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