Montgomery Ward MX-27129A User manual

HOMESTANDBY
ELECTRIC GENERATING SET
owner's guide
and PARTS LIST
MODEL NO.
MX-27129A
FORMNO.
89M-619B*
DEPT.j
READTHISMANUALCOMPLETELYBEFOREBEGINNINGINSTALLATION

SAFETY PRECAUTIONS
Thefollowingsymbolsinthismanualsignalpoten-
tiallydangerousconditionstotheoperatororequip-
ment.Readthismanualcarefullyandknowwhen
theseconditionsexist.Then,takenecessarystepsto
protectpersonnelaswellasequipment.
uiADuiuni Thissymbolis used through-
WA«mnu|
outthjsmanua|towarn of
possible serious personal injury.
This symbol refersto possible
equipmentdamage.
Listedbelowaresomegeneralprecautionsofpoten-
tialhazardswhichcouldresultinserious,personal
injury.Takecareinfollowingrecommendedproce-
dures.
•UseExtremeCautionNear Gasoline, Gaseous
Fuel and Diesel Fuel. A constantpotentialexplo-
sive or fire hazard exists.
Donotfillfueltanknearunitwithenginerunning.
Donotsmokeoruseopenflameneartheunitor
thefueltank.
Havea fireextinguishernearby.Besureextin-
guisherisproperlymaintainedandbefamiliar
withitsproperuse.ExtinguishersratedABCby
theNFPAareappropriateforallapplications.
Consultthelocalfiredepartmentforthecorrect
typeofextinguisherforvariousapplications.
•GuardAgainst Electric Shock
Disconnectallpowerandremovestartingbattery
cablesbeforeattemptinganymaintenanceor
service.
DONOTTOUCHelectricalequipmentwhileon
damporwell-groundedsurfaces.Userubber
insulativematsplacedondrywoodplatforms
whenworkingaroundelectricalequipment.Do
notweardampclothing(particularlywetshoes)
orallowskinsurfacestobedampwhenhandling
electricalequipment.
Jewelryisagoodelectricalconductorandshould
beremovedwhenworkingonelectricalequip-
ment.
Useextremecautionwhenworkingonelectrical
components.Highvoltagescauseinjuryordeath.
Followallstateandlocalcodesduringinstalla-
tion, operationandservice.Haveallelectrical
installationsandserviceperformedbya qualified
electricianorauthorizedservicerepresentative.
DoNotSmokeWhile Servicing Batteries.
Leadacidbatteriesemita highly-explosive hyd-
rogengaswhichcanbeignitedbyelectricalarc-
ing, anyflame,smoking,etc.
Keep theUnit Clean.
Removealloildepositsfromthecompartment
baseandtheunit.Accumulatedgreaseandoilon
theunitcancauseoverheating(andsubsequent
enginedamage)andmaypresenta potentialfire
hazard. Disposeofoilyrags.
Keepleaves,grassorweedsmowedaroundthe
compartmentarea.Obstructedairinletsoroutlet
cancauseunitoverheatingandincreasethe
potentialhazardofa fire.
Periodicallycheckscreenstoensuretheyare
securelyattachedtoprevententryofsmallanim-
als, debris,andhandsandfeetofchildren.
ProtectAgainst Moving Parts ofUnit
Avoidmovingpartsoftheunit.Donotwearloose
jackets,shirtsorsleevesduetodangerofbecom-
ingcaughtinmovingparts.
Makesureallnutsandboltsontheunitare
secure.Tightenallsupportsandclampsperiod-
ically.
Ifyoumustmakeadjustmentswhiletheunitis
running, useextremecautionwhenclosetohot
manifolds,movingparts,etc.
Donotworkonthisequipmentwhilementallyor
physicallyfatigued.
Keephousinglockedatalltimes.
Guard AgainstCarbon Monoxide
Donotoperateunitnearanopenwindowordoor.
Carbonmonoxidemaycausesicknessordeath.

TABLE OF CONTENTS
TITLEPAGE
Specifications
2
General Information 3
Installation4
Operation10
Periodic Maintenance15
Adjustments 20
Engine Troubleshooting24
Parts Catalog• 25
WARNING
]
TO AVOID POSSIBLE PERSONAL INJURY OR
EQUIPMENT DAMAGE, A QUALIFIED ELECTRI-
CIAN OR AN AUTHORIZED SERVICE
REPRESENTATIVE MUST PERFORM IN-
STALLATION AND ALL SERVICE.

SPECIFICATIONS
Dimensions- MX-27129A
Hejght
30-1/8in.(765mm)
Width.!!'. 33-13/16in.(859mm)
Length!!!!!!!!!!!!!!!!!!!!
48-5/8in-c-24mm)
NumberofCylinders2
Bore3-1/4in.(82.6mm)
Stroke3 in-(76-2mm)
Displacement49.8cuin.(716cucm)
CompressionRatio7.0to1
Compression(sealevel)105to110psi(7.38to7.7.3kg/sqcm)
EnginePower(1800rpm)10.2BHP(7.61Kilowatts)
Lubrication
FullPressureLubricationYes
OilCapacity4 u s- quarts (3-8'•*>
FuelSystem
Carburetor(CombinationGas-Gasoline)Downdraft
ChokeElectric
FuelTankCapacity(whereused)5 U.S.gallons(18.9lit)
Governor(withvacuumbooster)Enclosed,mechanicalflyball
GovernorRegulation5 percent
Ignition12-volt,battery
StartingElectric
BatteryRecommended
SAEGroup6012Volt
360ColdCrankingAmps(74A/Hr)
Generator
BasicDesignRevolvingarmature,4-pole
Rating(inwatts)5000Watts
BatteryChargeRate(FixedTwoStep)2 Amp& 5 Amp
FrequencyRegulation(no load, tofullload)5 percent
TUNE-UP SPECIFICATIONS
BreakerPointGap(fullseparation)0.020in.(0.51mm)
SparkPlugGap
Gasoline0.025in.(0.64mm)
Gaseous0.018in.(0.46mm)
IgnitionTiming19°BTC
CarburetorFloatClearance(betweenfloatbowlgasketandfloat)1/4in.(6.35mm)
ValveTappetClearance(enginecold)
|ntake0.006to0.008in.(0.15to0.20mm)
Exhaust0.015to0.017in.(0.38to0.43mm)
TORQUE SPECIFICATIONS*
CylinderHeadBolts29-31ft-lb(39.4to42.2N«m)
ManifoldScrews: ""take15-20ft-lb(20.4to27.2N»m)
Exhaust14-17ft-lb(19.0to23N»m)
*Torquewhenengineis cold. Becarefulnottostripthreads.

GENERAL INFORMATION
HOME STANDBY GENERATING SET
Thisunitisdesignedforhomestandbyapplications.
Uponreceiptofyourunit,checkitthoroughlyforany
damagethatmayhaveoccurredduringshipping.
Tightenlooseparts,replacemissingparts,andrepair
anydamagebeforeputtingtheunitintooperation.
Identifythemodelofyourunitbyreferringtothe
modelandspecificationnumbershownonthename-
plate. Electricalspecificationsareshownonthe
lowerportionofthenameplate.Thenameplateison
therightcylinderairhousingshroud.
YOUR MANUAL
Thismanualgivesyouoperationandmaintenance
instructionswhichcanhelpyoutokeepyourunit
runninglikenew.Readitcarefully.Remember...any
machine,regardlessofdesignortype,willperform
onlyinrelationtotheservicesitgets.
Throughoutthismanual,engineendisconsidered
frontofthegeneratingset.Leftandrightaredeter-
minedwhilefacingtheengineend.
Whereapplicable,metricequivalentappearsInparentheses fol-
lowingU.S.customaryunit.
EXPLANATION OFTHE MODELNUMBER
Followingisatypicalmodelnumberwithanexplana-
tionofthevariousparts.
5.0MX-27129 3CR / 21929
1. Kilowattratingofthegeneratingset.
2. Identificationofgeneratingsetseries.
3.Voltagecodeofgenerator.Number3 iscodefor
120/240volts,singlephase."C"indicatesthe
generatorcanbeconnectedfor120volts,2 wire;
240volts,2 wire;or120/240volts,3 wire.
4. Indicatestypeofstarting.
R—Remoteelectricstarting,atthegeneratingset
orremotestartingfromremotelocation.
5.Factorycodeforidentifyingoptionalequipment.
6.Specificationletterwhichadvanceswithfactory
productionmodifications..
OPTIONAL ACCESSORY ITEMS
MontgomeryWardcarriestwotypesoftransfer
switchesforusewithyourMX-27129standbygener-
atingset.A manualtransferswitch(orderarticleno.
89-27134)oranautomatictransferswitch(order arti-
cleno.89-27135)areavailabletocompleteyour
homestandbygeneratingsystem.Themanual
transferswitchkitenablestheowner/operatorto
switch, uptofourpossiblecircuits,toemergency
powerduringa utilitypoweroutage.Thetotalcircuit
loadrequirementsmustnotexceedthenameplate
ratingoftheMX-27129emergencypowergenerator
setwhichis5000watts.Themanualtransferswitch
kitisdesignedforindoorwallmountingpreferably
nearthemainpowerdistributionpanel.Theauto-
matictransferswitchisalsodesignedforindoorwall
mountingnearthemainpowerdistributionpanel.
Theautomatictransferswitchwillautomaticallystart
theemergencystandbygeneratorsetandassumethe
load(preselectedbythehomeownerpriortoinstalla-
tion)ofthetransferswitch.Maximumcurrentrating
oftheautomatictransferswitchis30amperes.Both
switchescomewithcompleteinstallationandoperat-
inginstructions.
WARNING Installationofthemanualswitchkitand
optionalcablekitmustbeperformedbya
qualifiedlicensedelectricianandinspectedaccordingtoalllocal
andstateelectricalcodes.

INSTALLATION
A QUALIFIED ELECTRICIAN, ELECTRICAL CONTRACTOR ORAUTHORIZED
SERVICE REPRESENTATIVE SHOULD INSTALL HOME STANDBY GENERAT-
INGSET.
GENERAL
TheMX-27129homestandbygeneratingsetisa
completelyself-containedunit,enclosedina com-
partment.Observesafetyprecautionsandlocalelec-
tricalcodesduringinstallation,operationand
service.
LOCATION
Chooseaninstallationareanearthebuildingandas
closeaspossibletothetransferswitch.Thearea
mustbelevel,dryandaccessibleforservice.Referto
localcodesfordistancefromthebuilding,distance
fromwindows,ordoors,etc.SeeFigure1.
WARNING Donotsit,stand,orplaceladderorother
equipmentonhousing.Housingmaybreak
causingseriousinjury.
CAUTION Replacehousingifcracked.Excessivemois-
ture, dirt,etc.,mayaccumulatewithinhous-
ingcausingdamagetoengine-generator.
WARNING Donotoperateunitnearahopenwindowor
door.Carbonmonoxidemaycausesickness
ordeath.
Shrubs,bushes,treesorgrassmustnotobstructthe
airinletsoroutletonthegeneratingsetcompart-
ment.Figure1 showsa typicalinstallation.
1. Althoughthecompartmentbaseisdesignedto
restdirectlyontheground,youmightpreferto
KEEPTHIS
AREACLEAR
OFSHRUBS
FIGURE1.TYPICALHOMESTANDBYGENERATINGSETINSTALLATION

MlO
M2O
M3 6
M4Q
TRANSFER
SWITCH MlO-
120V
M2
M3O
120V
M4O
r y0
^!
-TRANSFER
SWITCH
120V
120V
1
-LINE
120V
ONLYWHEN
CONNECTED
TOGEN.
L
O
A
D
FIGURE2.LOADCONNECTIONSAVAILABLE
makea baseofconcrete,rock,gravel,etc.,to
preventgrassorweedsfromgrowingaroundthe
compartment.Ifso,makethebaseatleast4
inches(100mm)largerinperimeterthantheunit.
SeetheSPECIFICATIONSsectionforunitdimen-
sions.
2. Unlatchthehousinglatchontherearsideofthe
housingpanel(wood).SeetheOPERATIONsec-
tionforunlatchingandopeninghousing.
3.Slidethehousingforwardandofftheunit.
Slidingthehousingofftheunitismucheasierthantryingto
liftoffthehousing.
4. Withsufficientmanpoweroramechanicallift,set
thegeneratingsetcompartmentonthebaseof
concrete,crushedrock,gravel,etc.
Ifotherthana concretebase,besure4x4inch(102 x
102mm)compartmentredwoodbasepiecesrestsquarelyon
thebasematerial.
5.Removetheshippingblocksundereacnsideof
thegeneratingsetbeforestartingisattempted.
CAUTION Ifshippingblocksarenotremovedbefore
generatingsetoperation,damagecouldoc-
curtotheunitmounts.
LOAD WIRING
Thegeneratingsetnameplatelocatedontheright
cylinderairhousingshroudgivesratedoutputin
watts, volts,phase,kVAandpowerfactor,amperes,
andhertz.GeneratorCode"3C"meansyoucan con-
nectthegeneratorfor120volt,2 wire;or120/240
volts, 3 wire.Figure2 showsthegeneratorload con-
nectionsavailable.
Allloadwiringandelectricalconnectionsmustbeinspectedbya
qualifiedservicemanorelectrician.
Loadconnectionsarelocatedonthesideofthe gen-
eratorbehindthecontrolbox.Removecontrolbox
coverforaccesstoloadconnections.SeeFigure3.
Loadwirescanexitthroughtherearorthefloorofthe
compartment.
Connecteachwiretothecorrectgeneratoroutput
wire. LeadsaremarkedMl,M2,M3,andM4.Each
correspondstomarkedleadsonthewiringdiagram
andthoseshowninFigure 2. Insulatebareendsofthe
wires.
Werecommendusingwatertight,flexibleconduit
betweenthebuildingconnectionandthegenerating
set.Ifrigidconduitisused,a minimumof1 foot
(305mm)flexibleconduitatthegeneratingsetmust
beused.
~FLEXIBLE
/CONDUIT
EXITLOADWIRES
THROUGHHOLES
PROVIDED
CONTROLBOX
FORLOADCONNECTIONS
(REMOVECOVER) ES-1021
FIGURE3.GENERATINGSETLOADCONNECTIONS

Thishomestandbygeneratingsetisinherentlyprotectedby
designagainstdamagetothegenerator,transferswitchandfeeder
conductors(ifproperlysized).Ifa shortcircuitorlargeoverload
occurs,generatoroutputdropstozeroandnodamageresults.
GROUNDING
WARNING Failuretogroundthegeneratingsetcould
resultinseriouselectricalshock.
Connecta #8wireorlarger(followingapplicable
codes)between:
1. A separategroundpipeorrodpenetratinginto
moistearth,and
2. thesolderlessconnectorwhichislocatedontop
ofthegeneratorfortheremotestartmodelsand
onthestart-stopcontrolboxfortheelectricstart
models.
WARNING ^TheNationalElectricalCode(NEC)requires
thatallseparatelyderivedACsystemsbe
groundedperArticle250-26.Manufacturerhasaddeda bonding
jumperperarticle250-26(a)fromthenoncurrentcarryingmetal
partstotheconductortobegrounded.Manufacturerdoesnot
supplytherequiredgroundingconductororgroundingelectrode
becauseitwouldbeimpossibletocovereveryexceptionandall
localcoderequirements.SeeyourlocalcodesandtheNECman-
ualforthepropergroundingforyourapplication.
Asa generalrule,donotuseelectricalequipmentinwetordamp
areas. Forconstructionsites,additionalrulesapplytoportable
alternatorswhenusedonconstructionsites,fromNEC,OSHAand
statecodes.Itistheresponsibilityoftheconsumertomeetthese
requirements.
GASOLINE TANK, HOLDER AND HOOD
Instructionsforinstallationandconnectionsforgaseousfuelare
includedwiththegaseousfuelpackage.
Theremotestartgas-gasolinemodelincludesagaso-
linetankbracketandtankhoodformountingthe
gasolinetankontherearofthecompartment.Usethe
followinginstructions.
1. Facingtherearofthecompartment,removethe
bottom, middlelagboltandwasher.SeeFigure4.
Donotdiscardtheboltorwasher.
2. Mountthegasolinecanbracketwiththeonelag
boltandwasherjustremoved(fromStep1)and
twohexhead5/16-18screws,flatwashers,lock
washerandnutsasshowninFigure4.Holesin
thepanelarealreadydrilledforthetopscrews.
3.Placethegasolinetankinthetankbracketsothe
tankcapisontheleftasyoufacetherearofthe
compartment.
4. Connectthefemaleconnectorontheendofthe
suppliedfuellinetothetankcapmaleconnector.
Pullthefemaleconnectorsleeveback,insertand
TANKHOLDER
5/I6-IN. SCREWS,FLAT
WASHERS.LOCKWASHERS
ANDNUTS.
MIDDLELAGBOLT
ANDWASHEROF
COMPARTMENTREAR
FIGURE4.INSTALLATIONOFGASOLINE
TANKHOLDER
holdoverthemaleconnectorandrelease.See
Figure5.
Besuretoconnectthefemaleconnectoronthefuellinetothe
tankcapbeforeroutingfuellinetofuelpump.Otherwise,you
mightaccidentallyplacetheconnectorontheinsideofthe
compartment.
FEMALECONNECTOR
FORGASOLINELINE
(NOTESLEEVEIS
MALESt.PULLEDBACK)
CONNECTOR
TANKCAP
5.
6.
7.
8.
FIGURE5. CONNECTIONOFFEMALE
CONNECTORTOTANKCAP
Runthelooseendofthefuelline(opposite con-
nectorend)throughthesmallholeontherearof
thecompartment.Figure6 showswhereline
entersinsidecompartment.
Slipthehoseclampoverthelooseendofthefuel
line(nowinsidethecompartment).SeeFigure6.
Connecttheendofthelinetotheunusedconnec-
toronthefuelpump(Figure6).Movetheclamp
neartheendofthefuelline(overfuelpump
connector).
Installthegasolinetankhoodwithfour 1/4-20
screws,flatwashers,lockwashersandnuts.
Mountthehoodsothehingesfacedownandwill

FUELPUMP
TOGENERATORSET
FS-1082
FIGURE6.FUELPUMPCONNECTIONS
becoveredwhenthehoodisdown.SeeFigure7.
Holesarepre-drilledinthepanel.
9.Tolockthegasolinetankshield,pushdownon
theshieldandslidethebarrelboltlock,onthe
insideofthecompartmentpanel,throughthe
holeoftheshieldpartwhichextendsthroughthe
panel. SeeFigure7.
REMOTE START-STOP CONNECTIONS
Theremotestart,homestandbymodelhasprovi-
sionsforremotestartandstopconnections.Locate
theremoteswitchinthehouse,garageorother con-
venientlocationforstartingandstoppingthegener-
atingset.
Forremoteconnectionstoanautomatictransferswitchwhich
automaticallystartsandstopsthegeneratingset,refertoinstruc-
tionsfurnishedwiththeautomatictransferswitch.
Fortheremoteswitch,usea single-pole,double-
throw,momentarycontact,center-offtypeswitch.
Youcanuse#18wirefordistancesupto250feet(76
meters)fromthegeneratingset.Severalremote
switchescanbeusedindifferentlocationsiftheyare
wiredinparallel.
Usea momentary-contact,start-stopswitchonly.Otherwise,the
exhaustblowerusedforthegas/gasolinemodelrunscontinuously
duringtheentireoperationperiod(afterremotestarting).
Remoteconnectionstothegeneratingsetaremade
accordingtoFigure 8. A wiringharnessrunsfromthe
connectorlocatedonthesideofthecontrolboxto
thetimedelaycontrollocatedontherearpanelofthe
housing(Figure13).Customerwiringisfromtime
delaycontroltotheremotemomentarycontact
switch.
1/4-20 SCREWS,FLATWASHERS,
LOCKWASHERSANDNUTS
BARRELBOLTLOCK
(LOCATEDINSIDE
COMPARTMENTPANEL) TANKHOOD
FIGURE7. FUELTANKHOODINSTALLATION
7

CONTROLBOXON
COMPARTMENTPANEL
(REMOVECOVER)
EXITREMOTE
START-STOPWIRES
THROUGHTHISOPENING
REMOTE
OPERATION
CONNECTOR
OCOH TROI— REMOTE
a
MOMENTARY
CONTACTSWITCH
SC-1036
FIGURE8.REMOTECONNECTIONONREMOTESTARTMODEL
BATTERY INSTALLATIONAND
CONNECTIONS
Thebatterycables,batteryhold-downframeand
hardwareareshippedloosewiththegeneratingset.
Battery Cables
Removeandsetthegasolinetankalongtheedgeof
thecompartment(itisnotnecessarytodisconnect
fuelorventlines)foreaseofconnections.
1. Removecontrolboxcover.
2. Inserttheeyeletterminalofthelongbatterycable
(positive+)throughthegrommetonthebottom
ofthecontrol.SeeFigure9.
3.Removetherightnutandwasherfromthestart
solenoid.
4. Connecttheeyeletterminalofthelongbattery
cabletothisterminalandreinstallthenutand
washer.
5.Reinstallthecontrolboxcover.
6.Setandsecurethegasolinetankbackinthe
compartment.
7.Removethethroughboltfromthegenerator
showninFigure10andconnecttheshortbattery
cable(negative-)eyeletterminal.Besure con-
nectioniscleanandtightafterreinstallingthe
throughbolt.
BATTERS
POSITIVE(+)
CABLE
FIGURE9.POSITIVEBATTERYCABLECONNECTION