Generac Power Systems 13694330200 User manual

-------------------
GENERAC®
Model: 13694330200
Type: SDI00
Engine: D6. 7.1
Owner's Manual
Stationary Emergency Generator
c@us
LISTED
This manual should remain with the unit.

Table of Contents
Safety Rules 2
Introduction 1
Read This Manual Thoroughly 1
Operation and Maintenance 1
How to Obtain Service 1
Authorized Service Dealer Locator Number ..' ... 1
Warranty 29
Notes 27
Maintenance 17
SERVICE SCHEDULE.............. . 17
Authorized Operator Maintenance Functions 17
Authorized Service Technician Maintenance Functions . 17
PERIODIC MAINTENANCE 18
Test Stationary Emergency Generator System Operation
and Components.. .. .. . 18
Inspect Battery... .. 18
Check Fluids. .. 19
Inspect Exhaust System.. . 19
Inspect/Test Fuel Supply System.. 19
REPAIR PARTS........ . 19
How to Order Parts.. . . 19
500 I\VV TO 600 I\VV STATIONARY EMERGENCY DIESEL
ENGINE DRIVEN GENERATOR SETS.. . .. 20
SERVICE MAINTENANCE INTERVAL INFORMATION .. ,,20
Operation 16
GENERATOR CONTROL AND OPERATION 16
OPERATING UNIT WITH MANUAL TRANSFER SWITCH . .. 16
Start-up and Transfer... 16
Retransfer and Shutdown.. ., .. 17
OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH .... 17
Installation 13
STATIONARY EMERGENCY GENERATOR INSTALLATION .13
NFPA Standards... . 13
Other Published Standards.. . .. 13
BASIC STATIONARY EMERGENCY ELECTRIC SYSTEM.. . 13
EMERGENCY CIRCUIT ISOLATION METHOD .. 14
TOTAL CIRCUIT ISOLATION METHOD . .. 14
GROUNDING THE GENERATOR... . 14
GENERATOR AC NEUTRAL CONNECTIONS.............. ..14
TRANSFER SWITCH START SIGNAL CONNECTIONS. . 14
BATTERY INSTALLATION..... . . 14
Vented Batteries..... . .15
PREPARATION BEFORE START-UP .. .. 15
Prior to Initial Start-up.. . .. 15
Start-up Inspection .. 16
. 5
ENGINE PROTECTIVE DEViCES.. 5
Coolant Temperature Sender 5
Low Coolant Level Sensor... . 5
Oil Pressure Sender 0
Overs peed Shutdown ;)
Overcrank Shutdown 5
RPM Sensor Loss Shutdown... . 5
DC FUSES.. 5
FUEL SYSTEM 6
Diesel Fuel System... . 6
SPECIFICATIONS 6
Generator 6
Engine Oil Recommendations 6
Coolant. 6
Gearbox Lubrication.. . 6
Fuel System Requirements and Recommendations..... . 7
BATTERY INSTALLATION.. . 7
THE BATTERY... 8
GENERATOR AC LEAD CONNECTIONS 8
Four-lead, Single-phase Stator.. . 8
12-lead, Broad Range Stators 9
Six-lead, 600 VAC, Three-phase Stator ..... 10
FIELD WIRING CONNECTIONS REQUIREMENTS 10
Field Wiring Connections to Buss Bars.. . 11
GENERATOR AND LOAD COMPATIBILITY 11
STARTING AIDS . 11
Engine Coolant Heaters.. .. . 11
Engine Oil Heater (Optional) .. . 11
Battery Warmers (Optional).. . 12
Battery Chargers.. . . 12
Generallnformation 4
IDENTIFICATION RECORD .4
Data Label ...
Generator Set XPL Label .
EQUIPMENT DESCRIPTION ;)
Standard Generator Features .

INTRODUCTION
Thank you for purchasing this model of the stationary emergency
generator set product line by Generac Power Systems, Inc"
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, contact the near-
est Authorized Service Dealer for starting, operating and servicing
procedures.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
service or operation that may be hazardous if performed incor-
rectly or carelessly. Observe them carefully. Their definitions are
as follows:
~
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
IAWARNING!I
Indicates a hazardous situation or action which, if not
avoided, could result in death or serious injury.
ACAUTIONI
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the action or 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:
A This symbol points out important safety information that,
.... if not followed, could endanger personal safety and/or
property of others.
A This symbol points out potential explosion hazard.
£ This symbol points out potential fire hazard.
Lh This symbol points out potential electrical shock hazard.
Introduction
The operator is responsible for proper and safe use of the equip-
ment. The manufacturer strongly recommends that the operator
read this Owner's Manual and thoroughly understand all instruc-
tions 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.
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 workman-
ship 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 an Authorized Service Dealer for service aids and acces-
sories.
Operating instructions presented in this manual assume that the
stationary emergency 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.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, contact an
Authorized Service Dealer for assistance. Service technicians are
factory-trained and are capable of handling all service needs.
When contacting an Authorized 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.
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED SERVICE
DEALER, please call this number:
1·800·333·1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER
or visit the website at
www.generac.com.

Safety Rules
It.. 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.
It.. SAVE THESE INSTRUCTIONS -This manual contains Important Instructions that should be followed
"'durlng Installation and maintenance of the generator and batteries.
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, effi-
ciently 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 and on
tags and decals affixed to the unit are, therefore, not all-inclusive.
If using a procedure, work method or operating technique 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.
~
It.. Despite the safe design of this genera·
... tor, 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.
~ 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.
It.. 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 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 of this (and related)
equipment must always comply with applicable codes, stan-
dards, laws and regulat'lons. 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, operat-
ed and serviced in accordance with the manufacturer's instruc-
tions and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.
2
• 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.
• Before performing any maintenance on the generator, discon-
nect 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 dan-
gerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.

ELECTRICAL HAZARDS
• All generators covered by this manual produce dangerous elec-
trical voltages and can cause fatal electrical shock. Utility power
delivers extremely high and dangerous voltages to the transfer
switch as well as the stationary emergency 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 oper-
ating 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 stand-
ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
• If people 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 generator set must be grounded in accordance with the
National Electrical Code and any state or local requirements.
• 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. See the Field Wiring
Requirements Table.
• 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 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.
• 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, immediately
shut down the source of electrical power. If this is not pos-
sible, 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.
Safety Rules
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.
• 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 properly installed, purged and leak tested
according to applicable fuel-gas codes before placing this
equipment into service,
• Diesel fuels are highly FLAMMABLE.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm
3

General Information
IDENTIFICATION RECORD
DATA LABEL
Figure 1.2 - XPL Label
GENERAC POWER SYSTEMS
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE ABOVE
INFORMATION
NOTE:
The above is a generic representation of an XPllabel. For actu-
al information related to this particular model, please refer to
the "construction document" located at the end of this manual,
or to the data cards affixed to the unit.
Every generator set has a DATA LABEL that contains important
information pertinent to the generator (Figure 1,1), 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, watt-
age capacity, phase, frequency, rpm, power factor, etc
Figure 1.1 - Data Label
MODEL NO OOA 00000 S
GROUP DESCRIPTION
A Generator
B Control Panel
C Mounting Base
D Engine & Accy,
E Fuel Systems
F Compartments
G Wiring Diagrams
H Kits
DATE 00/00/05
ASSEMBLY NUMBERS
00000 00000
00000 00000
00000
00000 00000 00000
00000 00000
00000
00000 00000
00000 00000 00000
00000 00000
NOTE:
The above is a generic representation of a data label. For actual
information related to this particular model, please refer to the
"construction document" located at the end of this manual, or
to the data labels affixed to the unit.
GENERATOR SET XPL LABEL
Every generator set has a XPL LABEL affixed to the lower con-
nection box (Figure 1,2), Additionally, a printed CONSTRUCTION
DOCUMENT containing identical information can be found at the
end of this manual.
When requesting information, ordering replacement parts, asking
for service, etc" one or more of the following may be needed:
• Generator Model Number
• Date of Manufacture
• Generator Identification Code
• Generator Assembly Groups
Generator Model Number
This number is the key to numerous engineering and manufactur-
ing details pertaining to the unit Always supply this number when
requesting service, ordering parts or seeking information,
4
Identification Code
Use this code to obtain important information about the generator,
For example, if the code is '"
SO 0100 A 617 4.5 0 18 HBYY3
- identify the generator as follows:
• SO - Stationary emergency diesel generator ("58" indicates a
stationary emergency gaseous fuel unit),
• 0100 - Rated output is 100,000 watts (100 kW),
• A- Voltage code (see "Voltage Codes"),
• G17 -Indicates engine MFG (for Generac use).
• 4,5 - Engine is 4,5 liter.
• 0 - Unit has diesel fuel system ("N" indicates natural gas;
'T' indicates LP Liquid Withdrawal; "v" indicates LP Vapor
Withdrawal),
• 18 - Alternator rpm rating (1,800 rpm); "36" indicates 3,600
rpm.
• H- Unit has an option "H" control panel ("G" panels are also
available on some units).
• B- Indicates a brushless unit ("P" indicates a permanent mag-
net excitation).
• Y- Unit is equipped with a standard enclosure ("N" indicates
no enclosure; "5' indicates Level 1 sound attenuation; "L" indi-
cates Level 2 sound attenuation),
• "Y" indicates a muffler has been mounted; N- Unit does not
have an exhaust muffler; "L:' indicates a muffler has been
shipped loose with the unit),
• 3- Emission designation (for factory use),

Groups and Assembly Numbers
The XPL label 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 gen-
erator model. These drawings are located in the back half of this
manual.
Voltage Codes
The identification code letter following the unit's kilowatt rating is
the generator's "voltage code." Anyone of the following voltage
codes may be listed.
A - 120/240 volts, single-phase, four-lead, 60 Hz
o - 120/240 volts, single- and three-phase, 12-lead, 60 Hz
G - 120/208 volts, three-phase, 12-lead, 60 Hz Broad Range
J 120/240 volts, three-phase, 12-lead, 60 Hz Broad Range
K - 277/480 volts, three-phase, 12-lead, 60 Hz Broad Range
L 346/600 volts, three-phase, six-lead, 60 Hz
M - 110/220 volts, single-phase, four-lead, 50 Hz
N - 115/200 volts, three-phase, 12-lead, 50 Hz Broad Range
P - 100/200 volts, three-phase, 12-lead, 50 Hz Broad Range
R - 231/400 volts, three-phase, 12-lead, 50 Hz Broad Range
S 277/480 volts, three-phase, six-lead, 50 Hz
EQUIPMENT DESCRIPTION
This equipment is a revolving field, alternating current generator
set. The generator was designed to supply electrical power for the
operation of compatible electrical loads-when the UTILITY power
supply is not available or has dropped to an unacceptable level.
The generator's revolving field is directly connected to and driven
by an engine by means of flexible discs. Generators with a four-
pole rotor are driven at rated speeds of 1,800 rpm to supply a
frequency of 60 Hertz.
Refer to the data label on this specific generator or to the data label
affixed to the unit for rated AC voltage, wattage, amperage, number
of phases, etc. See "Identification Code" for an explanation of the
way to identify the unit's features.
STANDARD GENERATOR FEATURES
This generator incorporates the following generator features:
• The rotor insulation system is Class "H" rated, and the stator
insulation is Class "H" rated as defined by NEMA MG1-22.4
and NEMA MG1-1.65.
• 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 MG1-22.
• All prototype tested models have passed three-phase sym-
metrical short circuit test to ensure system protection and
reliability.
General Information
ENGINE PROTECTIVE DEVICES
The stationary emergency 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.
NOTE:
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 infor-
mation.
COOLANT TEMPERATURE SENDER
This sender automatically shuts down the engine if the engine
coolant temperature rises above a safe level.
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.
OIL PRESSURE SENDER
This sender monitors oil pressure in the engine. If oil pressure
drops below a safe level, the control system automatically shuts
down the engine.
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.
OVERCRANK SHUTOOWN
After a prespecified duration of cranking, this function ends the
cranking if the engine has failed to start.
RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine shutdown
will occur.
DC FUSES
These fuses are located inside the front panel of the control sys-
tem. They protect the panel wiring and components from damag-
ing overload.
5

General Information
FUEL SYSTEM
DIESR FUEL SYSTEM
Diesel fuel is supplied to the generator set from a base-mounted
fuel tank or external source.
Diesel fuels are less volatile than gaseous fuels, however, careless
installation can lead to safety hazards and/or serious problems
with engine/generator performance and reliability.
NOTE:
Appropriate care should be taken in applications where
extremely low ambient temperatures are possible to ensure the
temperature of the diesel fuel is not allowed to fall below levels
where "gelling" could occur.
SPECIFICATIONS
GENERATOR
Refer to the data plate on the generator for rated watts, amperes,
frequency, voltage, phase and other pertinent information. Refer to
the drawings in the back of this manual for engine, cooling system,
and exhaust system specifications.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 15W-40 engine oil at the factory. Use
a high-quality detergent oil classified "For Service SJ and CG/CH".
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
(Figure 1.3).
COOLANT
Use only de-ionized water and Ethylene glycol antifreeze (Propylene
glycol can also be used but should not be mixed with Ethylene gly-
col - see DANGER below). When adding coolant, always add the
recommended 50-50 mixture.
~
A. Do not remove the radiator pressure cap
.... while the engine is hot or serious burns from
boiling liquid or steam could result.
A. 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 poi-
sonous to them.
ACAUTIONI
A. Do not use any chromate base rust Inhibitor
.... with propylene glycol base antifreeze. Using
any high silicate antifreeze boosters or addi-
tives also will cause overheating. We also
recommend that any soluble
011 Inhibitor Is
NOT USED for this equipment.
GEARBOX LUBBICATION
If the generator set is equipped with a gearbox, the appropriate
lubricant is SAE 90 gear oil.
Figure 1.3 - Engine Oil Recommendations
-35 -30 -25 -20 -15 -10 ·5 15 20 25 30 35 40 45 50'C
SAE lOW
II
SAE 20W
SAE 30
II
SAE 40
SAE 1 OW -30
SAE lOW -40
SAE 10W ·60
SAE l5W -40 mineral base
SAE 15W -40 semisynthetic base
SAE 20W ·60 semisynthetic base
SAE 5W -30 synthetic base
SAE OW ·30 synthetic base
6
-31 -22 -13 14 23 32 41 50 59 68 77 86 95 104 113 122 'F

General Information
BLACK
___________ RED LEAD
(FROM STARTER
CONTACTOR)
BLACK LEAD
~ (FROM FRAME)
---<~~
+
BATTERY
4. Connect the red battery cable (from starter contactor) to the
battery post indicated by a positive, pas or (+).
5. Connect the black battery cable (from frame ground) to the
battery post indicated by a negative, NEG or (-).
NOTE:
Damage will result if battery connections are made in reverse.
NOTE:
The generator is equipped with a battery trickle charger that is
active when the unit is set up for automatic operation. With the
battery installed and utility power source voltage available, the
battery receives a trickle charge while the engine is not run-
ning, to prevent self-discharge. The trickle charger is designed
to help extend the life of the battery by maintaining the battery
when the unit is not running. The trickle charge feature cannot
be used to recharge a discharged battery.
Before installing and connecting the battery, complete the follow-
ing steps:
1. Set the generator's AUTO/OFF/MANUAL switch to OFF.
2. Turn off utility power supply to the transfer switch.
3. Remove the 10A and 15A fuses from the generator control
panel.
Battery cables were factory connected at the generator (Figure
1.4). Connect cables to battery posts as follows:
Figure 1.4 - Battery Cable Connections
Diesel Engine Battery Size Minimum CCA
2.4L
3.4L
GRP 27 or GRP 31 650 or 925
4.5L
GRP 31 or GRP
925
31E
6.7L (100, 130Kw) 1 or 2X GRP 31 925
6.7L (150, 175Kw)
2X GRP 31 925
8.7L
10.3L
12.9L
13.0L
2x GRP 31 or 2x
16.0L
GRP 80
925 or 1155
18.0L
22.0L
Fill the battery with the proper electrolyte fluid if necessary and
have the battery fUlly charged before installing it.
BATTERY INSTALLATION
When a unit is supplied with out a battery or during replacement
use the following table to properly select the battery size and mini-
mum Cold Cranking Ampere required for a particular unit.
FUEL SYSTEM REDUIREMENTS AND RECOMMENDATIONS
Diesel Fuel System: See Chapter 8 of Engine-Generator Stationary
Emergency Electric Power Systems Installer's Guide and Reference
Manual (part no. 046622).
1. Beginning October 1, 2007, owners and operators that use
diesel fuel must use diesel fuel that meets:
A. Sulfur content of 500 parts per million (ppm) maximum.
B. Cetane index or aromatic content as follows:
• A minimum cetane index of 40 or;
• A maximum aromatic content of 35 volume percent.
2. Beginning October 1, 2010, owners and operators that use
diesel fuel must use diesel fuel that meets:
A. Sulfur content of 15 parts per million (ppm) maximum.
B. Cetane index or aromatic content as follows:
• A minimum cetane index of 40 or;
• A maximum aromatic content of 35 volume percent.
7

General Information
THE BATTERY
~
ADo not dispose of the battery In a fire. The
tAbattery Is capable of exploding.
/r\ A battery presents a risk of electrical shock
illand high short circuit current. The following
precautions are to be observed when work-
ing on batteries:
•Remove the 10A and 15A fuses from the gen-
erator control panel.
•Remove watches, rings or other metal objects;
•Use tools with Insulated handles;
•Wear rubber gloves and boots;
•Do not lay tools or metal parts on top of the
battery; and
•Disconnect charging source prior to connecting
or disconnecting battery terminals.
IA WARNING!1
Jt.. Do not open or mutilate the battery. Released
.... electrolyte has been known to be harmful to
the skin and eyes, and to be toxic.
AThe electrolyte Is a dilute sulfuric acid that Is
.... harmful to the skin and eyes. It is electrically
conductive and corrosive.
The following procedures are to be observed:
•Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash It off
Immediately with water;
• Where electrolyte contacts the eyes, flush
thoroughly and Immediately with water and
seek medical attention; and
• Spilled electrolyte Is to be washed down with
an acid neutralizing agent. A common practice
Is to use a solution of 1 pound (500 grams)
bicarbonate of soda to 1 gallon (4 liters) of
water. The bicarbonate of soda solution is to
be added until the evidence of reaction (foam-
ing) has ceased. The resulting liquid Is to be
flushed with water and the area dried.
&. lead-acid batteries present a risk of fire
Lmbecause they generate hydrogen gas. The
following procedures are to be followed:
•DO NOT SMOKE when near the battery;
•DO NOT cause flame or spark in battery area;
and
• Discharge static electricity from body before
touching the battery by first touching a ground-
ed metal surface.
ABe sure the AUTO/OFF/MANUAL switch is set
.... to 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 con-
nected.
8
ABe sure the utility power supply is turned off
tAand the 10A and 15A fuses are removed from
the generator control panel, or sparking may
occur at the battery posts as the cables are
attached and cause an explosion.
Servicing of the battery is to be performed or supervised by per-
sonnel knowledgeable of batteries and the required precautions.
Keep unauthorized personnel away from batteries.
A negative ground system is used. Battery connections are shown
on the wiring diagrams. Make sure the battery is correctly con-
nected and terminals are tight. Observe battery polarity when con-
necting the battery to the generator set.
GENERATOR AC LEAD
CONNECTIONS
See "Voltage Codes". This generator may be rated at anyone of
several voltages, either single-phase or three-phase. The electrical
wires in the unit's AG connection (lower) panel should be installed
according to the number of leads and the voltage/phase required
for the application. If there is any question regarding lead connec-
tion, refer to Figures 1.4 through 1.9 .
Voltage codes apply to the type of stator assembly installed on a
particular generator .
fOUR-LEAD, SINGLE-PHASE STATOR
Four-lead generators are dual voltage coils or windings (Figure
1.5). Units may be assigned any of the following voltage codes:
• "{:>:.' units are rated 120/240 VAG, single-phase, 60 Hertz.
• "M" units are rated 110/220 VAG, single-phase, 50 Hertz.
Each stator winding in this case delivers a 110 VAG or 120 VAG
output; connecting the two windings series results in a 220 VAG
or 240 VAC output.
The neutral line is formed by a junction of stator leads 22 and
33. Therefore, connection of 120 VAG (60 Hertz) or 110 VAC (50
Hertz) loads across leads 11 and neutral, or across leads 44 and
neutral can be made.
Figure 1.5 - Four-lead, Single-phase Stator
E
44~EJ
I I
I II 110/120
I VOLTS
JJ ] I : 00 b20h40
I I NEUTRAL:lloLTS
E
22
I
I : 110/120
I VOLTS
I I
I
11~E1
l _
CIRCUIT BREAKER

General Information
Figure 1.9 - Single-/Three-phase
Delta Stator Connection
Figure 1.10 - Six-lead Stator Connection
240V
SII
E2
240V
S6 I
S3~
-- 240V ----J
51
1 1
277V 50HZ 480V 50 HZ
346V60HZ 600V 60 HZ
!
S2
SIX-LEAD. 600 VAG, THREE-PHASE STATOR
This type of stator has three coils and six leads (Figure 1.10). Units
may be assigned any of the following voltage codes:
• "1.:' units are rated 346/600 VAG, three-phase, 60 Hertz.
• "5" units are rated 277/480 VAG, three-phase, 50 Hertz.
FIELD WIRING CONNECTIONS
REQUIREMENTS
The table should be used as a reference for: wire type, temperature
rating, and size range of output wires to be connected to the circuit
breakers. Wire sizes should be in accordance with table 310.16 of
the National Electric Gode (NEG).
FIELD WIRING REQUIREMENTS TABLE
Circuit Breaker
Breaker
Frame
Gircuit Breaker Range
Wire Type
Wire Temperature Lug AWG Wire
Torque to Wire
(A)
Rating Range / (Number of
Gonductors)
Series G- JG Frame 20 - 250
Cu
75
cC
4-350 kemil (1) 180 in-Ib
Series G- LG Frame 160 - 600
Cu/AI
75
CC
2-500 kemil (2) 3751n-lb
(#14-10) 35 In-Ib
15 - 100
Cu/AI
75
cC
14-1/0 (1)
(#8) 40 In-Ib
Series C- F Frame
(#6-4) 45 in-Ib
(#3-1/0) 50 in-Ib
60 - 200
CulAl
75
cC
4-4/0 (1)
120 in-Ib
100 - 225
Cu/AI
75°C
6-300 kemll (1)
120 in-Ib
Series C-J Frame
250 Cu
75°C
4-350 kemll (1)
275 in-Ib
225
CulAl
75°C
3-350 kemll (1)
275 in-Ib
Series C- K Frame
300
CulAl
75
DC
250-500 kemll (1)
375 In-Ib
350 - 400
Cu/AI
75
DC
3/0-250 kemil (2)
2751n-lb
450 - 500
Cu/AI
75°C
3/0-350 kemil (2)
275 in-Ib
Series C- L Frame
600 Cu/AI
75°C
400-550 kemll (2)
275 in-Ib
Series C- M Frame
700 - 800
Cu/AI
WC
3/0-400 kemll (3)
3751n-lb
900 - 1000
Cu/AI
75°C
4/0-500 kemll (4)
375 In-Ib
Series C- N Frame
1200
Cu/AI
WC
500-750 kemil (3)
450 In-Ib
Series C- R Frame
1400 - 1600
Cu/AI
75°C
500-1000 kemil (4)
550 in-Ib
NOTE: All field installations must meet the National Electric Code for wire size and bending space requirements.
10

General Information
FIELD WIRING CONNECTIONS TO BUSS BARS
ENGINE COOLANT HEATERS
500Kw Volvo and 500/600Kw Doosan powered units supplied
with Series C- R Frame Breakers rated 1400, 1600, 2000 and
2500A have Buss Bars supplied in the connection Module for the
connection of the Field Conductors. The following information
should be followed in order to obtain a suitable electrical connec-
tion to the Buss Bars.
• Conductor Lugs - The Buss Bars have been configured to
accept Aluminum Compression Lugs suitable for copper or
aluminum stranded wire .
• Suggested Manufacturer - PENN UNION CORP
• Manufacturers Part No. - BLUA060D2
• Type - Dual Rated (Al/CU), Two Studs spaced 1 3/4" Apart
• Wire Size - 600 kcmil
Required Hardware
Below is the recommended hardware required to attach the Lugs
to the Buss Bars,
• M12 x 65mm Grade 8,8 Hex Head Cap Screw, M12 Flat
Washers, Lock Washer and Nut
or
If the unit is equipped with an engine coolant (block) heater (Figure
1.11), it is powered by a circuit normally fed by the utility power
supply. This heats the engine coolant when the unit is not operat-
ing, This action keeps the engine warm even in cold weather,
helping to ensure quicker starts, Heated coolant in the engine
rises continuously drawing cold coolant into the heater, creating a
constant flow of warm coolant through the engine .
Figure 1.11- Typical Engine Coolant Heaters
OUTLET
TYPE A
Lubed 58 FHbs
Lubed 65 FHbs
STARTING AIDS
The stationary emergency generator may be equipped with one or
more starting aids that serve to provide quicker, easier starts under
varying climactic conditions.
This generator may have been mounted with (a) an engine coolant
heater, (b) an engine oil heater, (c) a battery warmer or (d) a bat-
tery charger. These aids are powered by a normal (utility) power
source during nonoperating periods.
GENERATOR AND LOAD
COMPATIBILITY
The generator must be fully compatible with the rated voltage,
phase and frequency of the connected electrical loads. The gen-
erator, connected electrical devices, or both, can be damaged if
voltage, phase and frequency are not compatible,
NOTE:
This manual assumes that the stationary emergency generator
has been properly selected, installed and interconnected by a
competent, qualified electrician or installation contractor. Once
the installation is complete, do nothing that may result in non-
compatibility between the generator and connected electrical
loads.
TYPES
The engine oil heater is designed for installations where the engine
oil must be kept near operating temperature at all times. If included
with this unit, a low-watt density heater and thermostat are mount-
ed in the engine's oil sump or on the sump pan (Figure 1.12). The
heater and thermostat do not require maintenance.
1. Disconnect battery cables to prevent accidental start-up.
Disconnect the negative battery cable first from the battery
post indicated by (-) or NEG,
2. Make sure power is off from the appropriate power source.
3. To connect the wires, hold the bare metal leads together and
place a wire nut over them, then twist clockwise until tight. For
all these connections, use the wire nuts provided.
4. Connect the ground wire from 120V power source to the
ground wire from oil heater,
5. Using wire nuts provided connect the white wire and black
wire from the oil heater as follows:
• The white (common) power wire from 120V power source
to 1 st wire from the oil heater.
• The wire from load side of thermostat to 2nd wire from the
oil heater.
ENGINE OIL HEATER (OPTIONAL)
Flat
• 1/2"-20 x 2.5" Grade SAE 5 Hex Head Cap Screw,
Washers, Lock Washer and Nut
Required Torque - Tighten fasteners to:
M12 Dry 75 Ft-Lbs
1/2" Dry 85 FHbs
11

Lubed 58 Ft-Lbs
Lubed 65 Ft-Lbs
-------_. __ _--_ .. _-------
FIELD WIRING CONNECTIONS TO BUSS BARS
Units supplied with Series C- R Frame Breakers rated 1600, 2000
and 2500A have Buss Bars suppled in the connection Module for
the connection of the Field Conductors. The following information
should be followed in order to obtain a suitable electrical connec-
tion to the Buss Bars.
• Conductor lugs - The Buss Bars have been configured to
accept Aluminum Compression Lugs suitable for copper or
aluminum stranded wire.
• Suggested Manufacturer - PENN UNION CORP
• Manufacturers Part No. - BLUA060D2
• Type - Dual Rated (AL/CU), Two 1/2" Studs spaced 1 3/4" Apart
• Wire Size - 600 kcmil
Required Hardware
Below is the recommended hardware required to attach the Lugs
to the Buss Bars.
• M12 x 65mm Grade 8.8 Hex Head Cap Screw, M12 Flat
Washers, Lock Washer and Nut
or
• 1/2"-20 x 2.5" Grade SAE 5 Hex Head Cap Screw, 1/2" Flat
Washers, Lock Washer and Nut
Required Torque - Tighten fasteners to:
M12 Dry 75 Ft-Lbs
1/2" Dry 85 Ft-Lbs
GENERATOR AND LOAD
COMPATIBILITY
The generator must be fully compatible with the rated voltage,
phase and frequency of the connected electrical loads. The gen-
erator, connected electrical devices, or both, can be damaged if
voltage, phase and frequency are not compatible.
NOTE:
This manual assumes that the stationary emergency generator
has been properly selected, installed and interconnected by a
competent, qualified electrician or installation contractor. Once
the installation is complete, do nothing that may result in non-
compatibility between the generator and connected electrical
loads.
STARTING AIDS
The stationary emergency generator may be equipped with one or
more starting aids that serve to provide quicker, easier starts under
varying climactic conditions.
This generator may have been mounted with (a) an engine coolant
heater, (b) an engine oil heater, (c) a battery warmer or (d) a bat-
tery charger. These aids are powered by a normal (utility) power
source during nonoperating periods.
General Information
ENGINE COOLANT HEATERS
If the unit is equipped with an engine coolant (block) heater (Figure
1.11), it is powered by a circuit normally fed by the utility power
supply. This heats the engine coolant when the unit is not operat-
ing. This action keeps the engine warm even in cold weather,
helping to ensure quicker starts. Heated coolant in the engine
rises continuously drawing cold coolant into the heater, creating a
constant flow of warm coolant through the engine.
Figure 1.11- Typical Engine Coolanl Healers
OUTLET
TYPE A
1~'_KE __ ~
TYPEB
ENGINE OIL HEATER (OPTIONALl
The engine oil heater is designed for installations where the engine
oil must be kept near operating temperature at all times. If included
with this unit, a low-watt density heater and thermostat are mount-
ed in the engine's oil sump or on the sump pan (Figure 1.12). The
heater and thermostat do not require maintenance.
1. Disconnect battery cables to prevent accidental start-up.
Disconnect the negative battery cable first from the battery
post indicated by (-) or NEG.
2. Make sure power is off from the appropriate power source.
3. To connect the wires, hold the bare metal leads together and
place a wire nut over them, then twist clockwise until tight. For
all these connections, use the wire nuts provided.
4. Connect the ground wire from 120V power source to the
ground wire from oil heater.
5. Using wire nuts provided connect the white wire and black
wire from the oil heater as follows:
• The white (common) power wire from 120V power source
to 1 st wire from the oil heater.
• The wire from load side of thermostat to 2nd wire from the
oil heater.
11

General Information
ACAUTIONI
A. Be sure no bare wire or wire strands are vis-
~Ible after making connections.
6. Push all wires and wire nuts into junction box.
7. Assemble junction box cover to junction box
8. Reconnect battery cables to battery posts. Connect the posi-
tive cable first to the battery post indicated by (+) or POS.
Figure 1.12 - Oil Heater Kit
BATTERY WARMERS (OPTIONAL)
When used in conjunction with a coolant (block) heater, battery
warmers (Figure 1.13) aid in ensuring that the engine will reach
maximum cranking speed.
1, Disconnect battery cables to prevent accidental start-up.
Disconnect the negative battery cable first from the battery
post indicated by (-) or NEG,
2. Make sure power is off from the appropriate power source,
3, To connect the wires, hold the bare metal leads together and
place a wire nut over them, then twist clockwise until tight. For
all these connections, use the wire nuts provided.
4, Connect the ground wire from 120V power source to the
ground wire from battery heater.
5, Using wire nuts provided connect the white wire and black
wire from the battery heater as follows:
• The white (common) power wire from 120V power source
to 1 st wire from the battery heater,
• The wire from load side of thermostat to 2nd wire from the
battery heater,
12
ACAUTIONI
A. Be sure no bare wire or wire strands are vis-
~ Ible after making connections.
6. Push all wires and wire nuts into junction box,
7. Assemble junction box cover to junction box,
8, Reconnect battery cables to battery posts, Connect the posi-
tive cable first to the battery post indicated by (+) or POS,
Figure 1.13 - Battery Warmer Kit
BATTERY CHARGERS
There are two types of battery chargers available: 2,5-amp and
10-amp (nine-amp UL) rated, The 2,5-amp charger is 12 VDC
only. The 1 Q-amp is available as 12 VDC or 24 VDC, as appropri-
ate for the engine's DC system voltage, These chargers are UL
component recognized for use on these generator sets.
Both of the chargers are fully automatic float types and are fully
fuse protected (input and output), They have automatic current
limiting to reduce risk of overcharging, and have automatic main-
tenance of charge voltage. Therefore, they can be connected to the
batteries continuously,
The chargers require the connection of a battery in order to turn
on, The battery provides boost voltage for the charger, so a com-
pletely dead battery will not allow the charger to operate. The boost
required is approximately nine to 11 volts for a 12 VDC system
and 18 to 22 volts for a 24 VDC system, If the battery is below the
boost voltage, it needs to be replaced.
They are not water resistant, so they must be installed within a rain
resistant enclosure.

Installation
STATIONARY EMERGENCY
GENERATOR INSTALLATION
~
k.. Connecting this generator to an electrical
illsystem normally supplied by an electric util-
ity shall
be by means of atransfer switch
(such as the "GTS" type transfer switch),
so as to isolate the electric system from the
utility distribution system when the genera-
tor is operating. Failure to isolate the electric
system by these means will result in damage
to the generator and may also result in injury
or death to utility workers due to backfeed of
electrical energy.
ACAUTIONI
t If an open bottom is used, the engine-gener-
Lmator is to be installed over non-combustible
materials and should be located such that
combustible materials are not capable of
accumulating under the generator set.
Only qualified, competent installation contractors or electricians
thoroughly familiar with applicable codes, standards and regula-
tions should install this stationary emergency electric power sys-
tem. The installation must comply strictly with all codes, standards
and regulations pertaining to the installation.
This genset must be installed on a level surface. The base frame
must be level within two (2) inches all around.
ACAUTIONI
AAfter the system has been installed, do noth-
..... ing that might render the installation in non·
compliance with such codes, standards and
regulations.
NOTE:
For more information about the installation of a stationary
emergency system, order Engine-Generator Stationary emer-
gency Electric Power Systems Installer's Guide and Reference
Manual (part #046622) from an Authorized Service Dealer.
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS
CODE.
• NFPA No. 10, INSTALLATION, MAINTENANCE AND USE OF
PORTABLE FIRE EXTINGUISHERS.
OTHER PUBLISHED STANDARDS
In addition to NFPA standards, the following information pertain-
ing to the installation and use of stationary emergency electric
systems is available:
• Article X, NATIONAL BUILDING CODE, available from the
American Insurance Association, 85 John Street, New York,
NY 10038,
o AGRICULTURAL WIRING HANDBOOK, obtainable from the Food
and Energy Council, 909 University Avenue, Columbia, MO,
65201.
• ASAE EP-364.2, INSTALLATION AND MAINTENANCE OF FARM
STANDBY ELECTRIC POWER, available from the American
Society of Agricultural Engineers, 2950 Niles Road, St. Joseph,
M149085.
• A52.1, AMERICAN NATIONAL STANDARD FOR CHIMNEYS,
FIREPLACES AND VENTING SYSTEMS, available from the
American National Standard Institute, 1430 Broadway, New
York, N.Y 10018.
BASIC STATIONARY EMERGENCY
ELECTRIC SYSTEM
Figure 2.1 shows a schematic diagram of a basic stationary
emergency electric system. Both the UTILITY power supply and
the STANDBY (GENERATOR) output are connected to an approved
transfer switch. The transfer switch is required by electrical code
and serves the following functions:
o Permits the LOAD circuits to be connected to only one power
supply at a time .
o Prevents electrical backfeed between the generator and the
UTILITY power circuits.
Notice that both the STANDBY and the UTILITY power supplies to
the transfer switch are protected against overload by a main line
circuit breaker.
Figure 2.1 - Basic Stationary Emergency Electric
System
MAIN UNE
CIRCUIT BREAKER
TRANSFER r---+-~
SWITCH
UTIUTY
POWER --t-/
SUPPLY '- - - - --
STANDBY --- --
GENERATOR --~' ,..;.-' --1
OUTPUT , ~
MAIN UNE
CIRCUIT BREAKER
TO LOAD
c--f---CIRCUITS
I-
I
,
. _ J,
,
'- -
NFPA STANDARDS
The following published standards booklets pertaining to station-
ary emergency electric systems are available from the National Fire
Protection Association (NFPA), Batterymarch Park, Quincy, MA
02269 or www.nfpa.org.
o NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS
TURBINES.
o NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR
HEALTH CARE FACILITIES.
o NFPA No. 220, STANDARD TYPES OF BUILDING CONSTRUCTION
o NFPA No. 68, GUIDE FOR EXPLOSION VENTING
o NFPA No. 70, NATIONAL ELECTRICAL CODE.
13

Installation
EMERGENCY CIRCUIT ISOLATION
METHOD
This prevents overloading the generator by keeping electrical
loads below the wattage/amperage capacity of the generator, If
the generator is powering only critical loads, within the wattage/
amperage capacity, during utility power outages, consider using
the emergency circuit isolation method,
Critical electrical loads are grouped together and wired into a sepa-
rate "Emergency Distribution Panel." Load circuits powered by that
panel are within the wattage/amperage capacity of the generator
set. When this method is used, it is difficult to overload the gen-
erator, The transfer switch must meet the requirements:
• It must have an ampere rating equal to the total amperage rating
of the emergency distribution panel circuit.
• Have it installed between the building's main distribution panel
and the emergency distribution panel.
TOTAL CIRCUIT ISOLATION
METHOD
When a generator capable of powering all electrical loads in the
circuit is to be installed, use the "Total Circuit Isolation Method," It
is possible for the generator to be overloaded when this isolation
method is employed, The following apply to the transfer switch in
this type of system,
• Ampere rating of the transfer switch must the ampere
rating of the normal incoming utility service,
• The transfer switch is installed between the utility service
entrance and the building distribution panel.
GROUNDING THE GENERATOR
The generator set must be grounded in accordance with the
National Electrical Code and any state or local requirements,
~
ADo not connect the ground wire to any pipe
~that carries aflammable or explosive sub-
stance -FIRE or an EXPLOSION may result.
Figure 2.2 - Grounding Electrode Terminal (typical)
Base Frame
Grounding Electrode Terminal
14
GENERATOR AC NEUTRAL
CONNECTIONS
Grounding is recommended only at one point in the system,
Consult local building codes for proper neutral grounding require-
ments,
TRANSFER SWITCH START SIGNAL
CONNECTIONS
If the generator is to be installed with a standard automatic transfer
switch, such as a GTS type switch, it will be necessary to connect
the two-wire start control system,
Connect the two-wire start signal from the automatic transfer
switch to the automatic start connection, which is located in the
lower rear of the AC connection panel. Match wires 178 (0) and
183 In the transfer SWitch to 178 (0) and 183 on the terminal strip
In the connection box, The conductors for the two-wire start circuit
must be in their own conduit.
If the generator is to be installed with an HTS-type transfer switch
a different connection method is needed, Use shielded 2-wir~
communications cable (such a Belden #9460) to make the con-
nection from the HTS transfer switch to the engine generator
connection panel. This cable is to be routed in a separate conduit
between the HTS transfer switch and the generator, The cable is to
be connected as follows:
HTS transfer switch -4 position terminal block, in the bottom of the
transfer switch enclosure (labeled "comm, Ports"),
Engine generator - terminal strip located in the lower rear of the
AC connection panel. Connect the RS485+ and RS485- to the
respective terminals in switch and generator. Do not connect the
shield at the transfer switch end.
BATTERY INSTALLATION
~
AStationary emergency generators installed
.... with automatic transfer switches will crank
and start automatically when NORMAL (UTIL-
ITY) source voltage is removed or is below
an acceptable preset level.
To prevent such
automatic start-up and possible injury to per-
sonnel, do not connect battery cables until
certain that normal source voltage at the
transfer switch is correct and the system Is
ready to be placed Into operation.
AStorage batteries give off explosive hydrogen
~gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the
gas and cause an explosion. Such an explo-
sion can shatter the battery and cause blind-
ness
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.

ABattery electrolyte fluid is an extremely
.... caustic sulfuric acid solution that can cause
severe burns. Do not permit fluid to contact
eyes, skin, clothing, painted surfaces, etc.
Wear protective goggles, protective clothing
and gloves when handling abattery. If fluid
is spilled, flush the affected area immedi-
ately with clear water.
IAWARNINGII
ADo not dispose of the battery in afire. The
~battery is capable of exploding.
ADo not open or mutilate the battery.
.... Released electrolyte can be toxic and harm-
ful to the skin and eyes.
Ir\ The battery represents arisk of high short
illcircuit current. When working on the battery,
always remove watches, rings or other metal
objects, and only use tools that have insu-
lated handles.
VENTED BATTERIES
ACAUTIONI
AThe electrolyte is adilute sulfuric acid that is
.... harmful to the skin and eyes. It is electrically
conductive and corrosive. The following pro-
cedures are to be observed:
oWear full eye protection and protective cloth-
ing,
oWhere electrolyte contacts the skin, wash it off
immediately with water,
oWhere electrolyte contacts the eyes, flush thor-
oughly and immediately with
water and seek
medical attention, and
oSpilled electrolyte is to be washed down with
an acid-neutralizing agent. Acommon practice
is to use asolution of one pound (500 grams)
bicarbonate of soda to one gallon (4 liters) of
water. The bicarbonate of soda solution is to be
added until the evidence of reaction (foaming)
has ceased. The resulting liquid is to be flushed
with
water and the area dried.
ALead acid batteries present arisk of fire
~because they generate hydrogen gas. The
following procedure are to be followed:
oDO NOT SMOKE when near batteries,
oDO NOT cause flame or spark in battery area,
and
oDischarge static electricity from body before
touching batteries by first touching agrounded
metal surface.
Operation
Servicing of batteries is to be performed or supervised by person-
nel knowledgeable of batteries and the required precautions, Keep
unauthorized personnel away from batteries.
For recommended batteries, see "Specifications," All batteries
must be at 1 00 percent state-of -charge before they are installed
on the generator.
When using maintenance-free batteries, it is not necessary
to check the specific gravity or electrolyte level. Have these
procedures performed at the intervals specified in Section 4,
"Maintenance," A negative ground system is used. Battery con-
nections are shown on the wiring diagrams, Make sure all batteries
are correctly connected and terminals are tight. Observe battery
polarity when connecting batteries to the generator set.
NOTE:
Damage will result if the battery connections are made in
reverse.
PREPARATION BEFORE START-UP
The instructions in this section assume that the stationary emer-
gency 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" on Pages
2 and 3, as well as all other safety information in this manual,
before attempting to operate this (and related) equipment.
PRIOR TO INITIAL START-UP
ACAUTIONI
APrior 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 rec-
ommended types and quantities of engine
fluids (oil, coolant, fuel, etc.)
may result in an
engine failure.
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 Section 4,
"Maintenance," and the "Service Schedule",
Transfer Switch
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 pre-
vents 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 genera-
tor and other standby components, must be properly located and
mounted in strict compliance with applicable codes, standards and
regulations,
15

Operation
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
If the unit has been idle for a long period of time, or if the fuel lines
or system components have been removed and reinstalled, the fuel
system may require bleeding to remove air from the system. Air in
the fuel system causes hard starting and rough operation. All fuel
system lines must be installed and must be tight A loose line may
show no sign of leakage, but may draw air into the system.
Rodent Protection
Make sure the four, 3-inch diameter cap plugs are properly
installed in the tie-down holes in the side rails of the unit's base
frame (Figure 2.3). The cap plugs are shipped in a plastic bag
located in the lower connection box. These plugs are needed to
prevent rodents from accessing the interior of the generator set
On acoustic units, cap plugs also are needed to stay within noise
specification limits.
Figure 2.3 - Base Frame Cap Plugs
ACAUTIONI
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
A standard form titled "Start-up Inspection for Stationary Emergency
Power Systems" (part no. 067377) should be completed by the
installation technician or engineer. As stated on the form, inspec-
tions are to be accomplished only by factory-trained personnel.
The technician performing the install should then scan and e-mail
the completed form to [email protected]. The form can also
be filled out at a dealer's Generac website.
3-INCH CIA.
PLUG
BASE
FRAME
STA8r-UP INSPECTION
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). This does not apply to automatic belt tensioning
systems.
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.
Check to ensure that there are no loose electrical connections,
Restrain any loose wires to keep them clear of any moving genera-
tor set components.
Engine Coolant
Have the engine cooling system properly filled with the recom-
mended coolant mixture. Check the system for leaks and other
problems. See "Specifications" and "Coolant"
AUse asuitable container to catch the fuel
.... that will spill during system bleeding pro-
cess. Clean up all spilled fuel after bleeding.
Generator Set Lubrication
Check the engine crankcase oil level befol'e 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"
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.
ENGINE STA8T-UP AND TRANSFE8
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
transfer switch.
16

~
AThe 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 infor-
mation.
ADo not proceed until certain that utility
.... source voltage is available to the transfer
switch and the transfer switch main contacts
are set to UTILITY.
/r\ Do not attempt manual operation until all
illpower supplies to the transfer switch have
been positively turned off,
or extremely dan-
gerous -possibly lethal -electrical shock
will result.
/i). 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 trans-
fer switch.
In order to manually 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 breaker).
• Set the transfer handle to its UTILITY (NORMAL) position with
load circuits connected to the utility power supply.
• Set the stationary emergency generator's main line circuit
breaker to its OFF (or OPEN) position.
• Start the generator.
• 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 stationary emergency generator's main line circuit
breaker to its ON (or CLOSED) position.
• Load circuits are now powered by the stationary emergency
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
transfer switch.
To manually transfer the load back to the utility power source and
shut down the generator, follow these directions:
• Set the stationary emergency generator's main line circuit
breaker to its OFF (or OPEN) position.
• Manually move the transfer switch handle to its UTILITY (NOR-
MAL) position, i.e., load cirCUits connected to the utility.
Maintenance
• 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.
OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH
If the generator has been installed along with an automatic transfer
switch, such as a GTS-type switch, the engine may be started and
stopped automatically or manually.
NOTE:
Refer to the applicable manual for the transfer switch and to
"Transfer Switch Start Signal Connections". In addition, please
note the dangers under "Engine Start-up and Transfer."
SERVICE SCHEDULE
AUTHORIZED OPERATOR MAINTENANCE FUNCTIONS
Every Month or 1 00 Hours (whichever comes first)
• Test stationary emergency generator system.
• Inspect battery (batteries) and cables.
• Check engine oil level.
• Check gearbox oil level (if so equipped).
• Check engine coolant level.
• Check generator ground connections.
• Test/inspect starting aids.
Every Three Months or Every 120 Hours (whichever comes first)
• Inspect and test fuel system and connections.
• Inspect exhaust system.
• Inspect/test fuel supply system.
AUTHORIZED SERVICE TECHNICIAN MAINTENANCE
FUNCTIONS
After First 30 Hours of Operation
• Inspect Wiring.
• Change engine crankcase oil and oil filter.
• Inspect engine fan belts.
• Inspect battery (batteries) and cables.
Every Six Months or Every 200 Hours (whichever comes first)
• Lubricate engine controls.
• Service engine air cleaner.
• Service engine fuel filter.
• Inspect AC generator.
• Test engine safety controls.
• Inspect fan belts.
• Check engine coolant level.
• Inspect engine cooling system hoses.
17

Maintenance
• Check optional starting aids.
• Check battery (batteries).
• Check engine compression.
• Check electrical connections.
• Check/test annunciator panel.
• Perform operational test
Annually or Every 600 Hours (whichever comes first)
• Change engine oil and filter.
• Inspect all wiring.
• Test engine starter operation.
• Drain water from fuel tank.
• Retorque fan bolts.
• Drain and refill gearbox (if so equipped).
Every Two Years
• Replace all rubber hoses.
• Replace engine fan belts.
• Inspect the Stationary Emergency Generator System.
• Drain, flush, refill cooling system.
Every 1,000 Operating Hours
• Inspect engine DC alternator.
• Inspect engine starter.
• Retorque engine mounting brackets.
• Remove/test fuel injection pump.
• Remove/test cooling system thermostat.
As Required
• Bleed engine fuel system.
PERIODIC MAINTENANCE
A rigorous program of scheduled periodic maintenance should
be established and maintained. Such a program, if adhered to
diligently, will provide added assurance that the power system
functions properly when it is needed.
Keeping a "Maintenance Log" is highly recommended. Such a
log should be a continuous record of repairs, parts replacements,
gauge and instrument readings during operational tests, etc.
The manufacturer requires that a "Scheduled Maintenance Plan"
be established between the user of this equipment and the install-
ing Authorized Service Dealer. Under this agreement, (Part No.
053263), an Authorized Service Technician performs prestart and
engine running tests and checks at six-month and one-year inter-
vals. Ask an Authorized Service Dealer about this agreement
The tasks listed in the "Service Schedule" cover the minimum
recommended maintenance requirements for this equipment.
Note that many of the tests and checks listed in the schedule are
to be performed only by an Authorized Service Technician. Fluid
capacities and recommendations, as well as other applicable
specifications, are listed in "Specifications".
18
TEST STATIONARY EMERGENCY GENERATOR SYSTEM
OPERATION AND COMPONENTS
An authorized operator should test the operation of the station-
ary emergency generator system and inspect its components
monthly (or 100 hours). This should include inspecting the trans-
fer switch for evidence of arcing, and pitted or burned contacts;
inspecting wiring and grounding connections (see "Grounding the
Generator"); and ensuring that starting devices are operational.
During this operational test, all instrument and gauge readings
should be recorded in a "Maintenance Log." The transfer system
also should be tested at this time; the engine should be run at least
30 minutes and any discrepancies corrected immediately.
Every six months (or 200 hours), an Authorized Service Technician
should perform a system operational test
INSPECT BAUERY
AStationary emergency generators Installed
.... with automatic transfer switches will crank
and start automatically when NORMAL (UTIL-
ITY) source voltage Is removed or Is below
an acceptable preset level. To prevent such
automatic start-up and possible Injury to
personnel, do not connect battery cables
until certain that normal source voltage at
the transfer switch Is correct and the system
Is ready to be placed Into operation.
AStorage batteries give off explosive hydrogen
~gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can Ignite the
gas and cause
an explosion. Such an explo-
sion can shatter the battery and cause blind-
ness 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.
ABattery electrolyte fluid Is an extremely
.... caustic sulfuric acid solution that can cause
severe burns.
Do not permit fluid to contact
eyes, skin, clothing, painted surfaces, etc.
Wear protective goggles, protective clothing
and gloves when handling abattery. If fluid
Is spilled, flush the affected area Immedi-
ately with clear water.
IAWARNINGII
A Do not dispose of the battery In afire. The
~battery Is capable of exploding.
A Do not open or mutilate the battery.
.... Released electrolyte can be toxic and harm-
ful to the skin and eyes.