC SPRING CLIP HOLDER .37-.62 SUPPORT RH ENGINE 2.4L WASHER LOCK M8-5/16 WASHER SHAKEPROOF INT 5/16 WASHER FLAT 5/16-M8 ZINC NUT HEX M8-1.25 G8 CLEAR ZINC SPACER ENGINE MOUNT (2.4L G1) SPACER LH ENGINE MOUNT (2.4L G2) 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 0F3408B 0F3411 025507 052212 046526 022131 050331A 050331 038805Y 03880400AE 045771 022129 0F3976 0C2454 022145 077483 1 1 REF REF REF REF REF REF 1 1 REF REF 1 4 REF REF BATTERY TRAY C1 CPL STRAP BATTERY RETAINMENT WASHER SHAKEPROOF EXT 7/16 STL SCREW HHC M10-1.25 X 25 G8.8 WASHER LOCK M10 WASHER FLAT 3/8-M10 ZINC BATTERY POST COVER RED + BATTERY POST COVER BLACK CABLE BATTERY BLACK #1 X 18.00 CABLE BATT RED #1 X 18.00 NUT HEX M8-1.25 G8 YEL CHR WASHER LOCK M8-5/16 BOOT CONTACTOR CABLES SCREW THF M6-1 X 16 N WA Z/JS WASHER FLAT 5/16-M8 ZINC BATTERY 12VDC 75-AH 26 1 2 3 4 5 6 7 8 9 0E6586 0E0519A 0C8127 052619 022127 062974 0G0190 037561 022097 1 1 1 4 1 1 1 1 1 GASKET BOSCH 32 & 40 ADAPTER CARBURETOR W/PVC CONN ELEMENT AIR CLEANER SCREW HHC M5-0.8 X 20 G8.8 NUT HEX 1/4-20 STEEL STUD TH 1/4-20 X 4-1/2 G2 ZNC PLATE, AIR CLEANER TOP 2.4L NUT WING 1/4-20 NYLK WASHER LOCK M6-1/4 1 2 3 4 5 (2) 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 (1) 36 37 38 39 (3) 40 (1) 44 45 46 47 48 49 50 51 52 (1) 53 54 55 56 57 59 (1) 60 61 62 63 (3) 64 65 (3) 66 0G0408 046526 039414 0G0149 0E9868A 0F3217 042574 0A8584 0F4612 057772 057765 043790 0C7649 069860E 063076 0G1394 052830 025507 062963 049821 022129 0D6029 0A6751 0E0502 022145 045771 022131 049813 046525 058306 022097 022473 043116 026073A 052243 0A8258 0G0664 0G1502 047290 049340 045757 0G0951 0G3910 0G0608 0F9965E 0D2244M 0F9420 0E9747 0G1472A 0G1476 0G0707 0G0950 0F9583 0G0792 0G0792A 0G1501 0F9501 0G0952 0D3488S 0G0788 0G2750 049721 026925 0F2776 052203 0F2776D 1 3 4 1 1 1 1 1 1 1 1 1 1 1 7 7 2 5 3 3 26 3 1 1 7 3 1 3 2 15 7 10 4 2 1 1 1(REF) 1 1 1 1 1(REF) 1 1 1 2 1 1 1 1(REF) 1 1(REF) 1 1 1 1 1 1(REF) 1 1 1 3 1 1 2 1 ENGINE 2.4L MITSUBISHI 4G64 WASHER LOCK M10 SCREW HHC M8-1.25 X 35 G8.8 SCREW SHC M14-1.5 X 35 G10.9 ALTERNATOR DC W/OUT PULLEY SPACER DC ALTERNATOR PULLEY ADAPTOR 1/8 NPTF TO 1/8 BSPT SWITCH OIL PRESSURE 10 PSI 2 POL (R-PANEL) SENDER OIL PRESSURE 1/8" NPT (H-PANEL) WASHER NYLON .565 ADAPTER M14-1.50 X 3/8 NPT BARBED EL 90 3/8 NPT X 3/8 CLAMP HOSE .38-.87 HOSE DRAIN ASSY 28" WASHER FLAT .531 ID X 1.062 OD SCREW HHC M12-1.25 X 20 G10.9 SCREW HHC M10-1.25 X 45 G8.8 WASHER SHAKEPROOF EXT 7/16 STL SCREW HHC M10-1.25 X 30 G8.8 SCREW SHC M8-1.25 X 30 G12.9 WASHER LOCK M8-5/16 SCREW THF M6-1 X 16 N WA Z/JS SWITCH HI-TEMP 245D X 3/8 NPT (R-PANEL) TEMPERATURE SENDER DELPHI (H-PANEL) WASHER FLAT 5/16-M8 ZINC NUT HEX M8-1.25 G8 CLEAR ZINC WASHER FLAT 3/8-M10 ZINC NUT HEX M6 X 1.0 G8 YEL CHR NUT HEX M10-1.25 G8 YEL CHR SCREW SHC M8-1.25 X 25 G12.9 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC SCREW HHC M6-1.0 X 12 G8.8 PLUG STD PIPE 1/4 STEEL SQ HD SCREW HHC M10-1.5 X 60 G8.8 SCREW HHC M8-1.25 X 25 G10.9 OIL FILTER G2 ENGINE COIL PACK HOSE 3/8 ID SINGLE BRAID (15” LG) BARBED EL 90 1/4 NPT X 3/8 SCREW HHC M6-1.0 X 25 G8.8 GASKET EXHAUST MANIFOLD EXHAUST MANIFOLD G2 (MACHINE) (35KW & 45KW) MANIFOLD EXHAUST (MACHINED) (25KW ONLY) FLEX PLATE 2 POLE 2.4L G2 ASSY MAGPICKUP(3/8-24 MALE) ADAPTER ENGINE 2.4L MACHINE STARTER, 12 VOLT CAM SENSOR PIN ASSY COVER CAM GEAR G2 REWORKED MANIFOLD INTAKE GASKET INTAKE MANIFOLD SPACER 2.4L G2 FLEX PLATE SHIELD HEAT G2 SHIELD HEAT SML BRACKET COIL PACK ADAPTER 2.4L CRANKSHAFT MACH POLY V-BELT G2 (3600 RPM) BELT SERPENTINE 37.0" (1800 RPM) PULLEY DC ALTERNATOR (3600 RPM) PULLEY 69 OD DC ALTERNATOR (1800 RPM) SCREW HHC M6-1.0 X 35 G8.8 BLK PLUG STD PIPE 3/8 STEEL SQ HD BRACKET, SIGNAL CONDITIONER SCREW HHC M8-1.25 X 70 G8.8 BRACKET SIGNAL CONDITONER (1) SUPPLIED WITH ENGINE. (2) NOT USED ON 1800 RPM UNITS. (3) USED WITH H-PANEL ONLY 1 2 3 4 5 6 0F9529 0F2608 0F5263 046526 059981 0F2776A 1 1 1 5 4 1 7 9 10 11 12 0F5050A 0F2573 0F4011 0F2572 0G2990 1 1 1 1 1 WELDMENT RADIATOR SUPPORT 2.4L RADIATOR 598 X 568 X 49 CPL RH V-BELT 31/64" X 57-3/8" WASHER LOCK M10 SCREW HHC M10-1.5 X 30 G10.9 BRACKET, SIGNAL CONDITIONER (USED ONLY WITH QTA PRODUCT) SHIELD RADIATOR C4 PULLEY FAN V-GROOVE 9" FAN COOL 22" DIA 10 BLADE LH ARM TENSIONER SHOULDER BOLT 3/8 X 1/2" 13 14 15 16 17 18 19 20 21 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 0F2862 0F2560 022131 0E2507 035685 0F2561 0C8145 052250 0C7043 022473 0C8146 022097 076749 048031C 031971 0F4496 042911 0F2872 022304 022195 022196 0F8651 070015 0F9867 0F2461 022145 022129 039414 082774 0G0795 0G0816 049813 052644 0C8566 0C2454 090283 080713 0G4376 1 1 4 1 4 1 8 2 12 8 4 16 1 1 1 1 1 1 2 1 1 9 1 1 1 1 10 1 1 1 1 8 1 16 2 1 1 1 SPRING TENSION CPL PULLEY V-BELT 4" FLANGED WASHER FLAT 3/8-M10 ZINC PROBE COOLANT LEVEL 3/8 NPTF CLAMP HOSE #28 1.32-2.25 HUB FLEX PLATE WASHER FLEX (THIN) TAPE FOAM 1 X 1 (26.75” LG) DISK FLEX WASHER FLAT 1/4-M6 ZINC SCREW HHC 5/16-24 X 1.124 WASHER LOCK M6-1/4 TANK COOLANT RECOVERY CLAMP HOSE BAND 1/4 BEARING #6205 2NSE C3 E SRI2 S PULLEY 4.5" DIA MACHINED SCREW HHC M10-1.5 X 30 G8.8 SCREW HHC 1/2-13 X 2" G8 WASHER FLAT 1/2 ZINC WASHER LOCK 1/2 NUT HEX 1/2-13 STEEL SCREW HHFC M8-1.25 X 20 W/M6 NUT HEX LOCK 5/16-18 NY INS SS SHAFT FAN DRIVE RETAINER BEARING WASHER FLAT 5/16-M8 ZINC WASHER LOCK M8-5/16 SCREW HHC M8-1.25 X 35 G8.8 KEY WOODRUFF 4 X 19D HOSE LOWER RADIATOR G2 HOSE UPPER RADIATOR G2 NUT HEX M6 X 1.0 G8 YEL CHR SPACER .5 X 1.5 X .25 STL/ZINC SCREW HHFC M6-1.0 X 20 G8.8 SCREW THF M6-1 X 16 N WA Z/JS CAP RADIATOR 13 PSI BRACKET COOLANT TANK WASHER BELLEVILLE .75X.38X.028 BEARING PRESS NOTE: APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO BEARING SURFACE ON ITEM 37 PRIOR TO PRESSING ITEM 28 ONTO ITEM 37. ALSO APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO THE OUTSIDE OF 28 PRIOR TO INSTALLING ITEM 28 INTO ITEM 38. 1 2 3 4 5 6 7 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 26 27 28 29 30 32 026915 075580 0F6390C 0F6390B 039253 022145 022129 045771 0E8286 026812 0F8379 057823 059057 047527 0D1509 050279 050280 0F2119 0E6586 0E4394 0E4395 040105 057753B 0G4573C 0G4573B 0F7790E 0F7790H 0E7121 022097 046580 035685 0F6155 047290 057823 2 1 1 1 2 2 2 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 2 1 1 2 NIPPLE CLOSE 3/4 X 1.375 FLANGE FUEL INLET REGULATOR ASSY 2.4L (25KW) REGULATOR ASSY 2.4L (35KW & 45KW) 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 45D 1/2 NPT BRASS ELBOW 90D 3/4 NPT NIPPLE PIPE 3/4 NPT X 7 CLAMP HOSE #10 .56 - 1.06 HOSE 3/4 ID SAE-30R2 (18” LG) BARBED STR 1/2 NPT X 3/4 DECAL INLET PRESSURE DECAL FUEL INLET NG (NATURAL GAS APPLICATION) DECAL FUEL INLET LPG (LP VAPOR APPLICATION) O-RING 45.63 ID X 2.62 WIDTH GASKET BOSCH 32 ACTUATOR BOSCH 40 GOVERNOR (45KW) ACTUATOR BOSCH 32 GOVERNOR (25 & 35KW) HOSE COOL 2 IN ID 20R4 (45KW) HOSE 1.5 ID X 2 LG 20R4 (35KW) MIXER ACTUATOR 32MM MACHINED (25KW) MIXER ACTUATOR 40MM MACHINED (35 & 45KW) VENTURI THROTTLE 26MM (35 & 45KW) VENTURI THROTTLE 19MM (25KW) O-RING 47.625 ID X 2.38 WIDTH WASHER LOCK M6-1/4 SCREW SHC M6-1.0 X 45 G12.9 CLAMP HOSE #28 1.32-2.25 HARNESS CPL FUEL JUMPER HOSE 3/8 ID SINGLE BRAID (18” LG) CLAMP HOSE #10 .56-1.06 RECONFIGURING THE FUEL SYSTEM Note: 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 Detail “A”). 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. Note: The jet sizes are stamped on the individual jets. The larger jet size is used for running on NG. 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 iron pipe onto the outlet port of the demand regulator. 10. Reverse steps 1-4 in this procedure to reactivate the demand regulator. 11. For LP vapor application substitute LPG fuel inlet decal p/n 050280 for NG fuel inlet decal p/n 050279 (Item 17). 12. When switching fuel types, the proper dip switch settings 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 0G0045 (XX) 0C2454 0F5849 (XX) 087233 0E3257 0F5852 (XX) 0F9833 (XX) 0F5851 (XX) 049813 077992 0F9835 (XX) 0F2786 0F2785 0F3364 0F4880 0F5049 0C2634A 022473 022097 022127 0F3072 078115 0F4051 0F4051A 0F5048D 0E5968 0F3760K 0F3760E 0F4051C 0F3890B 0F4051B 0F3890 0F3890A 0F3760L 042568 0912970094 022447 0F4051E 0F8869D 078115A 1 54 2 2 4 2 2 1 2 21 1 2 1 1 2 2 1 3 1 1 10 38 2 1 2 1 2 2 2 10 2 4 3 1 2 2 2 1 1 6 REAR WRAP C2 CPL 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 NUT HEX M6 X 1.0 G8 YEL CHR NUT HEX LOCK M6-1.0 SS NY INS ROOF C2 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 #4-40 INSULATION DOOR C2 INSULATION ROOF TOP VISE-ACTION LATCH SLOTTED CIR GASKET EXTRUDED TRIM (328” 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 INSULATION REAR WRAP KEY VISE-ACTION LATCH SLOT CIR WASHER SELF LOCKING DOME #8-32 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 * 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. 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 0F9794 0G0113 0G1007 0F2830 0F2962 080762 0E0170A 0C2454 0G0776 0G0007 044149 085917 0D2611 0E8816 049721 022097 022473 036797 022259 070006 088775 022241 085917 0F2809 0F2808B 2 1 1 2 2 5 1 4 1 1 1 2 2 1 4 4 4 1 2 2 2 10 10 1 1 MUFFLER 7" X 9" X 18-1/2" 2" IN/OUT EXHAUST ELBOW 2 1/4 OD 2 1/2OD BRACKET MUFFLER MUFFLER BRACKET STIFFENER MUFFLER STRAP BOLT U 3/8-16 X 2.62 EXHAUST BLANKET 988MM (C2) SCREW THF M6-1 X 16 N WA Z/JS PIPE EXHAUST G2 DIFFUSER EXHAUST WELDMENT GASKET EXHAUST RING WASHER LOCK 3/8 SS SCREW HHC 3/8-16 X 1-3/4 SS EXHAUST FLANGE 2" PIPE SCREW HHC M6-1.0 X 35 G8.8 BLK WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC BOLT U 5/16-18 X 2.25 NUT HEX 5/16-18 STEEL WASHER LOCK M8 SS WASHER FLAT 3/8 SS NUT HEX 3/8-16 STEEL WASHER LOCK 3/8 SS PIPE EXHAUST CROSSOVER PIPE EXHAUST MUFFLER OUT * NOT USED ON OPEN SET. 1.) A C2 UNITS 0F9832 0F9832GGS0R 0C2454 1 1 3 SHIELD CONN BOX C2 SHIELD CONTROL STAND C2 SCREW THF M6-1 X 16 N WA Z/JS B C3 UNITS 0F9832B 0F9832KGS0R 0C2454 1 1 3 SHIELD CONTROL STAND C3 SHIELD CONTROL STAND C3 SCREW THF M6-1 X 16 N WA Z/JS 3.) A B C4 UNITS 0F9832A 0C2454 1 2 SHIELD CONTROL STAND C4 SCREW THF M6-1 X 16 N WA Z/JS 4.) A C5 UNITS 0F9832C 0F9832D 0F9832EGS0R 0F9832HGS0R 0F9832JGS0R 0F9832FGS0R 0C2464 1 1 1 1 1 1 3 SHIELD CONTROL STAND C5 SHIELD CONTROL STAND C5 SHIELD CONTROL STAND C5 SHIELD CONTROL STAND C5 SHIELD CONTROL STAND C5 SHIELD CONTROL STAND C5 SCREW THF M6-1 X 16 N WA Z/JS B 2.) A B C BackPg001 Rev. A 04/07
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