Generac Qt 1 5L Users Manual Cover013 RevA 9 05

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QT
1.5L
20kW
Models

Serial Number

STANDBY GENERATOR

OWNER'S MANUAL

A new standard of reliability

This manual should remain with the unit.
Cover013 Rev. A 08/05

Part No. 0F7437

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
WARRANTY

Content004 Rev. 0 09/05

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

Standby Generator Sets
Important Safety Instructions



WARNING:

 GENERAL HAZARDS 

• For safety reasons, the manufacturer recommends
that this equipment be installed, serviced and
repaired by an Authorized Service Dealer or other
competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must
comply with all such codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the
generator is installed, operated and serviced in
accordance with the manufacturer’s instructions
and recommendations. Following installation, do
nothing that might render the unit unsafe or in
noncompliance with the aforementioned codes,
standards, laws and regulations.
• The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas,
if breathed in sufficient concentrations, can cause
unconsciousness or even death. For that reason,
adequate ventilation must be provided. Exhaust
gases must be piped safely away from any building
or enclosure that houses the generator to an area
where people, animals, etc., will not be harmed.
This exhaust system must be installed properly, in
strict compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
• Adequate, unobstructed flow of cooling and ventilating air is critical in any room or building housing the generator to prevent buildup of explosive
gases and to ensure correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect safe operation of the generator.
• Keep the area around the generator clean and
uncluttered. Remove any materials that could
become hazardous.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Inspect the generator regularly, and promptly
repair or replace all worn, damaged or defective
parts using only factory-approved parts.

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



WARNING:



This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become
familiar with this Owner’s Manual and with the unit.
The generator can operate safely, efficiently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to
follow simple and fundamental rules or precautions.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed
to the unit are, therefore, not all inclusive. If a procedure, work method or operating technique is used
that the manufacturer does not specifically recommend, ensure that it is safe for others. Also make
sure the procedure, work method or operating technique utilized does not render the generator unsafe.

DANGER
the safe design of this generator,
 Despite
operating this equipment imprudently, neglecting its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or maintain this equipment.
lethal voltages are generated by
 Potentially
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
of the generator are rotating and/or hot
 Parts
during operation. Exercise care near running
generators.

1-1

Safety 001 Rev. 0 08/05



SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas. Safety should be stressed to all
operators, potential operators, and service and repair technicians for this equipment.

Standby Generator Sets
Important Safety Instructions

• Generators installed with an automatic transfer
switch will crank and start automatically when
normal (utility) source voltage is removed or is
below an acceptable preset level. To prevent such
automatic start-up and possible injury to personnel, disable the generator’s automatic start circuit
(battery cables, etc.) before working on or around
the unit. Then, place a “Do Not Operate” tag on
the generator control panel and on the transfer
switch.
• In case of accident caused by electric shock, immediately shut down the source of electrical power.
If this is not possible, attempt to free the victim
from the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical
help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving components causing injury.

• Before performing any maintenance on the generator, disconnect its battery cables to prevent
accidental start-up. Disconnect the cable from the
battery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.

 ELECTRICAL HAZARDS 

• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as well as the standby generator. Avoid contact
with bare wires, terminals, connections, etc., on
the generator as well as the transfer switch, if
applicable. Ensure all appropriate covers, guards
and barriers are in place before operating the generator. If work must be done around an operating
unit, stand on an insulated, dry surface to reduce
shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• If personnel must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a
dry wooden platform. Work on the equipment only
while standing on such insulative mats.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts
of the generator to be connected to an approved
earth ground. This grounding will help prevent
dangerous electrical shock that might be caused
by a ground fault condition in the generator set or
by static electricity. Never disconnect the ground
wire.
• Wire gauge sizes of electrical wiring, cables and
cord sets must be adequate to handle the maximum electrical current (ampacity) to which they
will be subjected.
• Before installing or servicing this (and related)
equipment, make sure that all power voltage
supplies are positively turned off at their source.
Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied by an electric utility shall be by
means of a transfer switch so as to isolate the
generator electric system from the electric utility
distribution system when the generator is operating. Failure to isolate the two electric system power
sources from each other by such means will result
in damage to the generator and may also result
in injury or death to utility power workers due to
backfeed of electrical energy.

 FIRE HAZARDS 
• Keep a fire extinguisher near the generator at all
times. Do NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid
can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its
use. If there are any questions pertaining to fire
extinguishers, consult the local fire department.

 EXPLOSION HAZARDS 

• Properly ventilate any room or building housing
the generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
• These generator sets may operate using one of
several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks
immediately. Fuel supply lines must be properly installed, purged and leak tested according to
applicable fuel-gas codes before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous
fluids such as natural gas and liquid propane
(LP) gas are extremely EXPLOSIVE. Natural gas
is lighter than air, and LP gas is heavier than air;
install leak detectors accordingly.

1-2

Safety 001 Rev. 0 08/05

Standby Generator Sets
Important Safety Instructions

INTRODUCTION

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

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

The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly recommends that the operator read this Owner's Manual
and thoroughly understand all instructions before
using this equipment. The manufacturer also strongly recommends instructing other users to properly
start and operate the unit. This prepares them if they
need to operate the equipment in an emergency.

READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing procedures.

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

Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service
or operation that may be hazardous if performed
incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:

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

Proper maintenance and care of the generator ensure
a minimum number of problems and keep operating
expenses at a minimum. See an Authorized Service
Dealer for service aids and accessories.
Operating instructions presented in this manual
assume that the standby electric system has been
installed by an Authorized Service Dealer or other
competent, qualified contractor. Installation of this
equipment is not a “do-it-yourself” project.

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

HOW TO OBTAIN SERVICE

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

When the generator requires servicing or repairs,
simply contact an Authorized Service Dealer for
assistance. Service technicians are factory-trained
and are capable of handling all service needs.

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

When contacting an Authorized Service Dealer or the
factory about parts and service, always supply the
complete model number of the unit as given on the
front cover of this manual or on the DATA LABEL
affixed to the unit.

These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compliance with the special instructions while performing
the service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:

To locate the nearest AUTHORIZED
SERVICE DEALER, please call this number:

This symbol points out important safety information that, if not followed, could endanger
personal safety and/or property of others.

1-800-333-1322

symbol points out potential explosion
 This
hazard.

or locate us on the web at:

www.generac.com
1-3

Safety 001 Rev. 0 08/05



AUTHORIZED SERVICE DEALER LOCATION

Standby Generator Sets
General Information

IDENTIFICATION RECORD

Identification Code

DATA LABEL

Use this code to obtain important information about
the generator. For example, if the code is:

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.
MADE IN USA

RATED KVA

RATED KW

POWER FACTOR

PHASE

RATED AMPS

RATED VOLTAGE
HERTZ

ALT RPM

PRODUCTION DATE

ENGINE RPM

ALTERNATOR SUBTRANSIENT REACTANCE
ALTERNATOR TRANSIENT REACTANCE
CLASS

ROTOR

A N S N A

M — Designates generators capable of paralleling.
NOTE: Only 100kW and 150kW, 6.8L units
are currently available for this configuration.
QT — Quiet Test Generator Series
100 — kw Rating
5.4 — Engine Size in Liters
A — Voltage Code: A = 120/240, Single-phase;
G = 120/208, Three-phase; K = 277/480,
Three-phase; J = 120/240, Three-phase;
L = 346/600, Three-phase
N — Fuel: N = Natural Gas; V = Vapor Propane
S — Enclosure Material: A = Aluminum; S
= Steel (Corrosion Resistant Aluminum
Enclosure Material, Steel is Standard)
N — Emission Equipment: N = No Equipment;
Y = Catalytic Converter and Air/Fuel Ratio
Controller
A — Industrial Dealer Product

SERIAL

MODEL

STATOR WINDING INSULATION AT 25°C AMBIENT

GENERAC POWER SYSTEMS, INC.
WAUKESHA, WI

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.

Voltage Codes
The identification code letter following the unit’s
engine size is the generator’s “voltage code.”

Groups and Assembly Numbers

Generator Model and Serial Number

The manual drawing listing lists the groups and corresponding assembly numbers for each unit. The
assembly numbers refer to exploded view drawing
numbers that are applicable to the specific generator
model. These drawings are located in the back half
of this manual.

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.

2-1

Identy001 Rev. C 04/06

GENERATOR SET DATA

M Q T 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 CC, SD, SE, SF.” Detergent oils keep the
engine cleaner and reduce carbon deposits. Use oil
having the following SAE viscosity rating, based on
the ambient temperature range anticipated before the
next oil change:
Temperature
Above 80° F (27° C)
32° to 80° F (0° to 27° C)
Below 32° F (0° C)

radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.

Oil Grade (Recommended)
SAE 30W or 15W-40
SAE 20W-20 or 15W-40
See Note

attempt to crank or start the engine before
 Any
it has been properly serviced with the recommended oil may result in an engine failure.
NOTE:
For temperatures below 32° F, it is strongly recommended to use the optional Cold Weather Start Kit
(part number listed in the Specification Section).
The oil grade for temperatures below 32° F is 5W30 synthetic oil.

Equip002 Rev. 0 08/05

3-1

Standby Generator Sets
Engine Protective Devices

ENGINE PROTECTIVE DEVICES

OVERCRANK SHUTDOWN

The standby generator may be required to operate for
long periods of time without an operator on hand to
monitor such engine conditions as coolant temperature, oil pressure or rpm. For that reason, the engine
has several devices designed to protect it against
potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too
low, the coolant temperature is too high, the coolant
level is too low, or the engine is running too fast.

After a prespecified duration of cranking, this function ends the cranking if the engine has failed to
start. The overcrank LED will turn ON. Turn OFF the
AUTO/OFF/MANUAL switch, then turn switch back to
AUTO to reset the generator control board.
NOTE:
If the fault is not corrected, the overcrank feature
will continue to activate.

NOTE:

Approximate Crank Cycle Times

Engine protective switches and sensors are mentioned here for the reader’s convenience. Also
refer to the applicable control panel manual for
additional automatic engine shutdown information.

•
•
•
•
•

HIGH COOLANT TEMPERATURE SWITCH
This switches contacts close if the temperature should
exceed approximately 140° C (284° F), initiating an
engine shutdown. The generator will automatically
restart and the LED will reset once the temperature
has returned to a safe operating level.

15 seconds ON
7 seconds OFF
7 seconds ON
7 seconds OFF
Repeat for 45 seconds
Approximately 90 seconds total.

OVERSPEED SHUTDOWN
A speed circuit controls engine cranking, start-up,
operation and shutdown. Engine speed signals are
delivered to the circuit board whenever the unit is
running. Should the engine overspeed above a safe,
preset value, the circuit board initiates an automatic
engine shutdown. Contact the nearest Authorized
Dealer if this failure occurs.

LOW COOLANT LEVEL SENSOR
Should the engine coolant level drop below the level
of the high coolant temperature switch, it is possible
for the engine to overheat without automatic shutdown. To prevent such overheating, the engine has a
low coolant level sensor. If the level of engine coolant
drops below the level of the low coolant level sensor,
the engine automatically shuts down.

RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine
shutdown will occur.

DC FUSE

LOW OIL PRESSURE SWITCH

This fuse is located inside of the control panel. It
protects the panel wiring and components from
damaging overload. Always remove this fuse before
commencing work on the generator. The unit will
not start or crank if the fuse is blown. Replace the
fuse with one of the same size, type, and rating. (See
the exploded views and parts lists at the end of this
manual for replacement part number.)

4-1

EngProt001 Rev. 0 08/05

This switch has normally closed contacts that are
held open by engine oil pressure during cranking and
operating. Should oil pressure drop below the 8 psi
range, switch contacts close, and the engine shuts
down. The unit should not be restarted until oil is
added, and the AUTO/OFF/MANUAL switch must be
turned to OFF and then back to AUTO.

Standby Generator Sets
Fuel Systems

FUEL SYSTEM

PROPANE VAPOR WITHDRAWAL FUEL SYSTEM

FUEL REQUIREMENTS

This type of system utilizes the vapors formed above
the liquid fuel in the supply tank. Approximately 10
to 20 percent of the tank capacity is needed for fuel
expansion from the liquid to the vapor state. The
vapor withdrawal system is generally best suited for
smaller engines that require less fuel. The installer
should be aware of the following:

The standby generator may be equipped with one of
the following fuel systems:
• Natural gas fuel system
• Propane vapor (PV) fuel system
The Manual Drawing Listing that is affixed to the
unit includes the “Identification Code,” which may be
used to identify the type of fuel system installed on
the unit.

• The natural gas and LP gas systems are similar.
However, the natural gas system delivers gas at a
pressure of approximately five inches water column to the carburetor.
• When ambient temperatures are low and engine
fuel consumption is high, the vapor withdrawal
system may not function efficiently.
• Ambient temperatures around the supply tank
must be high enough to sustain adequate vaporization, or the system will not deliver the needed fuel
volume.
• In addition to the cooling effects of ambient air, the
vaporization process itself provides an additional
cooling effect.

Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at
least 2,520 Btus per cubic foot for LP gas. Ask the
fuel supplier for the Btu content of the fuel.
Required fuel pressure for natural gas is 5 inches
to 14 inches water column (0.18 to 0.5 psi); and
for liquid propane, 5 inches to 14 inches of water
column (0.18 to 0.5 psi).
NOTE:
Any piping used to connect the generator to the
fuel supply should be of adequate size to ensure
the fuel pressure NEVER drops below five inches
water column for natural gas or 5 inches water
column for propane vapor for all load ranges.

LP FUEL SYSTEM
LP is supplied as a liquid in pressure tanks. It is
usually made up of propane, butane, or a mixture of
the two gases. Propane tends to vaporize readily even
at temperatures as low as -20° F (-29° C). However,
butane reverts to its liquid state when temperatures
drop below 32° F (0° C).

NOTE:
It is the responsibility of the installer to make sure
that only the correct recommended fuel is supplied to the generator fuel system. Thereafter, the
owner/operator must make certain that only the
proper fuel is supplied.

LP in a liquid withdrawal system must be converted
to its gaseous state before it is introduced into the
engine carburetor. A vaporizer-converter is generally
used to accomplish this. In such a converter, heated
engine coolant is ported through the converter to
provide the necessary heat for conversion of the fuel
from a liquid to a gaseous state.

NATURAL GAS FUEL SYSTEM
Natural gas is supplied in its vapor state. In most
cases, the gas distribution company provides piping
from the main gas distribution line to the standby
generator site. The following information applies to
natural gas fuel systems.
• Gas pressure in a building is usually regulated by
national, state and local codes.
• To reduce gas pressure to a safe level before
the gas enters a building, a primary regulator is
needed. The natural gas supplier may or may not
supply such a regulator.
• It is the responsibility of the gas supplier to make
sure sufficient gas pressure is available to operate
the primary regulator.
• Gas pressure at the inlet to the fuel shutoff solenoid should not exceed approximately 14 inches
water column (0.5 psi). Optimum pressure at the
fuel shutoff solenoid is 11 inches water column
(0.4 psi).

FuelSys001 Rev. 0 08/05

5-1

Standby Generator Sets
Specifications

SPECIFICATIONS

Engine Lubrication System
Type of Oil Pump ...................................................................... Gear
Oil Filter .............................................................Full Flow, Cartridge
Crankcase Oil Capacity ....................................................4 U.S. qts.

GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ....................................................................Class F
Stator Insulation ...................................................................Class F
Total Harmonic Distortion .........................................................< 5%
Telephone Interference Factor (TIF) ..........................................< 50
Alternator Output Leads 3-phase ........................................... 4-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) ............................................20kW*
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,

COOLING SYSTEM
Type .......................................................................................Closed
Water Pump.................................................................... Belt Driven
Fan Speed ................................................................................ 2550
Fan Diameter .....................................................................15 inches
Fan Mode ..............................................................................Pusher
Air Flow (inlet air including alternator and
combustion air) .......................................................... 1528 ft3/min.
Coolant Capacity ...........................................................2.0 U.S. gal.
Heat Rejection to Coolant ..........................................107,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature................................50° C (140° F)

ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural
gas.

Excitation System ....................................................................Direct
Generator Output Voltage/kW - 60 Hz
kW
Amp CB Size
120/240V, 1-phase, 1.0 pf
20
83
100
120/208V, 3-phase, 0.8 pf
20
69
80
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208 3-phase ............................................. 34 KVA

FUEL SYSTEM
Type of Fuel .........................................Natural Gas, Propane Vapor
Carburetor ...................................................................... Down Draft
Secondary Fuel Regulator .................................................Standard
Fuel Shut-off Solenoid ........................................................Standard
Operating Fuel Pressure ...................... 5 in. - 14 in. Water Column

ENGINE
Make ................................................................................... Generac
Model ..................................................................................... In Line
Cylinders and Arrangement............................................................ 4
Displacement ....................................................................... 1.5 Liter
Bore ...................................................................................... 2.97 in.
Stroke ................................................................................... 3.23 in.
Compression Ratio ...............................................................9.4-to-1
Air Intake System ...............................................Naturally Aspirated
Valve Seats................................................................... Replaceable
Lifter Type .......................................................................... Hydraulic

Fuel Consumption - ft3/hr (Natural Gas/LPV)
Exercise
25%
50%
75%
100%
Cycle
Load
Load
Load
Load
60/24
124/49
188/75
250/99
315/125

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

Engine Parameters
Rated Synchronous RPM ..............................................60 Hz, 3600
HP at rated kW ..................................................................60 Hz, 32

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

Exhaust System
Exhaust Flow at Rated Output 60 Hz.................................. 177 cfm
Exhaust Temperature at Rated Output .................................. 910° F
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz ................................................... 70 cfm

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 ................................................... 182
3% for every 1000 ft. above ft. ................................................. 600

Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation........................................................± .25%
Adjustments:
Speed ............................................................................ Selectable

Controller .................................................R-100

GenSpec013 Rev. B 11/05

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

NEUTRAL

N1
N2
23
194

4- # 14 GA
WIRES TO
GENERATOR
CONNECTION
BOX

CIRCUIT
BREAKER

183
178
Battery
Charger
Input

Load
Out

186
178

TO GENERATOR
CONNECTION BOX

GROUND

120 Volt +
Neutral
Grd

To Generator Control Panel
FRAME RAIL

Ground Level
Concrete Slab

KW
20
20

STUB-UP AREA
See Install Dwg for
Dimensions

COLD WEATHER KIT

CIRCUIT BREAKER SIZE
VOLTS / AMPS
LUG SIZE
240 1 Ø
100
#4 to 1/0
208 3 Ø
80
#4 to 1/0

10. Reverse the procedure to convert back to natural
gas.
11. The Dip switch inside the control panel must be
in the LP or NG position when switching to different fuels.

For cold climates, optional cold weather kit (part
number 0F6148) is recommended. The kit includes:
• Battery Warmer
• 4” Junction Box with hardware
• 6 qt. pack 5W-30 synthetic oil (engine)

Figure 6.2 — Reconfigure the Fuel System
Port 2

Port 1

RECONFIGURING THE FUEL SYSTEM
NOTE:

PLUG

All models are configured for natural gas or LP
vapor from the factory.

FUEL HOSE

BRASS HOSE
FITTING
OUT
PORT 1

BRASS HOSE
FITTING

PLUG

OUT
PORT 2
HOUSING
PORTS

HOUSING
PORTS

To reconfigure the fuel system from NG to LP, follow
these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet
port (Port 1) of the demand regulator (Figure
6.2).
3. Remove the brass hose fitting from the outlet port
(Port 1) of the demand regulator.
4. Remove pipe plug from Port 2.
5. Install brass hose fitting into Port 2.
6. Install pipe plug into Port 1.
7. Connect carburetor gas hose to brass fitting.
8. Tighten all clamps and plugs.
9. Make sure fuel supply is of the proper pressure
and type for configuration.

NG FUEL SYSTEM

LP FUEL SYSTEM

NOTE:
Port 1 is for NG only and Port 2 is for LP vapor
only. No provision for dual fuel has been made.

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

GenSpec013 Rev. B 11/05

Standby Generator Sets
General Information

GENERATOR AC LEAD CONNECTIONS

ALTERNATOR POWER WINDING
CONNECTIONS

See “Voltage Codes”. This generator may be rated
at any one of three voltages, either single-phase or
three-phase. The electrical wires in the unit’s AC connection (lower) panel should be installed according to
the number of leads and the voltage/phase required
for the application. If there are any questions regarding lead connection, refer to the wiring diagrams at
the back of this manual.

3-PHASE ALTERNATORS
The generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected
at the factory to the main circuit breaker with a “Y”
configuration as shown in Figures 7.2 and 7.3.

Voltage codes apply to the type of stator assembly
installed on a particular generator.

The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is either 480V or 208V
depending on the model.

FOUR-LEAD, SINGLE-PHASE STATOR

The rated voltage between each circuit breaker terminal and the neutral point 00 is either 277V or 120V
depending on the model.

Four-lead generators (see Figure 7.1) are designed to
supply electrical loads with voltage code “A” (240V,
1-phase, 60 Hz). Electrical power is produced in the
stator power windings. These windings were connected at the factory to the main circuit breaker as
shown in Figure 7.1.

Figure 7.2 — Stator Power Winding
Connections - 3-phase, 277/480V (6 Lead)

The rated voltage between each circuit breaker terminal is 240V. The rated voltage between each circuit
breaker terminal and the neutral point 00 is 120V.

S1 E1

Figure 7.1 — Four-lead, Single-phase Stator

INTERNAL
CONNECTIONS
L-L

NEUTRAL

S5
E3 S3

L-N

Figure 7.3 — Stator Power Winding
Connections - 3-phase, 120/208V (6 Lead)
E1
S1

S3
E3

L-L

00 (NEUTRAL)

S6 S5

L-N
ACConn001 Rev. 0 08/05

7-1

Standby Generator Sets
Installation

PRIOR TO INITIAL START-UP

INSTALLATION
Refer to the separate “Installation Guide QT Product
Line” supplied with the unit.

to initially starting the generator, it must
 Prior
be properly prepared for use. Any attempt to

PREPARATION BEFORE START-UP
The instructions in this section assume that the
standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for
use by a competent, qualified installation contractor.
Be sure to read the “Safety Rules”, as well as all other
safety information in this manual, before attempting
to operate this (and related) equipment.

crank or start the engine before it has been
properly serviced with the recommended types
and quantities of engine fluids (oil, coolant, fuel,
etc.) may result in an engine failure.

ENGINE COOLANT
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
for leaks and other problems. See “Specifications”
and “Coolant” sections.

Before starting the generator for the first time, the
installer must complete the following procedures. For
follow-up maintenance information and/or service
intervals, please refer to the “Maintenance” section
and the “Service Schedule”.

BELT TENSION

TRANSFER SWITCH

Check-the engine-fan belt tension and condition prior
to placing the unit into service and at recommended
intervals. Belt tension is correct when a force of
approximately 22 pounds (10 kg), applied midway
between pulleys, deflects the belt about 3/8- to 5/8inch (10 to 16 mm).

If this generator is used to supply power to any electrical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (For additional information, see the applicable
transfer switch manual for this unit.) The transfer
switch, as well as the generator and other standby
components, must be properly located and mounted
in strict compliance with applicable codes, standards
and regulations.

ELECTRICAL SYSTEM
Make sure the generator is properly connected to an
approved earth ground.
Make sure the generator battery is fully charged,
properly installed and interconnected, and ready for
use.

FUEL SYSTEM

Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear
of any moving generator set components.

Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and (b) is properly purged and leak tested
according to code. No fuel leakage is permitted. See
“Specifications” for more information.

INITIAL INSPECTION FOR QT GENSET
STARTUP

GENERATOR SET LUBRICATION

Inspect for the following.
•
•
•
•
•

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

•
•

Check the oil level in the generator gearbox (if so
equipped) prior to initial use and at the intervals
indicated by the “Service Schedule.” The recommended oil is SAE 90 gear lubricant.

•
•

Also, if the engine is equipped with a mechanical governor, make sure the governor is properly lubricated
with clean engine oil.

•
8-1

Freight Damage.
Manuals present.
Fluid Levels (Oil, coolant, battery, Gear Drive).
Correct fuel piping.
Correct muffler installation for external application.
Adequate air flow, clearances and ventilation per
installation drawings and applicable codes.
Correct AC and DC wire size, connections and
grounding. Control and communication wiring to/
from the transfer switch must be run in a separate
conduit from the AC power leads.
Battery charger connection to 120 VAC.
Communication wires connected between transfer
switch and generator (HTS only).
Unit secured to pad.
Install001 Rev. C 05/06

Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level
below the dipstick “ADD” mark. See “Specifications”
and “Engine Oil Recommendations”.

Standby Generator Sets
Installation

START-UP CHECKLIST

• Check voltage at the generator terminals.
• For 3-phase units, check phase rotation at the
transfer switch terminals. The generator phase
rotation must match the utility phase rotation.
• Check for coolant, fuel, oil, and exhaust leaks.
• Close the generators main line circuit breaker.
• Turn the generator set off.
• Connect the UTILITY supply to the transfer
switch.
• Set the AUTO/OFF/MANUAL switch to AUTO.
• Disconnect utility power before the transfer
switch.
Engine should start, transfer to load.
Run at least 15 minutes on generator power.
Make certain all 3-phase loads are functioning
correctly (correct phase rotation).
• Reconnect Utility power
Transfer switch will transfer back to Utility and
engine will shut down within the given time
parameters set up for the specific transfer switch
and controller.
• Install all covers, access plates and door panels.
• Put the Owners Manual in a safe and accessible
place.
• Make certain the AUTO/OFF/MANUAL switch is in
the AUTO position.

working on the generator, ensure the fol Before
lowing:
• The AUTO/OFF/MANUAL switch is in the OFF
position.
• The 120VAC supply to the battery charger is
switched OFF.

PREPARATION FOR START-UP
• Ensure that the 120VAC circuit breaker to the battery charger is open.
• Remove the fuse from the the control panel. For
the H-100 and R-series: Open the front door of the
control box and remove the 15 Amp ATO fuse in
the lower left-hand corner of the control box.
• Connect the battery cables to the battery. Attach
negative battery cable last.
• Close the 120VAC circuit breaker to the battery
charger.
• Measure the voltage at the battery before and after
the charger is turned on.
• Verify all AC electrical connections are tight at the
circuit breaker and transfer switch.
• Visually inspect entire area looking for loose paper,
plastic wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or damage.
• Check all electrical plugs throughout the generator. Ensure each plug is seated correctly and fully
inserted into its receptacle.
• Verify the AUTO/OFF/MANUAL switch is in OFF
position.
• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel
lines).
• Open the generator main line circuit breaker.
• Connect a manometer to the gas line and record
the static pressure. It must be as listed in the
Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the MANUAL position. The engine should now crank and
start.

START-UP INSPECTION
When a start-up is performed by an Authorized
Service Dealer, a standard three-part form titled
“Start-up Inspection for Standby Power Systems”
(part no. 067377), should be completed by the installation technician or engineer. See page 1-3 for information on locating the nearest Authorized Service
Dealer. The installer should complete the form and
disseminate copies as follows:
• White copy: Mail to Generac Warranty Department,
P.O. Box 340, 211 Murphy Dr., Eagle, WI 531192062.
• Pink Copy: For service file of installing dealer.
• Yellow Copy: For the customer’s records.

8-2

Install001 Rev. C 05/06

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.

DANGER

To transfer the load back to the utility power source
and shut down the generator, follow these directions:

Maintenance Disconnect Switch and the
 The
AUTO/OFF/MANUAL switches (if so equipped)
must be set properly, or the generator will crank
and start as soon as the utility power to the
transfer switch is turned off. Refer to applicable
control panel and transfer switch manuals for
more information.

• Set the standby generator’s main line circuit breaker to its OFF (or OPEN) position.
• Manually move the transfer switch handle to its
UTILITY (NORMAL) position, i.e., load circuits
connected to the utility.
• Turn ON the utility power supply to the transfer
switch, using the means provided (such as the utility power source main line circuit breaker).
• Let the generator run at no-load for a few minutes
to stabilize internal temperatures.
• Shut down the generator.

not proceed until certain that utility source
 Do
voltage is available to the transfer switch and
the transfer switch main contacts are set to
UTILITY.
not attempt manual operation until all power
 Do
supplies to the transfer switch have been positively turned off, or extremely dangerous - possibly lethal - electrical shock will result.

OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH



Transfer switch enclosure doors should be kept
closed and locked. Only authorized personnel
should be allowed access to the transfer switch
interior. Extremely high and dangerous voltages
are present in the transfer switch.
In order to transfer load from the utility source to the
generator, follow these directions:

If the generator has been installed with an automatic
transfer switch, such as an RTS, HTS, or GTS-type
transfer switch, the engine may be started and
stopped automatically or manually.
NOTE:
Refer to the applicable manual for your transfer switch and to “Transfer Switch Start Signal
Connections”. In addition, please note the dangers
under “Engine Start-up and Transfer.”

9-1

Oper001 Rev. 0 08/05

• Turn OFF or disconnect the utility power circuit
to the transfer switch, using the means provided
(such as the utility source main line circuit breaker).
• Set the transfer handle to its UTILITY (NORMAL)
position with load circuits connected to the utility
power supply.
• Set the standby generator’s main line circuit breaker to its OFF (or OPEN) position.
• Start the generator.

Standby Generator Sets
Maintenance

MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE FACILITIES

COOLING SYSTEM
Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow.

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

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

• The AUTO/OFF/MANUAL switch is in the OFF
position.
• The 15A fuse has been removed from the control box.
• The 120VAC supply to the battery charger is
switched OFF.

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

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

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

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

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

ONCE ANNUALLY

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

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

resetting the circuit breaker or replacing the
fuse.

FIRST 30 OPERATING HOURS

CHECKING FLUID LEVELS

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

CHECK ENGINE OIL

FIRST 100 OPERATING HOURS

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

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

• Remove oil dipstick and wipe dry with a clean, lintfree cloth.
• Install oil dipstick, then remove again.
• Oil should be between FULL and ADD marks.
• If oil level is below the dipstick ADD mark, remove
oil fill cap-. Add the recommended oil to bring oil
level up to the FULL mark. DO NOT FILL ABOVE
THE “FULL” MARK. See “Engine Oil Recommendations” for recommended oils.

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

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

Maint006 Rev. B 12/05

1.
2.
3.
4.

Standby Generator Sets
Maintenance

EXERCISE SYSTEM

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Start the generator engine at least once every seven
days and let it run at least 20 minutes. See “Weekly
Exercise Cycle”.

OIL FILL CAP
OIL DIPSTICK

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

CHECK ENGINE COOLANT LEVEL
See “Checking Fluid Levels”.

PERFORM VISUAL INSPECTION
BATTERY FLUID

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.

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

INSPECT EXHAUST SYSTEM
Inspect the exhaust system at least once every three
months. Check all exhaust system pipes, mufflers,
clamps, etc. for condition, tightness, leaks, security,
damage.

ENGINE COOLANT
Check coolant level in coolant recovery bottle. See
Specifications.
• 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 an Authorized Service
Dealer. Inspect cooling system and coolant recovery system for leaks.

CHECK FAN BELT

MAINTENANCE OWNER/
OPERATOR CAN PERFORM

Visually inspect electronic governor.

CHECK ENGINE OIL LEVEL

not attempt to adjust the governor. Only
 Do
qualified service facilities should adjust the

• Inspect fan belts every three months. Replace any
damaged, deteriorated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted
midway between pulleys, should deflect about 3/8
to 5/8 of an inch. Adjust belt tension as required.

INSPECT ENGINE GOVERNOR

DANGER

Refer to “Checking Fluid Levels”.

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

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

10-2

Maint006 Rev. B 12/05

Standby Generator Sets
Maintenance

CHANGING ENGINE OIL

Figure 10.3 – Engine Air Cleaner

Refer to maintenance performed by authorized 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
6, for recommended inspection.
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 0.5-0.6 mm (0.020-0.025
inch) by carefully bending the ground electrode
(Figure 10.4).

OIL FILTER

5. Apply light coating of new engine oil to seal of new
oil filter.-Install FILTER and tighten by hand only.
DO NOT OVER TIGHTEN.
6. Remove OIL FILL CAP. Add recommended oil (see
SPECIFICATIONS). DO NOT FILL ABOVE THE
DIPSTICK “FULL” MARK. Crankcase oil capacity
is 4.0 U.S. quarts (3.8 liters).

Figure 10.4 – Setting the Spark Plug Gap
SET PLUG GAP AT 0.5 - 0.6 mm
(0.020 - 0.025 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, (part number
059402), simply remove the air cleaner cover and
replace the air filter making sure it is positioned
properly before reattaching the cover (Figure 10.3).

Every year, have an Authorized Service Facility drain,
flush and refill the cooling system. See “Specifications”
for cooling system recommendations.

See the “Service Schedule,” for air cleaner maintenance.
Maint006 Rev. B 12/05

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.

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.

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

electrolyte fluid is an extremely corro Battery
sive sulfuric acid solution that can cause severe

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

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.

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:

not use any jumper cables or booster battery
 Do
to crank and start the generator engine. If the
battery has completely discharged, remove it
from the generator for recharging.

• 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.

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

BATTERY REPLACEMENT
When replacing batteries, use the same number and
the type of battery that follows:
BCI Group No.
26

CCA
525 @ 0 deg. F

NOTE:
The BCI number should be located directly on the
battery.

BATTERY MAINTENANCE

PERIODIC REPLACEMENT PARTS

The battery should be inspected per Section 4.7,
Scheduled Maintenance. The following procedure
should be followed for inspection:

Part Name
Oil Filter
Radiator Cap
Air Cleaner
Spark Plug

1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
10-4

Part Number
# 0A4531A244
# 046627
# 059402
# 0A45310275

Maint006 Rev. B 12/05

Standby Generator Sets
Service Schedule

SERVICE SCHEDULE
The following is a recommended maintenance schedule for small standby and residential generator sets. The
established intervals in the schedule are the maximum recommended when the unit is used in an average service
application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use calendar time or accumulated run time, from the previous maintenance interval to determine the next
required maintenance interval.

Service Maintenance Interval Information:
The various service maintenance intervals are designated by interval numbers as follows:
1 An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas.
Performed monthly this requires approximately .5 man-hours per unit to complete.
This inspection may be performed by the end user providing the following safety steps are taken to prevent
the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
•
•
•
•

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

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

SrvSchd002 Rev. C 05/06

11-1

Standby Generator Sets
Service Schedule

Maintenance
Tasks

Level 1
Recommended
to be done
monthly
10 Hrs.

Level 2
Task
Comp.
(DateInitials)

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

1. Disable the unit from
operating per the first page
warning.
2. Check the engine oil level.
Adjust as necessary.
3. Check the engine coolant
level. Adjust as necessary.
4. Check the engine coolant
thermal protection level.
Correct as necessary.
5. Check the natural gas
delivery system on gas
engine driven units.
Tighten connections as
necessary.
6. Check the air inlets and
outlets for debris. Clean as
necessary.
7. Check the battery
electrolyte level if
accessible. Adjust as
necessary.
8. Check the battery posts,
cables, and charger for
loose connections,
corrosion, and proper
operation. Correct as
necessary.
9. Check the unit wiring for
loose connections,
corrosion, and damage.
Correct as necessary.
10. Check the engine
accessory drive belts for
wear, weather cracking,
and damage. Replace as
necessary.
11. Visually inspect the unit
looking for leaks, wear or
damage, loose connections
or components, and
corrosion. Correct as
necessary.
12. Test the engine and
transfer switch safety
devices. Correct and/or
adjust as necessary.

11-2

Level 3
Task
Comp.
(DateInitials)

Required
to be done
Semiannually
50 Hrs.

Level 4
Task
Comp.
(DateInitials)

Required
to be done
Annually
100 Hrs.

Task
Comp.
(DateInitials)

SrvSchd002 Rev. C 05/06

Standby Generator Sets
Service Schedule

Maintenance
Tasks

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

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

Level 3
Task
Comp.
(DateInitials)

Required
to be done
Semiannually
50 Hrs.

Level 4
Task
Comp.
(DateInitials)

Required
to be done
Annually
100 Hrs.

Task
Comp.
(DateInitials)

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

SrvSchd002 Rev. C 05/06

11-3

Standby Generator Sets
Troubleshooting

TROUBLESHOOTING GUIDE
PROBLEM

CAUSE

CORRECTION

Engine won’t crank.

1. 15 amp fuse blown.
2. Loose or corroded or defective
battery cables.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
6. 5 amp fuse blown.

1. Replace fuse.
2. Tighten, clean or replace
battery cables as necessary.
3. Replace contactor.*
4. Replace starter motor.*
5. Remove, change or replace battery.
6. Replace fuse.*

Engine cranks but won't start

1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14A from Engine Control
circuit board.
4. Spark plugs defective.
5. Door on tank not closed.

1. Replenish fuel.
2. Replace solenoid.*
3. Reconnect wire.

1. Flame arrestor (air cleaner) plugged or
damaged.
2. Plugged fuel line.
3. Defective spark plugs.
4. Fuel pressure incorrect.

1. Clean or replace as needed.

Engine starts 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.

Check main line circuit breaker.
Check circuit breaker & fuses.
Transfer switch set to NORMAL position
Generator internal failure.
Thermal circuit breaker open.

1.
2.
3.
4.
5.
6.
7.

Check oil and add oil as needed.
Check cooling system for leaks.
Replace switch.*
Replace switch.*
Replace board.*
Repair leak - Add coolant.
Replace Switch.*

1. Replace switch.*
2. Reconnect/close wire.

Reset to ON or CLOSED.
Reset and replace, if necessary.
Set to GENERATOR position.
*
Auto-reset - Wait 5 min. and
attempt restart.

*Contact the nearest Authorized Dealer for assistance.

12-1

Trblsht001 Rev. 0 08/05

No AC output from generator.

Engine oil level is low.
Engine is overheated.
Defective Low Oil Pressure Switch
Defective Coolant Temperature Switch
Defective Control Module circuit board.
Coolant Level is Low.
Defective Low Coolant Level Switch

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

Standby Generator Sets
Notes

1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

27
28
29
30
31
32 *
33 *
34 *
35 *
37 *
38
39
40

0F7135
0F7022
0F7021
0F7260
0F7136
0F6156
0F4464
0D4698
0F3824
057701
0F6146
081008
0C2267
049226
051713
0C2212
022264
0F6366A
0F6366B
022241
022237
057329
057073
023484J
0E3257
0E7890
0E6002
0D5544
062812
0A2077
040532
052619
023897
049226
051716
025433
0A1354A
0E3257
022473
022097
0F7194
057593
0F1733
023762

1
1
1
1
1
1
1
REF
1
REF
1
1
2
2
2
11
11
1
1
1
1
1
1
1
15
REF
REF
REF
REF
REF
REF
REF
REF
REF
REF
1
REF
REF
REF
REF
2
1
1
1

BREAKER TRAY BACK/BOTTOM
SUPPORT CONTROL PANEL SIDE RH
SUPPORT CONTROL PANEL SIDE LH
COVER CIRCUIT BREAKER 2P
COVER CIRCUIT BREAKER 3P
PLATE WIRE SNGL GALV
DECAL CUST CONN 120V UTILITY
BLOCK TERM 20A 6 X 3 X 1100V
DECAL UTIL SENSE/CUST CONN
BLOCK TERM 20A 8 X 6 X 1100V
HANG TAG 2 WIRE START (NOT SHOWN)
GROMMET 1.25 X .25 X .75
SCREW HHTT M5-0.8 X 12 BP
WASHER LOCK M5
WASHER FLAT M5
SCREW PHTT M4-0.7 X 16 ZYC
WASHER LOCK #8-M4
XFMR DUAL 104V/16V (3 PHASE)
XFMR DUAL 120V/16V (1 PHASE)
NUT HEX 3/8-16 STEEL
WASHER LOCK 3/8
LUG SLDLSS 350-#6 X 13/32 AL/CU
JUNCTION BLOCK 3/8-16
BUSHING SNAP SB-2000-26
SCREW HWHTF M6-1.0 X 16
BRKT CB MTG BACK 2P
MTG TRACK BQ SIEMENS CB 3P
CB 0100A 2P 240V S BQ2 LL (1.5L 2 POLE)
CB 0080A 3P 240V S BQ3 LL (1.5L 3 POLE)
CB 0125A 2P 240V S BQ2 LL (2.5L 2 POLE)
CB 0100A 3P 240V S BQ3 LL (2.5L 3 POLE)
SCREW HHC M5-0.8 X 20 G8.8 (NOT SHOWN)
WASHER FLAT #10 ZINC (NOT SHOWN)
WASHER LOCK M5 (NOT SHOWN)
NUT HEX M5-0.8 G8 CLEAR ZINC (NOT SHOWN)
LUG SLDLSS #6-14 X 13/64 CU
REGULATOR - DC ALT
SCREW HWHTF M6-1.0 X 16
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
BRACKET PANEL SUPPORT 1.5L C1
CABLE TIE MOUNT BLACK
DECAL CUSTOMER CONNECT INSIDE
WASHER SHAKEPROOF EXT #10 STL

* USED ON 1.5L ONLY.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
26 *
27
28
29
30
31
32
33
35
36

098675
0A5336A
0A1659
020746
049226
051713
022129
0F8218
0F8220
0A5382
075591
075476
0A5601A
075554B
0A9375
022152
097146
042558
0A5061
0A4989
053607
051769
049541
046526
045772
087599
077043E
022131
072578
0A7043
049808
058589
023365
0A8830
072080

1
1
1
4
4
4
4
1
1
1
1
4
1
4
4
4
1
1
1
1
1
6
4
4
4
2
1
4
1
5
5
1
4
4
1

ASSY ROTOR 20KW
HOUSING BLOWER
SCREEN AIR OUTLET
SCREW PPHM M5-0.8 X 8 ZINC
WASHER LOCK M5
WASHER FLAT M5
WASHER LOCK M8-5/16
ASSY STATOR 20KW 1PH A
ASSY STATOR 20KW 3PH GJK
BEARING CARRIER REAR
ASSY HOLDER BRUSH
SCREW PPHM M4-0.7 X 16
COVER REAR BEARING
BOLT STATOR X 16" LG
SCREW RHM #10-24 X 2
WASHER LOCK #10
FAN & RING GEAR ASSEM.
KEY SQ 3/8 X 1 STEEL
SPACER-FLEX PLATE
PLATE FLEX
SCREW HHC M12-1.75 X 35 G8.8
WASHER LOCK M12
SCREW HHC M10-1.5 X 35 G8.8
WASHER LOCK M10
NUT HEX M10-1.5 G8 YEL CHR
PLUG PLASTIC 3/8 NPT
FLEX CONDUIT 1" BLACK (NOT SHOWN)
WASHER FLAT 3/8-M10 ZINC
SPACER ROTOR SHAFT
SCREW HHC M12-1.25 X 25 G8.8
WASHER FLAT M12
DECAL WARN ENG START
WASHER SHAKEPROOF INT #8
WASHER FLAT .34 ID X .75 OD
DECAL DANGER STANBY UNITS

1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
36
37
38
39
40
41
42
43

0F1823A
0F3078
0F2606
036261
043181
052777
0F4245F
0F1262
0F1263
0F1264
0F1725C
067680
0E6875A
055911
0F5459
0F5462
0A5062J
029673
049350
0F1958
082573
0E4494
0F3215
0F5886
051713
049226
0F5752B
0F5884
0F5896
0C2265
0C3990
091526
051716
043182
051714
0F3192
0E7403C
0F4416
0F6305
0F6305A
0F2627

A
B
C
D
E
F

056739
022287
022473
022097
022127
0F6145

1
1
1
6
4
7
1
4
1
1
1
1
2
1
1
1
4
1
1
1
1
1
1
3
14
14
1
2
2
4
2
8
7
7
7
1
1
1
2
1
1

ENCL HSB CONTROL PANEL
COVER CONTROL PANEL
HINGE CONTINUOUS H-PNL
RIVET POP .125 X .275 SS
SCREW PHM M3-0.5 X 10MM
WASHER FLAT M3
ASSY PCB CPL CTRLR 3600 RPM
HOLDER FUSE WICKMANN 178.6150
ADPTR RH SIDE WICKMAN 178.6191
ADPTR LH SIDE WICKMAN 178.6192
ASSY PCB 2AMP 12V UL BATT CHGR
ASSY VOLTAGE REGULATOR 60HZ
RELAY 12VDC C FORM W/DIODE
BLOCK TERM 20A 12 X 6 X 1100V
DECAL CPL CONTROL PANEL FUSES
DECAL CPL 3.9L TB1
SPACER 9.5H 3.2 ID
DIO BRIDGE 25A 600V
CB 4 X 1 ETA 46-500-P
PLATE HARNESS CLAMP
SWITCH RKR DPST 125V SPD
SWITCH RKR DPDT ON-OFF-ON
DECAL CONTROL HSB
SCREW HHPM M5-0.8 X 12
WASHER FLAT M5
WASHER LOCK M5
RES WW 25R 5% 25W QK CONN
SCREW PHTT M3.5-0.6 X 10
SCREW PHTT M3.5-0.6 X 16
SCREW PHTT M4-0.7 X 12 ZYC
SCREW PHTT M4-0.7 X 10 ZYC
SCREW PPHM M5-0.8 X 12 ZNC
NUT HEX M5-0.8 G8 CLEAR ZINC
WASHER LOCK M3
NUT HEX M3-0.5 G8 YEL CHR
SUPPORT ANGLE PCB
FUSE ATO TYPE 15 AMP (BLUE)
HARN 1800RPM R-100 CONTROL PNL (NOT SHOWN)
SEAL COVER 3.18 X 12.7 X 382
SEAL COVER 3.18 X 12.7 X 283
PLATE COVER H PANEL

COMPONENTS INSTALLED PER OF7380D
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
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

0F3408B
0F3411
025507
052647
046526
022131
050331A
050331
038805J
038804U
045771
022129
027482
0F3976
0C2454
022145
077483
0742600131

1
1
REF
REF
REF
REF
REF
REF
1
1
REF
REF
REF
3
4
REF
REF
1

BATTERY TRAY C1 CPL
STRAP BATTERY RETAINMENT
WASHER SHAKEPROOF EXT 7/16 STL
SCREW SHC M10-1.5 X 25 G12.9
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
BATT POST COVER RED +
BATT POST COVER BLK CABLE BATTERY BLK #1 X 30.00
CABLE BATTERY RED #1 X 28.00
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
WASHER SHAKEPROOF EXT 5/16 STL
BOOT CONTACTOR CABLES
SCREW THF M6-1 X 16 N WA Z/JS
WASHER FLAT 5/16-M8 ZINC
BATTERY 12VDC 75-AH 26
ASSY WIRE #16 RED 1.6

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

0F7155
027482
070936
070936C
039253
022145
022129
045771
071956
051730
021991
026850
049813
055414
047411
022097
022473

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

MOUNTING BASE 1.5L C1 CPL
WASHER SHAKEPROOF EXT 5/16 STL
DAMPENER VIBRATION
VIB. ISO. 70-75 DURO
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
WASHER FLAT M8
SCREW HHC M8-1.25 X 60 G8.8
EARTH STRAP
WASHER SHAKEPROOF EXT 1/4 STL
NUT HEX M6 X 1.0 G8 YEL CHR
LUG SLDLSS #2-#8 X 17/64 CU
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

0F7211
0F7209
0F7210
0E9837A
0E1936
022129
0F7166
099502
069860C
035461
0A6258
046627
052250
022473
022097
0C8566
049813
0C2454
055816
0F7594
0F7595
0C7649
0F7320
0F1433
076749
048031C
029032
040976
022145
029107
026850

1
1
1
1
1
1
1
4
1
1
1
1
2
4
8
8
4
24
4
4
4
1
1
1
1
2
1
1
1
1
4

SUPPORT RADIATOR LH SIDE
VENTURI 15" DIA FAN
SUPPORT RADIATOR RH SIDE
RADIATOR 2.5L CPL
FAN COOLING 15"
WASHER LOCK M8-5/16
RADIATOR HOSE LWR 1.5L C1 CPL
CLAMP HOSE #24 B1.06-2.00
HOSE OIL DRAIN ASSY 21"
BARBED STR 1/4 NPT X 3/8
HOSE - UPPER RADIATOR
CAP RADIATOR
TAPE FOAM 1 X 1 (17” LG)
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
SCREW HHFC M6-1.0 X 20 G8.8
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW THF M6-1 X 16 N WA Z/JS
SCREW HHC M6-1.0 X 70 G8.8
GUARD FAN LH C1 CPL
GUARD FAN RH C1 CPL
CLAMP HOSE .38-.87
BLOCK OFF UPPER
BRACKET 2.5L FORD WATER BOTTLE
TANK COOLANT RECOVERY
CLAMP HOSE BAND 1/4
HOSE 9/32 ID (40” LG)
SCREW SHC M8-1.25 X 20 G12.9
WASHER FLAT 5/16-M8 ZINC
GROMMET 7/8 X 3/16 X 5/8
WASHER SHAKEPROOF EXT 1/4 STL

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

098290
098941A
098958A
098942A
098225
043146
022097
064526
098783
037398
0A7041
0A7106
074031
029333A
022507
022473

1
1
1
1
2
3
5
2
1
2
1
1
1
2
2

ASM MOTOR STEPPER
HOUSING GOVERNOR CONNECTOR
CONNECTOR INTERFACE ASSEMBLY
COVER CONNECTOR HOUSING
SCREW FHM #2 X 5/8 SELF TAP
SCREW HHC M6-1.0 X 10 G8.8
WASHER LOCK M6-1/4
SCREW TAP HWH #6-25 X 3/8 ZINC
LEVER STEPPER MOTOR
NUT LOCK HEX #10-32 NYL INS
ASSEMBLY CARBURATOR LINKAGE
BRACKET STEPPER MOTOR
LIQUID NEOPRENE
TIE WRAP 7.4"X.19" BLK UL
SCREW HHC 1/4-20 X 1/2 G5
WASHER FLAT 1/4 ZINC

1
2
3*
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
41
42
43
44
45
46
47
48
49
50
51
52
53
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70

0A4531
022473
055934C
0A45310258
0A4355
0E2632
022097
022507
052212
046526
022131
0C2499
055993
045772
023586
020692
0A7005
052243
0A4772
070901
051735
056768
022145
022129
022259
052213
047411
052830
0C3153
045771
058306
030795
0A2711A
048665
075885
0A45310257
0E1100
0E2507
0A6751
026925
061012
039253
0A5110
0A7006
025507
022500B
0A8584
036277
042574
026073A
0A6701
039414
051769
0A4800A
0A5839
0A1354B
0A4839
069860C
0F3856
058443
0A2628
0A5586
0A4814
0A45310244
0C1852
0912970066
070928
069860C

REF
2
1
REF.
1
1
4
2
4
4
20
2
1
1
2
1
2
1
1
2
3
3
12
19
2
11
2
1
1
12
5
2
1
1
1
REF.
1
1
1
2
1
5
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
REF.
1
1
1
1

ENGINE-1.5L
WASHER FLAT 1/4 ZINC
CLAMP VINYL .5 X .406 Z
GASKET-EXHAUST MANIFOLD
MANIFOLD-EXHAUST
HEAT SHIELD EXH 1.5L
WASHER LOCK M6-1/4
SCREW HHC 1/4-20 X 1/2 G5
SCREW HHC M10-1.25 X 25 G8.8
WASHER-LOCK-M10
WASHER FLAT 3/8 ZINC
STAMPING ENG FOOT
SPACER .41 X .75 X .12 STL/ZNC
NUT HEX M10-1.5 G8 YEL CHR
SCREW SHC 5/16-18 X 2 G8.8 NZ
STARTER-12V
SPACER .56 X 1 X .37 ST/ZNC
SCREW HHC M10-1.5 X 60 G8.8
ENGINE PLATE
SLEEVE DOWEL BLHSG
SCREW HHC M10-1.5 X 70 G8.8
SCREW HHC M10-1.5 X 90 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
SCREW HHC M10-1.25 X 20 G8.8
SCREW HHC M6-1.0 X 16 G8.8
SCREW HHC M10-1.25 X 45 G8.8
SCREW TBH M8-1.25 X 30
NUT HEX M8-1.25 G8 YEL CHR
SCREW SHC M8-1.25 X 25 G12.9
SCREW HHC 5/16-18 X 1 G5
ADAPTER-THERMOSTAT
GASKET THERMOSTAT
THERMOSTAT 195 DEG
GASKET INLET MANIFOLD
MANIFOLD INTAKE MACHINED
PROBE, COOLANT LEVEL 3/8NPTF
SW-TMP 245 DEG 3/8 NPT
PLUG STD PIPE 3/8 STEEL SQ HD
PLUG STD PIPE 1/8 SCKT HD
SCREW HHC M8-1.25 X 20 G8.8
PIPE WATER-INLET
O-RING 1-1/16 X 1-5/16 X 1/8
WASHER SHAKEPROOF EXT 7/16 STL
SPACER .41 X .75 X .25 ST/ZNC
SWITCH OIL PRESSURE
ELBOW 90D STREET 1/8
ADAPTOR 1/8 NPTF TO 1/8-28
PLUG STD PIPE 1/4 STEEL SQ HD
SCREW HHC M10-1.5 X 110 G8.8
SCREW HHC M8-1.25 X 35 G8.8
WASHER LOCK M12
PULLEY-CRANKSHAFT (3600 RPM)
BRACKET - ALT SUPPRT
DC ALTERNATOR-12V
ARM ADJUST ALTERNATOR
HOSE ASM.-OIL DRAIN
GUARD CRANKSHAFT 1.5L
SCREW CRIMPTITE 1/4-20 X 5/8
PULLEY - FAN 95 DIA
V-BELT 3/8 X 28.9D
SPACER PULLEY
FILTER OIL
ADAPTER DRAIN OIL
GROUND WIRE (STARTER)
CLAMP HOSE - OIL DRAIN
HOSE OIL DRAIN ASSY 21"

71
72
73
74 **
75 **
76 **
77 **
79
80

035473
077996
069811
0A1354A
0E3257
022473
022097
0D2244M
0F9483

1
1
1
1
2
2
2
1
1

CLAMP HOSE #12 .50-1.25
CAP ANTIFREEZE RUBBER
CAP HEX 1/4 NPT BRASS
REGULATOR - DC ALT
SCREW HWHTF M6-1.0 X 16
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
ASSY MAGPICKUP (3/8-24 MALE)
ASSY PCB WATERLEVEL SNSR INTFC

* CLAMP FOR WIRING HARNESS (NOT SHOWN)
** NOT SHOWN

1
2
3
4
5
6
7
8*
9
10
11
12
13
14
15
16 *
17
18
19
20
21 *
22 *
23
24
25
26
27 **
28
29
30 *
31 *
32 *
33 *
34 *
35 *
36 *
37 *
38 *
39 *
40
41
42
43 *
44
45

026812
075580
0F6364A
039253
022145
022129
045771
0F1570
032552
029032
025424
0F0397
0A5547
048031C
0D1509
0E0591
059402
037561
0E1028C
059401
091526
049226
026915
062522
022127
022259
050279
050280
0A6125
0F6155
0E1104
0E0668
0E0590
0C5133
0E0665
0E1108
033138
022152
0E0645
034339
059193D
057823
040173
089617
030340
0A7040

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

ELBOW 90D 3/4 NPT
FLANGE FUEL INLET
FUEL RGLTR 1.5L REWORK
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
BODY CARBURETOR ASSEMBLY
BARBED EL 90 5/16 X 1/8 NPT
HOSE 9/32 ID
NIPPLE PIPE 3/4 NPT X 6
HOSE CRANKCASE BREATHER
COVER AIR CLEANER
CLAMP HOSE BAND 1/4
DECAL INLET PRESSURE
ADAPTER CARB. TO AIR CLNR
FILTER ELEMENT
NUT WING 1/4-20 NYLK
ASSY CARBURETOR 1.5L C1 CPL
CARBURETOR GASKET
SCREW PPHM M5-0.8 X 12 ZNC
WASHER LOCK M5
NIPPLE CLOSE 3/4 X 1.375
STUD TH 1/4-20 X 3 G2 ZNC FULL
NUT HEX 1/4-20 STEEL
NUT HEX 5/16-18 STEEL
DECAL FUEL INLET NG
DECAL FUEL INLET LPG
STUD 5/16-18 X 1.25 F THR
HARNESS FUEL JUMPER SINGLE REG
GASKET AIR CLEANER ADAPTER
O-RING 2-028 1.38 X 1.50 X .06
VENTURI 18MM
O-RING 29.82 X 2.62
SCREW THROTTLE PIN STOP
THROTTLE ARM REWORK
SCREW HHM #10-32 X 5/8
WASHER LOCK #10
LEVER THROTTLE STOP
BARBED EL 90 3/8 NPT X 5/8
HOSE 5/8 ID X 20.5" LG
CLAMP HOSE #10 .56 - 1.06
CLAMP HOSE #5.5 .62-.62
BARBED STR 1/4 NPT X 1/4 MALE
HOSE 1/4 ID SAE 30R7
BRACKET-RAD HOSE

* INCLUDED IN ITEM 19 (CARBURETOR ASSY )
NOTES:
1.
2.

3.**
4.

REGULATOR (I/N 3) AS SHOWN IN ILLUSTRATION IS SET UP FOR
NATURAL GAS APPLICATION.
TO CONFIGURE REGULATOR FOR LP VAPOR, SWITCH HOSE BARB,
HOSE CLAMP (I/N 41) AND HOSE (I/N 40) FROM “OUT-1” TO “OUT-2”.
REPLACE PIPE PLUG FROM “OUT-2” TO “OUT-1”. USE PIPE SEALANT
ON HOSE BARB AND PIPE PLUG. MAKE SURE TO KEEP PORTS FREE
FROM DEBRIS DURING RECONFIGURATION PROCESS.
FOR LP VAPOR APPLICATION SUBSTITUE LPG FUEL INLET DECAL P/N
050280 FOR NG FUEL INLET DECAL P/N 050279 (ITEM 27).
WHEN SWITCHING FUEL TYPES, THE PROPER DIP SWITCH SITTINGS
MUST BE MADE TO THE CONTROL PANEL. SEE OWNERS MANUAL, FUEL
SECTION FOR MORE DETAILS.

1
2
3
4
5
6
7
8
9
10
11
12 **
13
14
15
16
17
18
19
20
21
22
23
24
25

0F7003 (XX)
0F7004 (XX)
0F7008 (XX)
0F7005 (XX)
0F7007 (XX)
0F7006 (XX)
0C2634A
0912970091
0912970090
0E5968
0E3257
077992
0F5049
0F5048D
022473
022097
022127
0C2454
078115
0F3890B
0F3890
0F7365
0F7365B
0F7365A
0F8869D

1
1
1
1
2
1
1
1
2
1
6
18
3
3
1
1
1
24
20
2
4
2
1
1
1

ROOF C1 CPL
CORNER POST LH SIDE C1 CPL
DOOR REAR C1 CPL
CORNER POST RH SIDE C1 CPL
DOOR LH & RH SIDE C1 CPL
DUCT FRONT DISCHARGE C1 CPL
ASSEMBLY COVER ACCESS
ASSY WIRE 14AWG 13.8" GRN/YEL
ASSY WIRE 14AWG 33.5" GRN/YEL
GASKET EXTRUDED TRIM (356” LG)
SCREW HWHTF M6-1.0 X 16
NUT HEX LOCK M6-1.0 SS NY INS
TAB PULL
VISE-ACTION LATCH SLOTTED CIR
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
SCREW THF M6-1 X 16 N WA Z/JS
WASHER SELF LOCKING DOME
RETAINER INSULATION (820)
RETAINER INSULATION (450)
INSULATION SIDE DOOR C1
INSULATION REAR DOOR C1 CPL
INSULATION ROOF C1 CPL
KEY VISE-ACTION LATCH SLOT CIR

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 18 & 11 THREAD FORMING
FASTENER AND ITEM 12 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD
FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN
ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE SECURED IN THE SAME
MANNER.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

0F7366
0F7647
0F8095
0F7538
0E3257
0F7644
0C6119
036434
036449
022129
022259
038750
0F7539
0E0170
0E2844
049813
022473
022097

1
1
1
1
4
2
1
3
3
8
6
1
1
1
1
1
6
1

MUFFLER C1
MUFFLER SADDLE
PIPE EXHAUST OUTLET
PIPE EXH INLET MUFLR SIDE 1.5L
SCREW HWHTF M6-1.0 X 16
MUFFLER STRAP
BOLT U 5/16-18 X 2-1/4
BOLT U 5/16-18 X 2.09
SADDLE 2 INCH
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
SCREW HHC M6-1.0 X 30 G8.8
PIPE EX INLET MANIFLD SIDE 1.5
EXHAUST BLANKET 800MM
NIPPLE TOE 1.5NPTX5.5 BLK IRON
NUT HEX M6 X 1.0 G8 YEL CHR
WASHER FLAT 1/4-M6 ZINC
WASHER LOCK M6-1/4

Standby Generator Sets
Warranty

GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR
HOME STANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELOW
For a period of two (2) years from the date of sale, or start-up by Authorized/Certified Generac Power Systems Dealer, or branch thereof, Generac
Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or
an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with
the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/
Certified Generac Power Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Generators used in "Standby"
applications, as Generac Power Systems, Inc. has defined Standby, provided said generator has been properly installed and inspected on-site by
appropriate personnel. Scheduled maintenance, as outlined by the generator owner's manual, is highly recommended. This should be performed by
an Authorized/Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been performed on the unit throughout the
warranty period.

WARRANTY SCHEDULE
YEARS ONE and TWO — Limited comprehensive coverage on mileage, labor, and parts listed.
• - ALL COMPONENTS
*Start-up and/or On-line Registration, or Registration Card, along with Proof of Purchase, must be performed and/or sent in.

Guidelines:
• Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer, or
branch thereof.
• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power
Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.
• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
• Use of Non-Generac replacement part(s) will void the warranty in its entirety.
• Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision (If
applicable).

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Any unit built/manufactured prior to January 1, 2005.
Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).
Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems have defined Prime Power,
Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition and warranty.
Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not
normally exist.
Failures caused by any external cause or act of God such as, but not limited to, collision, fire, theft, freezing, vandalism, riot or wars, lightning,
earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.
Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the
defective part(s).
Failure due to misapplication, misrepresentation, or bi-fuel conversion.
Telephone, facsimile, cell phone, satellite, internet, or any other communication expenses.
Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).
Overtime, holiday, or emergency labor.
Planes, ferries, railroad, busses, helicopters, snowmobiles, snow-cats, off-road vehicle or any other mode of transportation deemed abnormal.
Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct
cause of the problem.
Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/
owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner
specific legal rights. Purchaser/owner also may have other rights that vary from state to state.

Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187
Ph: (262) 544-4811 • Fax: (262) 544-4851
Bulletin 0171360SVE / Printed in U.S.A. 7.05

Printed in U.S.A.

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