Generac Power Systems 005191-1 User manual

STANDBY GENERATOR
OWNER'S MANUAL
This manual should remain with the unit.
Serial Number SG30
005191-1 GENERATOR
005200-1 TANK SET
005230-0 NATURAL GAS
RISER FRAME
 Not intended for use in critical life support applications. 
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
—CAUTION—
Cover034 Rev. 0 11/05 Part No. 0F8072

Standby Generator Sets
Table of Contents
SECTION PAGE
SAFETY RULES ......................................................... 1-1
INTRODUCTION .....................................................1-3
Read this Manual Thoroughly .............................................1-3
Operation and Maintenance.................................................1-3
How to Obtain Service.........................................................1-3
IDENTIFICATION RECORD.....................................2-1
Data Label ........................................................................... 2-1
EQUIPMENT DESCRIPTION ...................................3-1
Equipment Description ...........................................................3-1
Engine Oil Recommendations .................................................3-1
Coolant Recommendations......................................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
Coolant Temperature Sensing ............................................. 4-1
Low Coolant Level ...............................................................4-1
Oil Pressure Sensing ...........................................................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
NG/PV Dual Fuel System .....................................................5-1
Low Fuel Level Alarm .......................................................... 5-2
Gas Detector........................................................................5-2
Fluid Spill Alarm.................................................................5-2
SPECIFICATIONS ...................................................6-1
Generator ............................................................................6-1
Engine .................................................................................6-1
Cooling System....................................................................6-1
Fuel System ......................................................................... 6-1
Electrical System.................................................................6-1
Ignition Description.................................................................6-2
Ignition Power-up Input ("56 Line" Input) ............................6-2
Fuel Select Input.................................................................. 6-2
Ignition Shutdown on Loss of Flywheel or
Cam/Distributor Signals...................................................6-2
3.9L Engine Select Input ..................................................... 6-2
Diagnostic Blink Patterns (Ignition Red LED)......................6-3
GENERAL INFORMATION.......................................7-1
Generator AC Lead Connections ............................................. 7-1
Four-lead, Single-phase Stator.............................................7-1
INSTALLATION.......................................................8-1
Installation .............................................................................. 8-1
Unpacking ...........................................................................8-1
Generator Location..............................................................8-1
Generator Support ..............................................................8-1
Installation Rules ....................................................................8-2
Before Installation...................................................................8-2
NFPA Standards .................................................................. 8-2
Other Published Standards ................................................. 8-2
Preparation Before Start-up ....................................................8-3
Initial Inspection for Generator Start-up .............................8-3
Prior to Initial Start-up ........................................................... 8-3
Engine Coolant .................................................................... 8-3
Belt Tension ........................................................................8-3
Electical System ..................................................................8-3
Start-up Checklist ................................................................... 8-4
Start-up Inspection Form .................................................... 8-4
Electical Connections .............................................................. 8-4
Grounding the Generator ....................................................8-4
Battery Charger Connection ................................................8-5
Battery Installation .............................................................. 8-5
Table 1 - Vapor Capacity of Propane Storage Tanks ............ 8-6
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
Basic Standby Electric System................................................9-2
Standby Circuit Isoation Method............................................. 9-2
Total Circuit Isolation Method.................................................9-2
Connection Diagrams..............................................................9-2
MAINTENANCE.....................................................10-1
Maintenance Performed by Service Facilities.........................10-1
Every Three Months .......................................................... 10-1
Once Every Six Months ..................................................... 10-1
Once Annually ...................................................................10-1
First 100 Operating Hours ................................................10-1
Every 500 Operating Hours............................................... 10-1
Cooling System .....................................................................10-1
Checking Fluid Levels ...........................................................10-1
Check Engine Oil...............................................................10-1
Battery Fluid .....................................................................10-1
Engine Coolant .................................................................. 10-2
Maintenance Owner/Operator Can Perform...........................10-2
Check Engine Oil Level...................................................... 10-2
Check Battery....................................................................10-2
Exercise System ................................................................10-2
Inspect Cooling System ..................................................... 10-2
Check Engine Coolant Level .............................................. 10-2
Perform Visual Inspection ................................................. 10-2
Inspect Exhaust System .................................................... 10-2
Check Fan Belt .................................................................. 10-2
Inspect Engine Governor ................................................... 10-2
Changing Engine Oil..........................................................10-2
Changing the Engine Air Cleaner....................................... 10-3
Spark Plugs....................................................................... 10-3
Coolant Change .................................................................10-3
Miscellaneous Maintenance...................................................10-3
Cleaning the Generator...................................................... 10-3
Battery...............................................................................10-3
Battery Maintenance..........................................................10-4
Battery Replacement..........................................................10-4
Repair Parts ..........................................................................10-4
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
INSTALLATION DIAGRAM
WARRANTY
Content007 Rev. 0 11/05

Study these SAFETY RULES carefully before install-
ing, operating or servicing this equipment. Become
familiar with this Owner’s Manual and with the unit.
The generator can operate safely, efficiently and reli-
ably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to
follow simple and fundamental rules or precautions.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warn-
ings in this manual, and on tags and decals affixed
to the unit are, therefore, not all inclusive. If a pro-
cedure, work method or operating technique is used
that the manufacturer does not specifically recom-
mend, ensure that it is safe for others. Also make
sure the procedure, work method or operating tech-
nique utilized does not render the generator unsafe.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglect-
ing its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or main-
tain this equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
GENERAL HAZARDS 
• For safety reasons, the manufacturer recommends
that this equipment be installed, serviced and
repaired by an Authorized Service Dealer or other
competent, qualified electrician or installation tech-
nician who is familiar with applicable codes, stan-
dards and regulations. The operator also must
comply with all such codes, standards and regula-
tions.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electri-
cal and building codes. Comply with regulations
the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the
generator is installed, operated and serviced in
accordance with the manufacturer’s instructions
and recommendations. Following installation, do
nothing that might render the unit unsafe or in
noncompliance with the aforementioned codes,
standards, laws and regulations.
• The engine exhaust fumes contain carbon monox-
ide 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 stan-
dards.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
• Adequate, unobstructed flow of cooling and venti-
lating air is critical in any room or building hous-
ing the generator to prevent buildup of explosive
gases and to ensure correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seri-
ously affect safe operation of the generator.
• Keep the area around the generator clean and
uncluttered. Remove any materials that could
become hazardous.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Inspect the generator regularly, and promptly
repair or replace all worn, damaged or defective
parts using only factory-approved parts.
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas. Safety should be stressed to all
operators, potential operators, and service and repair technicians for this equipment.
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:

This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:

1-1
Standby Generator Sets
Important Safety Instructions

Safety 001 Rev. 0 08/05

• Before performing any maintenance on the gen-
erator, disconnect its battery cables to prevent
accidental start-up. Disconnect the cable from the
battery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating con-
ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
ELECTRICAL HAZARDS 
• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as well as the standby generator. Avoid contact
with bare wires, terminals, connections, etc., on
the generator as well as the transfer switch, if
applicable. Ensure all appropriate covers, guards
and barriers are in place before operating the gen-
erator. If work must be done around an operating
unit, stand on an insulated, dry surface to reduce
shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• If personnel must stand on metal or concrete while
installing, operating, servicing, adjusting or repair-
ing this equipment, place insulative mats over a
dry wooden platform. Work on the equipment only
while standing on such insulative mats.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts
of the generator to be connected to an approved
earth ground. This grounding will help prevent
dangerous electrical shock that might be caused
by a ground fault condition in the generator set or
by static electricity. Never disconnect the ground
wire.
• Wire gauge sizes of electrical wiring, cables and
cord sets must be adequate to handle the maxi-
mum electrical current (ampacity) to which they
will be subjected.
• Before installing or servicing this (and related)
equipment, make sure that all power voltage
supplies are positively turned off at their source.
Failure to do so will result in hazardous and pos-
sibly fatal electrical shock.
• Connecting this unit to an electrical system nor-
mally supplied by an electric utility shall be by
means of a transfer switch so as to isolate the
generator electric system from the electric utility
distribution system when the generator is operat-
ing. Failure to isolate the two electric system power
sources from each other by such means will result
in damage to the generator and may also result
in injury or death to utility power workers due to
backfeed of electrical energy.
• Generators installed with an automatic transfer
switch will crank and start automatically when
normal (utility) source voltage is removed or is
below an acceptable preset level. To prevent such
automatic start-up and possible injury to person-
nel, disable the generator’s automatic start circuit
(battery cables, etc.) before working on or around
the unit. Then, place a “Do Not Operate” tag on
the generator control panel and on the transfer
switch.
• In case of accident caused by electric shock, imme-
diately shut down the source of electrical power.
If this is not possible, attempt to free the victim
from the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a nonconducting imple-
ment, such as a dry rope or board, to free the vic-
tim from the live conductor. If the victim is uncon-
scious, apply first aid and get immediate medical
help.
• Never wear jewelry when working on this equip-
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com-
ponents causing injury.
FIRE HAZARDS 
• Keep a fire extinguisher near the generator at all
times. Do NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid
can deteriorate wiring insulation. Keep the extin-
guisher properly charged and be familiar with its
use. If there are any questions pertaining to fire
extinguishers, consult the local fire department.
EXPLOSION HAZARDS 
• Properly ventilate any room or building housing
the generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no com-
bustible materials are left in the generator com-
partment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround-
ing the generator clean and free from debris.
• These generator sets may operate using one of
several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulat-
ing the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks
immediately. Fuel supply lines must be prop-
erly installed, purged and leak tested according to
applicable fuel-gas codes before placing this equip-
ment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous
fluids such as natural gas and liquid propane
(LP) gas are extremely EXPLOSIVE. Natural gas
is lighter than air, and LP gas is heavier than air;
install leak detectors accordingly.
1-2
Standby Generator Sets
Important Safety Instructions
Safety 001 Rev. 0 08/05

1-3
INTRODUCTION
Thank you for purchasing this model of the standby
generator set product line.
Every effort was expended to make sure that the
information and instructions in this manual were
both accurate and current at the time the manual was
written. However, the manufacturer reserves the right
to change, alter or otherwise improve this product(s)
at any time without prior notice.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, con-
tact the nearest Authorized Service Dealer for start-
ing, operating and servicing procedures.
Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert person-
nel to special instructions about a particular service
or operation that may be hazardous if performed
incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in personal injury
or property damage.
After this heading, read instructions that, if not
strictly complied with, may result in personal
injury or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compli-
ance with the special instructions while performing
the service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:
This symbol points out important safety infor-
mation that, if not followed, could endanger
personal safety and/or property of others.
This symbol points out potential explosion
hazard.

This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly recom-
mends that the operator read this Owner's Manual
and thoroughly understand all instructions before
using this equipment. The manufacturer also strong-
ly recommends instructing other users to properly
start and operate the unit. This prepares them if they
need to operate the equipment in an emergency.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by an Authorized
Service Dealer. Normal maintenance service and
replacement of parts are the responsibility of the
owner/operator and, as such, are not considered
defects in materials or workmanship within the terms
of the warranty. Individual operating habits and usage
contribute to the need for maintenance service.
Proper maintenance and care of the generator ensure
a minimum number of problems and keep operating
expenses at a minimum. See an Authorized Service
Dealer for service aids and accessories.
Operating instructions presented in this manual
assume that the standby electric system has been
installed by an Authorized Service Dealer or other
competent, qualified contractor. Installation of this
equipment is not a “do-it-yourself” project.
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 an Authorized Service Dealer or the
factory about parts and service, always supply the
complete model number of the unit as given on the
front cover of this manual or on the DATA LABEL
affixed to the unit.


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
Standby Generator Sets
Important Safety Instructions
Safety 001 Rev. 0 08/05

IDENTIFICATION RECORD
DATA LABEL
Every generator set has a DATA LABEL that contains
important information pertinent to the generator. The
data label, which can be found attached to the gen-
erator’s lower connection box, lists the unit’s serial
number and its rated voltage, amps, wattage capacity,
phase, frequency, rpm, power factor, etc.
WAUKESHA
,
W
I
RATED KW
RATED V
O
LTA
GE
P
O
WER FA
C
T
OR
EN
G
INE RP
M
ALTERNAT
O
R
SU
BTRAN
S
IENT REA
C
TAN
CE
ALTERNAT
O
R TRAN
S
IENT REA
C
TAN
CE
CLAS
S
MODEL
QT
MADE IN
USA
PR
O
D
UC
TI
O
N DAT
E
GENERAC POWER SYSTEMS
,
INC
.
HERTZ
RATED KVA
G
ENERAT
O
R
S
ET DAT
A
RATED AMP
S
ALT RPM
PHA
SE
S
ERIA
L
ROTO
R
STATO
R
WINDING INSULATION AT 2
5
°
C AMBIEN
T
NOTE:
For actual information related to this particular
model, please refer to the Manual Drawing Listing
located at the end of this manual, or to the data
label affixed to the unit.
Generator Model and Serial Number
This number is the key to numerous engineering and
manufacturing details pertaining to your unit. Always
supply this number when requesting service, order-
ing parts or seeking information.


Identification Code
Use this code to obtain important information about
the generator. For example, if the code is ...
SD 100-- A 1 6 5.0 D 18 HB Y N C
– identify the generator as follows:
• SD – Standby diesel generator (“SG” indicates a standby
gaseous fuel unit).
• 100 – Rated output is 100,000 watts (100 kW).
• A – Voltage code (see “Voltage Codes” on this page).
• 1 – Indicates single-phase unit (3 – indicates three-phase
unit).
• 6 – Indicates unit rated 60 Hertz (Hz) (5 – indicates
50 Hz).
• 5.0 – Engine is 5.0 liter (304 cubic inches).
• D – Unit has diesel fuel system (“N” indicates natural
gas; “L” 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.
• B – Indicates a brushless unit (“D” indicates a direct
excited unit with brushes and slip rings; “P” indicates a
permanent magnet excitation).
• Y – Unit is equipped with a standard enclosure (“N” indi-
cates no enclosure; “S” indicates unit has an acoustic
enclosure).
• N – Unit does not have an exhaust muffler (“Y” indicates
a muffler has been mounted; “L” indicates a muffler has
been shipped loose with the unit).
• Y – Unit has a main line circuit breaker (“C” indicates
unit has a UL-listed circuit breaker; “N” indicates no
circuit breaker has been mounted).
Groups and Assembly Numbers
The Data Label lists the groups and correspond-
ing assembly numbers for each unit. The assembly
numbers refer to exploded view drawing numbers
that are applicable to the specific generator model.
These drawings are located in the back half of this
manual.
Voltage Codes
The identification code letter following the unit’s kilo-
watt rating is the generator’s “voltage code.” Any one
of the following voltage codes may be listed.
A – 120/240 volts, single-phase, four-lead, 60 Hz
D – 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



2-1
Standby Generator Sets
General Information
Identy003 Rev. 0 11/05

EQUIPMENT DESCRIPTION
This equipment is a revolving field, alternating cur-
rent generator set. It is powered by a propane vapor
or natural gas fueled engine operating at 1800 rpm
for 4-pole direct drive unit. The unit comes complete
with a sound attenuated enclosure, internally mount-
ed muffler, control console, mainline circuit breaker,
battery charger, fuel tank set and protective alarms as
explained in the following section.
All AC connections, including the power leads from
the alternator, and control connections to the transfer
switch are avail-able in the main connection box.
The generator incorporates the following generator
features:
• Rotor and Stator insulation is Class H rated as
defined by NEMA MG1-32.6, NEMA MG1-1.66.
• The generator is self ventilated and drip-proof con-
structed.
• The voltage waveform deviation, total harmonic
content of the AC waveform and telephone influ-
ence factor have been evaluated and are acceptable
according to NEMA MG1-32.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 15W-40 engine oil at
the factory. Use a high-quality detergent oil classified
"For Service CC. SD, SE, SF." Detergent oils keep the
engine cleaner and reduce carbon deposits. Use oil
having the following SAE viscosity rating, based on
the ambient temperature range anticipated before the
next oil change:
Any attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
NOTE:
For temperatures below 32° F, it is strongly recom-
mended to use the optional Cold Weather Start Kit
(part number listed in the Specification Section).
The oil grade for temperatures below 32° F is 5W-
30 synthetic oil.
COOLANT RECOMMENDATIONS
Use a mixture of propylene glycol base anti-freeze
and deionized water. Cooling system capacity is
about 8 U.S. quarts (7.6 liters). Use only deionized
water and only propylene anti-freeze. If desired, add
a high quality rust inhibitor to the recommended
coolant mixture. When adding coolant, always add
the recommended 50-50 mixture.
Do not use any chromate base rust inhibitor
with propylene glycol base anti-freeze. Engines
that have been operated with a chromate base
rust inhibitor must be chemically cleaned before
adding propylene glycol base anti-freeze. Using
any high silicate anti-freeze boosters or addi-
tives will also cause overheating. The manu-
facturer also recommends that any soluble oil
inhibitor is NOT used for this equipment.
DANGER
Do not remove the radiator pressure cap while
the engine is hot or serious burns from boiling
liquid or steam could result.
Ethylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.
Temperature Oil Grade (Recommended)
Above 80° F (27° C) SAE 30W or 15W-40
32° to 80° F (0° to 27° C) SAE 20W-20 or 15W-40
Below 32° F (0° C) See Note
3-1
Standby Generator Sets
Equipment Description
Equip004 Rev. 0 11/05

ENGINE PROTECTIVE DEVICES
The standby generator may be required to operate for
long periods of time without an operator on hand to
monitor such engine conditions as coolant tempera-
ture, oil pressure or rpm. For that reason, the engine
has several devices designed to protect it against
potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too
low, the coolant temperature is too high, the coolant
level is too low, or the engine is running too fast.
NOTE:
Engine protective switches and sensors are men-
tioned here for the reader's convenience. Also refer
to the applicable control panel manual for addi-
tional automatic engine shutdown information.
COOLANT TEMPERATURE SENSING
An analog Water Temperature Sender (WTS) is locat-
ed in the engine's cooling system. This sender is con-
nected to the panel and allows the panel to monitor
and display the temperature of the coolant system.
The WTS is a resistive device whose resistance chang-
es based on coolant temperature. The resistance of
the sender results in a voltage being developed across
the sender. As the Coolant temperature increases,
the resistance will decrease, causing the voltage to
decrease. This changing voltage is converted to 4-
20mA signal by a signal conditioner module. The
corresponding 4-20mA signal is read by the control
panel and displayed as the coolant temperature.
The control panel will monitor and display the cool-
ant temperature anytime the DC input to the control
panel is present.
If the temperature exceeds approximately 140° C
(284° F), the engine shutdown will be initiated. The
generator will automatically restart and the display
will reset once the temperature has returned to an
operating level.
LOW COOLANT LEVEL
A Low Coolant Level (LCL) sensor is placed in the
generators coolant system. This sensor allows the
panel to detect a Low Coolant Level condition.
The LCL is a resistive device whose resistance changes
rapidly based on the presence or absence of coolant.
The resistance of the LCL results in a voltage being
developed across the LCL. This voltage changes as
the resistance changes. This changing voltage is con-
verted to 4-20mA signal by a signal conditioner mod-
ule. The corresponding 4-20mA signal is read by the
control panel and displayed as the low coolant level.
If the level of the engine coolant drops below the level
of the low coolant level sensor, the engine shutdown
will be initiated.
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OIL PRESSURE SENSING
An analog Oil Pressure Sender (OPS) is used for
monitoring the engine oil pressure. This sender
allows the control panel to measure and display the
Engine oil pressure.
The OPS is a resistive device, whose resistance
changes based on engine oil pressure. The resistance
of the sender results in a voltage being developed
across the sender. As the oil pressure increases,
the resistance will decrease, causing the voltage to
decrease. This changing voltage is converted to 4-
20mA signal by a signal conditioner module. The
corresponding 4-20mA signal is read by the control
panel and displayed as the oil pressure.
The control panel will monitor and display oil pres-
sure anytime the DC input to the control panel is
present.
Should the oil pressure drop below the 8 psi range,
the engine shutdown is initiated. The unit should not
be restarted until oil is added. Turn the AUTO/OFF/
MANUAL switch to the OFF position, then back to
AUTO to restart.
OVERCRANK SHUTDOWN
When the control panel receives a start signal, it ini-
tiates the programmed starting sequence. The start
sequence consists of the number of crank attempts,
the length of each crank attempt, and the rest time
between each crank attempt. If the engine has not
started by the end of the final crank attempt, an
Overcrank alarm is generated, the control panel will
sound the alarm and display the message "Failed to
start".
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 over speed 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 FUSE
This fuse is located inside of the control panel. It
protects the panel wiring and components from
damaging overload. Always remove this fuse before
commencing work on the generator. The unit will
not start or crank if the fuse is blown. Replace the
fuse with one of the same size, type, and rating. (See
the exploded views and parts lists at the end of this
manual for replacement part number.)
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4-1
Standby Generator Sets
Engine Protective Devices
EngProt002 Rev. B 10/05

FUEL SYSTEM
FUEL REQUIREMENTS
This standby generator is equipped with one of the
following fuel systems:
Natural gas fuel system
Propane vapor (PV) fuel system
PV/NG dual fuel system
The Manual Drawing Listing that is affixed to the
unit includes the "Identification Code", which may be
used to identify the type of fuel system installed on
the unit.
Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at
least 2,520 Btus per cubic foot for LP gas. Ask the
fuel supplier for the Btu content of the fuel.
Required fuel pressure for natural gas and liquid
propane is five inches to 14 inches 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 liquid propane for
all load ranges.
NOTE:
It is the responsibility of the installer to make sure
that only the correct recommended fuel is sup-
plied to the generator fuel system. Thereafter, the
owner/operator must make certain that only the
proper fuel is supplied.
NATURAL GAS FUEL SYSTEM
Natural gas is supplied in its vapor state. In most
cases, the gas distribution company provides piping
from the main gas distribution line to the standby
generator site. The following information applies to
natural gas fuel systems.
Gas pressure in a building is usually regulated by
national, state and local codes.
To reduce gas pressure to a safe level before
the gas enters a building, a primary regulator is
needed. The natural gas supplier may or may not
supply such a regulator.
It is the responsibility of the gas supplier to make
sure sufficient gas pressure is available to operate
the primary regulator.
Gas pressure at the inlet to the fuel shutoff sole-
noid should not exceed approximately 14 inches
water column (0.5 psi). Optimum pressure at the
fuel shutoff solenoid is 11 inches water column
(0.4 psi).
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•
•
•
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•
•
•
•
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:
The natural gas and LPV gas systems are similar.
However, the natural gas system delivers gas at a
pressure of approximately five inches water col-
umn to the carburetor.
When ambient temperatures are low and engine
fuel consumption is high, the vapor withdrawal
system may not function efficiently.
Ambient temperatures around the supply tank
must be high enough to sustain adequate vaporiza-
tion, or the system will not deliver the needed fuel
volume.
In addition to the cooling effects of ambient air, the
vaporization process itself provides an additional
cooling effect.
NOTE:
The door on the fuel tank MUST be properly closed
for generator to operate (Figure 5.1).
Figure 5.1
Fuel Tank Door Properly Closed
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•
•
•
•
5-1
Standby Generator Sets
Fuel Systems
FuelSys004 Rev. A 11/05

NG/PV DUAL FUEL SYSTEM
This system may be set up to run primarily on either
natural gas or propane vapor. When the primary fuel
pressure drops below 4 inches of water, the generator
switches to run on the secondary fuel.
This unit is shipped for operation on both natural
gas, and liquid propane vapor (propane) fuel. The
natural gas low pressure switch is programmed as
an alarm only and will not shut the unit down. The
propane fuel will take over supplying the engine auto-
matically.
If the unit is to be used solely for natural gas usage,
the low pressure switch needs to be programmed
as a shut down function by an Authorized Service
Dealer.
LOW FUEL LEVEL ALARM
This standby generator is equipped with a low fuel
level alarm when propane vapor is used. When the
fuel level in the propane tank gets low, an alarm will
sound to notify operator.
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GAS DETECTOR
Either one or two gas detectors may be equipped on
this unit. They are located on the frame and detect if
there is a fuel leak. If the detector(s) senses a leak,
the unit will shut down.
FLUID SPILL ALARM
This alarm notifies the operator when there is a spill
inside the enclosure, i.e. coolant, oil.
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5-2
Standby Generator Sets
Fuel Systems
FuelSys004 Rev. A 11/05

SPECIFICATIONS
GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ................................................................... Class H
Stator Insulation .................................................................. Class H
Telephone Interference Factor (TIF)..........................................< 50
Alternator Output Leads 1-phase ........................................... 4-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) ............................................. 30kW
Excitation System............................................................. Brushless
Generator Output Voltage/kW - 60 Hz kW Amp CB Size
120/240V, 1-phase, 1.0 pf 30 125 150
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase ....................................................................... 60 kVa
ENGINE
Make................................................................................... Generac
Model...................................................................................... V-type
Cylinders and Arrangement............................................................ 6
Displacement....................................................................... 3.9 Liter
Bore...................................................................................... 3.91 in.
Stroke ................................................................................... 3.31 in.
Compression Ratio...............................................................9.1-to-1
Air Intake System ...............................................Naturally Aspirated
Valve Seats....................................................................... Hardened
Lifter Type .......................................................................... Hydraulic
Engine Parameters
Rated Synchronous RPM..............................................60 Hz, 1800
HP at rated kW..................................................................60 Hz, 62
Exhaust System
Exhaust Flow at Rated Output 60 Hz.................................. 274 cfm
Exhaust Temperature at Rated Output................................ 1250° F
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz ................................................. 105 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ..............................................................± 1%
Steady State Regulation........................................................± 1/2%
Adjustments:
Speed ............................................................................ Selectable
Engine Lubrication System
Type of Oil Pump...................................................................... Gear
Oil Filter .............................................................Full Flow, Cartridge
Crankcase Oil Capacity....................................................4 U.S. qts.
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COOLING SYSTEM
Type .......................................................................................Closed
Water Pump.................................................................... Belt Driven
Fan Speed ................................................................................ 2190
Fan Diameter.....................................................................22 inches
Fan Mode ..............................................................................Pusher
Air Flow (inlet air including alternator and
combustion air)...........................................................2725 ft3/min.
Coolant Capacity ........................................................ (3.0 U.S. gal.)
Heat Rejection to Coolant ..........................................153,000 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 (NG/PV)
Exercise 25% 50% 75% 100%
Cycle Load Load Load Load
93/33 148/59.5 285/115 360/140 420/168
ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 30 Amp
Static Battery Charger..........................................................10 Amp
Recommended Battery................................................ 24F 625CCA
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 ................................................... 182
3% for every 1000 ft. above ft. ................................................. 600
Controller .................................................H-100
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6-1
Standby Generator Sets
Specifications
GenSpec015 Rev. 0 11/05

*
*Ground shield on one end only.
Figure 1 — Interconnections
6-2
Standby Generator Sets
Specifications
IGNITION DESCRIPTION
When this ignition is used on a 3.9L engine, a mag
pick-up sensor and 164 tooth flywheel are used
to determine engine timing. A Hall based CAM/
Distributor sensor establishes the location of fly-
wheel tooth number one. The 3.9L engine uses one
(1) coil driver together with a single-fire coil.
Nominal Engine Timing versus Engine Speed:
RPM LP Timing (BTDC)
1800 rpm 23 degrees
IGNITION POWER-UP INPUT ("56 LINE"
INPUT)
When battery voltage is applied to this input the igni-
tion will power up. For the ignition to power itself
down, battery voltage must be removed from this
input. When flywheel and cam pulses are no longer
detected by the ignition and this input is no longer
connected to plus battery voltage, the ignition will
power itself down.
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FUEL SELECT INPUT
When this input is not connected (i.e. left open) the
ignition will operate in LP Fuel Mode.
IGNITION SHUTDOWN ON LOSS OF FLYWHEEL
OR CAM/DISTRIBUTOR SIGNALS
The ignition will stop firing the coils immediately fol-
lowing the loss of the flywheel signal. The ignition will
stop firing the coils approximately three (3) seconds
following the loss of the cam signal.
3.9L ENGINE SELECT INPUT
If this input is "low" when the ignition initially powers
up, the ignition will be configured for operation with
a 3.9L engine.
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GenSpec015 Rev. 0 11/05

DIAGNOSTIC BLINK PATTERNS (IGNITION RED
LED)
The diagnostic LED is located on the back of the igni-
tion control module, near one of the module mount-
ing bases. It will be necessary to remove the module
from the panel, and turn over, to view the LED.
• Normal Operation: LED flashes at a 0.5 second ON
and a 0.5 second OFF rate.
LED Fault Code with Priority as shown;
• No Crank Signal: LED blinks 2 times, is OFF for
3.0 seconds and then repeats
• No CAM Signal: LED blinks 3 times, is OFF for 3.0
seconds and then repeats
Only one fault is displayed at a time. If multiple faults
exist then the highest priority fault must be resolved
prior to a lower priority fault being displayed.
The diagnostic blink patterns provide flywheel and
CAM sensor diagnostics only during cranking follow-
ing the initial power-up of the ignition. The Generator
must have been in the OFF mode for 60 seconds
prior to cranking for the flywheel and CAM sensor
diagnostics to be valid (i.e. diagnostics are not valid
during a re-crank). The LED fault code blink pattern,
if present, is displayed for 60 seconds and then the
ignition will power itself down.
6-3
Standby Generator Sets
Specifications
Table 1 — Ignition 23 Pin "BLUE" Connector
J1 Pin # Pin Description
1 Coil Driver A
2 Coil Driver C
3 Coil Driver B
4 N/C
5 N/C
6 2.5L Engine Select Return*
7 N/C
8 2.5L Engine Select Input (connect to Pin 6 for 2.5L operation)
9 N/C
10 12V CAM/Distributor Voltage (Hall Sensor)
11 Power-Up Input ("56 Line" is connected to this input)
12 Fuel Select Input ("14 Line" = NG Fuel, Open/Unconnected = LP Fuel)
13 3.9L Engine Select Return
14 Flywheel or Crank Sensor Input
15 3.9L Engine Select Input (connect to Pin 13 for 3.9L operation)
16 12V Battery Input (fused input, 15 Amp, ATO Type)
17 Battery GND
18 Coil + (supply voltage to engine coil pack)
19 Digital Output
20 Flywheel or Crank Sensor Screen
21 Flywheel or Crank Sensor Return
22 Distributor Return
23 Distributor Input
GenSpec015 Rev. 0 11/05

GENERATOR AC LEAD CONNECTIONS
FOUR-LEAD, SINGLE-PHASE STATOR
Four-lead generators (see Figure 7.1) are designed to
supply electrical loads with voltage code “A” (240V,
1-phase, 60 Hz). Electrical power is produced in the
stator power windings. These windings were con-
nected at the factory to the main circuit breaker as
shown in Figure 7.1.
The rated voltage between each circuit breaker ter-
minal is 240V. The rated voltage between each circuit
breaker terminal and the neutral point 00 is 120V.
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7-1
Standby Generator Sets
General Information
ACConn004 Rev. 0 09/05
Figure 7.1 — Four-lead, Single-phase Stator

INSTALLATION
UNPACKING
Handle shipping cartons and crates with care. Use
care to avoid damage from dropping, bumping, colli-
sion, etc. Store and unpack cartons with the proper
side up, as noted on the shipping carton.
Do not lift the fuel storage tank assembly using
upper rails of tank frame. Damage to the fluid
containment pan and/or wiring may result
which will void warranty.
Fuel Storage tank must be lifted from under-
neath the bottom frame rails or through the
lifting points as shown on the INSTALLATION
DRAWING included in the back of this manual.
GENERATOR LOCATION
Install the generator set, in its protective enclosure
outdoors, where adequate cooling and ventilating air
always is available. Consider these factors:
• Install the unit where air inlet and outlet open-
ings will not become obstructed by leaves, grass,
snow, etc. If prevailing winds will cause blowing or
drifting, consider using a windbreak to protect the
unit.
• Install the generator on high ground where water
levels will not rise and endanger it.
• This genset must be installed on a level surface.
The base frame must be level within 1/2 inch all
around.
• Allow sufficient room on all sides of the generator
for maintenance and servicing. This unit must be
installed in accordance with current applicable
NFPA 37 and NFPA 70 standards, as well as any
other federal, state and local codes for minimum
distances from other structures.
• Where strong prevailing winds blow from one
direction, face the generator air inlet openings into
the prevailing winds.
• Install the generator as close as possible to the
transfer switch. This reduces the length of wiring
and conduit.
• Install the generator as close as possible to
the fuel supply, to reduce the length of piping.
HOWEVER, REMEMBER THAT LAWS OR CODES
MAY REGULATE THE DISTANCE.
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GENERATOR SUPPORT
Guidelines that should be followed are:
• When designing a concrete base slab, all federal,
state and local codes should be followed. Special
attention should be given to the concrete base slab
which should exceed the length and width of the
generator by a minimum of six (6) inches (0.152
meters) on all sides.
• The concrete base should be leveled to +/- .25
inches horizontally.
• Retain the generator set to the concrete slab with
masonry bolts.
Combustible Floor and Roof Protection
If the generator must be installed on any combustible
floor or roof, comply with the following rules:
• Place a layer of non-combustible insulation, fol-
lowed by a layer of sheet metal beneath the unit's
mounting base rails.
• Both the layer of insulation and the sheet metal
must extend beyond the generator base to a dis-
tance of at least 12 inches (30.5 cm) on all sides.
Figure 8.1 - Combustible Floor and Roof
Protection
NOTE:
Consult the local building codes, which may vary.
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8-1
Standby Generator Sets
Installation
Install003 Rev. A 06/06

INSTALLATION RULES
This equipment is a liquid-cooled, generator set. The
generator is designed to supply electrical power that
operates critical electrical loads during utility power
failure. The unit has been factory installed in a weath-
er resistant, all metal enclosure and is intenDed for
outdoor installation only.
If this generator is used to power electrical load
circuits normally powered by a utility power
source, it is required by code to install a trans-
fer switch. The transfer switch must effectively
isolate the electric system from the utility distri-
bution system when the generator is operating
(NEC 701). Failure to isolate an electrical system
by such means results in damage to the genera-
tor and may also result in injury or even death
to utility power workers due to backfeed of
electrical energy.
BEFORE INSTALLATION
Before installing this equipment, check the ratings
of both the generator and the transfer switch. Read
"Emergency Isolation Method" and "Total Circuit
Isolation Method" Paragraph.
The generator's rated wattage/amperage capacity
must be adequate to handle all electrical loads that
the unit will power. The critical (essential) loads may
need to be grouped together and wired into a sepa-
rate "emergency" distribution panel.
DANGER
Connecting this generator to an electrical system
normally supplied by an electric utility shall be
by means of a transfer switch, so as to isolate
the electric system from the utility distribution
system when the generator is operating. Failure
to isolate the electric system by these means
will result in damage to the generator and may
also result in injury or death to utility workers
due to backfeed of electrical energy.
If an open bottom is used, the generator is to
be installed over non-combustible materials and
should be located such that combustible materi-
als are not capable of accumulating under the
generator set.
Only qualified, competent installation contractors
or electricians thoroughly familiar with applicable
codes, standards and regulations should install this
standby electric power system. The installation must
comply strictly with all codes, standards and regula-
tions pertaining to the installation.
After the system has been installed, do nothing
that might render the installation in noncomplI-
ance with such codes, standards and regula-
tions.
NFPA STANDARDS
The following published standards booklets pertain-
ing to standby electric systems are available form
the National Fire Protection Association (NFPA).
Batterymarch Park, Quincy, MA 02269:
• NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES.
• NFPA No. 76A, ESSENTIAL ELECTRICAL
SYSTEMS FOR HEALTH CARE FACILITIES.
• NFPA No. 220, STANDARD TYPES OF BUILDING
CONSTRUCTION
• NFPA No. 68, GUIDE FOR EXPLOSION VENTING
• NFPA No. 70, NATIONAL ELECTRICAL CODE.
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE.
• NFPA No. 10, INSTALLATION. MAINTENANCE AND
USE OF PORTABLE FIRE EXTINGUISHERS.
NOTE:
It is essential to use the latest version of any stan-
dard to ensure correct and current information.
OTHER PUBLISHED STANDARDS
In addition to NFPA standards, the following informa-
tion pertaining to the installation and use of standby
electric systems is available:
• Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association. 85 John
Street, New York, N.Y. 10038.
• AGRICULTURAL WIRING HANDBOOK, obtainable
from the Food and Energy Council, 909 University
Avenue, Columbia, MO. 65201.
• ASAE EP-364.2, INSTALLATION AND
MAINTENANCE OF FARM STANDBY ELECTRIC
POWER, available from the American Society
of Agricultural Engineers, 2950 Niles Road, St.
Joseph. MI 49085.
• A52.1, AMERICAN NATIONAL STANDARD
FOR CHIMNEYS, FIREPLACES AND VENTING
SYSTEMS, available from the American National
Standard Institute, 1430 Broadway. New York. N.Y.
10018.
NOTE:
It is essential to use the latest version of any stan-
dard to ensure correct and current information.
The installer must comply with all applicable state
and local codes.
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8-2
Standby Generator Sets
Installation
Install003 Rev. A 06/06

PREPARATION BEFORE START-UP
The instructions in this section assume that the
standby generator has been mechanically properly
installed, serviced, adjusted and otherwise prepared
for use by a competent, qualified installation con-
tractor. Be sure to read the "Safety Rules", as well as
all other safety information in this manual, before
attempting to operate this (and related) equipment.
Before starting the generator for the first time, the
installer must complete the following procedures. For
follow up maintenance information and/or service
intervals, please refer to the "Maintenance" section
and the "Service Schedule".
INITIAL INSPECTION FOR GENERATOR
STARTUP
Inspect for the following.
• Freight Damage.
• Manuals present.
• Fluid Levels ( Oil, coolant, battery).
• Correct fuel piping (if other than provided by
Generac).
• Adequate air flow, clearances and ventilation per
installation drawings and applicable codes.
• Correct AC and DC wire size, connections and
grounding.
• Control and communication wiring to/from the
transfer switch must be run in a separate conduit
from the AC power leads.
• Battery charger connection to 120 VAC.
• Communication wires connected between transfer
switch and generator (HTS only).
• Unit secured to pad.
Transfer Switch
If this generator is used to supply power to any elec-
trical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents elec-
trical backfeed between two different electrical sys-
tems. (For additional information, see the applicable
transfer switch manual for this unit.) The transfer
switch, as well as the generator and other standby
components, must be properly located and mounted
in strict compliance with applicable codes, standards
and regulations.
Fuel System
Make sure the fuel supply system to the generator (a)
delivers the correct fuel at the correct pressure and (b)
is properly purged and leak tested according to code.
No fuel leakage is permitted. See "Specifications" and
"Preparation for Start-up" for more information.
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

Generator Set Lubrication
Check the engine crankcase oil level before operating
and add oil to the proper level, the dipstick "FULL"
mark. Never operate the engine with the oil level
below the dipstick "ADD" mark. See "Specifications"
and "Engine Oil Recommendations".
NOTE:
This engine is shipped from the manufacturer with
"break-in" oil. This oil should be changed after 30
hours of operation.
PRIOR TO INITIAL START-UP
Prior to initially starting the generator, it must
be properly prepared for use. Any attempt to
crank or start the engine before it has been
properly serviced with the recommended types
and quantities of engine fluids (oil, coolant,
fuel, etc.) may result in an engine failure.
ENGINE COOLANT
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
for leaks and other problems. See "Specifications"
and "Coolant" sections.
BELT TENSION
Check the engine fan belt tension and condition prior
to placing the unit into service and at recommended
intervals. Belt tension is correct when a force of
approximately 22 pounds (10 kg), applied midway
between pulleys, deflects the belt about 3/8- to 5/8-
inch (10 to 16 mm).
ELECTRICAL SYSTEM
Make sure the generator is properly connected to an
approved earth ground.
Make sure the generator battery is fully charged prop-
erly. installed and interconnected, and ready for use.
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.
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8-3
Standby Generator Sets
Installation
Install003 Rev. A 06/06

START-UP CHECK LIST
Before working on the generator, ensure the
following:
• The AUTO/OFF/MANUAL switch is in the OFF
position.
• The 120VAC supply to the battery charger is
switched OFF.
• Ensure the UTILITY supply is disconnected from
the transfer switch.
• Remove the fuse from the the control panel. For the
H-100 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. Attatch
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.
• 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 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.
• Reconnect Utility power. Transfer switch will trans-
fer 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 panel.
• 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 FORM
When a start-up is performed by an Authorized
Service Dealer, a standard three form titled "Start-
up Inspection for Standby Power Systems" (part no.
067377), should be completed by the installation
technician or engineer. The installer should complete
the form and disseminate copies as follows:
• White copy: Mail to Generac Warranty Dept, PO.
Box 340. 211 Murphy Dr., Eagle, WI 53119-2062.
• Pink Copy: For service file of installing dealer.
• Yellow Copy: For the customer's records.
ELECTRICAL CONNECTIONS
GROUNDING THE GENERATOR
A GROUNDING LUG is provided on the generator
mounting base for the purpose of grounding the
frame and the external electrically conductive parts
of this equipment to an approved earth ground and/
or grounding rods where required by the National
Electrical Code (Figure 8.2). Consult a qualified
electrician for grounding requirements in the area.
Grounding procedures must meet local regulations.
DANGER
Do not connect the ground wire to any pipe
that carries a flammable or explosive substance
- FIRE or an EXPLOSION may result.
Proper grounding helps protect personnel against
electrical shock in the event of a ground fault condi-
tion in the generator or in connected electrical devic-
es. In addition, grounding helps dissipate static elec-
tricity that often builds up in ungrounded devices.
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8-4
Standby Generator Sets
Installation
Install003 Rev. A 06/06

Figure 8.2 - Generator Grounding Lug (typical)
G
R
OU
NDIN
G
L
UG
BATTERY CHARGER CONNECTION
The generator has been equipped with a 10 Amp
battery charger installed. This charger needs to be
plugged into an appropriate 120VAC 15 amp outlet.
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BATTERY INSTALLATION
DANGER
Standby generators installed with automatic
transfer switches will crank and start automati-
cally when NORMAL (UTILITY) source voltage is
removed or is below an acceptable preset level.
To prevent such automatic start-up and pos-
sible injury to personnel, do not connect battery
cables until certain that; the AUTO/OFF/
MANUAL switch is in the OFF position; the 15A
fuse has been removed from the control box
(see Start-up Check List); normal source voltage
at the transfer switch is correct and the system
is ready to be placed into operation.
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 fluid is spilled, flush the
affected area immediately with clear water.
Do not dispose of the battery in a fire. The bat-
tery is capable of exploding.
Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
and eyes.
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8-5
Standby Generator Sets
Installation
Install003 Rev. A 06/06

8-6
Standby Generator Sets
Installation
TABLE 1 — VAPOR CAPACITY OF PROPANE STORAGE TANKS (FOR REFERENCE)
To Use: Go to the First column and pick the required kW load and then pick the minimum ambient temperature
(40º, 20º or 0º F) that the generator would be operating in. The third column (tank capacity) will give the required
tank size to continually produce the given fuel flow.
Propane storage tanks can provide either a liquid or a vapor supply to the generator. The above chart is for vapor
withdrawal only and provides the kW output or amount of vapor that can be withdrawn at a given temperature
while keeping the temperature of the liquid above the boiling point. If the withdrawal rate is too high, the LP
temperature goes below the boiling point, the pressure drops to zero and no vapor can be withdrawn. A primary
regulator is also required at the tank to reduce the line pressure to the generator to 5-14 inches of water column
for units less than 70kW or 11-14 inches of water column for units 70kW and above.
Propane Conversions: 36.38 ft3= 90,500 btu = 1 gal • 1lb = 21,500 btu = 8.56 ft3
Figure 1.5 — Propane Storage Tank
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Operating
Max kW Minimum Hours @ Tank Capacity Length Dia Overall
Vapor Temp Max kW (Gallons) Inches Inches Ht. Inches
30 40 24
20 20 35 120 57 24 33
10 0 67
35 40 26
25 20 36 150 68 24 33
12 0 72
60 40 26
40 20 38 250 94 30 39
20 0 74
80 40 26
50 20 40 325 119 30 39
25 0 77
100 40 31
60 20 51 500 119 37 46
30 0 100
150 40 35
100 20 53 850 165 41 50
50 0 105
170 40 36
120 20 51 1000 192 41 50
60 0 103
Install003 Rev. A 06/06