Generac Power Systems QT06030KVAN User manual

STANDBY GENERATOR
OWNER'S MANUAL
This manual should remain with the unit.
A new standard of reliability
Serial Number QT
3.0L
60kW
Models
Cover038A Rev. 0 03/07 Part No. 0G3660

Standby Generator Sets
Table of Contents
SECTION PAGE
SAFETY RULES ......................................................... 1-1
INTRODUCTION .....................................................1-3
Read this Manual Thoroughly...................................1-3
Operation and Maintenance......................................1-3
How to Obtain Service ..............................................1-3
IDENTIFICATION RECORD.....................................2-1
Data Label ................................................................2-1
EQUIPMENT DESCRIPTION ...................................3-1
Equipment Description ................................................3-1
Engine Oil Requirements .............................................3-1
Coolant Recommendations...........................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
High Coolant Temperature Switch ............................4-1
Low Coolant Level Sensor.........................................4-1
Low Oil Pressure Switch...........................................4-1
Overcrank Shutdown................................................4-1
Overspeed Shutdown................................................4-1
RPM Sensor Loss Shutdown.....................................4-1
DC Fuse ....................................................................4-1
FUEL SYSTEMS .....................................................5-1
Fuel Requirements....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP Fuel System .........................................................5-1
SPECIFICATIONS ...................................................6-1
Generator .................................................................6-1
Engine.......................................................................6-1
Cooling System .........................................................6-1
Fuel System ..............................................................6-1
Electrical System ......................................................6-1
Cold Weather Kit.......................................................6-2
Coolant Heater Kit ....................................................6-2
GENERAL INFORMATION.......................................7-1
Generator AC Lead Connections ..................................7-1
Four-lead, Single-phase Stator ..................................7-1
Alternator Power Winding Connections ........................7-1
3-phase Alternators ..................................................7-1
INSTALLATION.......................................................8-1
Installation ...................................................................8-1
Preparation Before Start-up .........................................8-1
Transfer Switch ........................................................8-1
Fuel System ..............................................................8-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Engine Coolant .........................................................8-1
Belt Tension..............................................................8-1
Electrical System ......................................................8-1
Initial Inspection for QT Genset Start-up .....................8-1
Start-up Checklist ........................................................8-2
Start-up Inspection ...................................................8-2
OPERATION ...........................................................9-1
Generator Control and Operation ................................9-1
Operating Unit with Manual Transfer Switch...............9-1
Engine Start-up and Transfer ...................................9-1
Retransfer and Shutdown .........................................9-1
Operating Unit with Automatic Transfer Switch...........9-1
MAINTENANCE.....................................................10-1
Maintenance Performed by Authorized
Service Dealer.........................................................10-1
Every Three Months ...............................................10-1
Once Every Six Months...........................................10-1
Once Annually.........................................................10-1
First 30 Operating Hours........................................10-1
First 100 Operating Hours......................................10-1
First 500 Operating Hours......................................10-1
Cooling System ..........................................................10-1
Checking Fluid Levels ................................................10-1
Check Engine Oil ....................................................10-1
Battery Fluid...........................................................10-2
Engine Coolant .......................................................10-2
Valve Lash Inspection .............................................10-2
Maintenance Owner/Operator Can Perform................10-2
Check Engine Oil Level ...........................................10-2
Check Battery .........................................................10-2
Exercise System......................................................10-2
Inspect Cooling System...........................................10-2
Check Engine Coolant Level....................................10-2
Perform Visual Inspection.......................................10-2
Inspect Exhaust System..........................................10-2
Check Fan Belt........................................................10-2
Inspect Engine Governor ........................................10-2
Changing Engine Oil ...............................................10-3
Changing the Engine Air Filter................................10-3
Spark Plugs ............................................................10-3
Coolant Change.......................................................10-4
Miscellaneous Maintenance........................................10-4
Cleaning the Generator ...........................................10-4
Battery ....................................................................10-4
Battery Maintenance ...............................................10-4
Battery Replacement ...............................................10-4
Repair Parts ...............................................................10-5
SERVICE SCHEDULE ...........................................11-1
30 kW - 150 kW Standby Gas Engine
Driven Generator Sets ............................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
WARRANTY
Content013 Rev. 0 03/07

1-1
INTRODUCTION
Thank you for purchasing this model of the Stationary Emergency
Generator set product line.
Every effort was expended to make sure that the information and
instructions in this manual were both accurate and current at the
time the manual was written. However, the manufacturer reserves
the right to change, alter or otherwise improve this product(s) at
any time without prior notice.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, 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:
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in serious per-
sonal injury, including death, or property damage.
After this heading, read instructions that, if not
strictly complied with, may result in personal
injury or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements that require
special emphasis.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the service are essential to prevent-
ing accidents.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
This symbol points out important safety informa-
tion that, if not followed, could endanger per-
sonal safety and/or property of others.
This symbol points out potential explosion
hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use of the 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 accessories.
Operating instructions presented in this manual assume that the
generator 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, simply contact
an Authorized Service Dealer for assistance. Service technicians
are factory-trained and are capable of handling all service needs.
When contacting a dealer about parts and service, always supply
the complete Model Number, Serial Number and Type Code (where
applicable) from the DATA LABEL that is affixed to the unit.
AUTHORIZED SERVICE DEALER LOCATION
To locate the nearest AUTHORIZED
SERVICE DEALER, please call this number:
1-800-333-1322
or locate us on the web at:
www.generac.com
Stationary Emergency Generator
Important Safety Instructions
Safety 001 Rev. C 08/09

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 manual, and on
tags and decals affixed to the unit are, therefore, not all inclusive.
If a procedure, work method or operating technique is used that
the manufacturer does not specifically recommend, ensure that it
is safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglect-
ing its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or main-
tain this equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
GENERAL HAZARDS 
For safety reasons, the manufacturer recommends that this• equipment be installed, serviced and repaired by an Authorized
Service Dealer or other competent, qualified electrician or instal-
lation technician who is familiar with applicable codes, standards
and regulations. The operator also must comply with all such
codes, standards and regulations.
Installation, operation, servicing and repair of this (and related)• equipment must always comply with applicable codes, stan-
dards, laws and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration (OSHA) has
established. Also, ensure that the generator is installed, 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.
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. This should
be considered prior to installing the generator. The unit should
be positioned to direct exhaust gasses safely away from any
building where people, animals, etc., will not be harmed. Any
exhaust stacks that ship loose with the unit must be installed
properly per the manufacturer's instruction, and in strict compli-
ance 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-• nectitsbatterycablestopreventaccidentalstart-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.
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in
potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians
for this equipment.
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:

This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:

1-2
Stationary Emergency Generator
Important Safety Instructions

Safety 001 Rev. C 08/09

ELECTRICAL HAZARDS 
All Stationary Emergency Generators covered by this manual• produce dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely high and dan-
gerous voltages to the transfer switch as well as the generator.
Avoid contact with bare wires, terminals, connections, etc.,
on the generator as well as the transfer switch, if applicable.
Ensure all appropriate covers, guards and barriers are in place
before operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to reduce
shock hazard.
Do not handle any kind of electrical device while stand-• ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
If personnel must stand on metal or concrete while installing,• operating, servicing, adjusting or repairing this equipment,
place insulative mats over a dry wooden platform. Work on the
equipment only while standing on such insulative mats.
The National Electrical Code (NEC) requires the frame and• external electrically conductive parts of the generator to be con-
nected to an approved earth ground. This grounding will help
prevent dangerous electrical shock that might be caused by a
ground fault condition in the generator or by static electricity.
Never disconnect the ground wire.
Wire gauge sizes of electrical wiring, cables and cord sets must• be adequate to handle the maximum electrical current (ampac-
ity) to which they will be subjected.
Before installing or servicing this (and related) equipment, make• sure that all power voltage supplies are positively turned off at
their source. Failure to do so will result in hazardous and pos-
sibly fatal electrical shock.
Connecting this unit to an electrical system 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.
Stationary Emergency Generators installed with an automatic• transfer switch will crank and start automatically when normal
(utility) source voltage is removed or is below an acceptable
preset level. To prevent such automatic start-up and possible
injury to personnel, disable the generator’s automatic start cir-
cuit (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.
FIRE HAZARDS 
Keep a fire extinguisher near the generator at all times. Do NOT• use any carbon tetra-chloride type extinguisher. Its fumes are
toxic, and the liquid can deteriorate wiring insulation. Keep the
extinguisher properly charged and be familiar with its use. If
there are any questions pertaining to fire extinguishers, consult
the local fire department.
EXPLOSION HAZARDS 
Properly ventilate any room or building housing the generator to• prevent build-up of explosive gas.
Do not smoke around the generator. Wipe up any fuel or oil• spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surrounding the
generator clean and free from debris.
These generators may operate using one of several types• of fuels. All fuel types are potentially FLAMMABLE and/or
EXPLOSIVE and should be handled with care. Comply with all
laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks immediately.
Fuel supply lines must be properly installed, purged and leak
tested according to applicable fuel-gas codes before placing
this equipment into service.
Diesel fuels are highly FLAMMABLE. Gaseous fluids such• as natural gas and liquid propane (LP) gas are extremely
EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier
than air; install leak detectors accordingly.
1-3
Stationary Emergency Generator
Important Safety Instructions
Safety 001 Rev. C 08/09

IDENTIFICATION RECORD
DATA LABEL
Every generator set has a DATA LABEL that contains important
information pertinent to the generator. The data label, which can be
found attached to the generator’s lower connection box, lists the
unit’s serial number and its rated voltage, amps, wattage capacity,
phase, frequency, rpm, power factor, production date, etc.
NOTE:
For actual information related to this particular model, please
refer to the Manual Drawing Listing located at the end of this
manual, or to the data label affixed to the unit.
Stationary Emergency Generator Model and Serial
Number
This number is the key to numerous engineering and manufactur-
ing details pertaining to your unit. Always supply this number
when requesting service, ordering parts or seeking information.
2-1
Stationary Emergency Generator
General Information
Identy005 Rev. C 05/09
Data Label

EQUIPMENT DESCRIPTION
This equipment is a revolving field, alternating current Stationary
Emergency Generator. It is powered by a gaseous fueled engine
operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for
2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear
units. See the Specifications section for exact numbers. The unit
comes complete with a sound attenuated enclosure, internally
mounted muffler, control console, mainline circuit breaker, bat-
tery charger, and protective alarms as explained in the following
paragraph.
All AC connections, including the power leads from the alterna-
tor, 120 volt battery charger input and control connections to the
transfer switch are available in the main connection box.
The Stationary Emergency Generator incorporates the following
alternator features:
• Rotor and Stator insulation class is rated as defined by NEMA
MG1-32.6, NEMA MG1-1.66. The generator is self ventilated
and drip-proof constructed. Refer to the Specifications section
or the data label for the class ratings.
• The voltage waveform deviation, total harmonic content of the
AC waveform and telephone influence factor have been evalu-
ated and are acceptable according to NEMA MG1-32.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 5W-20 engine oil at the factory. Use
a high-quality detergent oil classified “For Service SJ or SH.”
Detergent oils keep the engine cleaner and reduce carbon deposits.
When changing the engine oil, be sure to use 5W-30 engine oil.
Any attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
NOTE:
If not already equipped, it is strongly recommended to use the
optional Cold Weather Start Kit for temperatures below 32° F.
The part number for the Cold Weather Start Kit can be found
in the Specifications section or by contacting an authorized
dealer. The oil grade for temperatures below 32° F is 5W-30
synthetic oil.
COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol base anti-freeze
and deionized water. Cooling system capacity is listed in the
specifications. Use only deionized water and only low silicate
anti-freeze. If desired, add a high quality rust inhibitor to the rec-
ommended coolant mixture. When adding coolant, always add the
recommended 50-50 mixture.
Do not use any chromate base rust inhibitor
with ethylene glycol base anti-freeze or chro-
mium hydroxide (“green slime”) forms and will
cause overheating. Engines that have been
operated with a chromate base rust inhibitor
must be chemically cleaned before adding ethyl-
ene glycol base anti-freeze. Using any high sili-
cate anti-freeze boosters or additives will also
cause overheating. The manufacturer also rec-
ommends that any soluble oil inhibitor is NOT
used for this equipment.
DANGER
Do not remove the radiator pressure cap while
the engine is hot or serious burns from boiling
liquid or steam could result.
Ethylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.
3-1
Stationary Emergency Generator
Equipment Description
Equip001 Rev. F 06/09

ENGINE PROTECTIVE DEVICES
The Stationary Emergency Generator may be required
to operate for long periods of time without an opera-
tor 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 run-
ning too fast.
NOTE:
Engine protective switches and sensors are men-
tioned here for the reader’s convenience. Also
refer to the applicable control panel manual for
additional automatic engine shutdown informa-
tion.
HIGH COOLANT TEMPERATURE SWITCH
The switch will close if the temperature should
exceed approximately 140° C (284° F), initiating an
engine shutdown. The generator will automatically
restart and the LED will reset once the temperature
has returned to a safe operating level.
LOW COOLANT LEVEL SENSOR
To prevent overheating, the engine has a low coolant
level sensor. If the level of engine coolant drops below
the level of the low coolant level sensor, the engine
automatically shuts down.
LOW OIL PRESSURE SWITCH
This switch has normally closed contacts that are
held open by engine oil pressure during cranking and
operating. Should oil pressure drop below the 8 psi
range, switch contacts close, and the engine shuts
down. The unit should not be restarted until oil is
added, and the AUTO/OFF/MANUAL switch must be
turned to OFF and then back to AUTO.
OVERCRANK SHUTDOWN
After a prespecified duration of cranking, this func-
tion ends the cranking if the engine has failed to
start. The overcrank LED will turn ON. Turn OFF the
AUTO/OFF/MANUAL switch, then turn switch back to
AUTO to reset the generator control board.
NOTE:
If the fault is not corrected, the overcrank feature
will continue to activate.
Approximate Crank Cycle Times
• 15 seconds ON
• 7 seconds OFF
• 7 seconds ON
• 7 seconds OFF
• Repeat for 45 seconds
Approximately 90 seconds total.
OVERSPEED SHUTDOWN
A speed circuit controls engine cranking, start-up,
operation and shutdown. Engine speed signals are
delivered to the circuit board whenever the unit is
running. Should the engine overspeed above a safe,
preset value, the circuit board initiates an automatic
engine shutdown. Contact the nearest Authorized
Dealer if this failure occurs.
RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine
shutdown will occur.
DC FUSES
Fuse F1 (15 amp) is located inside of the control
panel. It protects the panel wiring and components
from damaging overload. Always remove this fuse
before commencing work on the generator. The
unit will not start or crank if the fuse is blown.
Fuse F2 (25 amp) is located in the engine wire har-
ness adjacent to the DC alternator. It is used to pre-
vent circuit failure due to DC alternator falure. If this
fuse is blown, battery charging will not occur while
the engine is running. Replace these fuses with the
same size, type, and rating. (See the exploded views
and parts lists at the end of this manual for replace-
ment part number.)
4-1
Stationary Emergency Generator
Engine Protective Devices
EngProt001 Rev. B 09/08

FUEL SYSTEM
FUEL REQUIREMENTS
The Stationary Emergency Generator may be equipped with one of
the following fuel systems:
Natural gas fuel system• Propane vapor (PV) fuel system• Liquid propane (LP) fuel system•
Recommended fuels should have a Btu content of at least 1,000
Btu's per cubic foot for natural gas; or at least 2,520 Btu's per
cubic foot for LP gas. Ask the fuel supplier for the Btu content of
the fuel.
Required fuel pressure for natural gas is 5 inches to 14 inches
water column (0.18 to 0.5 psi); and for liquid propane, 5 inches
to 14 inches of water column (0.18 to 0.5 psi).
NOTE:
Any piping used to connect the generator to the fuel supply
should be of adequate size to ensure the fuel pressure NEVER
drops below five inches water column for natural gas or 5
inches water column for propane vapor for all load ranges. The
fuel supply piping shall be sized according to the installation
manual using the fuel consumption requirements identified in
the Specifications section of the Owner's Manual.
NOTE:
It is the responsibility of the installer to make sure that only
the correct recommended fuel is supplied to the generator fuel
system. Thereafter, the owner/operator must make certain that
only the proper fuel is supplied.
NATURAL GAS FUEL SYSTEM
Natural gas is supplied in its vapor state. In most cases, the gas
distribution company provides piping from the main gas distribu-
tion line to the standby generator site. The following information
applies to natural gas fuel systems.
Gas pressure in a building is usually regulated by national, state• and local codes.
To reduce gas pressure to a safe level before the gas enters a• building, a primary regulator is needed. The natural gas supplier
may or may not supply such a regulator.
It is the responsibility of the gas supplier to make sure sufficient• gas pressure is available to operate the primary regulator.
Gas pressure at the inlet to the fuel shutoff solenoid should not• exceed approximately 14 inches water column (0.5 psi).
PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
This type of system utilizes the vapors formed above the liquid
fuel in the supply tank. Approximately 10 to 20 percent of the tank
capacity is needed for fuel expansion from the liquid to the vapor
state. The vapor withdrawal system is generally best suited for
smaller engines that require less fuel. The installer should be aware
of the following:
When ambient temperatures are low and engine fuel consump-• tion is high, the vapor withdrawal system may not function
efficiently.
Ambient temperatures around the supply tank must be high• enough to sustain adequate vaporization, or the system will not
deliver the needed fuel volume.
In addition to the cooling effects of ambient air, the vaporization• process itself provides an additional cooling effect.
LP LIQUID FUEL SYSTEM
LP is supplied as a liquid in pressure tanks. It is usually made up
of propane, butane, or a mixture of the two gases. Propane tends
to vaporize readily even at temperatures as low as -20° F (-29° C).
However, butane reverts to its liquid state when temperatures drop
below 32° F (0° C).
LP in a liquid withdrawal system must be converted to its gaseous
state before it is introduced into the engine carburetor. A vaporizer-
converter is generally used to accomplish this. In such a converter,
heated engine coolant is ported through the converter to provide
the necessary heat for conversion of the fuel from a liquid to a
gaseous state.
5-1
Stationary Emergency Generator
Fuel Systems
FuelSys001 Rev. D 07/09

SPECIFICATIONS
GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ................................................................... Class H
Stator Insulation .................................................................. Class H
Total Harmonic Distortion ......................................................< 3.5%
Telephone Interference Factor (TIF).......................................... < 50
Alternator Output Leads 3-phase ........................................... 6-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) ............................................60kW*
*NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural
gas.
Excitation System....................................................................Direct
Generator Output Voltage/kW - 60 Hz kW Amp CB Size
120/240V, 1-phase, 1.0 pf 60 250 300
120/208V, 3-phase, 0.8 pf 60 208 250
277/480V, 3-phase, 0.8 pf 60 90 100
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208 3-phase............................................. 92 KVA
480V, 3-phase .................................................................. 105 KVA
ENGINE
Cylinders and Arrangement................................................ 6, V-type
Displacement....................................................................... 3.0 Liter
Bore...........................................................................89mm (3.5 in.)
Stroke ...................................................................79.5mm (3.13 in.)
Compression Ratio.............................................................10.5-to-1
Air Intake System ...............................................Naturally Aspirated
Lifter Type ............................................................ Shim Over Bucket
Engine Parameters
Rated Synchronous RPM..............................................60 Hz, 3600
HP at rated kW..................................................................60 Hz, 94
Exhaust System
Exhaust Flow at Rated Output 60 Hz.................................. 590 cfm
Exhaust Temperature at Rated Output................................ 1050° F
Combustion Air Requirements
Flow at rated power, 60 Hz ................................................. 210 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation........................................................± 1/2%
Adjustments:
Speed............................................................................ Selectable


Engine Lubrication System
Type of Oil Pump...................................................................... Gear
Oil Filter .............................................................Full Flow, Cartridge
Crankcase Oil Capacity.................................................6.5 U.S. qts.
COOLING SYSTEM
Type ....................................................................................... Closed
Water Pump.................................................................... Belt Driven
Fan Speed .........................................................................2180 rpm
Fan Diameter.....................................................................22 inches
Fan Mode ................................................................................ Puller
Air Flow (inlet air including alternator and
combustion air).......................................................... 4380 ft3/min.
Coolant Capacity ........................................................ (2.5 U.S. gal.)
Heat Rejection to Coolant ..........................................270,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature................................50° C (140° F)
FUEL SYSTEM
Type of Fuel.........................................Natural Gas, Propane Vapor
Carburetor ...................................................................... Down Draft
Secondary Fuel Regulator .................................................Standard
Fuel Shut-off Solenoid........................................................Standard
Operating Fuel Pressure ...................... 5 in. - 14 in. Water Column
Fuel Consumption - ft3/hr(Natural Gas/LPV)
Exercise 25% 50% 75% 100%
Cycle Load Load Load Load
123/48.2 260/101.9 500/196 700/274.4 960/376.3
*Engine is not field convertible between natural gas and propane. Jet size and ignition timing are
factory set for the specific fuel.
ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 30 Amp
Static Battery Charger............................................................2 Amp
Recommended Battery................................................ 24F 525CCA
System Voltage.....................................................................12 Volts
Voltage Regulator
Type .................................................................................. Electronic
Sensing........................................................................ Single-phase
Regulation ................................................................................± 1%
Features .................................................V/F Adjustable, Adjustable
Voltage and Gain LED Indicators
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C..................................................... 25
1.65% for every 10° above °F .................................................... 77
Altitude Deration
1% for every 100 m above m ................................................... 183
3% for every 1000 ft. above ft. ................................................. 600
Controller .................................................R-200



6-1
Standby Generator Sets
Specifications
GenSpec036 Rev. 0 03/07

COLD WEATHER KIT
For cold climates, an optional Cold Weather Kit (part
number 0F6148) is recommended. The kit includes:
Battery Warmer
4” Junction Box with hardware
6 qt. pack 5W-30 Synthetic Oil (engine)
COOLANT HEATER KIT
The optional Coolant Heater Kit (part number
0G2675) is available to be used in cunjuntion with
the Optional Cold Weather Kit. This kit includes:
1000 watt, 120 volt Engine Block Heater
Heater Mounting Bracket
All fittings, hoses and hardware to mount and
plumb heater

•
•
•

•
•
•
Figure 1 — Interconnections
6-2
Standby Generator Sets
Specifications
GenSpec036 Rev. 0 03/07

GENERATOR AC LEAD CONNECTIONS
See “Voltage Codes”. This Stationary Emergency
Generator may be rated at any one of five voltages,
either single-phase or three-phase. The electrical
wires in the unit’s AC connection (lower) panel should
be installed according to the number of leads and the
voltage/phase required for the application. If there
are any questions regarding lead connection, refer to
the wiring diagrams at the back of this manual.
Voltage codes apply to the type of stator assembly
installed on a particular generator.
ALTERNATOR POWER WINDING
CONNECTIONS
FOUR-LEAD, SINGLE-PHASE STATOR
Four-lead generators are built to supply electrical
loads with voltage code "A" (240V, 1-phase, 60Hz).
Electrical power is produced in the stator power
windings. These windings were connected at the fac-
tory to the main circuit breaker as shown in Figure
7.1.
The rated voltage between each circuit breaker ter-
minal is 240V. The rated voltage between each circuit
breaker terminal and the neutral point 00 is 120V.
Figure 7.1 — Four-lead, Single-phase Stator
3-PHASE ALTERNATORS ("Y" CONFIGURATION)
The Stationary Emergency Generator is designed
to supply 3-phase electrical loads. Electric power is
produced in the alternator power windings. These
windings were connected at the factory to the main
circuit breaker with a “Y” configuration as shown in
Figures 7.2, 7.3, and 7.4.
The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is either 480V or 208V
depending on the model.
The rated voltage between each circuit breaker termi-
nal and the neutral point 00 is either 277V or 120V
depending on the model.
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 120/208V (12 Lead)
E1
S10
S12
S4
S5
S2
S8
S11
S6
S3
S9
S7 S1
E2
E3
L - N
L - L
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 277/480V (12 Lead)
E1
S1
S4
S7
S12 S11
S10
S8
S5
S2
E2
S9
S6
S3
E3 L - N
L - L
7-1
Stationary Emergency Generator
General Information
ACConn005 Rev. A 09/08

Figure 7.1 — Stator Power Winding
Connections - 3-phase, 346/600V (6 Lead)
S6
E
3
S3
INTERNAL
CO
NNE
C
TI
O
N
S
L-
N
L
-
L
S4
E2
S2
S5
S1
E1
NE
U
TRA
L
3-PHASE ALTERNATORS
("DELTA" CONFIGURATION)
The Stationary Emergency Generator is designed
to supply 3-phase electrical loads. Electric power is
produced in the alternator power windings. These
windings were connected at the factory to the main
circuit breaker with a “Delta” configuration as shown
in Figures 7.5.
The rated voltage between circuit breaker terminals
E1-E2, E1-E3 and E2-E3 is 208V.
The rated voltage between E1 or E3 and the neutral
point 00 is 120V.
Figure 7.5 — Stator Power Winding
Connections - 3-phase, 120/240V (12 Lead)
E2
E1
E
7-2
Stationary Emergency Generator
General Information
ACConn005 Rev. A 09/08

INSTALLATION
Refer to the separate “Installation Guide QT Product
Line” supplied with the unit.
PREPARATION BEFORE START-UP
The instructions in this section assume that the
Stationary Emergency Generator has been properly
installed, serviced, tested, adjusted and otherwise
prepared for use by a competent, qualified installa-
tion contractor. Be sure to read the “Safety Rules”, as
well as all other safety information in this manual,
before attempting to operate this (and related) equip-
ment.
Before starting the generator for the first time, the
installer must complete the following procedures. For
follow-up maintenance information and/or service
intervals, please refer to the “Maintenance” section
and the “Service Schedule”.
TRANSFER SWITCH
If this generator is used to supply power to any elec-
trical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents elec-
trical backfeed between two different electrical sys-
tems. (For additional information, see the applicable
transfer switch manual for this unit.) The transfer
switch, as well as the generator and other electrical
components, must be properly located and mounted
in strict compliance with applicable codes, standards
and regulations.
FUEL SYSTEM
Make sure the fuel supply system to the genera-
tor (a) delivers the correct fuel at the correct pres-
sure and (b) is properly purged and leak tested
according to code. No fuel leakage is permitted. See
“Specifications” for more information.
GENERATOR SET LUBRICATION
Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level
below the dipstick “ADD” mark. See “Specifications”
and “Engine Oil Recommendations”.
NOTE:
This engine is shipped from the manufacturer
with “break-in” oil. This oil should be changed
after 30 hours of operation.
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 recom-
mended oil is SAE 90 gear lubricant.
Also, if the engine is equipped with a mechanical gov-
ernor, make sure the governor is properly lubricated
with clean engine oil.
PRIOR TO INITIAL START-UP
Prior to initially starting the generator, it must
be properly prepared for use. Any attempt to
crank or start the engine before it has been
properly serviced with the recommended types
and quantities of engine fluids (oil, coolant, fuel,
etc.) may result in an engine failure.
ENGINE COOLANT
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
for leaks and other problems. See “Specifications”
and “Coolant” sections.
BELT TENSION
Check-the engine-fan belt tension and condition prior
to placing the unit into service and at recommended
intervals. Belt tension is correct when a force of
approximately 22 pounds (10 kg), applied midway
between pulleys, deflects the belt about 3/8- to 5/8-
inch (10 to 16 mm).
ELECTRICAL SYSTEM
Make sure the generator is properly connected to an
approved earth ground.
Make sure the generator battery is fully charged,
properly installed and interconnected, and ready for
use.
NOTE:
Battery charger must be connected to 120 VAC, 15
amp circuit to operate.
Check to ensure that there are no loose electrical con-
nections. Restrain any loose wires to keep them clear
of any moving generator set components.
INITIAL INSPECTION FOR QT GENSET
STARTUP
Inspect for the following.
• Freight Damage.
• Manuals present.
• Fluid Levels (Oil, coolant, battery, Gear Drive).
• Correct fuel piping.
• Correct muffler installation for external applica-
tion.
• Adequate air flow, clearances and ventilation per
installation drawings and applicable codes.
• Correct AC and DC wire size, connections and
grounding. Control and communication wiring to/
from the transfer switch must be run in a separate
conduit from the AC power leads.
8-1
Stationary Emergency Generator
Installation
Install001 Rev. E 11/08

• Battery charger connection to 120 VAC.
• Communication wires connected between transfer
switch and generator (HTS only).
• Unit secured to pad.
START-UP CHECKLIST
Before working on the Stationary Emergency
Generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF
position.
• The 120VAC supply to the battery charger is
switched OFF.
PREPARATION FOR START-UP
• Ensure that the 120VAC circuit breaker to the bat-
tery charger is open.
• Remove the fuse from the the control panel. For
the H-100 and R-series: Open the front door of the
control box and remove the 15 Amp ATO fuse in
the lower left-hand corner of the control box.
• Connect the battery cables to the battery. Attach
negative battery cable last.
• Close the 120VAC circuit breaker to the battery
charger.
• Measure the voltage at the battery before and after
the charger is turned on.
• Verify all AC electrical connections are tight at the
circuit breaker and transfer switch.
• Visually inspect entire area looking for loose paper,
plastic wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or dam-
age.
• Check all electrical plugs throughout the genera-
tor. Ensure each plug is seated correctly and fully
inserted into its receptacle.
• Verify the AUTO/OFF/MANUAL switch is in OFF
position.
• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel
lines).
• Open the generator main line circuit breaker.
• Connect a manometer to the gas line and record
the static pressure. It must be as listed in the
Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the MAN-
UAL position. The engine should now crank and
start.
• Check voltage at the generator terminals.
• For 3-phase units, check phase rotation at the
transfer switch terminals. The generator phase
rotation must match the utility phase rotation.
• Check for coolant, fuel, oil, and exhaust leaks.
• Close the generators main line circuit breaker.
• Turn the generator set off.
• Connect the UTILITY supply to the transfer
switch.
• Set the AUTO/OFF/MANUAL switch to AUTO.
• Disconnect utility power before the transfer
switch.
Engine should start, transfer to load.
Run at least 15 minutes on generator power.
Make certain all 3-phase loads are functioning
correctly (correct phase rotation).
• Reconnect Utility power
Transfer switch will transfer back to Utility and
engine will shut down within the given time
parameters set up for the specific transfer switch
and controller.
• Install all covers, access plates and door panels.
• Put the Owners Manual in a safe and accessible
place.
• Make certain the AUTO/OFF/MANUAL switch is in
the AUTO position.
START-UP INSPECTION
When a start-up is performed by an Authorized
Service Dealer, a standard three-part form titled
“Start-up Inspection for Standby Power Systems”
(part no. 067377), should be completed by the instal-
lation technician or engineer. See page 1-3 for infor-
mation on locating the nearest Authorized Service
Dealer. The installer should complete the form and
disseminate copies as follows:
• White copy: Mail to Generac Warranty Department,
P.O. Box 340, 211 Murphy Dr., Eagle, WI 53119-
2062.
• Pink Copy: For service file of installing dealer.
• Yellow Copy: For the customer’s records.
8-2
Stationary Emergency Generator
Installation
Install001 Rev. E 11/08

STATIONARY EMERGENCY
GENERATOR CONTROL AND
OPERATION
Refer to the appropriate control panel operator’s manual for this
unit.
OPERATING UNIT WITH MANUAL
TRANSFER SWITCH
If the Stationary Emergency Generator was installed in conjunction
with a transfer switch capable of manual operation only, the fol-
lowing procedure applies. A manually operated transfer switch is
one that will not provide automatic start-up and does not include
an intelligence circuit.
ENGINE START-UP AND TRANSFER
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
specific transfer switch.
DANGER
The Maintenance Disconnect Switch and the
AUTO/OFF/MANUAL switches (if so equipped)
must be set properly, or the generator will crank
and start as soon as the utility power to the
transfer switch is turned off. Refer to applicable
control panel and transfer switch manuals for
more information.
Do not proceed until certain that utility source
voltage is available to the transfer switch and
the transfer switch main contacts are set to
UTILITY.
Do not attempt manual operation until all power
supplies to the transfer switch have been posi-
tively turned off, or extremely dangerous - pos-
sibly lethal - electrical shock will result.
Transfer switch enclosure doors should be kept
closed and locked. Only authorized personnel
should be allowed access to the transfer switch
interior. Extremely high and dangerous voltages
are present in the transfer switch.
In order to transfer load from the utility source to the generator,
follow these directions:
Turn OFF or disconnect the utility power circuit to the transfer• switch, using the means provided (such as the utility source
main line circuit breaker).
Set the transfer handle to its UTILITY (NORMAL) position with• load circuits connected to the utility power supply.
Set the generator’s main line circuit breaker to its OFF (or OPEN)• position.
Start the generator.•
Do not crank the engine continuously for longer
than 30 seconds, or the heat may
damage the starter motor.
Let engine stabilize and warm up.• Check all applicable instrument and gauge readings. When• certain that all readings are correct, move the transfer switch
manual handle to the STANDBY (or EMERGENCY STANDBY)
position, i.e., load circuits supplied by the generator.
Set the generator’s main line circuit breaker to its ON (or• CLOSED) position.
Load circuits are now powered by the generator.•
RETRANSFER AND SHUTDOWN
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
specific transfer switch.
To transfer the load back to the utility power source and shut down
the generator, follow these directions:
Set the generator’s main line circuit breaker to its OFF (or OPEN)• position.
Manually move the transfer switch handle to its UTILITY• (NORMAL) position, i.e., load circuits connected to the utility.
Turn ON the utility power supply to the transfer switch, using• the means provided (such as the utility power source main line
circuit breaker).
Let the generator run at no-load for a few minutes to stabilize• internal temperatures.
Shut down the generator.•
OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH
If the Stationary Emergency Generator has been installed with an
automatic transfer switch, the engine may be started and stopped
automatically or manually. NOTE:
Refer to the applicable manual for your transfer switch and to
“Transfer Switch Start Signal Connections”. In addition, please
note the dangers under “Engine Start-up and Transfer.”
9-1
Stationary Emergency Generator
Operation
Oper001 Rev. C 08/09

MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE DEALER
Before working on the generator, ensure the fol-
lowing:
The AUTO/OFF/MANUAL switch is in the OFF
position.
The 15A fuse has been removed from the con-
trol box.
The 120VAC supply to the battery charger is
switched OFF.
The NEGATIVE battery cable has been
REMOVED.
EVERY THREE MONTHS
1. Check battery state of charge and condition.
2. Inspect and test fuel system.
3. Check transfer switch.
4. Inspect exhaust system.
5. Check engine ignition system.
6. Check fan belts.
ONCE EVERY SIX MONTHS
1. Test Engine Safety Devices (low oil pressure, low
coolant level, high coolant temperature).
ONCE ANNUALLY
1. Test engine governor. Adjust or repair, if needed.
2. Clean, inspect generator.
3. Flush cooling system.
4. Clean/regap spark plugs or replace as necessary.
FIRST 30 OPERATING HOURS
1. Change engine "break-in" oil and filter.
FIRST 100 OPERATING HOURS
1. Change engine oil and oil filter. (After initial
change, service engine oil and filter at 150 operat-
ing hours or 6 months, whichever comes first.)
EVERY 500 OPERATING HOURS
1. Service air cleaner.
2. Check starter.
3. Check engine DC alternator.
•
•
•
•






COOLING SYSTEM
Air intake and outlet openings in the generator com-
partment must be open and unobstructed for contin-
ued proper operation. This includes such obstruc-
tions as high grass, weeds, brush, leaves and snow.
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to shut down.
The exhaust system parts from this product get
extremely hot and remain hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.
CHECKING FLUID LEVELS
CHECK ENGINE OIL
Check engine crankcase oil level (Figure 10.1) at least
every 20 hours of operation, or prior to use.
Remove oil dipstick and wipe dry with a clean, lint-
free cloth.
Install oil dipstick, then remove again.
Oil should be between FULL and ADD marks.
If oil level is below the dipstick ADD mark,
remove oil fill cap. Add the recommended oil to
bring oil level up to the FULL mark. DO NOT
FILL ABOVE THE “FULL” MARK. See “Engine Oil
Recommendations” for recommended oils.
Figure 10.1 - Oil Dipstick and Oil Fill Cap
Oil Fill Cap
Oil
Dipstick

•
•
•
•
10-1
Standby Generator Sets
Maintenance
Maint015 Rev. 0 03/07

BATTERY FLUID
Check battery electrolyte fluid at least once weekly.
Fluid should cover separators in all battery cells. If
fluid level is low, add distilled water to cover tops of
separators. DO NOT USE TAP WATER IN BATTERY.
ENGINE COOLANT
Check coolant level in coolant recovery bottle. See the
“Specifications” section.
Add recommended coolant mixture as necessary.
Periodically remove radiator pressure cap to make
sure the coolant recovery system is functioning
properly. Coolant should be at bottom of radiator
filler neck. If coolant level is low, inspect gasket in
radiator pressure cap. Replace cap, if necessary.
To have pressure cap tested, contact an Authorized
Service Dealer. Inspect cooling system and coolant
recovery system for leaks.
VALVE LASH INSPECTION
Valve lash should be checked every two years by an
Authorized Service Dealer. Extensive periods of run
time at 75% or greater of full rated load will require
valve lash to be checked more frequently.
MAINTENANCE OWNER/
OPERATOR CAN PERFORM
Before working on the generator, ensure the fol-
lowing:
The AUTO/OFF/MANUAL switch is in the OFF
position.
The 15A fuse has been removed from the con-
trol box.
The 120VAC supply to the battery charger is
switched OFF.
The NEGATIVE battery cable has been
REMOVED.
CHECK ENGINE OIL LEVEL
Refer to the “Checking Fluid Levels” section.
CHECK BATTERY
Check battery fluid level each week as outlined
under “Check Fluid Levels”.
Check battery cables for condition, tightness, cor-
rosion or damage. Clean, tighten or replace as
necessary.


•
•

•
•
•
•


•
•
EXERCISE SYSTEM
Start the generator engine at least once every seven
days and let it run at least 20 minutes. For more
detailed exercise information, see the respective sec-
tions in the Control Panel Technical Manual that is
supplied with the unit.
INSPECT COOLING SYSTEM
Inspect engine cooling system at least once each
month.
Check hoses for damage, deterioration, leaks, etc.
Correct any discrepancies found.
Check hose clamps for tightness.
CHECK ENGINE COOLANT LEVEL
See the “Checking Fluid Levels” section.
PERFORM VISUAL INSPECTION
Complete a thorough visual inspection of the entire
engine-generator monthly. Look for obvious damage,
loose, missing or corroded nuts, bolts and other fas-
teners. Look for fuel, oil or coolant leaks.
INSPECT EXHAUST SYSTEM
Inspect the exhaust system at least once every three
months. Check all exhaust system pipes, mufflers,
clamps, etc. for condition, tightness, leaks, security,
damage.
CHECK FAN BELT
Inspect fan belts every three months. Replace any
damaged, deteriorated, worn or otherwise defec-
tive belt.
Check fan belt tension. Thumb pressure, exerted
midway between pulleys, should deflect about 3/8
to 5/8 inch. Adjust belt tension as required.
INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
DANGER
Do not attempt to adjust the governor. Only
qualified service dealer should adjust the gover-
nor. Excessively high operating speeds are dan-
gerous and increase the risk of personal injury.
Low speeds impose a heavy load on the engine
when adequate engine power is not available
and may shorten engine life. Correct rated fre-
quency and voltage are supplied only at the
proper governed speed. Some connected electri-
cal load devices may be damaged by incorrect
frequency and/or voltage. Only qualified service
technicians should adjust the governed speed.


•
•
•




•
•

Standby Generator Sets
Maintenance
10-2
Maint015 Rev. 0 03/07

CHANGING ENGINE OIL
Refer to maintenance performed by authorized service
dealer for engine oil and filter change frequencies.
Drain the oil while the engine is still warm from run-
ning. This means warm up the engine, shut it down
and drain immediately as follows:
1. Remove OIL DRAIN HOSE from its retaining
clip.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain
oil completely into suitable container.
3. When all oil has drained, install and tighten OIL
DRAIN HOSE CAP, and re-install into its retaining
clip.
4. Turn OIL FILTER (Figure 10.2) counterclockwise
and remove. Dispose of old filter.
5. Apply light coating of new engine oil to seal of new
oil filter.-Install FILTER and tighten by hand only.
DO NOT OVERTIGHTEN.
6. Remove OIL FILL CAP. Add recommended oil (see
SPECIFICATIONS). Crankcase oil capacity is 6.5
U.S. quarts (6.15 liters) including oil filter.
After refilling the crankcase with oil, always
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
7. Start engine and check for oil leaks.
8. Shut off engine. Wait 10 minutes for oil to settle
down into the oil pan. Recheck oil level on dip-
stick.
Figure 10.2 - Oil Filter
Oil Filter
CHANGING THE ENGINE AIR FILTER
To replace the engine air filter, remove the air cleaner
cover and replace the air filter making sure it is posi-
tioned properly before reattaching the cover (Figure
10.3).


See the “Service Schedule” section for air cleaner
maintenance.
Figure 10.3 - Air Filter
Wing Nut
Cover
Air Filter
SPARK PLUGS
Reset the spark plug gap or replace the spark plugs
as necessary.
1. Clean the area around the base of the spark plugs
to keep dirt and debris out of the engine. Clean
by scraping or washing using a wire brush and
commercial solvent. Do not blast the spark plugs
to clean.
2. Remove the spark plugs and check the condition.
Replace the spark plugs if worn or if reuse is
questionable. See the “Service Schedule” section
for recommended inspection.
3. Check the spark plug gap using a feeler gauge.
Adjust the gap to 1.12 mm (0.044 inch) by care-
fully bending the ground electrode (Figure 10.4).
Figure 10.4 – Setting the Spark Plug Gap

SET PLUG GAP AT 1.12 mm
(0.044 inch)
Standby Generator Sets
Maintenance
10-3
Maint015 Rev. 0 03/07

COOLANT CHANGE
Every year, have an Authorized Service Dealer
drain, flush and refill the cooling system. See the
“Specifications” section for cooling system recom-
mendations.
MISCELLANEOUS MAINTENANCE
CLEANING THE GENERATOR
Keep the generator as clean and as dry as possible.
Dirt and moisture that accumulates on internal gen-
erator windings have an adverse effect on insulation
resistance.
Periodically clean generator exterior surfaces. A soft
brush may be used to loosen caked on dirt. Use a
vacuum system or dry, low pressure air to remove
any accumulations of dirt. The generator is housed
inside an all-weather enclosure, clean the enclosure
with a soft, damp cloth or sponge and water.
Once each year, have the generator cleaned and
inspected by an Authorized Service Dealer. That
dealer will use dry, low pressure air to clean internal
windings. Parts inside the control console should be
cleaned and inspected at this time as well.
Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
excessively low, the generator may require drying.
BATTERY
All lead-acid storage batteries discharge when not in
use. Refer to specific instructions and warnings that
accompany the battery. If such information is not
available, observe the following precautions when
handling a battery:
DO NOT use jumper cables and a booster battery
to crank or start the generator engine.
DO NOT recharge a weak battery while it is
installed in the generator. Remove battery from
generator and recharge in a well-ventilated area,
away from fuel vapors, sparks, heat or flames.
Battery electrolyte fluid is an extremely caustic
sulfuric solution that can cause severe burns. DO
NOT permit fluid to contact eyes, skin, clothing,
painted surfaces, wiring insulation, etc. If any bat-
tery fluid is spilled, flush the affected area with
clear water immediately.
Always wear safety glasses, rubber apron and
gloves when handling a battery.
Batteries give off explosive hydrogen gas while
charging. The gas can form an explosive mixture
around the battery for several hours after charging.
Any spark, heat or flames can ignite the gas and
cause an explosion which can shatter the battery,
causing blindness or other serious injury.



•
•
•
•
•
BATTERY MAINTENANCE
The battery should be inspected per the “Service
Schedule” section. The following procedure should
be followed for inspection:
1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with DISTILLED WATER
ONLY. DO NOT USE TAP WATER IN BATTER-
IES.
3. Have the state of charge and condition checked.
This should be done with an automotive-type bat-
tery hydrometer.
DANGER
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after charg-
ing. The slightest spark can ignite the gas and
cause an explosion. Such an explosion can shat-
ter the battery and cause blindness or other
injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smok-
ing, open flame, sparks or any spark producing
tools or equipment near the battery.
Battery electrolyte fluid is an extremely caus-
tic sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If the fluid is spilled, flush
the affected area immediately with clear water.
Do not use any jumper cables or booster battery
to crank and start the generator engine. If the
battery has completely discharged, remove it
from the generator for recharging.
Be 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 connected.
Be sure the 120VAC power supply to the battery
is turned OFF, or sparking may occur at the bat-
tery posts as the cables are attached and cause
an explosion.
BATTERY REPLACEMENT
When replacing batteries, use the same number
and the type of battery that was supplied with the
unit, and is listed in the parts list in the back of this
manual.


Standby Generator Sets
Maintenance
10-4
Maint015 Rev. 0 03/07