CAC / BDP FOR BYPASS AND FAN POWERED HUMIDIFIERS User manual

STANDBY GENERATOR
OWNER'S MANUAL
This manual should remain with the unit.
A new standard of reliability
Serial Number
4.2L
48kW
Models
Not intended for use in critical life support applications. 
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
—CAUTION—
Cover138 Rev. A 07/08 Part No. 0H0170

Standby Generator Sets
Table of Contents
SECTION PAGE
SAFETY RULES ......................................................... 1-1
INTRODUCTION .....................................................1-3
Read this Manual Thoroughly...................................1-3
Operation and Maintenance......................................1-3
How to Obtain Service ..............................................1-3
IDENTIFICATION RECORD.....................................2-1
Data Label ................................................................2-1
EQUIPMENT DESCRIPTION ...................................3-1
Equipment Description ................................................3-1
Engine Oil Recommendations ......................................3-1
Coolant Recommendations...........................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
High Coolant Temperature Switch ............................4-1
Low Coolant Level Sensor.........................................4-1
Low Oil Pressure Switch...........................................4-1
Overcrank Shutdown................................................4-1
Overspeed Shutdown................................................4-1
RPM Sensor Loss Shutdown.....................................4-1
DC Fuse ....................................................................4-1
FUEL SYSTEMS .....................................................5-1
Fuel Requirements....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP Fuel System .........................................................5-1
SPECIFICATIONS ...................................................6-1
Generator .................................................................6-1
Engine.......................................................................6-1
Cooling System .........................................................6-1
Fuel System ..............................................................6-1
Electrical System ......................................................6-1
Cold Weather Kit.......................................................6-2
Coolant Heater Kit ....................................................6-2
Reconfiguring the Fuel System..................................6-2
4.2L Ignition Description .............................................6-3
Ignition Power-up Input ("56 Line Input)...................6-3
Diagnostic Blink Patterns (Red LED) ........................6-3
GENERAL INFORMATION.......................................7-1
Generator AC Lead Connections ..................................7-1
Four-lead, Single-phase Stator ..................................7-1
Alternator Power Winding Connections ........................7-1
3-phase Alternators ..................................................7-1
INSTALLATION.......................................................8-1
Installation ...................................................................8-1
Preparation Before Start-up .........................................8-1
Transfer Switch ........................................................8-1
Fuel System ..............................................................8-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Engine Coolant .........................................................8-1
Belt Tension..............................................................8-1
Electrical System ......................................................8-1
Initial Inspection for Genset Start-up ...........................8-1
Start-up Checklist ........................................................8-2
Preparation for Start-up............................................8-2
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 Service Dealer .................10-1
Every Three Months ...............................................10-1
Once Every Six Months...........................................10-1
Once Annually.........................................................10-1
First 30 Operating Hours........................................10-1
Every 100 Operating Hours ....................................10-1
Every 500 Operating Hours ....................................10-1
Cooling System ..........................................................10-1
Checking Fluid Levels ................................................10-1
Check Engine Oil ....................................................10-1
Battery Fluid...........................................................10-2
Engine Coolant .......................................................10-2
Maintenance Owner/Operator Can Perform................10-2
Check Engine Oil Level ...........................................10-2
Check Battery .........................................................10-2
Exercise System......................................................10-2
Inspect Cooling System...........................................10-2
Check Engine Coolant Level....................................10-2
Perform Visual Inspection.......................................10-2
Inspect Exhaust System..........................................10-2
Check Fan Belt........................................................10-2
Inspect Engine Governor ........................................10-2
Changing Engine Oil ...............................................10-3
Changing the Engine Air Filter................................10-3
Spark Plugs ............................................................10-3
Coolant Change.......................................................10-4
Miscellaneous Maintenance........................................10-4
Cleaning the Generator ...........................................10-4
Battery ....................................................................10-4
Battery Maintenance ...............................................10-4
Battery Replacement ...............................................10-5
Repair Parts ...............................................................10-5
SERVICE SCHEDULE ...........................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
Content017 Rev. B 09/07

Study these SAFETY RULES carefully before install-
ing, operating or servicing this equipment. Become
familiar with this Owner’s Manual and with the unit.
The generator can operate safely, efficiently and reli-
ably 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 warn-
ings in this manual, and on tags and decals affixed
to the unit are, therefore, not all inclusive. If a pro-
cedure, work method or operating technique is used
that the manufacturer does not specifically recom-
mend, ensure that it is safe for others. Also make
sure the procedure, work method or operating tech-
nique utilized does not render the generator unsafe.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglect-
ing its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or main-
tain this equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
GENERAL HAZARDS 
• For safety reasons, the manufacturer recommends
that this equipment be installed, serviced and
repaired by a Service Dealer or other competent,
qualified electrician or installation technician who
is familiar with applicable codes, standards and
regulations. The operator also must comply with
all such codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electri-
cal 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 mon-
oxide gas, which can be DEADLY. This dangerous
gas, if breathed in sufficient concentrations, can
cause unconsciousness or even death. For that
reason, adequate ventilation must be provided.
This should be considered prior to installing the
generator. The unit should be positioned to direct
exhaust gasses safely away from any building
where people, animals, etc., will not be harmed.
Any exhaust stacks that ship loose with the unit
must be installed properly per the manufacturer's
instruction, and in strict compliance with appli-
cable 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 venti-
lating air is critical in any room or building hous-
ing 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 seri-
ously 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.
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.
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.
WARNING:

1-1
Standby Generator Sets
Important Safety Instructions

Safety004 Rev. B 08/07

• Before performing any maintenance on the gen-
erator, 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 con-
ditions 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 gen-
erator. 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 repair-
ing 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 maxi-
mum 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 pos-
sibly fatal electrical shock.
• Connecting this unit to an electrical system nor-
mally 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 operat-
ing. 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.
• 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 person-
nel, 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, imme-
diately 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 imple-
ment, such as a dry rope or board, to free the vic-
tim from the live conductor. If the victim is uncon-
scious, apply first aid and get immediate medical
help.
• Never wear jewelry when working on this equip-
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com-
ponents causing injury.
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 extin-
guisher 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 com-
bustible materials are left in the generator com-
partment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround-
ing 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 regulat-
ing the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks
immediately. Fuel supply lines must be prop-
erly installed, purged and leak tested according to
applicable fuel-gas codes before placing this equip-
ment 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
Standby Generator Sets
Important Safety Instructions
Safety004 Rev. B 08/07

1-3
INTRODUCTION
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.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, con-
tact the nearest Service Dealer for starting, operating
and servicing procedures.
Throughout this publication, and on tags and decals
affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert person-
nel 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 serious person-
al injury, including death, or property damage.
After this heading, read instructions that, if not
strictly complied with, may result in personal
injury or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compli-
ance 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:
This symbol points out important safety infor-
mation that, if not followed, could endanger
personal safety and/or property of others.

This symbol points out potential explosion
hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly recom-
mends that the operator read this Owner's Manual
and thoroughly understand all instructions before
using this equipment. The manufacturer also strong-
ly recommends instructing other users to properly
start and operate the unit. This prepares them if they
need to operate the equipment in an emergency.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by a Service Dealer.
Normal maintenance service and replacement of parts
are the responsibility of the owner/operator and, as
such, are not considered defects in materials or work-
manship within the terms of the warranty. Individual
operating habits and usage contribute to the need for
maintenance service.
Proper maintenance and care of the generator ensure
a minimum number of problems and keep operating
expenses at a minimum. See a Service Dealer for ser-
vice aids and accessories.
Operating instructions presented in this manual
assume that the standby electric system has been
installed by a Service Dealer or other competent,
qualified contractor. Installation of this equipment is
not a “do-it-yourself” project.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
simply contact a Service Dealer for assistance.
Service technicians are factory-trained and are capa-
ble of handling all service needs.
When contacting a Service Dealer about parts and
service, always supply the complete model number of
the unit as given on the front cover of this manual or
on the DATA LABEL affixed to the unit.


Standby Generator Sets
Important Safety Instructions
Safety004 Rev. B 08/07

IDENTIFICATION RECORD
DATA LABEL
Every generator set has a DATA LABEL that contains
important information pertinent to the generator. The
data label, which can be found attached to the gen-
erator’s lower connection box, lists the unit’s serial
number and its rated voltage, amps, wattage capacity,
phase, frequency, rpm, power factor, etc.

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.
Generator Model and Serial Number
This number is the key to numerous engineering and
manufacturing details pertaining to your unit. Always
supply this number when requesting service, order-
ing parts or seeking information.

2-1
Standby Generator Sets
General Information
Identy 005 Rev. A 03/07
MANUFACTURING INFORMATION
Data Label

EQUIPMENT DESCRIPTION
This equipment is a revolving field, alternating cur-
rent 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, main-
line circuit breaker, battery charger, and protective
alarms as explained in the following paragraph.
All AC connections, including the power leads from
the alternator, 120 volt battery charger input and
control connections to the transfer switch are avail-
able in the main connection box.
The generator incorporates the following generator
features:
• Rotor and Stator insulation is Class H rated as
defined by NEMA MG1-32.6, NEMA MG1-1.66.
The generator is self ventilated and drip-proof con-
structed.
• The voltage waveform deviation, total harmonic
content of the AC waveform and telephone influ-
ence factor have been evaluated and are acceptable
according to NEMA MG1-32.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 5W-20 engine oil at the
factory. Use a high-quality detergent oil classified “For
Service SJ or SH.” Detergent oils keep the engine
cleaner and reduce carbon deposits. When changing
the engine oil, be sure to use 5W-30 engine oil.
Any attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
NOTE:
For temperatures below 32° F, it is strongly recom-
mended to use the optional Cold Weather Start Kit
(part number listed in the Specification Section).
The oil grade for temperatures below 32° F is 5W-
30 synthetic oil.
COOLANT RECOMMENDATIONS
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 deion-
ized 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.
Do not use any chromate base rust inhibitor
with ethylene glycol base anti-freeze or chro-
mium hydroxide (“green slime”) forms and will
cause overheating. Engines that have been oper-
ated 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.
DANGER
Do not remove the radiator pressure cap while
the engine is hot or serious burns from boiling
liquid or steam could result.
Ethylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the
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.
3-1
Standby Generator Sets
Equipment Description
Equip001 Rev. C 09/08

ENGINE PROTECTIVE DEVICES
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 tempera-
ture, 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.
NOTE:
Engine protective switches and sensors are men-
tioned here for the reader’s convenience. Also
refer to the applicable control panel manual for
additional automatic engine shutdown informa-
tion.
HIGH COOLANT TEMPERATURE SWITCH
The switch will 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.
LOW COOLANT LEVEL SENSOR
To prevent 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.
LOW OIL PRESSURE SWITCH
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.
OVERCRANK SHUTDOWN
After a prespecified duration of cranking, this func-
tion 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.
Approximate Crank Cycle Times
• 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.
RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine
shutdown will occur.
DC FUSES
Fuse F1 (15 amp) 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.
Fuse F2 (25 amp) is located in the engine wire har-
ness adjacent to the DC alternator. It is used to pre-
vent circuit failure due to DC alternator falure. If this
fuse is blown, battery charging will not occur while
the engine is running. Replace these fuses with the
same size, type, and rating. (See the exploded views
and parts lists at the end of this manual for replace-
ment part number.)
4-1
Standby Generator Sets
Engine Protective Devices
EngProt001 Rev. A 06/08

FUEL SYSTEM
FUEL REQUIREMENTS
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.
Recommended fuels should have a Btu content of at
least 1,000 Btu's per cubic foot for natural gas; or at
least 2,520 Btu's 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.
NOTE:
It is the responsibility of the installer to make sure
that only the correct recommended fuel is sup-
plied to the generator fuel system. Thereafter, the
owner/operator must make certain that only the
proper fuel is supplied.
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 sole-
noid should not exceed approximately 14 inches
water column (0.5 psi). Optimum pressure at the
fuel shutoff solenoid is 11 inches water column
(0.4 psi).
PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
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:
• 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 vaporiza-
tion, 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.
LP LIQUID 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).
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.
5-1
Standby Generator Sets
Fuel Systems
FuelSys001 Rev. A 06/08

SPECIFICATIONS
GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ................................................................... Class H
Stator Insulation .................................................................. Class H
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) ............................................48kW*
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural
gas.
Excitation System....................................................................Direct
Generator Output Voltage/kW - 60 Hz kW Amp CB Size
120/240V, 1-phase, 1.0 pf 48 200 200
120/240V, 3-phase, 0.8 pf 48 144 150
120/208V, 3-phase, 0.8 pf 48 166 175
277/480V, 3-phase, 0.8 pf 48 72 80
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208, 3-phase (48kW) ............................... 90 KVA
480V, 3-phase (48kW)...................................................... 120 KVA
ENGINE
Make................................................................................... Generac
Cylinders and Arrangement................................................ 6, V-type
Displacement....................................................................... 4.2 Liter
Bore.....................................................................96.8 mm (3.81 in.)
Stroke .....................................................................95 mm (3.74 in.)
Compression Ratio...............................................................9.3-to-1
Air Intake System ...............................................Naturally Aspirated
Valve Seats......................................... Precision Ground, Hardened
Lifter Type ...............................................................Roller, Hydraulic
Engine Parameters
Rated Synchronous RPM..............................................60 Hz, 1800
HP at rated kW (48kW) ................................................................ 71
Exhaust System
Exhaust Flow at Rated Output 60 Hz (48kW)..................... 250 cfm
Exhaust Temp. at Rated Output (48kW).............................. 1100° F
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz (48kW)..................................... 120 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation......................................................± 0.25%
Engine Lubrication System
Type of Oil Pump...................................................................... Gear
Oil Filter ............................................... Full Flow Spin-on, Cartridge
Crankcase Oil Capacity.................................................5.0 U.S. qts.
COOLING SYSTEM
Type ...................................................Pressurized Closed Recovery
Water Pump.................................................................... Belt Driven
Fan Speed .........................................................................1300 rpm
Fan Diameter.....................................................................22 inches
Fan Mode ................................................................................Puller
Air Flow (inlet air including alternator and
combustion air)...........................................................2460 ft3/min.
Coolant Capacity .............................................11.4 L (3.0 U.S. gal.)
Heat Rejection to Coolant (48kW)..............................165,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature................................50° C (140° F)
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
Fuel Consumption - ft3/hr (Natural Gas/LPV)
Exercise 25% 50% 75% 100%
Cycle Load Load Load Load
48kW 88/34.4 205/81 370/147 516/204 661/261
ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 30 Amp
Static Battery Charger.........................................................2.5 Amp
Recommended Battery.....................................Group 24F, 525CCA
System Voltage.....................................................................12 Volts
Voltage Regulator
Type .................................................................................. Electronic
Sensing........................................................................ Single-phase
Regulation ................................................................................± 1%
Features .................................................V/F Adjustable, Adjustable
Voltage and Gain LED Indicators
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C (48kW) ........................................ 25
1.65% for every 10° above °F (48kW) ....................................... 77
Altitude Deration
1% for every 100 m above m (48kW) ...................................... 183
3% for every 1000 ft. above ft. (48kW)..................................... 600
Controller .................................... R-200B Series
6-1
Standby Generator Sets
Specifications
GenSpec053 Rev. A 07/08

COLD WEATHER KIT
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)•
COOLANT HEATER KIT
The optional Coolant Heater Kit (part number
0G6446) is available to be used in cunjuntion with
the Optional Cold Weather Kit. This kit includes:
1000 watt, 120 volt Engine Block Heater•
Heater Mounting Bracket•
All fittings, hoses and hardware to mount and•
plumb heater
RECONFIGURING THE FUEL SYSTEM
NOTE:
All models are configured to run on natural gas
from the factory.
To reconfigure the fuel system from NG to LP, follow
these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet
port of the demand regulator (see Figure 6.2).
Figure 6.2 — Reconfigure the Fuel System
NEUTRAL
N1
N2
23
194
186
178
To Generator Control Panel
Utility In
Load
Out
Gen
Transfer Switch
4- # 14 GA
WIRES TO
GENERATOR
CONNECTION
BOX TO GENERATOR
CONNECTION BOX
This is a generic representation of the components contained in the transfer switch and connection box.
Refer to the wiring and schematic diagrams for generator specific connections.
Figure 1 — Interconnections
6-2
Standby Generator Sets
Specifications
GenSpec053 Rev. A 07/08

6-3
Standby Generator Sets
Specifications
GenSpec053 Rev. A 07/08
3. Disconnect the power wires from the fuel sole-
noid located on top of the regulator assembly.
4. Loosen the spring clamp on the small fuel enrich-
ment line and remove the hose from the hose
barb.
5. Remove the black pipe assembly from the outlet
port of the demand regulator.
6. Remove the NG fuel jet (loosen counter clockwise)
from the outlet port.
7. Remove the LP fuel jet (loosen counter clockwise)
from the jet keeper port on the regulator housing.
Install this jet into the outlet port in the regulator
casting.
NOTE:
The jet sizes are stamped on the individual jets.
The larger jet size is used for running on NG.
8. Install the previously removed NG jet into the jet
keeper port on the regulator housing.
9. Install the previously removed black pipe onto
the outlet port of the demand regulator. Use pipe
sealant on pipe threads.
10. Reverse steps 1-4 in this procedure to reactivate
the demand regulator.
DANGER
Serious injury or damage may occur if not con-
figured properly. Please consult an Authorized
Dealer with any questions.
4.2L IGNITION DESCRIPTION
This single-fire ignition is intended to operate a 6-cyl-
inder, 4.2L, 1800rpm ignition. The 4.2L engine uses
a 36-1 crank sensor, a CAM sensor and coil-on-plug
coils for each spark plug. Engine Timing for the 4.2L,
1800rpm engine is 15 degrees BTDC for both LP and
NG.
The Cam Sensor is factory set to the FULL coun-
ter-clockwise position. Tampering with the posi-
tion of the Cam Sensor could result in engine
failure.
IGNITION POWER-UP INPUT (“56 LINE INPUT)
When battery voltage is applied to this input the igni-
tion will power-up. For the ignition to power itself
down, the battery voltage must be removed from this
input.
DIAGNOSTIC BLINK PATTERNS (RED LED)
During normal ignition operation the RED LED,
located on the ignition control board, flashes at a 0.5
second ON and a 0.5 second OFF rate. This is con-
sidered one (1) blink.
RED LED Fault Codes with priority as shown:
1. Ignition cannot initialize: LED is ON continu-
ously during cranking.
2. Engine Overspeed: LED blinks four (4) times, is
OFF for three (3) seconds and then repeats.
3. No Crank Signal: LED blinks two (2) times, is
OFF for three (3) seconds and then repeats.
4. No Cam Signal: LED blinks three (3) times, is
OFF for three (3) seconds and then repeats.
Only one LED fault code is displayed at a time.
If multiple fault codes exist then the highest priority
fault must be resolved prior to a lower priority fault
code being displayed.
The LED fault code blink pattern is displayed for 60
seconds after a fault and then the ignition will power
itself down.
The Generator must have been in the OFF mode for
60 seconds prior to cranking for the Crank and CAM
LED fault diagnostics to be valid.
The Crank and CAM LED fault codes are not valid
during a re-crank.
NOTE:
There are openings inside the customer wiring
panel that allow the RED LED inside the ignition
module to be seen without removing the ignition
module.

GENERATOR AC LEAD 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 con-
nection (lower) panel should be installed according to
the number of leads and the voltage/phase required
for the application. If there are any questions regard-
ing lead connection, refer to the wiring diagrams at
the back of this manual.
Voltage codes apply to the type of stator assembly
installed on a particular generator.
FOUR-LEAD, SINGLE-PHASE STATOR
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 con-
nected at the factory to the main circuit breaker as
shown in Figure 7.1.
The rated voltage between each circuit breaker ter-
minal is 240V. The rated voltage between each circuit
breaker terminal and the neutral point 00 is 120V.
Figure 7.1 — Four-lead, Single-phase Stator
ALTERNATOR POWER WINDING
CONNECTIONS
3-PHASE ALTERNATORS
The generator is designed to supply 3-phase electri-
cal loads. Electric power is produced in the alterna-
tor power windings. These windings were connected
at the factory to the main circuit breaker with a “Y”
configuration as shown in Figures 7.2, 7.3 and 7.4.
The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is 480V, 208V or 600V
depending on the model.
The rated voltage between each circuit breaker termi-
nal and the neutral point 00 is 277V, 120V, or 346V
depending on the model.
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 277/480V (6 Lead)
S6
E
3
S3
INTERNAL
CO
NNE
C
TI
O
N
S
L-
N
L
-
L
S4
E2
S2
S5
S1
E1
NE
U
TRA
L
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 120/208V (6 Lead)
E
3
E2
00
(
NEUTRAL
)
E1
L
-
L
L
-
N
S1
S1
S4
S4
S
6
S6
S3
S3
S5
S5
S2
S2
7-1
Standby Generator Sets
General Information
ACConn006 Rev. B 09/08

Figure 7.4 — Stator Power Winding
Connections - 3-phase, 346/600V (6 Lead)
S6
E
3
S3
INTERNAL
CO
NNE
C
TI
O
N
S
L-
N
L
-
L
S4
E2
S2
S5
S1
E1
NE
U
TRA
L
3-PHASE ALTERNATORS
("DELTA" CONFIGURATION)
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 “Delta”
configuration as shown in Figures 7.5.
The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is 240V.
The rated voltage between E1 or E3 and the neutral
point 00 is 120V.
Figure 7.5 — Stator Power Winding
Connections - 3-phase, 120/240V (6 Lead)
E2
E1 E3
7-2
Standby Generator Sets
General Information
ACConn006 Rev. B 09/08

INSTALLATION
Refer to the separate “Installation Guide” supplied
with the unit.
PREPARATION BEFORE START-UP
The instructions in this section assume that the
standby generator has been properly installed, ser-
viced, 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.
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”.
TRANSFER SWITCH
If this generator is used to supply power to any elec-
trical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents elec-
trical backfeed between two different electrical sys-
tems. (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.
FUEL SYSTEM
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.
GENERATOR SET LUBRICATION
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”.
NOTE:
This engine is shipped from the manufacturer
with “break-in” oil. This oil should be changed
after 30 hours of operation.



PRIOR TO INITIAL START-UP
Prior to initially starting the generator, it must
be properly prepared for use. Any attempt to
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.
BELT TENSION
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 5/8-
inch (10 to 16 mm).
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.
NOTE:
Battery charger must be connected to 120 VAC, 15
amp circuit to operate.
Check to ensure that there are no loose electrical con-
nections. Restrain any loose wires to keep them clear
of any moving generator set components.
INITIAL INSPECTION FOR GENSET
STARTUP
Inspect for the following.
• Freight Damage.
• Manuals present.
• Fluid Levels (Oil, coolant, battery, Gear Drive).
• Correct fuel piping.
• Adequate air flow, clearances and ventilation per
installation drawings and applicable codes.
• Correct AC and DC wire size, connections and
grounding. Control and communication wiring to/
from the transfer switch must be run in a separate
conduit from the AC power leads.




8-1
Standby Generator Sets
Installation
Install002 Rev. C 01/07

• Battery charger connection to 120 VAC.
• Communication wires connected between transfer
switch and generator (HTS only).
• Unit secured to pad.
START-UP CHECKLIST
Before working on the generator, ensure the fol-
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 bat-
tery charger is open.
• Remove the fuse from the the control panel. Open
the front door of the control box and remove the
15 Amp ATO fuse in the lower left-hand corner of
the control box.
• Connect the battery cables to the battery. Attach
negative battery cable last.
• Close the 120VAC circuit breaker to the battery
charger.
• Measure the voltage at the battery before and after
the charger is turned on.
• Verify all AC electrical connections are tight at the
circuit breaker and transfer switch.
• Visually inspect entire area looking for loose paper,
plastic wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or dam-
age.
• Check all electrical plugs throughout the genera-
tor. 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 man-
ual position. The engine should now crank and
start.
• Check voltage at the generator terminals.
• For 3-phase units, check phase rotation at the
transfer switch terminals. The generator phase
rotation must match the utility phase rotation.
• Check for coolant, fuel, oil, and exhaust leaks.
• Close the generators main line circuit breaker.
• Turn the generator set off.
• Connect the UTILITY supply to the transfer
switch.
• Set the AUTO/OFF/MANUAL switch to AUTO.
• Disconnect utility power before the transfer
switch.
Engine should start, transfer to load.
Run at least 15 minutes on generator power.
Make certain all 3-phase loads are functioning
correctly (correct phase rotation).
• Reconnect Utility power
Transfer switch will transfer back to Utility and
engine will shut down within the given time
parameters set up for the specific transfer switch
and controller.
• Install all covers, access plates and door panels.
• Put the Owners Manual in a safe and accessible
place.
• Make certain the AUTO/OFF/MANUAL switch is in
the AUTO position.
8-2
Standby Generator Sets
Installation
Install002 Rev. C 01/07

GENERATOR CONTROL AND
OPERATION
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
For additional information, refer to the applicable
control panel manual for this unit, as well as any lit-
erature pertaining to the specific transfer switch.
DANGER
The Maintenance Disconnect Switch and 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.
Do not proceed until certain that utility source
voltage is available to the transfer switch and
the transfer switch main contacts are set to
UTILITY.
Do not attempt manual operation until all power
supplies to the transfer switch have been posi-
tively turned off, or extremely dangerous - pos-
sibly lethal - electrical shock will result.
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:
• Turn OFF or disconnect the utility power circuit
to the transfer switch, using the means provided
(such as the utility source main line circuit break-
er).
• Set the transfer handle to its UTILITY (NORMAL)
position with load circuits connected to the utility
power supply.
• Set the standby generator’s main line circuit break-
er to its OFF (or OPEN) position.
• Start the generator.

Do not crank the engine continuously for longer
than 30 seconds, or the heat may
damage the starter motor.
• Let engine stabilize and warm up.
• Check all applicable instrument and gauge read-
ings. When certain that all readings are correct,
move the transfer switch manual handle to its
STANDBY (GENERATOR) position, i.e., load cir-
cuits supplied by the generator.
• Set the standby generator’s main line circuit break-
er 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 lit-
erature pertaining to the specific transfer switch.
To transfer the load back to the utility power source
and shut down the generator, follow these direc-
tions:
• Set the standby generator’s main line circuit break-
er 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 util-
ity 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.
OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH
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 trans-
fer switch and to “Transfer Switch Start Signal
Connections”. In addition, please note the dangers
under “Engine Start-up and Transfer.”

9-1
Standby Generator Sets
Operation
Oper001 Rev. 0 08/05

MAINTENANCE PERFORMED BY
SERVICE DEALER
Before working on the generator, ensure the fol-
lowing:
• The AUTO/OFF/MANUAL switch is in the OFF
position.
• The 15A fuse has been removed from the con-
trol box.
• The 120VAC supply to the battery charger is
switched OFF.
• The NEGATIVE battery cable has been
REMOVED.
EVERY THREE MONTHS
1. Check battery state of charge and condition.
2. Inspect and test fuel system.
3. Check transfer switch.
4. Inspect exhaust system.
5. Check engine ignition system.
6. Check fan belts.
ONCE EVERY SIX MONTHS
1. Test Engine Safety Devices (low oil pressure, low
coolant level, high coolant temperature).
ONCE ANNUALLY
1. Test engine governor. Adjust or repair, if needed.
2. Clean, inspect generator.
3. Flush cooling system.
4. Clean/re-gap spark plugs or replace as neces-
sary.
5. Visually inspect Cam Sensor position. Cam sen-
sor should be set in full counter-clockwise posi-
tion up against the retaining washer. (Figure
10.1).
Figure 10.1 - Cam Sensor Position
Cam Sensor (turn
counter-clockwise)
Cam
Sensor
Stop
Retaining
Washer
FIRST 30 OPERATING HOURS
1. Change engine "break-in" oil and oil filter.
FIRST 100 OPERATING HOURS
1. Change engine oil and oil filter. (After initial
change, service engine oil and filter at 150 oper-
ating hours or six (6) months, whichever comes
first.)
EVERY 500 OPERATING HOURS
1. Service air cleaner.
2. Check starter.
3. Check engine DC alternator.
COOLING SYSTEM
Air intake and outlet openings in the generator com-
partment must be open and unobstructed for contin-
ued proper operation. This includes such obstruc-
tions as high grass, weeds, brush, leaves and snow.
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to shut down.
The exhaust system parts from this product get
extremely hot and remain hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.
CHECKING FLUID LEVELS
CHECK ENGINE OIL
Check engine crankcase oil level (Figure 10.2) at least
every 20 hours of operation, or prior to use.
• Remove oil dipstick and wipe dry with a clean, lint-
free 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.
10-1
Standby Generator Sets
Maintenance
Maint016 Rev. B 02/08

Figure 10.2 - Oil Dipstick and Oil Fill Cap
OIL FILL
CAP
OIL FILTER
OIL DIPSTICK
BATTERY FLUID
Check battery electrolyte fluid based on the
Maintenance Schedule. Fluid should cover separa-
tors in all battery cells. If fluid level is low, add dis-
tilled water to cover tops of separators. DO NOT USE
TAP WATER IN BATTERY.
ENGINE COOLANT
Check coolant level in coolant recovery bottle. See the
“Specifications” section.
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap to make
sure the coolant recovery system is functioning
properly. Coolant should be at bottom of radiator
filler neck. If coolant level is low, inspect gasket in
radiator pressure cap. Replace cap, if necessary.
To have pressure cap tested, contact a Service
Dealer. Inspect cooling system and coolant recov-
ery system for leaks.
MAINTENANCE OWNER/
OPERATOR CAN PERFORM
Before working on the generator, ensure the fol-
lowing:
• The AUTO/OFF/MANUAL switch is in the OFF
position.
• The 15A fuse has been removed from the con-
trol box.
• The 120VAC supply to the battery charger is
switched OFF.
• The NEGATIVE battery cable has been
REMOVED.
CHECK ENGINE OIL LEVEL
Refer to the “Checking Fluid Levels” section.
CHECK BATTERY
• Check battery fluid level each week as outlined
under “Check Fluid Levels”.
• Check battery cables for condition, tightness, cor-
rosion or damage. Clean, tighten or replace as
necessary.
EXERCISE SYSTEM
Start the generator engine at least once every seven
days and let it run at least 20 minutes. For more
detailed exercise information, see the respective sec-
tions in the Control Panel Technical Manual that is
supplied with the unit.
INSPECT COOLING SYSTEM
• Inspect engine cooling system at least once each
month.
• Check hoses for damage, deterioration, leaks, etc.
Correct any discrepancies found.
• Check hose clamps for tightness.
CHECK ENGINE COOLANT LEVEL
See the “Checking Fluid Levels” section.
PERFORM VISUAL INSPECTION
Complete a thorough visual inspection of the entire
engine-generator monthly. Look for obvious damage,
loose, missing or corroded nuts, bolts and other fas-
teners. Look for fuel, oil or coolant leaks.
Standby Generator Sets
Maintenance
10-2
Maint016 Rev. B 02/08

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.
CHECK FAN BELT
• Inspect fan belts every three months. Replace any
damaged, deteriorated, worn or otherwise defec-
tive belt.
• Check fan belt tension. Thumb pressure, exerted
midway between pulleys, should deflect about 3/8
to 5/8 inch. Adjust belt tension as required.
INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
DANGER
Do not attempt to adjust the governor. Only
qualified service dealers should adjust the gov-
ernor. 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 incor-
rect frequency and/or voltage. Only qualified
service technicians should adjust the governed
speed.
CHANGING ENGINE OIL
Refer to "Maintenance Performed by Service Dealer"
for engine oil and filter change frequencies.
Drain the oil while the engine is still warm from run-
ning. 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 10.3) counterclockwise
and remove. Dispose of old filter.
5. Apply light coating of new engine oil to seal of new
oil filter.-Install FILTER and tighten by hand only.
DO NOT OVERTIGHTEN.
6. Remove OIL FILL CAP. Add recommended oil (see
“Specifications”). Crankcase oil capacity is listed
in the “Specifications”.
Figure 10.3 - Oil Filter
OIL FILTER
OIL DIPSTICK
After refilling the crankcase with oil, always
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
7. Start engine and check for oil leaks.
8. Shut off engine. Wait 10 minutes for oil to settle
down into the oil pan. Recheck oil level on dip-
stick. (DO NOT FILL ABOVE THE DIPSTICK
“FULL” MARK.)
CHANGING THE ENGINE AIR FILTER
To replace the engine air filter, remove the air cleaner
cover and replace the air filter making sure it is posi-
tioned properly before reattaching the cover (Figure
10.4).
Figure 10.4 — Engine Air Filter
AIR
CLEANER
COVER
See the “Service Schedule” section for air cleaner
maintenance.
Standby Generator Sets
Maintenance
10-3
Maint016 Rev. B 02/08