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oFF�tKCOG Town of Southold 3/7/2020 y� P.O.Box 1179 0 a' 53095 Main Rd Southold,New York 11971 CERTIFICATE OF OCCUPANCY No: 41114 Date: 3/9/2020 THIS CERTIFIES that the building GENERATOR Location of Property: 1705 Meday Ave,Mattituck SCTM#: 473889 Sec/Block/Lot: 113.-9-8.1 Subdivision: Filed Map No. Lot No. conforms substantially to the Application for Building Permit heretofore filed in this office dated 1/24/2020 pursuant to which Building Permit No. 44650 dated 1/31/2020 was issued, and conforms to all of the requirements of the applicable provisions of the law. The occupancy for which this certificate is issued is: "as built" generator as applied for. The certificate is issued to Divello Frances C Rev Trust of the aforesaid building. SUFFOLK COUNTY DEPARTMENT OF HEALTH APPROVAL ELECTRICAL CERTIFICATE NO. 44650 2/12/2020 PLUMBERS CERTIFICATION DATED Authorized Signature TOWN OF SOUTHOLD BUILDING DEPARTMENT y TOWN CLERK'S OFFICE "o • SOUTHOLD, NY BUILDING PERMIT (THIS PERMIT MUST BE KEPT ON THE PREMISES WITH ONE SET OF APPROVED PLANS AND SPECIFICATIONS UNTIL FULL COMPLETION OF THE WORK AUTHORIZED) Permit#: 44650 Date: 1/31/2020 Permission is hereby granted to: Divello Frances C Rev Trust PO BOX 234 Mattituck, NY 11952 To: legalize "as built" generator as applied for. At premises located at: 1705 Meday Ave, Mattituck SCTM # 473889 Sec/Block/Lot# 113.-9-8.1 Pursuant to application dated 1/24/2020 and approved by the Building Inspector. To expire on 8/1/2021. Fees: AS BUILT-ACCESSORY $200.00 ELECTRIC $170.00 CO -RESIDENTIAL $50.00 Total: $420.00 spector Form No.6 TOWN OF SOUTHOLD BUILDING DEPARTMENT TOWN HALL 765-1802 APPLICATION FOR CERTIFICATE OF OCCUPANCY This application must be filled in by typewriter or ink and submitted to the Building Department with the following: A. For new building or new use: 1. Final survey of property with accurate location of all buildings,property lines, streets, and unusual natural or topographic features. 2. Final Approval from Health Dept. of water supply and sewerage-disposal(S-9 form). 3. Approval of electrical installation from Board of Fire Underwriters. 4. Sworn statement from plumber certifying that the solder used in system contains less than 2/10 of I%lead. 5. Commercial building,industrial building,multiple residences and similar buildings and installations,a certificate of Code Compliance from architect or engineer responsible for the building. 6. Submit Planning Board Approval of completed site plan requirements. B. For existing buildings (prior to April 9, 1957) non-conforming uses,or buildings and "pre-existing"land uses: 1. Accurate survey of property showing all property lines, streets,building and unusual natural or topographic features. 2. A properly completed application and consent to inspect signed by the applicant.If a Certificate of Occupancy is denied,the Building Inspector shall state the reasons therefor in writing to the applicant. C. Fees 1. Certificate of Occupancy-New dwelling$50.00,Additions to dwelling$50.00,Alterations to dwelling$50.00, Swimming pool$50.00,Accessory building$50.00,Additions to accessory building$50.00,Businesses$50.00. 2. Certificate of Occupancy on Pre-existing Building- $100.00 3. Copy of Certificate of Occupancy-$.25 4. Updated Certificate of Occupancy- $50.00 5. Temporary Certificate of Occupancy-Residential$15.00, Commercial$15.00 Date. I �� New Construction: /� Old o re-existing Building: (check one) Location of Property: CT House No. Stre t Hamlet Owner or Owners of Property:_ 0. (,LA) Suffolk County Tax Map No 1000, Section J Block Lot Subdivision (( //10 Filed Map. Lot: Permit No. LN 0 Date of Permit. Applicant: Health Dept. Approval: Underwriters Approval: Planning Board Approval: / Request for: Temporary Certificate Final Certificate: L- (check one) Fee Submitted: $ Applicant Signature OF SOUry®l Town Hall Annex ~ ® Telephone(631)765-1802 54375 Main Road Fax(631)765-9502 P.O.Box 1179 G • Q roper.riche rt(aZtown.south old.ny.us Southold,NY 11971-0959 BUILDING DEPARTMENT TOWN OF SOUTHOLD CERTIFICATE OF ELECTRICIAL COMPLIANCE SITE LOCATION Issued To- Divello Address. 1705 Meday Ave City* Mattituck St: New York Zip: 11952 Building Permit#. 44650 Section 113 Block 9 Lot 81 WAS EXAMINED AND FOUND TO BE IN COMPLIANCE WITH THE NATIONAL ELECTRIC CODE Contractor- AS BUILT DBA- REP Electric License No. 46288-ME SITE DETAILS Office Use Only Residential X Indoor X Basement X Service Only Commerical Outdoor X 1st Floor Pool New Renovation 2nd Floor Hot Tub Addition Survey X Attic Garage INVENTORY Service 1 ph Heat Duplec Recpt Ceiling Fixtures HID Fixtures Service 3 ph Hot Water GFCI Recpt Wall Fixtures Smoke Detectors Main Panel A/C Condenser Single Recpt Recessed Fixtures CO Detectors Sub Panel A/C Blower Range Recpt Fluorescent Fixture Pumps Transformer Appliances Dryer Recpt Emergency Fixtures Time Clocks Disconnect Switches Twist Lock Exit Fixtures TVSS Other Equipment- "AS BUILT" "ELECTRICAL SURVEY" "NO VISUAL DEFECTS" Notes 25 KW standby generator,with 200a automatic transfer switch Inspector Signature: 124�LA_!j5� Date: February 12 2020 81-Cert Electrical Compliance Form As TOWN OF SOUTHOLD BUILDING PERMIT APPLICATION CHECKLIST BUILDING DEPARTMENT Do you have or need the following,before applying? TOWN HALL Board of Health SOUTHOLD, NY 11971 4 sets of Building Plans TEL: (631) 765-1802 Planning Board approval FAX: (631) 765-9502 Survey Southoldtownny.gov PERMIT NO. Check Septic Form N.Y.S.D E.C. r Trustees C.O.Application Flood Permit Examined 20 Single&Separate Truss Identification Form Storm-Water Assessment Form �f Contact: Approved 7 20 Mail to: Disapproved a/c Phone: (� I Expiration. - 20 —1�(� ,C)(9 +_ +C.[ Buildi Inspector �S°7loS JAN 2 4 2020 APPLICATION FOR BUILDING PERMIT Date , 202-PD ,': 's : '` ';'" =% INSTRUCTIONS a.This application MUST be completely filled in by typewriter or in ink and submitted to the Building Inspector with 4 sets of plans, accurate plot plan to scale. Fee according to schedule. b. Plot plan showing location of lot and of buildings on premises,relationship to adjoining premises or public streets or areas, and waterways. c. The work covered by this application may not be commenced before issuance of Building Permit. d. Upon approval of this application,the Building Inspector will issue a Building Permit to the applicant. Such a permit shall be kept on the premises available for inspection throughout the work. e.No budding shall be occupied or used in whole or in part for any purpose what so ever until the Building Inspector issues a Certificate of Occupancy. f Every building permit shall expire if the work authorized has not commenced within 12 months after the date of issuance or has not been completed within 18 months from such date. If no zoning amendments or other regulations affecting the property have been enacted in the interim,the Building Inspector may authorize,in writing,the extension of the permit for an addition six months. Thereafter, a new permit shall be required. APPLICATION IS HEREBY MADE to the Building Department for the issuance of a Building Permit pursuant to the Building Zone Ordinance of the Town of Southold, Suffolk County,New York, and other applicable Laws, Ordinances or Regulations,for the construction of buildings, additions, or alterations or for removal or demolition as herein described. The applicant agrees to comply with all applicable laws,ordinances,building code,housing code,and regulations, and to admit authorized inspectors on premises and in building for necessary inspections. a, ����� i.�f:�.wv d��, (Signature of applicant or name,if a corporation) 2o6- 7 Id (Mailing address of applicant) I� --7q( State whether applicant is owner; lessee,/gent, ar itect, engineer, general contractor, electrician, plumber or builder Name of owner of premises J (As on the tax roll or latest deed) If applicant is a corporation, signature of duly authorized officer (Name and title of corporate officer) Builders License No. Plumbers License No. Electricians License No. Other Trade's License No. 1. Location_qY landV icpro2aA— use ed work will be done: Number treet Hamlet County Tax Map No. 1000 Section Block Lot U . Subdivision Filed Map No. Lot 2. State existing use and occupancy of premises and intended use and occupancy of proposed construction: a. Existing use and occupancy b. Intended use and occupancy 3. Nature of work(check which applicable): New Building Addition Alter tion Repair Removal Demolition Other Work 47,61 � (Description) 4. Estimated Cost Fee (To be paid on filing this application) 5. If dwelling, number of dwelling units Number of dwelling units on each floor If garage, number of cars 6. If business, commercial or mixed occupancy, specify nature and extent of each type of use. 7. Dimensions of existing structures, if any: Front Rear Depth Height Number of Stories Dimensions of same structure with alterations or additions: Front Rear Depth Height Number of Stories 8. Dimensions of entire new construction: Front Rear Depth Height Number of Stories 9. Size of lot: Front Rear Depth 10. Date of Purchase Name of Former Owner 11. Zone or use district in which premises are situated 12. Does proposed construction violate any zoning law, ordinance or regulation? YES NO 13. Will lot be re-graded? YES NO Will excess fill be removed from premises?YES NO 14. Names of Owner of premises Address Phone No. Name of Architect Address Phone No Name of Contractor Address Phone No. 15 a. Is this property within 100 feet of a tidal wetland or a freshwater wetland? *Y S NO *,IF YES, SOUTHOLD TOWN TRUSTEES &D.E.C. PERMITS MAY BER UIRED. b. Is this property within 300 feet of a tidal wetland? * YES NO IF YES, D.E.C. PERMITS MAY BE REQUIRED. 16. Provide survey, to scale, with accurate foundation plan and distances to property lines. 17. If elevation at any point on property is at 10 feet or below, must provide topographical data on suivey. 18. Are there any covenants and restrictions with respect to this property? * YES NO * IF YES, PROVIDE A COPY. STATE OF NEW YORK) CONNIE D.BUNCH SS Notary Public,State of New York COUNTY OF ) No.01BU6185050 Qualified in Suffolk County Commission Expires April 14;,iAo-ak,u " being duly sworn, deposes and says that(s)he is the applicant (Name of individual signing contract) above named, (S)He is the (Contractor,Agent, Corporate Officer, etc.) of said owner or owners, and is duly authorized to perform or have pe fl ed'h"aid work and to make and file this application; that all statements contained in this application are true to the best of 's knowledg and belief- and that the work will be performed in the manner set forth in the application filed therewith. Sworn to before me thi \ day ofGl/11A {. 2002 b0ti� '/��kk�h I Notary Public i nature of Applicant �SufFO(Kc BUILDING DEPARTMENT- Electrical Inspector TOWN OF SOUTHOLD Town Hall Annex - 54375 Main Road - PO Box 1179 o - Southold, New York 11971-0959 Telephone (631) 765-1802 - FAX (631) 765-9502 rogerr(c�southoldtownny.gov — seand(c�southoldtownny.gov APPLICATION FOR ELECTRICAL INSPECTION ELECTRICIAN INF RMATION (All Information Required) Date.- Company ate:Company Name: Name: License No.: G`( ,Z��j ,(/t/� email: Address: Phone No.: 7- JOB SITE INFORMATION (All Information Required) Name: Address: d , Cross Street: 7( lk Phone No.: 6'3( - — (� �_3 Bldg.Permit#: LH email: yl, w Tax Map District: 1000 Section: Block: Lot: BRIEF DESCRIPTION OF WORK (Please Print Clearly) Circle All That Apply: Is job ready for inspection?: YES NO Rough In Final Do you need a Temp Certificate?: YES / NO Issued On Temp Information: (All information required) Service Size 1 Ph 3 Ph Size: A # Meters Old Meter# New Service - Fire Reconnect- Flood Reconnect - Service Reconnected - Underground - Overhead # Underground Laterals 1 2 H Frame Pole Work done on Service? Y N Additional Information: c PAYMENT DUE WITH APPLICATION Request for Inspection Form As ti EN-CONSULTANTS mc, V-7-_,. 1319 NORTH SEA RD.3'-O' a� PILE (TYP.) MAPES CREEK SOUTHAMPTON, N,y, 11968 Z 631-283-6360 6' X 20' FLOAT , (WIDTH > 200') i._3. 3' X 18' RAMP :t40. AL ALWi SL � PPROV€DBY 4' X 126' FIXED CATWALK I RD OF TRUSTEfS AL AL AHW TO W OLD AL AL ATE ,,,o LAND LAND ARD EDC 'OF ADJ. STEPS AL AL as AL AL BY � ,L n,o w /SJDS BOUNDARY. EN—CONSULTANTS, INC., tA nm fAARCN 28. 200 BO�00 OF , x nw a TOP OF N ' > Mps 1" = 40' PLATFORM AND STEPS ±68, jE Boy,d of TILSlr COW- Lit ••-�p',Riwein wwa � � i,d •b- �� I7lstarce scaward of Water A-W 6160j, -I06, to--of 6A Notes: 1ti�j 20' 1, Private boat dockage .A -� `d' cs 30' -2'-0'• 2. Patum: ALV4' 3, All timber to be CCA-treated 4. Water depths recorded during low tide \ y�1 C 9:40AM, I'OOPM, 5-12-04> V% 5, Pand float shall be removed seasonally ppOpO5r1p POCK FOP, FFZANC�5 AN12 JOHN b PorOrtitl bn' on of caalk located seaward of ALVd �! to be Supported by?5-pile bents ,5�° PIMA O ON HOWAPP'5 [3MCH 0f 7 Project location- 1705 MMaq Averue W111UCK CEM, MATTITUCK, 5UFFOLK CO,, NY Mathtuck,SC'MAI No. 1000-113-9-8.1 5H��T I OF 2 B/22105, 11/ �7/03, 1/ 29104 2 Sl 3 16 VR PCB s 22 BLUE 1 234 5 5 345575810111213141515 171; 77 LUE 225A N.C. 1 ISI'S 6 29 B BLE LUE 15 II2 B JJ15 1 14 1 b 1 C RID 1 TE 2:5A S15 TO CT11 TOR GOVERNOR 78 SIB ORANGE 1 8 23 9YELLOWOWN B LUE 2IS23 1 T 1 8 F GCU BLAOC W1 �p 5 113 BLUE 15A 5C 17 15A 15 17 AUTO F 5 15A 15E B CK R 225A F1 1 13 1 HM ° 1 � 2 1 11 44 ° 14 4 i 0/40 . 1-PHI SE B E X14 LUE 14 T2 1 S1 C81 E1 TO E2 240. C}YELLOW 22 E1 TO 00 . 7 ] 120V. 11,18 14 14 9 85 O O E2 TO 00 1 se O O EC 22 E1 E2 171 O O 14 8 1 14 4 33� NB r---ALTk78iA1E TRI T 1725LL—&ACK- 1�22 =J3 g 1 1 1 S1 S18 G t S CAP 1 1 B 0 (BLACK)—MV.2, i 3 L ----- --� 1621 R m ro 1i Ate o CB2 4 REO O O O Sl 1 1 1—� OLDER sM�TS� TS2 1 1 0 MOUNTING SGREW C0N n STmmlum com TO DSA as T�(EO pN BRUSH WITH RED LEAD 04- LEDtElB CLOSEST TO BEARING AS- ALTERNATOR STAT13R FL- FAULT LIAR SW2- SET E%ERCI SWITCH ' CAP- CAPACITOR GCU- VER GOPJ R CMM"" RNSFRMR TRI-T , UTILITY SENSING - CBI- CIRCUIT BREAKER HI- HOUR METER TS1- TERMINAL STRIP 20 POS. CB2- FIELD BREAKER NB- NEUTRAL BLOCK TS2- TERMINAL STRIP 2 POS. Cti S AMPS SA- SU EC- ENGINE CONfECTIW -PRE-PACK CIRCUIT BOARD TS3- TERMINAL STRIP 7 POS t' F - FUSE 1PRESSIGN ASSEMBLY YR- V1LTAM REGULATOR .�� 00 SWI-AUTO/OMF/MA UAL SWITCH - GROUP G WTS 85 LOS J W _ za a WLS a� �a 0 0 z 0 I 0 56 CC 0 14 14 FS 0 14 14 13 4 49 + - ISC 0 4 49 a :FA 0 4 12V BATTERY o w 13 13 0 RED +� I I BLACK W 0c �—16 SM J _ p 0 GRD J z H CL Oix w oo LEGEND z o z o CC - CONTROL CONTACTOR o o c�a DCA - DC ALTERNATOR o EH - ENGINE HEATER ~ ACTUATOR FS - FUEL SOLENOID CONNECTOR GRD - GROUND ISC - IGNITION SYSTEM CONTACT LOS - LOW OIL SWITCH F —BLACK SM - STARTER MOTOR WTS - WATER TEMPERATURE SWITCH WLS - WATER LEVEL SWITCH A Ln —WHITE EH 0 —GREEN N_� o NOTE, ENGINE HEATERS ARE NOT AVAILABLE ON HOME STAND-BY UNITS. SCHEMATIC-DIAGRAM REVISION:G-4604-C 1.51,PRE-PAK DATE:1/21/05 DRAWING#:OA7182 -1, i yy' UNITS i'f{* •WITHOUT ` ARE ' • • LOCATIONS• • r,I 91 11 7�� F 1 LISTED 0 '-r STATIONARY k ENGINEFOR ELECTRICAL " UIPMENT ONLY GENERATOR " ASSEMBLY STAND26Y SERVICE ocasSIAM t 1 i �---1 AWIBIEN p277/4810Y ONFIGURED FOR: GE HERTZ PHASE 0 60 1 60 3 0D 60 3 603 0Y 60 3 0D 50 1 " 115/200Y 50 3 100/200D 50 3 231/400 50 1 3 D=DELTA, Y=WYE UNBALANCED LOAD CAPABILITY-25% E tC y , 16a APPRO ED AS NOTED DATE: B.P.# FEE: 13�: NOTIFY BUILDING DE"ARTMENT AT OCCUPANCY OR 765-1802 8 AM TO 4 PM FOP, THE FOLLOWING INSPECFONS: USE IS UNLAWFUL 1. FOUNDATION - TWO REQUIRED FOR POURED CONCFETE WITHOUT CERTIFICATE 2. ROUGH - FRAMING & PLUMBING OF OCCUPANCY 3. INSULATION 4. FINAL - CONSTRUC'ION MUST BE COMPLETE FOR -, O. ALL CONSTRUCTICN SHALL MEET THE REQUIREMENTS OF .,-E CODES OF NEW YORK STATE. NOT RESPONSIBLE FOR DESIGN OR CONSTRUCTION ERRORS. COMPLY WITH ALL CODES OF INSPECTION REQUIRED NEW YORK STATE & TOWN CO AS REQUIRED AND CONDITIONS OF `S6bTH6ORA gcrr_ urn n Tnw��pl ANNING BOARD SOU T$llSTEES i . . JAN 2 8 2020 ARr-11AN f.xf by Generac Power Systems,Inc. Owner's Manual Liquid-cooled, Prepackaged Standby Generators Model Numbers 004721-0, 004722-0, 004723-0, 004724-0, 1 ^l 004725-0, 004725-1, mow - — _ 004725-2, 004725-3, OUARDIA004726-0 M� }� z..-, •= i ZEE �= j .. i 0 Not intended for use in critical life support applications. 0 A CAUTION A ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! This manual should remain with the unit. INTRODUCTION The operator is responsible for proper and safe use Thank you for purchasing this model of the standby of the equipment. The manufacturer strongly recom- generator set product line by Generac Power mends that the operator read this Owner's Manual Systems. and thoroughly understand all instructions before using this equipment. The manufacturer also strong- Every effort was expended to make sure that the ly recommends instructing other users to properly information and instructions in this manual were start and operate the unit. This prepares them if they both accurate and current at the time the manual was need to operate the equipment in an emergency. written. However,the manufacturer reserves the right to change, alter or otherwise improve this product(s) A OPERATION AND MAINTENANCE at any time without prior notice. It is the operator's responsibility to perform all safety ♦ READ THIS MANUAL THOROUGHLY checks, to make sure that all maintenance for safe operation is performed promptly, and to have the If any portion of this manual is not understood, con- equipment checked periodically by an Authorized tact the nearest Authorized Service Dealer for start Service Dealer. Normal maintenance service and ing, operating and servicing procedures. replacement of parts are the responsibility of the Throughout this publication, and on tags and decals owner/operator and, as such, are not considered affixed to the generator, DANGER, WARNING, defects in materials or workmanship within the CAUTION and NOTE blocks are used to alert person- terms of the warranty. Individual operating habits nel to special instructions about a particular service and usage contribute to the need for maintenance or operation that may be hazardous if performed service. incorrectly or carelessly. Observe them carefully. Proper maintenance and care of the generator ensures Their definitions are as follows: a minimum number of problems and keeps operat- ing perating expenses at a minimum. See an Authorized A ' A Service Dealer for service aids and accessories. After this heading, read instructions that, if not Operating instructions presented in this manual strictly complied with,will result in serious person- assume that the standby electric system has been al injury, including death, or property damage. installed by an Authorized Service Dealer or other competent, qualified contractor. Installation of this A WARNING A equipment is not a"do-it-yourself" project. After this heading, read instructions that, if not HOW TO OBTAIN SERVICE strictly complied with,may result in personal injury or property damage. When the generator requires servicing or repairs, CAUTION A contact an Authorized Service Dealer for assistance. Service technicians are factory-trained and are capa- After this heading, read instructions that, if not ble of handling all service needs. strictly complied with,could result in damage to When contacting an Authorized Service Dealer about equipment and/or property. parts and service, always supply the complete model NOTE: number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit. 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- AUTHORIZED SERVICE ance with the special instructions while performing the service are essential to preventing accidents. DEALER LOCATION Four commonly used safety symbols accompany the To locate the nearest AUTHORIZED DEALER, DANGER, WARNING and CAUTION blocks. The type please call this number: of information each indicates is as follows: 0 This symbol points out important safety informa- 1-800-333-1322 tion that,if not followed,could endanger personal OR safety and/or property of others. Locate us on the web at: A This symbol points out potential explosion hazard. www.generac.com ®This symbol points out potential fire hazard. Q This symbol points out potential electrical shock hazard. Table of Contents F TABLE Liquid-cooled 15 kW,20 kW and 25 kW Generators OF CONTENTS INTRODUCTION ................................. IFC Section 3 - OPERATION....................12 Read this Manual Thoroughly............................IFC 3.1 Using a Standard"GTS"Transfer Switch ...12 Operation and Maintenance...............................IFC 3.2 Control Console Components......................13 How to Obtain Service........................................IFC 3.3 Manual Transfer and Startup......................13 SAFETY RULES......................................2 3.4 Automatic Operation...................................13 3.5 Weekly Exercise Cycle.................................13 Section 1 - GENERAL 3.6 Engine Heater..............................................14 INFORMATION..................4 Section 4 - MAINTENANCE...............14 1.1 Generator......................................................4 4.1 Maintenance Performed by Authorized 1.2 Transfer Switch.............................................4 Service Facilities..........................................14 1.3 Automatic System Operation.........................4 4.2 Cooling System...........................................15 1.4 Generator AC Connection Systems................4 4.3 Overload Protection for Engine DC 1.5 Main Circuit Breaker.....................................4 Electrical System.........................................15 1.6 Generator Fuel System..................................4 4.4 Checking Fluid Levels.................................15 1.7 Engine Protective Devices..............................5 4.5 Maintenance Owner/Operator 1.8 Unpacking 6 Can Perform................................................16 1.9 Lifting the Generator.....................................6 4.6 Miscellaneous Maintenance.........................17 1.10 Specifications 7 4.7 Scheduled Maintenance...............................19 1.11 Fuel Consumption.........................................7 Section 5 - TROUBLESHOOTING .....22 1.12 Reconfiguring the Fuel System......................7 5.1 Troubleshooting Points ...............................22 1.13 Torque Specifications....................................8 Section 6 - NOTES............................23 1.14 Engine Oil Recommendations.......................8 1.15 Coolant Recommendations............................8 Section 7 - INSTALLATION DIAGRAM.......................25 1.16 Before Installation.........................................8 Section 2 - INSTALLATION.................8 Section 8 - ELECTRICAL DATA........26 2.1 StandbyGenerator Installation 8 Section 9 - EXPLODED VIEWS AND PARTS LISTS .................30 2.2 Generator Location.......................................9 2.3 Generator Mounting and Support.................9 Section 10 - WARRANTY ..................48 2.4 Basic Standby Electric System......................9 2.5 Emergency Circuit Isolation Method...........10 2.6 Total Circuit Isolation Method.....................10 2.7 Grounding the Generator............................10 2.8 Generator AC Neutral Connections.............10 2.9 Transfer Switch Start Signal Connections...10 2.10 Battery Installation......................................11 2.11 Preparation Before Start-Up........................11 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS I Liquid-cooled 15 kW,20 kW and 25 kW Generators QSAVE THESE INSTRUCTIONS-The manufacturer suggests that these rules for safe operation Q 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. QSAVE THESE INSTRUCTIONS -This manual contains important instructions that should be Q followed during installation and maintenance of the generator and batteries. WARNING: 0 0 GENERAL HAZARDS The engine exhaust from this product For safety reasons, the manufacuter recommends contains chemicals known to the state that this equipment be installed, serviced and of California to cause cancer,birth repaired by an Authorized Service Dealer or other defects or other reproductive harm. competent, qualified electrician or installation tech- nician who is familiar with applicable codes, stan- dards and regulations. The operator also must QA ' 0 comply with all such codes, standards and regula- This product contains or emits chemicals tions. known to the state of California to cause •Installation, operation, servicing and repair of this cancer,birth defects or other reproductive harm. (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 Study these SAFETY RULES carefully before install- the Occupational Safety and Health Administration ing, operating or servicing this equipment. Become (OSHA) has established. Also, ensure that the familiar with this Owner's Manual and with the unit. generator is installed, operated and serviced in The generator can operate safely, efficiently and reli- accordance with the manufacturer's instructions ably only if it is properly installed, operated and and recommendations. Following installation, do maintained. Many accidents are caused by failing to nothing that might render the unit unsafe or in follow simple and fundamental rules or precautions. noncompliance with the aforementioned codes, The manufacturer cannot anticipate every possible standards, laws and regulations. circumstance that might involve a hazard. The Varn- The engine exhaust fumes contain carbon monox- ings in this manual, and on tags and decals affixed to ide gas, which can be DEADLY. This dangerous the unit are, therefore, not all inclusive. If using a gas, if breathed in sufficient concentrations, can procedure, work method or operating technique that cause unconsciousness or even death. For that rea- the manufacturer does not specifically recommend, son, adequate ventilation must be provided. ensure that it is safe for all personnel.Also make sure Exhaust gases must be piped safely away from any the procedure, work method or operating technique building or enclosure that houses the generator to utilized does not render the generator unsafe. an area where people, animals, etc., will not be harmed. This exhaust system must be installed A A properly, in strict compliance with applicable codes and standards. Q Despite the safe design of this generator, Keep hands, feet, clothing, etc., away from drive operating this equipment imprudently, neglect- belts, fans, and other moving or hot parts. Never ing its maintenance or being careless can cause remove any drive belt or fan guard while the unit is possible injury or death. Permit only responsible operating. and capable persons to install, operate or main- Adequate, unobstructed flow of cooling and venti- tain this equipment. lating air is critical in any room or building hous- ing the generator to prevent buildup of explosive ® Potentially lethal voltages are generated by gases and to ensure correct generator operation. these machines. Ensure all steps are taken to Do not alter the installation or permit even partial render the machine safe before attempting to blockage of ventilation provisions, as this can seri- work on the generator. ously affect safe operation of the generator. Q Parts of the generator are rotating and/or hot • Keep the area around the generator clean and during operation. Exercise care near running uncluttered. Remove any materials that could generators. become hazardous. • When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued. 2 IMPORTANT SAFETY INSTRUCTIONS SAFETY RULES Liquid-cooled 15 kW,20 kW and 25 kW Generators I • Inspect the generator regularly, and promptly Generators installed with an automatic transfer repair or replace all worn, damaged or defective switch will crank and start automatically when parts using only factory-approved parts. normal (UTILITY) source voltage is removed or is • Before performing any maintenance on the genera- below an acceptable preset level. To prevent such tor, disconnect its battery cables to prevent acci- automatic start-up and possible injury to person- dental start-up. Disconnect the cable from the bat nel, disable the generator's automatic start circuit tery post indicated by a NEGATIVE, NEG or (-) (battery cables, etc.) before working on or around first. Reconnect that cable last. the unit. Then, place a"Do Not Operate"tag on the • Never use the generator or any of its parts as a generator control panel and on the transfer step. Stepping on the unit can stress and break switch. parts, and may result in dangerous operating con- In case of accident caused by electric shock, imme- ditions from leaking exhaust gases,fuel leakage, oil diately shut down the source of electrical power. If leakage, etc. this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT Q ELECTRICAL HAZARDS 0 WITH THE VICTIM. Use a nonconducting imple- ment, such as a dry rope or board, to free the vic- • All generators covered by this manual produce dan- tim from the live conductor. If the victim is uncon- gerous electrical voltages and can cause fatal elec- scious, apply first aid and get immediate medical trical shock. Utility power delivers extremely high help. and dangerous voltages to the transfer switch, as Never wear jewelry when working on this equip- does the standby generator.Avoid contact with bare ment. Jewelry can conduct electricity resulting in wires,terminals,connections,etc.,on the generator electric shock,or may get caught in moving compo- as well as the transfer switch, if applicable. Ensure nents causing injury. 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 ® FIRE HAZARDS insulated, dry surface to reduce shock hazard. Keep a fire extinguisher near the generator at all • Do not handle any kind of electrical device while times. Do NOT use any carbon tetra-chloride type standing in water,while barefoot,or while hands or extinguisher. Its fumes are toxic, and the liquid can feet are wet. DANGEROUS ELECTRICAL SHOCK deteriorate wiring insulation.Keep the extinguisher MAY RESULT. properly charged and be familiar with its use. If • If people must stand on metal or concrete while there are any questions pertaining to fire extin- installing, operating, servicing, adjusting or repair- guishers, consult the local fire department. ing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats. ® EXPLOSION HAZARDS • The National Electrical Code (NEC), Article 250 requires the frame and external electrically con- • Properly ventilate any room or building housing the ductive parts of the generator to be connected to an generator to prevent build-up of explosive gas. approved earth ground and/or grounding rods. • Do not smoke around the generator. Wipe up any This grounding will help prevent dangerous electri- fuel or oil spills immediately. Ensure that no com- cal shock that might be caused by a ground fault bustible materials are left in the generator com- condition in the generator set or by static electric- partment, or on or near the generator, as FIRE or ity. Never disconnect the ground wire. EXPLOSION may result. Keep the area surround- • Wire gauge sizes of electrical wiring, cables and ing the generator clean and free from debris. cord sets must be adequate to handle the maxi- These generator sets may operate using one of sev- mum electrical current (ampacity) to which they eral types of fuels. All fuel types are potentially will be subjected. FLAMMABLE and/or EXPLOSIVE and should be • Before installing or servicmi this (and related) equipment, make sure that all power voltage sup- handled with care. Comply with all laws regulating plies are positively turned off at their source. the storage and handling of fuels. Inspect the unit's Failure to do so will result in hazardous and pos- fuel system frequently and correct any leaks imme- sibly fatal electrical shock. diately.Fuel supply lines must be properly installed, • Connecting this unit to an electrical system nor- purged and leak tested according to applicable mally supplied by an electric utility shall be by fuel-gas codes before placing this equipment into means of a transfer switch so as to isolate the gen- service. erator electric system from the electric utility dis- Diesel fuels are highly FLAMMABLE. Gaseous flu- tribution system when the generator is operating. ids such as natural gas and liquid propane(LP)gas Failure to isolate the two electric system power are extremely EXPLOSIVE. Natural gas is lighter sources from each other by such means,will result than air, and LP gas is heavier than air; install leak in damage to the generator and may also result in detectors accordingly. injury or death to utility power workers due to backfeed of electrical energy. 3 Section 1 - General Information GENERAL INFORMATION Liquid-cooled 15 kW,20 kW and 25 kW Generators 1.1 GENERATOR 1.3 AUTOMATIC SYSTEM OPERATION This equipment is a liquid-cooled, engine-driven gen- When this generator,along with its transfer switch,has erator set. The generator is designed to supply elec- been installed and interconnected, a circuit board in trical power that operates critical electrical loads the generator panel constantly monitors utility power during utility power failure. The unit has been facto- source voltage. Should that voltage drop below a pre- ry-installed in a weather resistant,all metal enclosure set value, and remain at such a low state for a preset and is intended for outdoor installation only. Use this amount of time,the generator cranks and starts.After generator as a source of electrical power for the the generator starts, the transfer switch transfers load operation of 120 and/or 240 volts, single phase circuits so the generator can power them. loads. When utility source voltage has been restored, the These models are available.They are rated as follows: switch re-transfers back to the utility source voltage Models 0047210 and 0047220: Provides 15,000 and the generator then shuts down. watts (15 kW) of single phase power. Please reference the transfer switch manual for spe- Models 0047230 and 0047240: Provides 20,000 cific information. watts (20 kW) of single phase power. 1.4 GENERATOR AC CONNECTION Models 0047250, 0047251, 0047252, 0047253, and 0047260: Provides 25,000 watts (25 kW) of SYSTEMS single phase power. The generator was shipped from the factory with its stator AC output leads connected in a single-phase, AmWARNING A three-wire generator AC connection system (Figure 1.1).The stator assembly in this system consists of a Al!this generator is used to power electrical load pair of stationary windings, with two leads brought circuits normally powered by a utility power out of each winding. Each single winding can supply source, it is required by code to install a transfer 120 volts AC, 60 Hertz. When the two windings are switch.The transfer switch must effectively iso- connected in series, a 240 volts, 60 Hertz AC output late the electric system from the utility distribu- results.Typically the two"hot'leads in the circuit are tion system when the generator is operating Wires No. 11 and 44. The "Neutral" leads are the (NEC 701). Failure to isolate an electrical system junction of Wires 22 and 33. by such means results in damage to the genera- tor and may also result in injury or even death Figure 1.1 - Generator AC Connection System to utility power workers due to backfeed of electrical energy. , ---- BLACK T3 1.2 TRANSFER SWITCH This generator system may include a matched auto- ; V0LTS matic transfer switch which is intended to be used in 22240 conjunction with the Guardian generator. It is sup- WHITE voLTs plied in either a NEMA 1 enclosure (15 kW model ' 004721, 20 kW models 004723) or a NEMA 3R tsu s enclosure (25 kW models 004725). The NEMA 1 enclosure is intended for indoor use only. The NEMA ® � _R� voLT 3R enclosure is weather proof and can be used Ti240 VOLTS indoors or outdoors. Follow these rules: ciRcurr13REAKER • Install the transfer switch on a firm, sturdy sup- porting structure. 1•5 MAIN CIRCUIT BREAKER • To prevent switch distortion,level the switch if nec- essary. This can be done by placing washers The generator's main circuit breaker is included with between the switch enclosure and the mounting the unit as shipped from the factory. The breaker for surface. each unit is described in Figure 1.2. • Never install the switch where water or any corro- sive substance might drip onto the enclosure. 1.6 GENERATOR FUEL SYSTEM • Protect the switch at all times against excessive The generator has been factory tested and adjusted moisture,dust, dirt,lint,construction grit and cor- using a natural gas fuel system. If propane (LP rosive vapors. requirements)gas is preferred,contact an authorized • Failure to utilize a Generac/Guardian transfer service dealer. Refer to "Reconfiguring the Fuel switch with this generator will void the warranty. System. 4 Section 1 - General Information GENERAL Liquid-cooled 15 kW,20 kW and 25 kW Generators INFORMATION Figure 1.2 - Main Circuit Breaker Model Rating Phase Actual Current C/B Rating* %over rating Circuit Breaker 004721/004722 15,000 1 62.5 70 112% 70A BQ2 004723/004724 20,000 1 83.3 90 108% 90A BQ2 004725/004726 25,000 1 104.2 125 120% 125A BQ2 *Amp Rating of CB structured under model. Recommended fuels should have a Btu content of at I 1,7,} LOW OIL PRESSURE SWITCH least 1,000 Btus per cubic foot for natural gas and at least 2,520 Btus per cubic foot for LP gas. Ask the This switch is normally-closed (N.C.), but is held fuel supplier for the Btu content of the fuel being open by engine oil pressure during engine running. used. Should operating oil pressure drop below about 8-10 psi (55-68 kPa), the switch contacts close and the Fuel pressure for a natural gas set up should be five engine shuts down automatically(Figure 1.4). inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges. Figure 1.4 -Low Oil Pressure Switch Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.4 to 0.5 psi) at all load ranges. NOTE: A seperate gas line and regulator may be needed to assure proper gas pressure to the generator. Improper gas pressure can cause hard starting and affect engine durability. A WARNING A • 0 Gaseous fuels such as natural and LP(propane) gas are highly explosive. Even the slightest * 1,7.2 HIGH COOLANT TEMPERATURE SWITCH spark can ignite such fuels and cause an explo- sion. No leakage of fuel is permitted. Natural This normally open (N.O.), thermostatic switch has gas,which is lighter than air,tends to collect in sensing tip which is immersed in captive coolant. high areas. LP gas is heavier than air and tends Should coolant temperature exceed about 230°F to settle in low areas. (110°C), the switch contacts close, which causes the engine to shut down automatically(Figure 1.5). 1.7 ENGINE PROTECTIVE DEVICES The engine has several safety switches which cause Figure 1.5- High Coolant Temperature Switch the engine to automatically shut down under the fol- lowing conditions: low oil pressure, high coolant temperature, engine overspeed, low coolant level or overcrank (Figure 1.3). Figure 1.3 - Engine Protective Devices WGH= W WWWOLM 7EMPOMM LMSWM SW= WWOIL PHESSM 6WIICN O ♦ 1.7.3 LOW COOLANT LEVEL SWITCH Should engine coolant level drop below the level of the high coolant temperature switch,it is possible for _ the engine to overheat without automatic shutdown. To prevent such overheating without automatic shut down,the engine has a low coolant level sensor. If the engine coolant drops too low, the engine automati- cally shuts down (Figure 1.6). 5 Section 1 —General Information GENERAL INFORMATION Liquid-cooled 15 kW,20 kW and 25 kW Generators Figure 1.6- Low Coolant Level Sensor LED 2 is YELLOW.This LED is on when the circuit board battery charger is on. This LED will cycle on and off with the battery charger, 4.85 hours on the 4.85 hours off. ® LED 3 is GREEN. This LED will flash when the circuit board has load voltage available to it. This LED will function when voltage is available across T1 and T2. 1 1.7.6 OVERCRANK SHUTDOWN 0 After 90 seconds of crank-rest cycles, this function ends cranking if the engine fails to start in that 90-second span. ♦ 1.7.4 OVERSPEED SHUTDOWN 1 1.7.6 OC FUSE The Pre-pack circuit board on liquid cooled units This clearly labeled fuse is located on the front panel receives AC frequency(rpm) signals directly from the of the control system. It protects the panel wiring and stator AC power windings, via sensing leads S15 and components from damaging overload.Always remove S16. Should AC frequency exceed about 72 Hz, cir- this fuse before commencing work on the genera- cuit board action will automatically shutdown the tor. The unit will not start or crank if the fuse is engine (Figure 1.7). blown. Replace the fuse with one of the same size, *Rated power of generator is subject to and limit- type, and rating. The manufacturer normally uses an ed by such factors as ambient temperature, alti- AGC fuse rated at 15 amps (part number 022676). tude, engine condition, and other factors. Engine power will decrease about 3.5%for each 1000 feet 1.8 U N PACKI N G above sea level and will decrease an additional 1% for each 107 above 60°F. Maximum output power ♦ 1.8.1 UNPACKING PRECAUTIONS of the generator is limited by maximum engine Handle shipping cartons and crates with care. Use power. care to avoid damage from dropping, bumping, colli- sion, etc. Store and unpack cartons with the proper Figure 1.7- Control Module Assembly side up, as noted on the shipping carton. Circuit Board 1 1.8.2 INSPECTION aI a n s a „,pREACYAGED STMN After unpacking, carefully inspect the generator for any damage that may have occurred during ship- 0 ment. If loss or damage is noted at the time of deliv- ery,have the person(s) making delivery note all dam- „ e ,,, •e a.a. age on the freight bill or affix their signature under o� the consignor's memo of loss or damage. �Se � P � �51�5��5�55��1T III�S� 0 (/� ���'' 1.9 LIFTING THE GENERATOR 0 YEMA-CU o � � �o� '° A WARNING A YW205YM M S.A Q When lifting or hoisting equipment is used, be careful not to touch overhead power lines.The generators weight of more than 900 pounds 1 1.7.5 PCB OPERATION LED'S requires proper tools,equipment, and qualified • LED 1 is RED. The LED is on when utility sensing personnel to be used in all phases of handling is NOT available to the circuit board.This LED will and unpacking. function only when the Auto/Off/Manual switch is set in the Auto position. s Section 1 — General Information Liquid-cooled IS kW,20 kW and 25 kW Generators INFORMA710N 1.10 SPECIFICATIONS NOTE: Fuel consumption is given at rated maximum con- - ♦ 1.10.1 GENERATOR SPECIFICATIONS tinuous power output when using natural gas rated at 1000 Btu per cubic foot and LP gas rated Single-Phase 2520 Btu per cubic foot. Actual fuel consumption Model 004725 004723 004721 obtained may vary depending on such variables as 004726 004724 004722 applied load, ambient temperature, engine condi- tions and other environmental factors. Rated Max. Cont.AC Power output(kW) 25 20 15 Fuel pressure for a natural gas set up should be five Rated voltage (volts) 120/240 inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges. No. of Rotor Poles 2 4 Fuel pressure for an LP vapor set up should be 11 Driven Speed of Rotor 3600 F3600 1800 inches to 14 inches of water column (0.4 to 0.5 Rotor Excitation Direct excited brush type psi) at all load ranges. System Type of Stator 4 Wire 1.12 RECONFIGURING THE FUEL Rotor/Stator Insulation Class F SYSTEM ♦ 1.10.2 ENGINE SPECIFICATIONS NOTE: Make..............................................................................Mitsubishi All models are configured for natural gas from the Displacement..............................................92 inches3(1.5 liters) factory. Cylinder Arrangement 4, in-line To reconfigure the fuel system from NG to LP, follow Valve Arrangement...............................................Overhead Cam these steps: Firing Order.......................................................................1-3-4-2 1. Turn the main gas supply off. Number of Main Bearings...........................................................5 2. Remove the carburetor fuel hose from the outlet Compression Ratio..............................................................9 to 1 port (Port 1) of the demand regulator (Figure No.of Teeth on Flywheel.........................................................104 1.8). Ignition Timing 3. Remove the brass hose fitting from the outlet port at 1800 rpm...................................................35 degrees BTDC (Port 1) of the demand regulator. at 3600 rpm...................................................43 degrees BTDC 4. Remove pipe plug from Port 2. Spark Plug Ga 0.020-0.025 inch 5. Install brass hose fitting into Port 2. Recommended Spark Plugs 6. Install pipe plug into Port 1. Champion RN11YC4 7. Connect carburetor gas hose to brass fitting. p' ................................................................... Oil Pressure....................................................................30-50 psi 8. Tighten all clamps and plugs. Crankcase Oil Capacity""""""""""""3.0 U.S.quarts(2.8 liters) 9. Make sure fuel supply is of the proper pressure and type for configuration. Recommended Engine Oil.......................................SAE 15W-40 10.Reverse the procedure to convert back to natural Type of Cooling System.................Pressurized,closed recovery g Cooling Fan...............................................................Pusher Type Cooling System Capacity......................2 U.S.gallons(7.6 liters) Figure 7.8—Reconfigure the Fuel System Recommended Coolant............................Use a 50-50 mixture of Port, Porte ethylene glycol base. -- MFLHOSE 1.11 FUEL CONSUMPTION FLUO SMSS HOSE SHASS HOS PLUG Ffl'TINO F1Ti1NO OU O R PORfi POfR2 25 kW Models 0 HOUSING Poems OHCH LG G Using Natural Gas........................................441 cu.ft.per hour o 0 0 0 OD Using LP Gas.............................175 cubic ft.(4.8 gal.) per hour 20 kW Models o 0 0 0 o Using Natural Gas........................................359 cu.ft.per hour a 0 0 0 0 Using LP Gas............................143 cubic ft.(4.0 gal.)per hour 15 kW Models o 0 0 0 Using Natural Gas........................................277 cu.ft.per hour NG FUEL SYSTEM LP FUEL SYSTEM Using LP Gas.............................110 cubic ft.(3.1 gal.)per hour 7 INSTALLATION Section 2 — Installation Liquid-cooled 15 kW,20 kW and 25 kW Generators NOTE: 1.16 BEFORE INSTALLATION Port 1 is for NG only and Port 2 is for LP vapor Before installing this equipment, check the ratings of only. No provision for simultaneous fuels has been both the generator and the transfer switch. Read the made. "Emergency Isolation Method" and "Total Circuit AA Isolation Method" sections. The generator's rated wattage/amperage capacity 0 Serious injury or damage may occur if not config- must be adequate to handle all electrical loads that ured properly. Please consult an Authorized the unit will power. The critical (essential) loads may Service Dealer with any questions. need to be grouped together and wired into a sepa- rate "emergency" distribution panel. 1.13 TORQUE SPECIFICATIONS This generator can be installed in conjunction with a Cylinder Head.............................................15(+90°+90°)ft.lb. standard "GTS" type transfer switch, if desired. Intake Manifold................................................................13 ft.lb. The standard transfer switch has no sensing or con- Exhaust Manifold.............................................................13 ft.lb. trolling circuit boards. Instead, the generator control console houses a "Printed Circuit Board Assembly", 1.14 ENGINE OIL RECOMMENDATIONS which controls all phases of operation, including The unit has been filled with 15W-40 engine oil at the engine start up and load transfer. factory. Use a high-quality detergent oil classified"For Service CC,SD,SE,SF."Detergent oils keep the engine 2.1 STANDBY GENERATOR cleaner and reduce carbon deposits.Use oil having the following SAE viscosity rating, based on the ambient INSTALLATION temperature range anticipated before the next oil change: A ' A Temperature Oil Grade(Recommended) Q Connecting this generator to an electrical system Above 80°F(27°C) SAE 30W or 15W-40 normally supplied by an electric utility shall be 32°to 80°F(-1°to 27°C) SAE 20W-20 or 15W-40 by means of a transfer switch, so as to isolate the electric system from the utility distribution Below 32°F(0°C) SAE 10W or 15W-40 system when the generator is operating. Failure to isolate the electric system by these means will ACAUTION A result in damage to the generator and may also result in injury or death to utility workers due to 0 Any attempt to crank or start the engine before it backfeed of electrical energy. has been properly serviced with the recommend- A If an open bottom is used,the engine-generator ed oil may result in an engine failure. is to be installed over non-combustible materials 1.15 COOLANT RECOMMENDATIONS and should be located such that combustible materials are not capable of accumulating under Use a mixture of half low silicate ethylene glycol base the generator set. anti-freeze and deionized water. Cooling system Only qualified, competent installation contractors or capacity is about 8 U.S. quarts (7.6 liters). Use only electricians thoroughly familiar with applicable codes, deionized water and only low silicate anti-freeze. If standards and regulations should install this standby desired, add a high quality rust inhibitor to the rec- electric power system. The installation must comply ommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture. strictly with all codes, standards and regulations per- taining to the installation. ACAUTIONA— This genet must be installed on a level surface. The base frame must be level within 1/2 inch all around. 0 Do not use any chromate base rust inhibitor with ethylene glycol base anti-freeze or chromiumhy- A CAUTION A droxide("green slime")forms and will cause over- heating. Engines that have been operated with a Q After the system has been installed, do nothing chromate base rust inhibitor must be chemically that might render the installation in noncompli- cleaned before adding ethylene glycol base anti- ance with such codes,standards and regulations. freeze. Using any high silicate anti-freeze boosters or additives will also cause overheating.The man- ufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment. 8 Section 2 —Installation INSTALLATION Liquid-cooled 15 kW,20 kW and 25 kW Generators P110 ♦ 2.1.1 NEPA STANDARDS • Where strong prevailing winds blow from one direction, face the generator air inlet openings into The following published standards booklets pertain- the prevailing winds. ing to standby electric systems are available form the • Install the generator as close as possible to the National Fire Protection Association (NFPA), transfer switch. This reduces the length of wiring Batterymarch Park, Quincy, MA 02269: and conduit. • NFPA No. 37, STATIONARY COMBUSTION • Install the generator as close as possible to the fuel ENGINES AND GAS TURBINES. supply, to reduce the length of i HOWEVER, P�P�• • NFPA No. 76A, ESSENTIAL ELECTRICAL REMEMBER THAT LAWS OR CODES MAY SYSTEMS FOR HEALTH CARE FACILITIES. REGULATE THE DISTANCE. • NFPA No. 220, STANDARD TYPES OF BUILDING CONSTRUCTION 2.3 GENERATOR MOUNTING AND • NFPA No. 68, GUIDE FOR EXPLOSION VENTING SUPPORT • NFPA No. 70, NATIONAL ELECTRICAL CODE. • NFPA No. 30, FLAMMABLE AND COMBUSTIBLE Retain the generator compartment to a concrete slab LIQUIDS CODE. with 1/4-inch masonry type anchor bolts. Be sure the • NFPA No. 10,INSTALLATION,MAINTENANCE AND bolts are long enough to retain the compartment.The USE OF PORTABLE FIRE EXTINGUISHERS. slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least ♦ 2.1.2 OTHER PUBLISHED STANDARDS three inches on all sides. See the Installation Diagram. In addition to NFPA standards,the following informa- tion pertaining to the installation and use of standby 2.4 BASIC STANDBY ELECTRIC electric systems is available: • Article X, NATIONAL BUILDING CODE, available SYSTEM from the American Insurance Association,85 John Figure 2.1 shows a schematic diagram of a basic Street, New York, N.Y. 10038. standby electric system. Both the UTILITY power • AGRICULTURAL WIRING HANDBOOK, obtainable supply and the STANDBY(generator) output are con- from the Food and Energy Council, 909 University nected to an approved transfer switch. The transfer Avenue, Columbia, MO, 65201. switch is required by electrical code and serves the • ASAE EP-364.2, INSTALLATION AND following functions: MAINTENANCE OF FARM STANDBY ELECTRIC • Permits the LOAD circuits to be connected to only POWER, available from the American Society of one power supply at a time. Agricultural Engineers, 2950 Niles Road, St. • Prevents electrical backfeed between the generator Joseph, MI 49085. and the UTILITY power circuits. • A52.1, AMERICAN NATIONAL STANDARD FOR Notice that both the STANDBY and the UTILITY CHIMNEYS, FIREPLACES AND VENTING power supplies to the transfer switch are protected SYSTEMS, available from the American National against overload by a main line circuit breaker. Standard Institute, 1430 Broadway, New York,N.Y. 10018. Figure 2.1 —Basic Standby Electric System 2.2 GENERATOR LOCATION MAINLINE Install the generator set, in its protective enclosure CIRCUITBREAKER outdoors, where adequate cooling and ventilating air UTILITY W N ' always is available. Consider these factors: SUPPLY ---- TRANSFER • Install the unit where air inlet and outlet openings SWITCH will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or drift TO LOAD ing, consider using a windbreak to protect the CIRCUITS unit. • Install the generator on high ground where water -- - --- levels will not rise and endanger it. • Allow sufficient room on all sides of the generator STANDBY ----; for maintenance and servicing. A good rule is to 6O�ITT allow five feet of space on all sides. MAIN LINE CIRCUIT BREAKER - 9 INSTALLATION Section 2 - Installation P110 Liquid-cooled 15 kW,20 kW and 25 kW Generators NOTE: A A The manufacturer recommends the use of a"GTS" type transfer switch in conjunction with this gen- ®Do not connect the ground wire to any pipe that erator. carries a flammable or explosive substance- FIRE or an EXPLOSION may result. 2.5 EMERGENCY CIRCUIT ISOLATION Proper grounding helps protect personnel against electrical shock in the event of a ground fault condi- METHOD tion in the generator or in connected electrical devic- This prevents overloading the generator by keeping es. In addition, grounding helps dissipate static elec- electrical loads below the wattage/amperage capacity tricity that often builds up in ungrounded devices. of the generator. If the generator is powering only critical loads, within the wattage/amperage capacity, Figure 2.2- Generator Grounding Lug (typical) during utility power outages, consider using the emergency circuit isolation method. BASE Critical electrical loads are grouped together and FRAME wired into a separate"Emergency Distribution Panel." Load circuits powered by that panel are within the wattage/amperage capacity of the generator set.When this method is used, it is difficult to overload the gen- erator. The transfer switch must meet the following requirements: • It must have an ampere rating equal to, or greater than, the total amperage rating of the emergency distribution panel circuit. 1 • Have it installed between the building's main distri- bution panel and the emergency distribution GROUNDING panel. LUG 2.6 TOTAL CIRCUIT ISOLATION METHOD 2.8 GENERATOR AC NEUTRAL When a generator capable of powering all electrical CONNECTIONS loads in the circuit is to be installed, use the "Total The manufacturer uses an UNGROUNDED AC neu- Circuit Isolation Method." It is possible for the gen- tral. Grounding is recommended only at the main erator to be overloaded when this isolation method is service entrance. If the neutral wire is grounded and employed. The following apply to the transfer switch one of the phase loads becomes grounded, the exces- in this type of system. sive current opens the load circuit breaker or col- • Ampere rating of the transfer switch must be equal lapses the generator field. The actual result depends to,or greater than,the ampere rating of the normal on the electrical characteristics of the particular incoming utility service. installed generator. • The transfer switch is installed between the utility service entrance and the building distribution 2.9 TRANSFER SWITCH START SIGNAL panel. CONNECTIONS 2.7 GROUNDING THE GENERATOR if the generator is to be installed with an automatic transfer switch, such as an engineered GTS-type The National Electrical Code requires the frame and switch, it is necessary to connect the two-wire start external electrically conductive parts of this equip- control system. ment to be properly connected to an approved earth ground and/or grounding rods. For that purpose, a Connect the two-wire start signal from the automatic GROUND LUG (Figure 2.2) is provided on the gen- transfer switch to the automatic start connection, erator mounting base. Consult a qualified electrician which is located in the right hand corner inside the for grounding requirements in the area. Grounding control panel. Match wires 178 and 183 in the trans- procedures must meet local regulations. fer switch to 178 and 183 on the terminal strip in the control panel. The conductors for the two-wire start circuit must be in their own conduit. olo Section 2 — Installation INSTALLATION Liquid-cooled 15 kW,20 kW and 25 kW Generators F)" , 2.10 BATTERY INSTALLATION Spilled electrolyte is to be washed down with an acid-neutralizing agent. A common practice is to A A use a solution of one pound (500 grams) bicarbon- ate of soda to one gallon (4 liters) of water. The !Q Standb generators installed with automatic bicarbonate of soda solution is to be added until y g the evidence of reaction (foaming) has ceased.The transfer switches will crank and start automati- resulting liquid is to be flushed with water and the cally when NORMAL(UTILITY)source voltage is area dried. removed or is below an acceptable preset level. A Lead acid batteries present a risk of fire because To prevent such automatic start-up and possible they generate hydrogen gas.The following pro- injury to personnel,do not connect battery cedure are to be followed: cables until the NORMAL source voltage at the . DO NOT SMOKE when near batteries, transfer switch is correct and the system is ready . DO NOT cause flame or spark in battery area, and to be put into operation. • Discharge static electricity from body before touch- ®Storage batteries give off explosive hydrogen ing batteries by first touching a grounded metal gas.This gas can form an explosive mixture surface. around the battery for several hours after charg- Servicing of batteries is to be performed or super- ing.The slightest spark can ignite the gas and vised by personnel knowledgeable of batteries and cause an explosion. Such an explosion can shat- the required precautions.Keep unauthorized person- ter the battery and cause blindness or other nel away from batteries. injury.Any area that houses a storage battery The recommended battery is Group 26, 12V negative must be properly ventilated. Do not allow smok- ground, 525 CCA/75 AH minimum. All batteries ing, open flame,sparks or any spark producing must be at 100 percent state-of-charge before they tools or equipment near the battery. are installed on the generator. 0 Battery electrolyte fluid is an extremely caustic When using maintenance-free batteries, it is not nec- sulfuric acid solution that can cause severe essary to check the specific gravity or electrolyte burns. Do not permit fluid to contact eyes,skin, level. Have these procedures performed at the inter- clothing, painted surfaces,etc.Wear protective vals specified in the"Maintenance"section.A negative goggles, protective clothing and gloves when ground system is used. Battery connections are handling a battery. If the fluid is spilled,flush shown on the wiring diagrams. Make sure all batter- the affected area immediately with clear water. ies are correctly connected and terminals are tight. AWARNING A Observe battery polarity when connecting batteries to the generator set. A Do not dispose of the battery in a fire.The bat- NOTE: tery is capable of exploding. Damage will result if the battery connections are Q Do not open or mutilate the battery. Released made in reverse. electrolyte can be toxic and harmful to the skin and eyes. 3,11 PREPARATION BEFORE START-UP ©The battery represents a risk of high short circuit The instructions in this section assume that the current. When working on the battery,always standby generator has been properly installed, ser- remove watches, rings or other metal objects, viced, tested, adjusted and otherwise prepared for and only use tools that have insulated handles. use by a competent, qualified installation contractor. Be sure to read the "Safety Rules" on Pages 2 and 3, ♦ 2.10.1 VENTED BATTERIES as well as all other safety information in this manual, CAUTION before attempting to operate this (and related) equip- ment. 0 The electrolyte is a dilute sulfuric acid that is ♦ 2.11.1 PRIOR M INITIAL START-UP START-UP harmful to the skin and eyes. It is electrically conductive and corrosive.The following proce- dures are to be observed: A CAUTION • Wear full eye protection and protective clothing, 0 I prior to initially starting the generator, it must • Where electrolyte contacts the skin, wash it off Yt be properly prepared for use. Any attempt to immediately with water, crank or start the engine before it has been • Where electrolyte contacts the eyes, flush thor- properly serviced with the recommended types oughly and immediately with water and seek and quantities of engine fluids(oil,coolant,fuel, medical attention,and etc.) may result in an engine failure. It*1 OPERATION Section 3 —Operation :[�E Liquid-cooled 15 kW,20 kW and 25 kW Generators Before starting the generator for the first time, the ♦ 2.11.7 ELECTRICAL SYSTEM installer must complete the following procedures.For follow-up maintenance information and/or service Make sure the generator is properly connected to an intervals, please refer to the "Maintenance" section. approved earth ground and/or ground rod. Make sure the generator battery is fully charged, ♦ 2.11.2 TRANSFER SWITCH properly installed and interconnected, and ready for If this generator is used to supply power to any elec- use. trical system normally powered by an electric utility, Check to ensure that there are no loose electrical con- the National Electrical Code requires that a transfer nections. Restrain any loose wires to keep them clear switch be installed.The transfer switch prevents elec- of any moving generator set components. trical backfeed between two different electrical sys- tems. (For additional information, see the applicable 3,1 USING A STANDARD "GTS" transfer switch manual for this unit.) The transfer switch, as well as the generator and other standby TRANSFER SWITCH components, must be properly located and mounted When required, the pre-packaged standby generator in strict compliance with applicable codes,standards can be installed with a "GTS" type engineered auto- and regulations. matic transfer switch. ♦ 2.11.3 FUEL SYSTEM When a GTS type transfer switch is used, it controls automatic operation and automatic transfer as fol- Make sure the fuel supply system to the generator (a) lows: delivers the correct fuel at the correct pressure and • Solid state circuits in the transfer switch monitor (b) is properly purged and leak tested according to utility power source voltage. code. No fuel leakage is permitted. See the . When utility source voltage drops below a pre-set "Specifications" section for more information. level, transfer switch action closes the circuit. The engine then cranks and starts as controlled by the ♦ 2.11.4 GENERATOR SET LUBRICATION pre-packaged generator's Control Module circuit Check the engine crankcase oil level before operating board. and add oil to the proper level-the dipstick "FULL" After the engine starts and when the generator AC mark. Never operate the engine with the oil level output voltage and frequency have reached a pre- below the dipstick `ADD" mark. See "Specifications" set value, transfer switch circuits signal the trans- and "Engine Oil Recommendations" sections. fer switch main contacts to actuate to the"Standby" power source side. Generator AC output then pow- NOTE: ers load circuits. This engine is shipped from the manufacturer When the utility power source voltage is restored with 15W-40 oil. This oil should be changed after above a pre-set level, transfer switch solid state 30 hours of operation. circuits signal the switch main contacts to move back to their utility power source side. ♦ 2.11.5 ENGINE COOLANT • Following re-transfer back to the utility power source side, transfer switch circuit board action Have the engine cooling system properly filled with opens the circuit. Engine then shuts down. the recommended coolant mixture. Check the system NOTE: for leaks and other problems. See "Specifications" and "Coolant' sections. If the generator is installed in conjunction with a GTS type transfer switch, refer to the applicable ♦ 2.11.6 BELT TENSION transfer switch manual for exact operating param- eters and timing sequences. 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). 12 Section 3 -Operation OPERATION Liquid-cooled 15 kW,20 kW and 25 kW Generators 3.2 CONTROL CONSOLE ♦ 3.2.4 15 AMP FUSE COMPONENTS The fuse protects the control console's DC control The components of a liquid-cooled generator control circuit against electrical overload. If the fuse has console (Figure 3.1) are as follows: melted open because of an overload, engine cranking and startup cannot occur. If replacement of the fuse Figure 3.1 - Liquid-Cooled Generator Panel is necessary,use only an identical 15-amp fuse. (lype 9 9 AGC, part number 022676). o�o ♦ 3.2.5 IS AMP INLINE FUSE FUSE FAULT � This inline fuse is connected in the 15A line that runs HOUR METER GC INDICATOR between the AUTO/OFF/MANUAL switch and position 10 of the 76009A PCB. This fuse protects the start, fuel, field boost, and transfer outputs from the PCB and will open if there is excessive current draw on AUTO any one of these outputs. O OFF EXERCISE 0 NOTE: F1 4 SET ON MANUAL This fuse will not remove the positive (+) battery input power from the PCB when it opens. This 3.2.1 HOURMETER means the exercise timer will not be reset. If this fuse does open, carefully check the wiring to the Indicates time the engine-generator has operated, in start, fuel, field boost and transfer outputs before hours and tenths of hours. Use the hourmeter along replacing the fuse. with the periodic maintenance schedule for the gen- erator set. ♦ 3.2.6 SET EXERCISE TIME SWITCH ♦ 3.2.2 AUTO/OFF/MANUAL SWITCH This switch allows for programming the generator to start and exercise automatically.See"Weekly Exercise Use this three-position switch as follows: Cycle". • Set the switch to AUTO for fully automatic opera- tion. See the `Automatic Operation" section. 3.3 MANUAL TRANSFER AND • Set switch to MANUAL position to crank and start START-UP the generator engine. To transfer electrical loads to the STANDBY (GEN- • Set switch to OFF position to shut down an operat ERATOR) power source side and start the engine ing engine. With OFF selected, operation will not manually, refer to the Owner's Manual of the particu- be possible. lar transfer switch. A A- A With switch set to AUTO, engine can crank and 3.4 AUTOMATIC OPERATION start suddenly without warning. Such automatic To set the system for fully automatic operation, pro- start up normally occurs when utility source ceed as follows: voltage drops below a pre-set level.To prevent • Check that load circuits are connected to the utility possible injury that might be caused by such power supply. sudden starts, set AUTO/OFF/MANUAL switch to • Set the AUTO/OFF/MANUAL switch to its AUTO OFF before working on or around the unit.Then, position. place a "DO NOT OPERATE"tag on control con- • Set the generator main circuit breaker to its ON or sole. CLOSED position. ♦ 3.2.3 FAULT INDICATOR LAMP 3.5 WEEKLY EXERCISE CYCLE The lamp goes ON when one or more of the following The generator will start and exercise once every seven engine faults occurs and when engine shuts down. days. During this weekly exercise, the unit runs for • Low oil pressure • Overcrank about 20 minutes and shuts down. Transfer of loads • High coolant temperature • Overspeed to generator output does not occur during the exer- • Low coolant level cise. 13 Section 4 —Maintenance MAINTENANCE Liquid-cooled 15 kW,20 kW and 25 kW Generators To select day and time for exercising, proceed as fol- Figure 3.3 - Engine Block Heater lows: • Set the AUTO/OFF/MANUAL switch to OFF. • Set generator main circuit breaker to OFF or OPEN. • Locate the rocker switch on the control panel iden- tified with the words "Set Exercise Time" (Figure 3.2). • Push"Set Exercise Time"switch to ON position for o 20 to 30 seconds and then release. Switch will spring back into its original position when released. o • Wait 30 seconds before setting the AUTO/OFF/ MANUAL switch to AUTO position. A CAUTION A 0 If the AUTO/OFF/MANUAL switch is switched Refer to applicable wiring diagram(s) and electrical too soon,the engine may start. If engine does schematic(s) at back of manual for wiring connec- start, it will shut down automatically in about tions. Customer supplies a 120V 15A Utility fed cir- two(2) minutes. cuit for the block heater. • Set the generator main circuit breaker to its ON or CLOSED'position. 4.1 MAINTENANCE PERFORMED BY • Generator is now programmed to start and exer- cise every seven days thereafter,on day and time of AUTHORIZED SERVICE FACILITIES day the switch was actuated. • Place a sign on the generator control panel and the A. EVERY THREE MONTHS transfer switch, indicating the day and time the I.Check battery state of charge and condition. generator will be exercising. 2.Inspect and test fuel system. NOTE: 3.Check transfer switch. If battery terminals are disconnected, the exercise 4.Inspect exhaust system. timer needs to be reset for correct automatic exer- 5.Check engine ignition system. cise operation. 6.Check fan belts. Figure 3.2 - "Set Exercise"Switch ♦ B. ONCE EVERY SIX MONTHS SET 1.Test Engine Safety Devices (low oil pressure, low EXERCISE coolant level, high coolant temperature). TIME ♦ C. ONCE ANNUALLY ON 1.Test engine governor.Adjust or repair, if needed. 2.Clean, inspect generator. FAULT 3.Flush cooling system. AUTO INDICATOR ♦ D. FIRST 100 OPERATING HOURS 0 OFF 1.Change engine oil and oil filter. (After initial change,service engine oil and filter at 150 operat MANUAL ing hours or six months, whichever comes first.) 2.Retorque cylinder head. See the "Torque Specs" 3.6 ENGINE HEATER section. This standby generator comes equipped with a block 3.Retorque intake and exhaust manifold. See the heater (Figure 3.3), similar to the block heaters used 'Torque Specs" section. in automotive applications. The block heater is wired to a grounded plug. 14 Section 4— Maintenance Liquid-cooled 15 kW,20 kW and 25 kW Generators MAINTENANCE ♦ E. EVERY 500 OPERATING HOURS 4.4 CHECKING FLUID LEVELS 1.Service air cleaner. ♦ 4.4.1 CHECK ENGINE OIL 2.Check starter. 3.Check engine DC alternator. Check engine crankcase oil level (Figure 4.1) at least every 20 hours of operation, or prior to use. ♦ F. EVERY 800 OPERATING HOURS - Remove oil dipstick and wipe dry with a clean,lint 1.Retorque cylinder head. See the "Torque Specs" free cloth. section. - Install oil dipstick, then remove again. 2.Retorque intake and exhaust manifold. See the - Oil should be between FULL and ADD marks. "Torque Specs" section. - If oil level is below the dipstick ADD mark, remove 3.Check engine compression. oil fill cap. Add the recommended oil to bring oil 4.Check valve clearance. level up to the FULL mark. DO NOT FILL ABOVE THE "FULL' MARK. See the "Engine Oil 4.2 COOLING SYSTEM Recommendations" section for recommended oils. Air intake and outlet openings in the generator com- Figure 4.1 - Oil Dipstick and Oil Fill Cap partment must be open and unobstructed for contin- ued proper operation. This includes such obstruc- tions as high grass, weeds, brush, leaves and snow. c OIL FILL CAP Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it ,� OIL DIPSTICK to shut down. (See the"Installation Diagram"for vent locations.) I A WARNING A ®The exhaust system parts from this product get ' • ��� • I I �� extremely hot and remains hot after shutdown. High grass,weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may 0 • ignite and burn from the heat of the exhaust system. • 0 0• i o �/ ®• 4.3 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking, start up and running are controlled ♦ 4.4.2 BATTERY FLUID by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via a Check battery electrolyte fluid at least once weekly. 15 amp fuse. These overcurrent protection devices Fluid should cover separators in all battery cells. If will open if the circuit is overloaded. fluid level is low, add distilled water to cover tops of separators. DO NOT USE TAP WATER IN BATTERY. A CAUTION A ♦ 0 If a circuit breaker opens or a fuse element 4.4.3 ENGINE COOLANT melts,find the cause of the overload before Check coolant level in coolant recovery bottle. See resetting the circuit breaker or replacing the the "Specifications" section. fuse. - 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. *15 OPERATION Section 4 — Maintenance Liquid-cooled 15 kW,20 kW and 25 kW Generators 4.5 MAINTENANCE OWNER/ A A OPERATOR CAN PERFORM Q Do not attempt to adjust the governor. Only ♦ 4.5.1 CHECK ENGINE OIL LEVEL qualified service facilities should adjust the gov- ernor. Excessively high operating speeds are Refer to "Checking Fluid Levels" section. dangerous and increase the risk of personal inju- ry. Low speeds impose a heavy load on the ♦ 4.5.2 CHECK BATTERY engine when adequate engine power is not • Check batteryfluid level each week as outlined available and may shorten engine life. Correct rated frequency and voltage are supplied only at under"Check Fluid Levels". the proper governed speed. Some connected • Check battery cables for condition, tightness, cor- electrical load devices may be damaged by incor- rosion or damage. Clean, tighten or replace as rect frequency and/or voltage. Only qualified necessary. service technicians should adjust the governed ♦ 4.5.3 EXERCISE SYSTEM speed. Start the generator engine at least once every seven ♦ 4.5.10 CHANGING ENGINE OIL days and let it run at least 20 minutes. See section Refer to maintenance performed by authorized ser- "Weekly Exercise Cycle". vice facilities for engine oil and filter change frequen- cies. ♦ 4.5.4 INSPECT COOLING SYSTEM Drain the oil while the engine is still warm from run- Inspect engine cooling system at least once each ning. This means warm up the engine, shut it down month. and drain immediately as follows: • Check hoses for damage, deterioration, leaks, etc. 1. Remove OIL DRAIN HOSE from its retaining Correct any discrepancies found. clip. • Check hose clamps for tightness. 2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container. ♦ 4.5.5 CHECK ENGINE COOLANT LEVEL 3. When all oil has drained, install and tighten OIL See the "Checking Fluid Levels" section. DRAIN HOSE CAP and re-install into its retaining clip. ♦ 4.5.6 PERFORM VISUAL INSPECTION 4. Tum OIL FILTER (Figure 4.2) counterclockwise and remove. Dispose of old filter. Complete a thorough visual inspection of the entire Figure 4.2 - Oil Filter engine-generator monthly. Look for obvious damage, loose, missing or corroded nuts, bolts and other fas- teners. Look for fuel, oil or coolant leaks. ' ♦ 4.5.7 INSPECT EXHAUST SYSTEM i Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, •®• clamps, etc. for condition, tightness, leaks, security, Imo' damage. o ° o ♦ 4.5.8 CHECK FAN BELT • Inspect fan belts every three months. Replace any OIL FILTER damaged, deteriorated, worn or otherwise defec- tive belt. • Check fan belt tension. Thumb pressure, exerted 5. Apply light coating of new engine oil to seal of new midway between pulleys, should deflect about 3/8 oil filter. Install FILTER and tighten by hand only. to 3/4 inch.Adjust belt tension as required. DO NOT OVERTIGHTEN. 6. Remove OIL FILL CAP.Add recommended oil(see ♦ 4.5.9 INSPECT ENGINE GOVERNOR SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK "FULL" MARK. Crankcase oil capacity Visually inspect electronic governor. is 4.0 U.S. quarts (3.8 liters). is Section 4— Maintenance Liquid-cooled 15 kW,20 kW and 25 kW Generators MAINTENANCE Figure 4.4—Setting the Spark Plug Gap A CAUTIONA— SET PLUG GAP AT 0.5-0.6 mm 0 After refilling the crankcase with oil, always (0.020-0.025 inch) check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK"ADD" MARK. 7. Start engine and check for oil leaks. ♦ 4.5.11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner, (part number 059402), simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover (Figure 4.3). A 4.5.13 COOLANT CHANGE Every year, have Authorized Service Facility drain, Figure 4.3-Engine Air Cleaner flush and refill the cooling system.See"Specifications" for cooling system recommendations. Air Cleaner 4.6 MISCELLANEOUS MAINTENANCE ♦ 4.6.1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal gen- —ellerator windings have an adverse effect on insulation R�10* 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 (Doors Removed for Clarity) inside an all-weather enclosure, clean the enclosure with a soft, damp cloth or sponge and water.Apply a coat of automotive type wax once a year to help pre- See the "Scheduled Maintenance" section for air vent corrosion. cleaner maintenance. Once each year, have the generator cleaned and 4.5.12 SPARK PLUGS inspected by an Authorized Service Dealer. That dealer will use dry, low pressure air to clean internal Reset the spark plug gap or replace the spark plugs windings. Parts inside the control console should be as necessary. See the "Scheduled Maintenance" sec- cleaned and inspected at this time as well. tion. Finally, have the insulation resistance of stator and 1. Clean the area around the base of the spark plugs rotor windings checked. If insulation resistances are to keep dirt and debris out of the engine. Clean excessively low, the generator may require drying. 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 "Scheduled Maintenance" section for recommended inspection. 3. Check the spark plug gap using a wire feeler gauge.Adjust the gap to 0.5-0.6 mm(0.020-0.025 inch) by carefully bending the ground electrode (Figure 4.4). 17 Section 4 — Maintenance MAINTENANCE Liquid-cooled 15 kW,20 kW and 25 kW Generators ♦ 4.6.2 BATTERY 0 Battery electrolyte fluid is an extremely caustic All lead-acid storage batteries discharge when not in sulfuric acid solution that can cause severe use. Refer to specific instructions and warnings that burns. Do not permit fluid to contact eyes,skin, accompany the battery. If such information is not clothing, painted surfaces, etc. Wear protective available, observe the following precautions when goggles, protective clothing and gloves when handling a battery: handling a battery. If the fluid is spilled,flush • DO NOT use jumper cables and a booster battery the affected area immediately with clear water. to crank or start the generator engine. Q Do not use any jumper cables or booster battery • DO NOT recharge a weak battery while it is to crank and start the generator engine. If the installed in the generator. Remove battery from battery has completely discharged, remove it generator and recharge in a well-ventilated area, from the generator for recharging. away from fuel vapors, sparks, heat or flames. • Battery electrolyte fluid is an extremely caustic sul- A WARNING A furic solution that can cause severe burns. DO Be sure the AUTO/OFF/MANUAL switch is set to NOT permit fluid to contact eyes, skin, clothing, the OFF position before connecting the battery painted surfaces, wiring insulation, etc. If any bat tery fluid is spilled, flush the affected area with cables. If the switch is set to AUTO or MANUAL, clear water immediately. the generator can crank and start as soon as the • Always wear safety glasses, rubber apron and battery cables are connected. gloves when handling a battery. ®Be sure the utility power supply is turned off, or • Batteries give off explosive hydrogen gas while sparking may occur at the battery posts as the charging. The gas can form an explosive mixture cables are attached and cause an explosion. around the battery for several hours after charging. Any spark, heat or flames can ignite the gas and ♦ 4.6.4 BATTERY REPLACEMENT cause an explosion which can shatter the battery, When replacing batteries, use the same number and causing blindness or other serious injury the type of battery that follows: ♦ 4.6.3 BATTERY MAINTENANCE BCI Group No. CCA The battery should be inspected per the "Scheduled 26/26R 525 Q 0 deg.F Maintenance"section.The following procedure should be followed for inspection: NOTE: 1. Inspect the battery posts and cables for tightness The BCI number should be located directly on the and corrosion. Tighten and clean as necessary. battery. 2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTER- PERIODIC REPLACEMENT PARTS IES. Part Name Part Number 3. Have the state of charge and condition checked. Oil Filter #OA45310244 This should be done with an automotive-type bat- tery attery hydrometer. Radiator Cap #046627 A A Air Cleaner #059402 Spark Plug #OA45310275 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. 18 Section 4 — Maintenance Liquid-cooled 15 kW,20 kW and 25 kW Generators MAINTENANCE 4.7 SCHEDULED MAINTENANCE The following is a recommended maintenance schedule for small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased(performed more frequently)if the unit is used in a severe application. Use the unit hour meter or calendar time,whichever occurs first,from the previous maintenance interval to deter- mine the next required maintenance interval. Service Maintenance Interval Information: The various service maintenance intervals are designated by interval numbers as follows: 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten- tial problem areas. Performed monthly or following each 10 hours of operation of the unit and requires approximately .5 man- hours per unit to complete. This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning: To prevent injury,perform the following steps in the order indicated before starting any maintenance: • Disable the generator set from starting and/or connecting to the load by setting the control panel AUTO/OFF/MANUAL switch to the OFF position. • Remove the control panel fuse. • Turn off utility supply to engine water heater. • Turn off the battery charger by turning off utility supply to the transfer switch. • Remove the negative battery cable. The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits. Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required. 2 A break-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit and requires approximately 2.5 man-hours per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer. 3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed semi-annually orfollowing each 50 hours of operation of the unit and requires approximately 1.5 man-hours per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer. 4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed annually or following each 100 hours of operation of the unit and requires approximately 4.0 man-hours per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer. 19 Section 4 —Maintenance MAINTENANCE Liquid-cooled 15 kW,20 kW and 25 kW Generators Maintenance Level Level Level Level Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) 10 hrs. 30 hrs. 50 hrs. 100 hrs. 1. Disable the unit from operating per the first page O O O O warning. 2. Check the engine oil level. O O O O Adiust as necessary. 3. Check the engine coolant O O O O level.Ad'ust as necessary, 4. Check the engine coolant thermal protection level. O Correct as necessary, 5. Check the natural gas delivery system on gas engine driven units. O O O Tighten connections as necessary. 6. Check the air inlets and outlets for debris.Clean as O O O O necessary, 7. Check the battery electrolyte level if O O O O accessible.Adjust as necessary, 8. Check the battery posts, cables,and charger for loose connections, O O O O corrosion, and proper operation.Correct as necessary, 9. Check the unit wiring for loose connections, corrosion, and damage. O Correct as necessary, 10.Check the engine accessory drive belts for wear,weather cracking, O and damage.Replace as necessary, 11.Visually inspect the unit looking for leaks,wear or damage, loose connections O O O O or components, and corrosion.Correct as necessary, 12.Test the engine and transfer switch safety O devices.Correct and/or ad'ust as necessary, 20 Section 4 — Maintenance Liquid-cooled 15 kW,20 kW and 25 kW Generators MAINTENANCE Maintenance Level Level Level Level Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials) 10 hrs. 30 hrs. 50 hrs. 100 hrs. 13.Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections O O or components, and abnormal operating conditions.Correct as necessary, 14.Start and exercise the unit at full rated load(use a load bank if the site load is not enough)for at least 2 hours looking for leaks, O loose connections or components,and abnormal operating conditions. Correct as necessary. 15.Change the engine oil. O O 16.Replace the engine oil O O filter(s). 17.Replace the engine air filter(s). O 18.Check the engine spark plugs on gas engine driven O O units.Clean and re-gap or replace as necessarV. 19.Perform a 5 minute no-load operational run of the unit O O looking for any post service problems. 20.Return the unit to standby setup for operation when O O O O required. 21 TROUBLESHOOTING Section 5 -Troubleshooting SKLiquid-cooled 15 kW,20 kW and 25 kW Generators 5.1 TROUBLESHOOTING POINTS Problem Cause Correction Engine won't crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defective battery cables. 2. Tighten,clean or replace battery cables as necessary. 3. Defective starter contactor. 3. Replace contactor. 4. Defective starter motor. 4. Replace starter motor. 5. Dead or Defective Battery. 5. Remove,change or replace battery. Engine cranks but won't start. 1. Out of fuel. 1. Replenish fuel. 2. Fuel solenoid(FS)is defective. 2. Replace solenoid. 3. Open Wire#14 from Engine Control circuit 3. Reconnect wire. board. 4. Spark plugs defective. 4. Clean,regap or replace plugs. Engine starts hard,runs rough. 1. Flame arrestor(air cleaner)plugged or 1. Clean or replace as needed. damaged. 2. Plugged fuel line. 2. Unclog fuel line. 3. Defective spark plugs. 3. Clean,regap or replace plugs. Engine starts then shuts down. 1. Engine oil level is low. 1. Check oil and add oil as needed. 2. Engine is overheated. 2. Check cooling system for leaks. 3. Defective Low Oil Pressure Switch. 3. Replace switch. 4. Defective Coolant Temperature Switch. 4. Replace switch. 5. Defective Control Module circuit board. 5. Replace board. 6. Coolant Level is Low. 6. Repair leak-Add coolant. 7. Defective Low Coolant Level Switch. 7. Replace Switch. AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch. 1. Replace switch. engine continues to run. 2. Open/disconnected wire#15A between AUTO/ 2. Reconnect/close wire. OFF/MANUAL switch and Control Module cir- cuit board. 3. Defective Control Module circuit board. 3. Replace board. No AC output from generator. 1. Check main line circuit breaker. 1. Reset to ON or CLOSED. 2. Check circuit breaker&fuses. 2. Reset and replace,if necessary. 3. Transfer switch set to NORMAL position. 3. Set to GENERATOR position. 4. Generator internal failure. 4. Contact an Authorized Service facility. 5. Thermal circuit breaker open. 5. Auto-reset-Wait five min.and attempt restart. 22 Section 6 — Notes NOTES Liquid-cooled 15 kW,20 kW and 25 kW Generators 23 NOTES Section 6 — Notes Liquid-cooled 15 kW,20 kW and 25 kW Generators 24 1360 153,54'3 53 106 19 NOTES BASE FOOTPRINT 12,09'] 14,17'7 10,75'1 ELECTRICAL TYP 1. STANDARD BLOCK HEATER REQUIRES 120V AC CONNECTION STUB-UP 2, CONNECTION POINTS FOR AC LOAD LEADS AND ENGINE AUTOMATIC AREA o 0 0 START/STOP CONTROL WIRES PROVIDED IN CONTROL PANEL, 3. 12 VOLT NEGATIVE GROUND SYSTEM BATTERY TRAY INSIDE DIMENSIONS, 162 x 220 [6,38' X S.66'] 6 4, 2,0' I,D. FLEX EXHAUST, STANDARD WITH COMPARTMENT C54 UNITS2554, OPTIONAL WITHOUT 5, MAIN LINE CIRCUIT BREAKER. 475 ® lum BASE [18.70'] ° FOOTPRINT WEIGHT DATA 616 UNIT, 390 kg 1860 lbs] [24,25'7 O O it O TYP UNITS, mm CINCHES] OO o ENGINE SERVICE CONNECTIONS 0 0' INLET LP VAPOR = 3/4' NPT COUPLING 89.5 ¢ O INLET NATURAL GAS = 3/4' NPT COUPLING 13.52'3 015,06 12V BATTERY NOTE 1 207 OIL DRAIN = 1/4' NPT COUPLING 100.59'] SEE NOTE 3 473 [8,15'] EXHAUST OUTLET - 2' OD MUFFLER OUTLET (6 PLCS) 946 118,62'] TYP TYP 137,24'1 TYP C TOP VIEW n O O 1722 759 167,80'1 CL 129,88'] RADIATOR N NOTE 4 ACCESS mC C O 0 7 NOTE 5 V NOTE 2 wo �o ora H LR 917,5 00 Z O 136.12'] n o - (Dm 000 w ' C) 3 38 O o O o O° ® • 11.50'3 30 654 LUG GROUNDING (FAR IDE) NATURAL CONNECTI N 3/4P NPTPOR 1906'] 125,75'] Z REAR VIEW (SHOWN WITH DOOR REMOVED) WEATHER PROOF & ACOUSTIC II COMPARTMENTS N O Z m � t m a l � 2 S15 1 3S16 PCB 4 BLUE SW2 VR 5 229-1111 1 2 3 4 5 B 2 3 4 5 5 7 B 9 10 11 12 13 14 15 16 17 1B _17'_ BLUE 225A 15 BLUE N C S15 56 238 BLUE TO GOVERNOR 162 0 516 4 23 178 0 T1 BLUE 15C 6 4 194 14 15C RE� T2 S15 S = ACTUATOR cy —178 15E SIB ORANGE (� 178 —239 229 YELLOW 7 C BROWN BLUE Oq a C d. 1e3 FL GCU eucK 239 START 17^ — O 01 OQ L9 9 115 183 ell/\\�i AS BLUE 1 239 teA 15C 176 ISA 15 a R1 178 AUTO F •7 It 225A �— BLACK I j.� 15A 1E 15E 0 RD A5 225A F1 19 13 15 5 0 44 _ HM ° 15 4—# Bs 33222 611 L] O G 6 2 T C7 rt 15 11 44 y GI ° 4 4 OUTPUT CONNECTION 14 4 S15 120240V 1-PHASE 1D a BLUE 14 0 S16 Sis I w 'BLUE 14 T2 13 S16 CB1 =E1 0 N -YELLOW RE 0 T 4 4 229 Q1 14 14 4 Q Q178 14 4 22s : IF &5 8S 65 33 7 L7 04 ° EC E1 E2 04 L _+ - I 7 0 183 0 0 ° O 14 S16 0 "�4 178LL A_LTFRNATETRI 0 D 3 D T3 14 S4 22 0 V 1 14 33 NB O H (RED)-224 i BLACK 0 14 BLACK m 1 14 S76 S76 0 A I I 194 T2 g v CAP 1 1 14 4 56 Ul I I Q1 g 0 0 13 14 ¢ 4 56 85 85 I I 23 T1 m 0 85 I(BLADI()—N1A 1 I LIBLACpN2 I 162 j 8 yy 1B3 '' �� � ' 47� ma3 CB r oAl 11 a 4 RED O O D " 9 °TSi 1 1—® TG3 a 9 1 ISO BRUSH HOLDER PoAFrx.1.KOWSTDI T52 14 MOUNTING SCREW SWtiO1CO:ihplOCfl SfAIIOPtiaGBMMC 0 D 5� SB TRANSFER SWITCH +5� 150 4 CONNECTION 1 BRUSH WITH RED LEAD 04 LEDOEND CLOSEST TO BEARING AS- ALTERNATOR STATOR FL- FAULT LIGHT SW2- SET EXERCISE SWITCH CAP- CAPACITOR OCU- GOVERN OR CONTROLLER TRI-TRNSFRMR.UTILITY SENSING CBI- CIRCUITBREAKER HM- HOUR METER TSI- TERMINALSTMP20 POS CB2- FIELD BREAKER NB- NEUTRALBLOCK T52- TERMINAL STRIP 2P09. EC- ENGINE CONNECTION PCB'PREPACK CIRCUIT BOARD 753- TER MINALSTRIP7POS F- FUSE 15 AMPS SA- SUPRESSION ASSEMBLY VR- VOLTAGE REGULATOR- FUSE INUNE7S AMP 6W1-AUTOIOFFRMANUAL SWITCH , Section 8 - Electrical Data Liquid-cooled 15 kW,20 kW and 25 kW Generators CAL Wiring Diagram– 1.5L Engine–Drawing No.OE0343-B [:4:7 '♦ —► LOS DIS WLS DC—VR 1 2 3 4 5 C C ITWTS FS 48 0 49 13 1414 13 ji56 0 16 85 13 85 0 01 RED O 0 3 —85 85 CONTROL 4 —85 PANEL 6 —56 0 CONNECTION o 0 14 8 —o 0- 9 9 —13 GRD o • 00000 DEUTSCH 10 —14 0000 • • 11 —14 12 —14 16 DC—A 49 48 RED SM LEGEND = CC — CONTROL CONTACTOR 12—V. BLACK DIS — DISTRIBUTOR _ DCA — DC ALTERNATOR + BATTERY G R D EH — ENGINE HEATER FS — FUEL SOLENOID GRD — GROUND LOS — LOW OIL PRESSURE SWITCH TO SM — STARTER MOTOR ELECTRONIC GOVERNOR WTS – WATER TEMPERATURE SWITCH WLS – WATER LEVEL SENSOR GOVERNOR ACTUATOR CONTROLLER ACTUATOR CONNECTOR EH TO 120V/1 5A —BLACK UTILITY FED —WHITE N❑TE1 CIRCUIT —GREEN ENGINE HEATERS ARE NOT AVAILABLE ON HOME STAND—BY UNITS. 87 N t N I- a� a� l � CAP TS1-14 229 229 EC-9 13 13 �. H EC-10 RED 183 5, EC-11 14 14 14 + HM 0 .5 i•F EG72 0 BLACK 56 14 13 15A FFF PONSMON EC EC-8 66 13 v EC-6 85 85 SA 14 IV A00 QCcc 239 15C 00 — EC-3 0 15C SW2 NC @ d T EC-4 4 65 14 239 178 150 3 A ECC-5 f4R 0 3 a 4 SWl 15A 15 15 R F176 a q o F1 U/ , 1 13 2 5 7 D 11 9 105A62 VR m 1z 150 1sC 1s--6�-13162 1 n PCB E 178 178 BLUE Fn 0 SIS 5 O 4 194 194 C •C�CD 4 3 23 23 178 C d 6 \�6 6 B A 17 16 14 15 225A BLU S18 S16 S15 T1 T2 RED 183 6 5� RED 7 d C82 T2 N /\ T1 TS2 Im @ C 8 2 2 0-162 0 0 y im 2 WIFE DPE START •n AS FORSTANDARD ID m GENERAL TRANSFER SWITCH CONNECTION Z fD C a 11 22 33 7." 15 m m m m O pl C 5 O IRE 04lEM1REFOP¢bVt1 S'9lcua O minty wow raw zmv it ays��o S76 m nasuure urnrs�nvn� m ORANGEYGOV TOLi "' N YELLOW ALTERNATE TRI NGCU BLRAO KNACTUATOR 1RIll (RED) (BLUE) N I ucK 225 BL KLZ LEGEND (, TR, 1 CB7 T7 T2 N7 N2 23 194 NTA N2 El oo Ez AR -ALTERNATOR ROTOR GCU-GOVERNOR CONTROL UNIT AS -ALTERNATOR STATOR HM -HOURMETER CAP-CAPACITOR PCB -CIRCUIT BOARD CONTROLLER (BLACK) (BLACK) CUSTOMER CONNECTION CB1,2-CIRCUIT BREAKERS SA -SUPRESSIONASSEMBLY PREPACKAGE DPE-EXCITATION WINDING SWI -AUTO/OFF/MANUALSWITCH TRANSFER SWITCH 120/240V 1-PHASE EC-ENGINE CONNECTION SW2 -SET EXERCISE SWITCH CONNECTIONTS3 F -FUSEI5AMPS TR1 -TRANSFORMER,UTILITY SENSING F1 -FUSE 7 5 AMPS IN LINE TSl A3-TERMINAL BOARDS FL -LIGHT FAULT INDICATOR VR -VOLTAGE REGULATOR Section 8 - Electrical Data Liquid-cooled 15 kW,20 kW and 25 kW Generators 7ELECTRICALElectrical Schematic— 1.5L—Drawing No.OA7182-C ATA WTS 85 LOS a n WLS oCO 0 0 0: 13 0 O 0 0 56 56 cc O 14 14 FS 0 14 14 13 _ 49 49 + - ISC 0 49 49 DC-A 0 F_- Q 14 12V BATTERY 0 Ld 13 13 RED (+� I BLACK — 0 W 0 CC � Q -16 J 0 > ^ 0 U GRD J W z � n-o- oo EG LEND J Z J 00 W U W CC - CONTROL CONTACTOR 0 00 0 0 0 a DCA - DC ALTERNATOR EH - ENGINE HEATER ACTUATOR FS - FUEL SOLENOID CONNECTOR GRD - GROUND ISC - IGNITION SYSTEM CONTACT > LOS - LOW OIL SWITCH ~ SM - STARTER MOTOR —BLACK WTS - WATER TEMPERATURE SWITCH 0 0 WLS - WATER LEVEL SWITCH A <- WHITE EH' U 0 0- GREEN 0 NOTE: ENGINE HEATERS ARE ~ NOT AVAILABLE ON HOME STAND-BY UNITS. 09 PARTS� Section 9-Exploded trews and Parts LISTS 0 Liquid-cooled 15 kW,20 kW and 25 kW Generators ({p)) Governor Assembly—Drawing No.OE1331-B 5 4 3 2 ° ITEM(13)NEOPRENE COATING ° ° 1 ° 6 14 7 10 ` r 0. jot: WIRE HARNESS /\8 15 SECURE WIRE HARNESS ab WITH TIE WRAP AS SHOWN. 12 7 9 'A• 16 17 TOW 8 /J 10 7 INTAKE MANIFOLD CARBURETOR ARM 6 (REF.) (REF.) 11 ITEM PART NO. OTY, DESCRIPTION 1 098290 1 ASM MOTOR STEPPER 2 098941A 1 HOUSING GOVERNOR CONNECTOR 3 098958A REF CONNECTOR INTERFACE ASSEMBLY 4 098942A 1 COVER CONNECTOR HOUSING 5 098225 2 SCREW FHM#2 X 5/8 SELF TAP 6 043146 3 SCREW HHC M6-1.0 X 10 G8.8 7 022097 5 WASHER LOCK M6-1/4 8 084543A 1 SCREW PHM M3-0.5 X 12MM 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX#10-32 NYL INS 11 OE1326 1 ASSY.CARBURETOR LINKAGE ROD 12 OA7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 10 TIE WRAP 7.4"X.19"BLK UL 15 022507 2 SCREW HHC 1/4-20 X 1/2 G5 16 022473 2 WASHER FLAT 1/4 ZINC 17 064526 1 SCREW TAP HWH#6-25 X 3/8 ZINC 18 OE1694 1 SPRING,ANTI LASH 30 Section 9-Exploded Views and Parts �� STS Liquid-cooled 15 kW,20 kW and 25 kW Generators 0� Mounting Base—Drawing No.OEO768-B �8 7 6 14 i 5 13 i i 7 46 m . 8 �5 y, 15—��� 9 �b� �`� i, m 0 �76 7 172 ` 20 �'� i 816 i � 21 19 ! g 1 i .ISI a 40 e i GY 9 � B X10 1 i 22\ o �Q- 15 20 0 o " �o, o 22 0 ITEM PART NO. OTY, DESCRIPTION 1 OD8656 1 BASE MOUNTING 1.5L STNRD&ACSTC 2 027482 2 WASHER SHAKEPROOF EXT 5/16 STL 3 070936 2 DAMPENER VIBRATION 4 070936C 2 VIB.ISO.70-75 DURO 5 039253 8 SCREW HHC M8-1.25 X 20 G8.8 6 022145 12 WASHER FLAT 5/16 ZINC 7 022129 16 WASHER LOCK M8-5/16 8 045771 4 NUT HEX M8-1.25 G8 YEL CHR 9 071956 4 WASHER FLAT M8 10 051730 4 SCREW HHC M8-1.25 X 60 G8.8 11 021991 1 EARTH STRAP 13 OD9335 2 PANEL SUPPORT 14 OD9336 2 PANEL BRACKET 15 OC2454 16 SCREW TH-FRM M6-1 X 16 N WA Z/JS 16 047411 1 SCREW HHC M6-1.0 X 16 G8.8 17 022097 1 WASHER LOCK M6-1/4 18 022473 1 WASHER FLAT 1/4-M6 ZINC 19 055414 1 LUG SLDLSS#248 X 17/64 CU 20 049813 5 NUT HEX M6 X 1.0 G8 YEL CHR 21 026850 1 WASHER SHAKEPROOF EXT 1/4 STL 22 OA1694 2 1-1/2"BUTTON PLUG 31 N 21 *3WELD STUD UNDER ROOF PANEL FOR ACCESS COVER Z- 1 CABLE 11� . 28 13 I ; 2 4 14 17 m 29 a �; rl "'C j-12 16 °Y° I 23-0 a 11 2610 JI- 4 20- 3 ma x / J 2630 d o . 10 0 a , m CL I °Y° 15CL 1819 d 5 4 11 J 17 c 8 03 2610' �6 15 // m 9 V 24 '17 1918 \ 24 3 10 26 15 6 26 � 30 1819 ®® 15 ��®�� � NOTE: a., 10 USE DOOR LATCH 10 FASTENER TO SECURE 5 ® GROUND WIRE. NOTE: 7 24 USE LOCTITE ON NUTS ITEM#26. r I 0 Section 9-Exploded Views and Parts PARTS Liquid-cooled 15 kW and 20 kW Generators STS 0�Standard Compartment—Drawing No.OE0771-J ITEM PART NO. QTY, DESCRIPTION 1 OD8666(A) 1 ROOF ACSTC&STND CMPRTMNT 1.5L 2 OD8664C(G) 1 DUCT CENTER 1.5L 3 OD8657(A) 1 SUPPORT RADIATOR 1.5L MITSU 4 OD8660(A) 2 BRACE SIDE 1.5L MITSU 5 OA7568(A) 2 DOORWELDMENT 1.5EPS 6 OD8659(A) 1 CORNER POST REAR RH SIDE 1.5L 7 OD8662(A) 1 DOOR REAR COMPARTMENT 1.5L 8 OD8661 (A) 1 BRACE REAR 1.5L MITSU 9 OD8658(A) 1 CORNER POST REAR LH SIDE 1.5L 10* 067042 3 LATCH&CAM 11 OC2454 40 SCREW TH-FRM M6-1 X 16 N WA Z/JS 12 033530 3 SCREW PHM#10-32 X 5/8 ZINC 13 051716 3 NUT HEX M5-0.8 G8 YEL CHR 14 022152 3 WASHER LOCK#10 15 0912970064 3 ASSEMBLY BASE-DOOR GROUND WIRE 16 023762 3 WASHER SHAKEPROOF EXT#10 STL 17 0912970063 3 GRD WIRE ASSY 99HSB 18 022264 6 WASHER LOCK#8-M4 19 067035 6 SCREW PPHM#8-32 X 5/16 20 022127 1 NUT HEX 1/4-20 STEEL 21 OC2634A 1 ASSEMBLY COVER ACCESS 22 022473 1 WASHER FLAT 1/4 ZINC 23 022097 1 WASHER LOCK M6-1/4 24 OD2023 3 GASKET CLIP-ON SELF GRIPPING 26 037337 6 NUT HEX JAM 3/8-24 SS 27 OD2023 21 GASKET CLIP-ON SELF GRIPPING 28 OD8664A(E) 1 DUCT LH SIDE 1.5L 29 OD8664B(F) 1 DUCT RH SIDE 1.5L 30 077992 20 NUT HEX LOCK M6-1.0 SS NY INS * NOTE:THE KEY FOR THIS LOCK IS P/N 067042A OPTIONAL COMPARTMENT MATERIALS: ALL P/N'S WITH A( )SUFFIX INDICATE ALUMINUM MATERIAL OPTION. ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 11 THREAD FORMING FASTENER AND ITEM 30 LOCK NUT.LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS.ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER. 33 w � a 21 WELD STUD UNDER ROOF v� PANEL FOR ACCESS COVER CABLE 11 " 13 T 48 n 4 14 17 2 C C 47 FA 016 .}�16Ir 22--4C G /10 11 12 10 ryo � 23--T' 549 24-41518 24uNi O 45n 00, 26 a i �p 9 J 17 �� Z 4545 15 Q STATES FOAM IS ON NEAR SIDE 0 36 8 `\ X24 1019 (j STATES FOAM IS ON FAR SIDE c �� 18 .91, 3 10 15 42 42 17 v N k321 3 49 00 ` 10 458 9 �, ®® �� 20 25 �® ` 5 /// � 10 X381 � ROOF PANTYPIEL SECURE S SHOWCAL OF FRONT DUCTN. l 15 7 NOTE: `. NOTE: USE DOOR LATCH USE LOCTITE ON �. 41 FASTENER TO SECURE NUT#037337. GROUND WIRE. ° Section 9-Exploded Views and Parts PARTS Liquid-cooled 25 kW Generators LISTS t7�Acoustic Compartment-Drawing No.OE0772-M ITEM PART NO. OTY, DESCRIPTION 1 OD8666(A) 1 ROOF ACSTC&STND CMPRTMNT 1.5L 2 OD8664C(G) 1 DUCT CENTER 1.5L 3 OD8657(A) 1 SUPPORT RADIATOR 1.5L MITSU 4 OD8660(A) 2 BRACE SIDE 1.5L MITSU 5 OA7568(A) 2 DOOR WELDMENT 1.5 EPS 6 OD8659(A) 1 CORNER POST REAR RH SIDE 1.5L 7 OD8662(A) 1 DOOR REAR COMPARTMENT 1.5L 8 OD8661 (A) 1 BRACE REAR 1.5L MITSU 9 OD8658(A) 1 CORNER POST REAR LH SIDE 1.5L 10* 067042 3 LATCH&CAM 11 OC2454 40 SCREW TH-FRM M6-1 X 16 N WA Z/JS 12 033530 3 SCREW PHM#10-32 X 5/8 ZINC 13 051716 3 NUT HEX M5-0.8 G8 YEL CHR 14 022152 3 WASHER LOCK#10 15 0912970063 3 ASSY WIRE 14AWG 7.5#0 GRN/YEL 16 023762 3 WASHER SHAKEPROOF EXT#10 STL 17 0912970064 3 ASSY WIRE 14AWG 7.5#0 GRN/YEL 18 022264 6 WASHER LOCK#8-M4 19 067035 6 SCREW PPHM#8-32 X 5/16 20 078115 13 WASHER SELF LOCKING DOME 21 OC2634A 1 ASSEMBLY COVER ACCESS 22 022473 9 WASHER FLAT 1/4 ZINC 23 022097 9 WASHER LOCK M6-1/4 24 022127 9 NUT HEX 1/4-20 STEEL 25 OD8663 2 BAFFLE CNTRL PNL 1.5L ACOUSTIC 26 OD8665 2 BAFFLE DOOR 1.5L ACOUSTIC UNIT 27 OE0072D 1 ACSTC INSLTN 1.5L DUCT RH PNL 28 OE0072B 1 ACSTC INSLTN 1.5L DUCT LH PNL 29 OE0072Q 2 ACSTC INSLTN 1.5L RAD SUPPORT 30 OE0072C 1 ACSTC INSLTN 1.5L DUCT FNT PNL 31 OE0072A 1 ACSTC INSLTN 1.5L ROOF PANEL 32 OE0072M 2 ACSTC INSLTN 1.5L SIDE DR PNL 33 OE0072P 2 ACSTC INSLTN 1.5L SIDE DR PNL 34 OE0072L 2 ACSTC INSLTN 1.5L SIDE BRC PNL 35 OE0072N 2 ACSTC INSLTN 1.5L DR BAFFLE PL 36 OE0072G 2 ACSTC INSLTN 1.5L RR CRNR TOP 37 OE0072J 2 ACSTC INSLTN 1.5L RR CRNR BOTT 38 OE0072F 1 ACSTC INSLTN 1.5L REAR DR PNL 39 OE0072E 1 ACSTC INSLTN 1.5L REAR BRC PNL 40 OE0072K 2 ACSTC INSLTN 1.5L BAFFLE PANEL 41 OE0072H 2 ACSTC INSLTN 1.5L CNTRL SUPPT 42 OD2023 3 GASKET CLIP-ON SELF GRIPPING 45 037337 6 NUT HEX JAM 3/8-24 SS 46 OD8664A(E) 1 DUCT LH SIDE 1.5L 47 OD8664B(F) 1 DUCT RH SIDE 1.5L 48 OE0072R 2 INSUL ACO 1.5L DUCT FRNT PNL 49 077992 20 NUT HEX LOCK M6-1.0 SS NY INS * NOTE:THE KEY FOR THIS LOCK IS P/N 067042A OPTIONAL COMPARTMENT MATERIALS: ALL P/N'S WITH A( )SUFFIX INDICATE ALUMINUM MATERIAL OPTION. ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 11 THREAD FORMING FASTENER AND ITEM 49 LOCK NUT.LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS.ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER. 35 PARTS Section 9- Exploded Views and Parts LISTS 0� Liquid-cooled 15 kW,20 kW and 25 kW Generators ({p)) Control Panel—Drawing No.OE0778-G 0 0 0 0 C $ 6 p Po O O No s 7 0 0 R $ p 0 & � W o 0 0 0 $ s � o � _ 0 c 0 $ eo e o 0 e e 0 0 � s w s $ o 0 0 0 p $ a $ $ R '1 0F-101 0 I p D-1 36 Section 9-Exploded Views and Parts PARTS (./� �, Liquid-cooled 15 kW,20 kW and 25 kW Generators USTS0� Control Panel—Drawing No.OEO778-G ITEM PART NO. QTY, DESCRIPTION ITEM PART NO. OTY, DESCRIPTION 1 OD9322 1 PANEL BACK&BOTTOM GUARDIAN 30 OC2267 14 SCREW HHTT M5-0.8 X 12 BP 2 OD9332 1 PANEL LH SIDE GUARDIAN&SPRN 31 023897 15 WASHER FLAT#10 ZINC 3 OD9325A 1 PANEL FRONT CONTROL GUARDIAN 32 OC2454 4 SCREW TH-FRM M6-1X16 N WA Z/JS W/SILKSC 33 054199 1 DECAL HIGH VOLTAGE 4 OD9330 1 PANEL RH SIDE C-PANEL SML BRK 34 081988 1 DECAL EXERCISE INFO 5 OC1457 1 HOURMETER 35 OE2514 1 STRAIGHT WIRE CONNECTOR 11/2" 6 064009 1 LIGHT 12VDC.02A LED RED PILOT 36 OA1354A 1 REGULATOR-DC ALT 7 032300 1 HOLDER FUSE 37 074908 4 SCREW HHTT M5-0.8 X 10 BP 8 022676 1 FUSE 15A X AGC15 38 020911 4 SCREW PPHM M5-0.8 X 30 ZINC 9 OE4494 1 SWITCH ROC DPDT ON-OFF-ON 39 051713 5 WASHER FLAT M5 10 082573 1 SWITCH ROCKER DPST 125V SPD 40 049226 5 WASHER LOCK M5 11 083048 1 ASSEMBLY REGULATOR POTTED 41 051716 5 NUT HEX M5-0.8 G8 YEL CHR 12 083264 1 TFMR ASM CMA 240/12V 42 036261 4 RIVET POP.125 X.129-.133/#30 13 076009A 1 PP LOGIC ASM 50/60HZ 43 OD9334 1 PANEL,TOP 14* OE0331 1 HARNESS CONTROL PANEL PP 44 061979 1 BUS BAR GUARDIAN 45 022237 1 WASHER LOCK 3/8 15 056739 1 RELAY SOLENOID 12VDC PNL MNT 46 022241 1 NUT HEX 3/8-16 STEEL 16 049350 1 CIRCT BRK 4 X 1 ETA 46-500-P 47 057073 1 JUNCTION BLOCK 3/8-16 17 047822 1 BLOCK TERM 20A 7 X 6 X 1100V 48 055440 1 SCREW HHC M5-0.8 X 25 G8.8 18 048766 1 BLOCK TERM 20A 2 X 6 X I IOOV 49 OD8671 1 HINGE CONTINUOUS 1.5L CNTL PNL 19 057335 1 BLOCK TERM 20A 20 X 6 X 1100V 50 0912970080 1 WIRE ASSEMBLY 20 098647 1 ASSY L.C.ELECT GOV 51 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR 21 OE1454 1 DECAL CUST.CONNT.PRE-PACKI.5L 52 033121 1 SCREW HHC#10-32 X 1/2 22 OE1459 1 DECAL TERMINAL STRIP PRE-PACK 53 026850 1 WASHER SHAKEPROOF EXT 1/4 STL 23 072566 4 NUT SPACER.250 PCB 54 022158 1 NUT HEX#10-32 STEEL 24 080882 4 SCREW PPH TAPPING#6 X 5/8 SS 55 022152 1 WASHER LOCK#10 25 OA8955 2 SCREW PHM M6-1.0 X 20MM 56 OA3968 1 CAPACITOR FILTER ASY 26 022097 3 WASHER LOCK M6-1/4 57 OC2323 2 SCREW PHTT#6-32 X 5/8 ZYC 27 022473 2 WASHER FLAT 1/4-M6 ZINC 58 OE3783 1 DECAL WARNING REMOVE FUSE 28 OC2212 10 SCREW PHTT M4-0.7 X 16 ZYC 29 023762 2 WASHER SHAKEPROOF EXT#10 *NOT SHOWN STL 37 PARTS� Section 9-Exploded Views and Parts usrs 0 Liquid-cooled 15 M,20 M and 25 M Generators �(Q)) Engine—Drawing No.OE1228-J �3 Is N � 3 / m a o C9 13 % — ---- DD L7� / N L——7 p N N / N Q T r T \ \ /•\/VV ice$ --® -- / s CO T \ r \ vT \ r TO N T ®,R W m 38 Section 9-Exploded Views and Parts PARTS Liquid-cooled 15 kW;20 kW and 25 kW Generators STS t7� Engine-Drawing No.OE1228-J ITEM PART NO. OTY, DESCRIPTION ITEM PART NO, OTY, DESCRIPTION 1 OA4531 1 ENGINE-1.5L 45 OA7006 1 0-RING 1-1/16 X 1-5/16 X 1/8 2 022473 6 WASHER FLAT 1/4 ZINC 46 025507 2 WASHER SHAKEPROOF EXT 7/16 4 OA45310258 1 GASKET-EXHAUST MANIFOLD STL 5 OA4355 1 MANIFOLD-EXHAUST 47 022500B 2 SPACER.41 X.75 X.25 ST/ZNC 6 OE2632 1 HEAT SHIELD EXH 1.51- 48 OA8584 1 SWITCH OIL PRESSURE 7 022097 8 WASHER LOCK M6-1/4 49 036277 1 ELBOW 90D STREET 1/8 8 022507 2 SCREW HHC 1/4-20 X 1/2 G5 50 042574 1 ADAPTOR 1/8 NPTF TO 1/8-28 9 052212 2 SCREW HHC M10-1.25 X 25 G8.8 51 026073A 1 PLUG STD PIPE 1/4 STEEL SQ HD 10 046526 4 WASHER-LOCK-M10 52 OA6701 1 SCREW HHC M10-1.5 X 110 G8.8 11 022131 20 WASHER FLAT 3/8 ZINC 53 039414 1 SCREW HHC M8-1.25 X 35 G8.8 12 OC2499 2 STAMPING ENG FOOT 54 OA5568 1 SCREW HHC M12-1.25 X 55 G8.8 13 055993 1 SPACER.41 X.75 X.12 STL/ZNC 55 051769 1 WASHER LOCK M12 14 045772 1 NUT HEX M10-1.5 G8 YEL CHR 56 OA4804 1 PULLEY-CRANKSHAFT(1800 RPM) 15 023586 2 SCREW SHC 5/16-18 X 2 G8.8 NZ BUILT PRIOR TO 11/20/02 16 020692 1 STARTER-12V OA4804A 1 PULLEY-CRANKSHAFT(1800 RPM) 17 OA7005 2 SPACER.56 X 1 X.37 ST/ZNC BUILT AFTER 11/20/02 18 052243 1 SCREW HHC M10-1.5 X 60 G8.8 OA4800 1 PULLEY-CRANKSHAFT(3600 RPM) 19 OA4772 1 ENGINE PLATE BUILT PRIOR TO 11/20/02 20 070901 2 SLEEVE DOWEL BLHSG OA4800A 1 PULLEY-CRANKSHAFT(3600 RPM) 21 051735 3 SCREW HHC M10-1.5 X 70 G8.8 BUILT AFTER 11/20/02 22 056768 3 SCREW HHC M10-1.5 X 90 G8.8 57 OA5839 1 BRACKET-ALT SUPPRT 23 022145 12 WASHER FLAT 5/16 ZINC 58 OA1354B 1 DC ALTERNATOR-12V 24 022129 19 WASHER LOCK M8-5/16 59 OA4839 1 ARM ADJUST ALTERNATOR 25 022259 2 NUT HEX 5/16-18 STEEL 60 055816 4 SCREW HHC M6-1.0 X 70 G8.8 26 052213 11 SCREW HHC M10-1.25 X 20 G8.8 62 OE1936 1 FAN COOLING 15" 27 047411 2 SCREW HHC M6-1.0 X 16 G8.8 63 OA2628 1 PULLEY-FAN 95 DIA 28 052830 1 SCREW HHC M10-1.25 X 45 G8.8 64 OA5275 1 V-BELT 3/8 X 32-1/8 1.5L 30 045771 12 NUT HEX M8-1.25 G8 YEL CHR OA5586 1 V-BELT 3/8 X 28.9 1.5L 31 058306 5 SCREW SHC M8-1.25 X 25 G12.9 65 OA4814 1 SPACER PULLEY 32 030795 2 SCREW HHC 5/16-18 X 1 G5 66 OA45310244 1 FILTER OIL 33 OA2711A 1 ADAPTER-THERMOSTAT 67 OC1852 1 ADAPTER DRAIN OIL 34 048665 1 GASKET THERMOSTAT 68 0912970066 1 GROUND WIRE(STARTER) 35 075885 1 THERMOSTAT 195 DEG 69 070928 1 CLAMP HOSE-OIL DRAIN 36 OA45310257 1 GASKET INLET MANIFOLD 70 069860C 1 HOSE ASM.-OIL DRAIN 37 OE1100 1 MANIFOLD INTAKE MACHINED 71 069811 1 CAP HEX 1/4NPT BRASS 38 OE2507 1 PROBE,COOLANT LEVEL 3/8NPTF 72 058443 2 SCREW CRIMPTITE 1/4-20 X 5/8 39 OA6751 1 SW-TMP 245 DEG 3/8 NPT 73 OF3856 1 GUARD CRANKSHAFT 1.5L 40 034339 1 BARBED EL 90 3/8 NPT X 5/8 74' 055934C 1 CLAMP VINYL.5 X.406 Z 41 026925 1 PLUG STD PIPE 3/8 STEEL SQ HD 75 OF9483 1 ASSY PCB WATERLEVEL SNSR 42 061012 1 PLUG STD PIPE 1/8 SCKT HD INTFC 43 039253 5 SCREW HHC M8-1.25 X 20 G8.8 44 OA5110 1 PIPE WATER-INLET 'CLAMP FOR WIRING HARNESS(NOT SHOWN) 39 ATO ENGINE BYPASS ON INTAKE MANIFOLD C 7 6 12 1 11 22 5 14 7 . �' d� m 7 16 '� �� a a '' oA 32 15 12 t x \ 23 TO WATER INLET TUBE � N c V 26 (MIDWAY UP ENGINE BLOCK) 13 a o �� 0 CL o N 5 9'1., 8 20 8 TOTHERMOSTAT m M ADAPTER c y ` V I 32 "A" �� ki a 14 (BOTTOM ONLY) 21 8 \\ 12 24 1 19 ��� n I o 29 o I "All 10 8 d 2S 1 I �1 I i 10 l � 17 N 1 �. 1 �� TO BASE OF I 30 2 ` WATER INLET _ TUBE(ON BLOCK) o L 28 31 27/® \\ 1 36 35 1 36 3 �� ��. �� �\33 34 14 12 18 4 34 17 33 Section 9- Exploded trews and Parts PARTS Liquid-cooled 15 kW,20 kW and 25 kW Generators STS 0� Radiator—Drawing No.OE0769-L ITEM PART NO. CITY, DESCRIPTION 1 OD8657 1, SUPPORT RADIATOR 1.5L MITSU 2 OA5734 1 RADIATOR 1.5L 3 OA6237 1 VENTURI 1.5L MODINE 4* OA6238 1 GUARD FAN 1.5L MODINE 5 084918 1 HEATER ENGINE 0500W 120V 084918A 1 HEATER BLOCK 1000W 120V 6 051520N 1 TUBING 5/8 ID X 12 7 048031C 4 CLAMP HOSE BAND 1/4 8 099502 4 CLAMP HOSE#24 B1.06-2.00 9 083709 1 CLAMP WIRE HOSE.573-.551 10 052250 2 TAPE FOAM 1 X 1 (12"LG) 11 047411 4 SCREW HHC M6-1.0 X 16 G8.8 12 022097 8 WASHER LOCK M6-1/4 13 049813 2 NUT HEX M6 X 1.0 G8 YEL CHR 14 022473 9 WASHER FLAT 1/4 ZINC 15 084427 1 BRACKET HEATER 16 051520Z 1 TUBING 5/8 ID X 18"LG 17* 058443 6 SCREW CRIMPTITE 1/4-20 X 5/8 18 056892 4 SCREW CRIMPTITE 10-24 X 3/8 19 OA6284 1 HOSE-LOWER RADIATR 20 OA6258 1 HOSE-UPPER RADIATR 21 029032 1 HOSE 9/32 ID(36"LG) 22 031669 4 BOLT CARR 1/4-20 X 1-3/4 JS500 23 060035 4 SPACER.41 X.75 X.87 ST/ZNC 24 022127 4 NUT HEX 1/4-20 STEEL 26 046627 1 CAP RADIATOR 27 OC7649 1 CLAMP HOSE.38-.87 28 OC2454 4 SCREW TH-FRM M6-1 X 16 N WA Z/JS 29 076749 1 TANK COOLANT RECOVERY 30 OE0726 1 BRACKET WATER BOTTLE 1.5L MIT 31 035461 1 BARBED STR 1/4 NPT X 3/8 32 OA7275 3 FOAM 1.5 X 1 ADH BAK 33 OA2111 2 SCREW SWAGE 10-32 X 5/16 Z/YC 34 065852 2 SPRING CLIP HOLDER.37-.62 35 047290A 1 ASSY.RAD.DRAIN HOSE 36 050275 2 DECAL WARNING-FAN *FAN GUARD KIT OE3596(NOT USED WITH LEVEL ONE GUARDING) 47 PARTS Section 9-Exploded Views and Parts LISTS Q� Liquid-cooled 15 kW,20 kW and 25 kW Generators �(p)) Fuel System—Drawing No.OE0774-G 18 13 8 ° 24 /21 ° 25 X22 J 17 HCU 16 4 �' "C" i I o 29 "D" 30 12 i i 34 31 32 i 3637 35 33 38 40 ai 19 - 39 41 • 20 i �26 oOo 28 0 0 .' PORT 41 'OUT 1 p (NATURAL GAS) r 3 ° 6 / � 11 43 9 14 i 44 10 "D" i �42 l 40 --23 7 41 a 6 PORT °m, 2 burr 3 15 ' ' B 11 <�5 27 4 L.P.VAPOR 42 Section 9-Exploded Views and Parts PARTS Liquid-cooled 15 kW,20 kW and 25 kW Generators STS 0� Fuel System—Drawing No.OEO774-G ITEM PART NO, CITY- DESCRIPTION 1* --------- 1 WELDMENT MOUNTING BASE 2 075580 1 FLANGE FUEL INLET 3 OE1006 1 ASSY REGULATOR 1.5L N.G.OR LPV 4 039253 2 SCREW HHC M8-1.25 X 20 G8.8 5 022145 2 WASHER FLAT 5/16 ZINC 6 022129 6 WASHER LOCK M8-5/16 7 045771 2 NUT HEX M8-1.25 G8 YEL CHR 8 OA7040 1 BRACKET-RAD HOSE 9 032552 1 BARBED EL 90 5/16 X 1/8 NPT 10 029032 1 HOSE 9/32 ID 11" 11 OE1056 1 FUEL HOSE ASSM.NAT.GAS/L.P.V. 12 029032 1 HOSE 9/32 ID 7.5" 13 OA5547 1 COVER AIR CLEANER 14 048031C 4 CLAMP HOSE BAND 1/4 15 OD1509 1 DECAL INLET PRESSURE 16** OE0591 1 ADAPTER,CARB.TO AIR CLNR 17 059402 1 FILTER ELEMENT 18 037561 1 NUT WING 1/4-20 NYLK 19 OE1028 1 CARBURETOR ASSY.I.5L 20 059401 1 CARBURETOR GASKET 21 ** 091526 4 SCREW PPHM M5-0.8 X 12 ZNC 22** 049226 4 WASHER LOCK M5 23 026307 1 ELBOW 90D STREET 3/4 24 062522 1 STUD TH 1/4-20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1/4-20 STEEL 26 022259 2 NUT HEX 5/16-18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 OA6125 2 STUD 5/16-18 X 1.25 F THR 29 OD8492W 1 DECAL EMISSION CTRL 1.5NG 2006(10-15KW NATURAL GAS) 30** OE1104 1 GASKET AIR CLEANER ADAPTER 31** OE066B 1 0-RING 2-0281.38 X 1.50 X.06 32** OE0590 1 VENTURI 18MM 33** 005133 1 0-RING 29.82 X 2.62 34** OE0665 1 SCREW THROTTLE PIN STOP 35** OE1108 1 THROTTLE ARM REWORK 36** 033138 1 SCREW HHM#10-32 X 5/8 37** 022152 1 WASHER LOCK#10 38** OE0645 1 LEVER THROTTLE STOP 39** 063463A 1 BARBED STR 3/8NPT X 1/2 WNS 40 OE1558 1 HOSE LPG&NAT GAS 1/2 ID(231G) 41 057823 2 CLAMP HOSE#10.56-1.06 42 OE1111 1 PLATE,GAS REGULATOR MOUNTING 43 042907 2 SCREW HHC M8-1.25 X 16 G8.8 44 OC2454 2 SCREW TH-FRM M6-1 X 16 N WA Z/JS * SHOWN IN OTHER VIEW **INCLUDED IN ITEM 19(CARBURETOR ASY.) 43 PARTS Section 9-Exploded Views and Parts LISTS O Liquid-cooled 15 kW,20 kW and 25 kW Generators Alternator—Drawing No.OA9348-H W Q Z_ 2 UY ZZ N W 1 � U / U) CO d. T O Go / ^\ N r N / N / � r Cm T r / N CO NCO / N \� \/ / N / CO / r Cr) / f N � � O � m CO) 1—O = // O / / ON O (O \ CO 44 Section 9-Exploded Views and Parts PARTS Liquid-cooled 15 kW,20 kW and 25 kW Generators STS 0�Alternator—Drawing No.OA9348-H ITEM PART NO. QTY, DESCRIPTION 1 098671 1 ASSY ROTOR 10KW 098681 1 ASSY ROTOR 15KW 098675 1 ASSY ROTOR 20KW 098936 1 ASSY ROTOR 25KW 2 OA5336A 1 HOUSING BLOWER 3 OA1659 1 SCREEN AIR OUTLET 4 071912 4 SCREW PPHM M5-0.8 X 8 SS 5 049226 4 WASHER LOCK M5 6 051713 4 WASHER FLAT M5 7 022129 4 WASHER LOCK M8-5/16 8 098672 1 ASSY STATOR 10KW A 098673 1 ASSY STATOR 10KW D 098674 1 ASSY STATOR 10KW GJK 098682 1 ASSY STATOR 15KW 1 PH A 098683 1 ASSY STATOR 15KW 3PH D 098684 1 ASSY STATOR 15KW 1 PH GJK 098676 1 ASSY STATOR 20KW 1 PH A 098677 1 ASSY STATOR 20KW 1 PH D 098678 1 ASSY STATOR 20KW 1 PH GJK 097620 1 ASSY STATOR 25KW 1 PH A 098937 1 ASSY STATOR 25KW IPH D 097621 1 ASSY STATOR 25KW 3PH D 9 OA5382 1 BEARING CARRIER REAR 10 075591 1 ASSY HOLDER BRUSH 11 075476 4 SCREW PPHM M4-0.7 X 16 12 OA5601A 1 COVER REAR BEARING 13 075554B 4 BOLT STATOR X 16"LG 14 OA9375 4 SCREW RHM#10-24 X 2 15 022152 4 WASHER LOCK#10 16 097146 1 FAN&RING GEAR ASSEM. 17 042558 1 KEY SQ 3/8 X 1 STEEL 18 OA5061 1 SPACER-FLEX PLATE 19 OA4989 1 PLATE FLEX 20 053557 1 SCREW HHC M12-1.75 X 40 G8.8 21 051769 6 WASHER LOCK M12 22 049541 4 SCREW HHC M10-1.5 X 35 G8.8 23 046526 4 WASHER LOCK M10 24 045772 4 NUT HEX M10-1.5 G8 YEL CHR 26* 087599 1 PLUG PLASTIC 3/8 NPT 27 077043E 1 FLEX CONDUIT 1"BLACK(NOT SHOWN) 28 022131 4 WASHER FLAT 3/8-M10 ZINC 29 072578 1 SPACER ROTOR SHAFT 30 OA7043 5 SCREW HHC M12-1.25 X 25 G8.8 31 049808 5 WASHER FLAT M12 32 058589 1 DECAL WARN ENG START 33 023365 4 WASHER SHAKEPROOF INT#8 35 OA8830 4 WASHER FLAT.34 ID X.75 OD 36 072080 1 DECAL DANGER STANBY UNITS *USED ON PRE-PACKAGED UNITS ONLY 45 PARTS Section 9-Exploded Views and Parts LISTS 0� Liquid-cooled 15 M,20 M and 25 M Generators ({p)) Battery—Drawing No.OEO77O-C 8 TO STARTER 8 o STARTER 2 SOLENOID 17� 1 17 4 14 3 1 TO ENGINE BLOCK 16 5 i 7 i i o i 9 � v i 15 ITEM PART NO. OTY. DESCRIPTION 1 077483 REF BATT 12VDC 75-AH 26(NOT INCLUDED) 2 038804D 1 CABLE BATT RED#4 X 20.00 3 0388058 1 CABLE BATT BLK#4 X 23.00 4 0742600131 1 ASSY,WIRE#16 RED 1.6 5 022131 1 WASHER FLAT 3/8 ZINC 6 046526 1 WASHER LOCK M10 7 052213 1 SCREW HHC M10-1.25 X 20 G8.8 8 075763 3 BOOT,BATTERY CABLE 9 OD8668 1 BRACKET,BATTERY HOLD DOWN 1.5 13 050331A 1 BATTERY POST COVER(RED+) 14 050331 1 BATTERY POSTCOVER(BLACK-) 15 OC2454 2 SCREW TH-FRM M6-1X16 N WA Z/JS 16 025507 1 WASHER SHAKEPROOF EXT 7/16 STL 17 027482 2 WASHER SHAKEPROOF EXT 5/16 STL 46 Section 9-Exploded Views and Parts PARTS STS Liquid-cooled 15 kW,20 kW and 25 kW Generators (7� Muffler—Drawing No.OEO773-B 10 9 r 8 � > ' 6 `� 11 12 13 p 0 9 3 3 5 4 3 2 1 ° ° ITEM PART NO. CITY, DESCRIPTION 1 OA4355 1 MANIFOLD EXHAUST 1.5L 2 OE2844 1 NIPPLE TOE 1.5 NPT X 5.5 BLK IRON 3 036434 3 BOLT U 5/16-18 X 2.09 036449 3 SADDLE 2 INCH 4 OE0109 1 PIPE EXHAUST 1.5L STNDRD&ACSTC 5 OC1318 1 FLEX PIPE EXHAUST 6 OD8657 1 SUPPORT RADIATOR 1.5L MITSU 7 027837 2 SCREW RHM 1/4-20 X 2-1/4 8 OD9437 1 MUFFLER 1.5L ACOUSTIC&STANDARD 9 060366 2 STRAP MUFFLER 6"DIA 10 039253 4 SCREW HHC M8-1.25 X 20 G8.8 11 022145 4 WASHER FLAT 5/16 ZINC 12 022129 4 WASHER LOCK M8-5/16 13 045771 4 NUT HEX M8-1.25 G8 YEL CHR 47 Section 10 —Warranty WARW9 Liquid-cooled 15 kW,20 kW and 25 kW Generators CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board(CARB)and Generac Power Systems,Inc. (Generac)are pleased to explain the Emission Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be designed, built and equipped to meet the state's stringent anti-smog standards. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse,neglect,unapproved modifica- tion or improper maintenance of your engine. Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will repair your engine at no cost to you for diagnosis,replacement parts and labor, should a warrantable condition occur. MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY COVERAGE: Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, dur- ing such warranty period, any emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility. PURCHASER'S/OWNER'S WARRANTY RESPONSIBILITIES: As the engine purchaser/owner,you are responsible for the completion of all required maintenance as listed in your factory supplied Owner's Manual. For warranty purposes, Generac recommends that-you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance. As the engine purchaser/owner,you should, however,be aware that Generac may deny any and/or all warranty coverage or responsibility if your engine, or a part/component thereof,has failed due to abuse,neglect,improper maintenance or unap- proved modifications, or the use of counterfeit and/or`grey market'parts not made, supplied or approved by Generac. You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a problem occurs.The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility. To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number: 1-800-333-1322 IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the "Generac Limited Warranties for Generac Power Systems, Inc.," which is enclosed herewith on a separate sheet, also provided to you by Generac.The ECS Warranty applies only to the emission control system of your new engine.If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period.Both the ECS Warranty and the Generac Warranty describe impor- tant rights and obligations with respect to your new engine. Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty ser- vice, evidence must be presented showing the date of the sale to the original purchaser/owner. H you have any questions regarding your warranty rights and responsibilities,you should contact Generac at the fol- lowing address: ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS, INC. P.O. BOX 297 WHITEWATER,WI 53190 Part 1 48 Section 10 —Warranty Liquid-cooled 15 kW,20 kW and 25 kW Generators WpRRpA1N EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty(ECS Warranty) for 1995 and later model year engines: (a)Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall con- tinue for 24 consecutive months thereafter. (b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or equipment and to each subsequent purchaser/owner that each of its engines is ... (1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority, and (2)Free from defects in materials and workmanship which, at any time during the ECS Warranty Period,may cause a war- ranted emissions-related part to fail to be identical in all material respects to the part as described in the engine manu- facturer's application for certification. (c)The ECS Warranty only pertains to emissions-related parts on your engine, as follows: (1)Any warranted,emissions-related parts that are not scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period,it shall be repaired or replaced by Generac according to Subsection(4)below.Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period. (2)Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted for the ECS Warranty Period.A statement in such written instructions to the effect of"repair or replace as necessary"shall not reduce the ECS Warranty Period.Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period. (3)Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part.If the part fails prior to the first scheduled replacement,the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part. (4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility. (5)When the engine is inspected by a Generac Authorized Warranty Service Facility,the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable. (6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission-related part covered by the ECS Warranty. (7)Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand for such emission-related parts. (8)Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac ECS Warranty obligations. (9)Unapproved, add-on, modified, counterfeit and/or"grey market"parts may not be used to modify or repair a Generac engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or"grey market"part. EMISSION RELATED PARTS INCLUDE THE FOLLOWING: 1)Fuel Metering System: 3)Ignition System including. 1.2) LPG/Natural Gas carburetion assembly and its internal a)Spark plug components. b)Ignition module a)Fuel controller(if so equipped) 4)Catalytic Muffler Assembly(if so equipped)including: b)Mixer and its gaskets(if so equipped) a)Muffler gasket c)Carburetor and its gaskets(if so equipped) b)Exhaust manifold d)Primary gas regulator(if so equipped) 5)Crankcase Breather Assembly including: e)LP liquid vaporizer(if so equipped) a)Breather connection tube 2)Air Induction System including: a)Intake pipe/manifold b)Air cleaner *Generac engine types covered by this warranty statement include the following: 1)Prepackaged Standby Generator 2)Auxiliary Power Unit(APU)Generator 3)Standby Generator Part 2 49 Section 10—Warranty WARRN0 Liquid-cooled 15 kW,20 kW and 25 kW Generators GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Generac Power Systems, Inc.(Generac)warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below.Generac will,at its option,repair or replace any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer,is found to be defective. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Guardian Authorized Warranty Service Dealer.All transportation costs under the warranty, including return to the factory,are to be borne and prepaid by the purchaser/owner.This warranty applies only to Generac Guardian prepackaged emergency automatic standby generators sold and rated for use in"Standby"applications. WARRANTY SCHEDULE YEARS ONE and TWO- 100%(one hundred percent)transferable coverage on Labor and Part(s) listed (proof of purchase and main- tenance is required): Engine-All Components Alternator-All Components Transfer System-All Components Steel enclosures are warranted against rusting for the first year of ownership only.Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty.Nicks,scrapes, dents or scratches to the painted enclosure should be repaired promptly by the owner. All warranty expense allowances are subject to the conditions defined in Guardian's Warranty Policies, Procedures and Flat Rate Manual. THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING: • Guardian generators that utilize non-Guardian/Generac replacement parts. • Guardian generators utilizing non-Guardian/Generac automatic transfer switches. • Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by Generac Power Systems. • Any Guardian generators used as rental or trailer mounted applications. • Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist. • Costs of normal maintenance,adjustments, installation and start-up. • Steel enclosures that are rusting due to the improper installation, location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised. • Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts. • Failures due, but not limited,to normal wear and tear,accident, misuse, abuse, negligence or improper installation.As with all mechanical devices,the Generac engines need periodic part(s)service and replacement to perform well.This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine. • Failures caused by any external cause or act of God,such as collision,theft,vandalism, riot or wars, nuclear holocaust,fire, freezing, lightning, earthquake,windstorm, hail,volcanic eruption, water or flood,tornado or hurricane. • Damage related to rodent and/or insect infestation. • Products that are modified or altered in a manner not authorized by Generac in writing. • Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s). • Failure due to misapplication. • Telephone, cellular phone,facsimile, internet access or other communication expenses. • Living or travel expenses of person(s)performing service,except as specifically included within the terms of a specific unit warranty period. • Expenses related to"customer instruction"or troubleshooting where no manufacturing defect is found. • Rental equipment used while warranty repairs are being performed. • Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.;cranes, hoists, lifts, etc.) • Overnight freight costs for replacement part(s). • Overtime labor. • Starting batteries,fuses, light bulbs and engine fluids. THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED.SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.Some states do not allow limitations on how long an implied warranty lasts,so the above limitation may not apply to you. GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S)AS STATED ABOVE.IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE.Some states do not allow the exclusion or limitation of incidental or consequential damages,so the above limitation may not apply to you. This warranty gives you specific legal rights.You also have other rights from state to state. GENERAC@ POWER SYSTEMS, INC. P.O. BOX 297 • WHITEWATER, WI 53190 Revision 02/01/05 Part No.OE1 151 Revision P(01/15/081 Printed in U.S.A. GROUP C T � ♦/ 7 14 5 I 13 ♦ i Y 9 \� a ° ' 1 q 5 14 15 ® i All 11 5 �20 '�18 95 1 2 I 21 Is 5 .� o 11 9 I e - 0 10 22 o 15 o i o • 20 e 0 0 0 'voo e i' 0 0 o 22 0 =IA)DIED VIEW: : REVISIOR 0-1334-B MOUNTING BASE 1.51. DATM 1019103 PAOB 1 OF 2 IIDRAAWW(CT#:OEDM EXPIDIIDED VMW:MOUNTING BASE IAL BDItAMNO#:mom (GROUP C APPLICABLE TO: 1TSM< PART# QTY. DHSCR�TION 1 OD8656 1 BASE MOUNTING 1.51-STNRD&ACSTC 2 027482 2 WASHER SHAKEPROOF EXT 5116 STL 3 070936 2 DAMPENER VIBRATION 4 070936C 2 VIB.ISO.70-75 DURO 5 039253 8 SCREW HHC M8.1.25 X 20 G8.8 6 022145 12 WASHER FLAT 5116 ZINC 7 022129 16 WASHER LOCK M8.5116 8 045771 4 NUT HEX M8.1.25 G8 YEL CHR 9 071956 4 WASHER FLAT M8 10 051730 4 SCREW HHC M8.1.25 X 60 G8.8 11 021991 1 EARTH STRAP 13 OD9335 2 PANEL SUPPORT 14 OD9336 2 PANEL BRACKET 15 OC2454 16 SCREW TH-FRM M6.1 X 16 N WA Z1JS 16 047411 1 SCREW HHC M6.1.0 X 16 G8.8 17 022097 1 WASHER LOCK M6.114 18 022473 1 WASHER FLAT 114-M6 ZINC 19 055414 1 LUG SLDLSS#248 X 17164 CU 20 049813 5 NUT HEX M6 X 1.0 G8 YEL CHR 21 026850 1 WASHER SHAKEPROOF EXT 114 STL 22 OA1694 2 1.112"BUTTON PLUG C RE VMON-0-1334B DATE: 1019103 PACE 2 OF 2 GROUP C 8 TO 8 c STARTER STARTER 2 SOLENOID 17� 1 ' 4 17 14 3 1 TO ENGINE BLOCK 16 5 o , 7 � o 9 i NI\ EXPLODED VlEW: REVISION: G-6280-C 15 BATTERY 1.5L 1OKW 25KW DATE: 8/22/05 PAGE I OF 2 DRAWING M OE0770 EXPLODED VIEW:BATTERY 1.5L 1OKW-25KW DRAWING M OE0770 GROUP C APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 1 077483 REF BATT 12VDC 75-AH 26(NOT INCLUDED) 2 038804D 1 CABLE BATT RED#4 X 20.00 3 0388058 1 CABLE BATT BLK#4 X 23.00 4 0742600131 1 ASSY,WIRE#16 RED 1.6 5 022131 1 WASHER FLAT 318 ZINC 6 046526 1 WASHER LOCK M10 7 052213 1 SCREW HHC Ml 0-1.25 X 20 G8.8 8 075763 3 BOOT,BATTERY CABLE 9 OD8668 1 BRACKET,BATTERY HOLD DOWN 1.5 13 050331A 1 BATTERY POST COVER(RED+) 14 050331 1 BATTERY POSTCOVER(BLACK.) 15 OC2454 2 SCREW TH-FRM M6-1X16 N WA ZIJS 16 025507 1 WASHER SHAKEPROOF EXT 7116 STL 17 027482 2 WASHER SHAKEPROOF EXT 5116 STL REVISION: G-6280-C DATE: 8/22/05 PAGE 2 OF 2 GROUP F 21 WELD STUD UNDER ROOF L ' PANEL FOR ACCESS COVER CABLE 11 , ' 28 13 I 2 4 14 17 29 I j-12 �16 �, y 22-6 X11 2610 L130 20-4 I � 26 10 \\ i Q . j lye 15 11 y� 1819 "7° 9 17 8 26 26 15 10 � 24 17 1924 102 15 6 18 �� 3 30 26 g 9 "Z' 15 NOTE: v ^I 10 0 � USE DOOR, FASTENER O SECURE I 5 ~GROUND WIRE. I l NOTE: ��. 7 24 USE LOCTITE ON NUTS ITEM#26. r I 11�\ EXPLODED VIEW: REVISION: G-6190—J ° COMPARTMENT STANDARD 1.5L DATE: 8/16/05 PAGE 1 OF 2 DRAWING#:OE0771 EXPLODED VIEW:COMPARTMENT STANDARD 1.5L DRAWING#:OE0771 GROUP F APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 1 OD8666(A) 1 ROOF ACSTC&STND CMPRTMNT 1.5L 2 OD8664C(G) 1 DUCT CENTER 1.5L 3 OD8657(A) 1 SUPPORT RADIATOR 1.5L MITSU 4 OD8660(A) 2 BRACE SIDE 1.5L MITSU 5 OA7568(A) 2 DOORWELDMENT 1.5EPS 6 OD8659(A) 1 CORNER POST REAR RH SIDE 1.5L 7 OD8662(A) 1 DOOR REAR COMPARTMENT 1.5L 8 OD8661(A) 1 BRACE REAR 1.5L MITSU 9 OD8658(A) 1 CORNER POST REAR LH SIDE 1.5L 10* 067042 3 LATCH&CAM 11 OC2454 40 SCREW TH-FRM M6.1 X 16 N WA ZIJS 12 033530 3 SCREW PHM#10.32 X 518 ZINC 13 051716 3 NUT HEX M5.0.8 G8 YEL CHR 14 022152 3 WASHER LOCK#10 15 0912970064 3 ASSEMBLY BASE-DOOR GROUND WIRE 16 023762 3 WASHER SHAKEPROOF EXT#10 STL 17 0912970063 3 GRD WIRE ASSY 99HSB 18 022264 6 WASHER LOCK#8-M4 19 067035 6 SCREW PPHM#8.32 X 5116 20 022127 1 NUT HEX 114.20 STEEL 21 OC2634A 1 ASSEMBLY COVER ACCESS 22 022473 1 WASHER FLAT 114 ZINC 23 022097 1 WASHER LOCK M6.114 24 OD2023 3 GASKET CLIP-ON SELF GRIPPING 26 037337 6 NUT HEX JAM 318.24 SS 27 OD2023 21 GASKET CLIP-ON SELF GRIPPING 28 OD8664A(E) 1 DUCT LH SIDE 1.5L 29 OD8664B(F) 1 DUCT RH SIDE 1.5L 30 077992 20 NUT HEX LOCK M6.1.0 SS NY INS * NOTE:THE KEY FOR THIS LOCK IS PIN 067042A OPTIONAL COMPARTMENT MATERIALS: ALL PIN'S WITH A( )SUFFIX INDICATE ALUMINUM MATERIAL OPTION. ALUMINUM ENCLOSURE NOTE:ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 11 THREAD FORMING FASTENER AND ITEM 30 LOCK NUT.LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS.ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER. REVISION: G-6190-J DATE: 8/16/05 PAGE 2 OF 2 21 GROUP F . ' WELD STUD UNDER ROOF PANEL FOR ACCESS COVER CABLE 11� 13 ' 46 4 14 17 I �3�) I 2 47 �161 1481 12 22-4 28 30 /10 j 1 10 23--T 49 24--4 5 15 4518 tJ . 19 29 I 26 I I ® X29) 11 i 9 j 17 45 45 15 ��� O STATES FOAM IS ON NEAR SIDE 36 8 22/ 2324 101 STATES FOAM IS ON FAR SIDE 39) x y�� 18 42 42 17 �� 3 10 15 \3 10 49 8 9 39 \ 1� 20 6 v 5 25 10 X38) / TYPICAL OF FRONT DUCT&ROOF 42 �� 49 PANEL.SECURE AS SHOWN. 15 7 NOTE: USE DOOR LATCH NOTE: 41 FASTENER TO SECURE USE LOCTITE ON 11 �� GROUND WIRE. NUT#037337. c EXPLODED VIEW: REVISION: G-6190-M COMPARTMENT ACOUSTIC 1.51- DATE: 8/16/05 PAGE I OF 2 DRAWING#:OE0772 EXPLODED VIEW:COMPARTMENT ACOUSTIC 1.5L DRAWING#:OE0772 GROUP F APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 1 OD8666(A) 1 ROOF ACSTC&STND CMPRTMNT 1.5L 2 OD8664C(G) 1 DUCT CENTER 1.5L 3 OD8657(A) 1 SUPPORT RADIATOR 1.5L MITSU 4 OD8660(A) 2 BRACE SIDE 1.5L MITSU 5 OA7568(A) 2 DOOR WELDMENT 1.5 EPS 6 OD8659(A) 1 CORNER POST REAR RH SIDE 1.5L 7 OD8662(A) 1 DOOR REAR COMPARTMENT 1.5L 8 OD8661(A) 1 BRACE REAR 1.5L MITSU 9 OD8658(A) 1 CORNER POST REAR LH SIDE 1.5L 10' 067042 3 LATCH&CAM 11 OC2454 40 SCREW TH-FRM M6-1 X 16 N WA ZIJS 12 033530 3 SCREW PHM#10.32 X 518 ZINC 13 051716 3 NUT HEX M5.0.8 G8 YEL CHR 14 022152 3 WASHER LOCK#10 15 0912970063 3 ASSY WIRE 14AWG 7.5#0 GRNIYEL 16 023762 3 WASHER SHAKEPROOF EXT#10 STL 17 0912970064 3 ASSY WIRE 14AWG 7.5#0 GRNIYEL 18 022264 6 WASHERLOCK#8-M4 19 067035 6 SCREW PPHM#8.32 X 5116 20 078115 13 WASHER SELF LOCKING DOME 21 OC2634A 1 ASSEMBLY COVER ACCESS 22 022473 9 WASHER FLAT 114 ZINC 23 022097 9 WASHER LOCK M6.114 24 022127 9 NUT HEX 114.20 STEEL 25 OD8663 2 BAFFLE CNTRL PNL 1.5L ACOUSTIC 26 OD8665 2 BAFFLE DOOR 1.5L ACOUSTIC UNIT 27 OE0072D 1 ACSTC INSLTN 1.5L DUCT RH PNL 28 OE0072B 1 ACSTC INSLTN 1.5L DUCT LH PNL 29 OE0072Q 2 ACSTC INSLTN 1.5L RAD SUPPORT 30 OE0072C 1 ACSTC INSLTN 1.5L DUCT FNT PNL 31 OE0072A 1 ACSTC INSLTN 1.5L ROOF PANEL 32 OE0072M 2 ACSTC INSLTN 1.5L SIDE DR PNL 33 OE0072P 2 ACSTC INSLTN 1.5L SIDE DR PNL 34 OE0072L 2 ACSTC INSLTN 1.5L SIDE BRC PNL 35 OE0072N 2 ACSTC INSLTN 1.5L DR BAFFLE PL 36 OE0072G 2 ACSTC INSLTN 1.5L RR CRNR TOP 37 OE0072J 2 ACSTC INSLTN 1.5L RR CRNR BOTT 38 OE0072F 1 ACSTC INSLTN 1.5L REAR DR PNL 39 OE0072E 1 ACSTC INSLTN 1.5L REAR BRC PNL 40 OE0072K 2 ACSTC INSLTN 1.5L BAFFLE PANEL 41 OE0072H 2 ACSTC INSLTN 1.5L CNTRL SUPPT 42 OD2023 3 GASKET CLIP-ON SELF GRIPPING 45 037337 6 NUT HEX JAM 318.24 SS 46 OD8664A(E) 1 DUCT LH SIDE 1.5L 47 OD8664B(F) 1 DUCT RH SIDE 1.5L 48 OE0072R 2 INSUL ACO 1.5L DUCT FRNT PNL 49 077992 20 NUT HEX LOCK M6.1.0 SS NY INS * NOTE:THE KEY FOR THIS LOCK IS PIN 067042A OPTIONAL COMPARTMENT MATERIALS: ALL PIN'S WITH A( )SUFFIX INDICATE ALUMINUM MATERIAL OPTION. ALUMINUM ENCLOSURE NOTE:ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 11 THREAD FORMING FASTENER AND ITEM 49 LOCK NUT.LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS.ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER. REVISION: G-6190-M DATE: 8/16/05 PAGE 2 OF 2 GROUP E 18 13 8 24 �21 25 X22 J 17 �ic�� 16 r/ � 4 liCil I j o 29 T"14 'I I 30 \ i 34 31 32 i 3637 35 33 I I _ f38 40 19 39 41oo 20 6 0 ° I 28 PORT ° 41 GOUT 10 1 (NATURAL GAS) 1 0 ' 3 r 6 11 43� 9 14 10 ` °�° i T 42 l o �23 o .' < 7 40 �`''� 6 '0 2 41 15 PORT � "OUT 2° 34 5 27 0 11 L.P. VAPOR EXPLODED VIEW: REVISION: G-7134-G FUEL SYSTEM N.G IRN. DATE: 1/4/06 PAGE 1 OF 2 DRAWING#:OE0774 EXPLODED VIEW:FUEL SYSTEM N.G./L.P.V. DRAWING#:OE0774 GROUP E APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 1* ------- 1 WELDMENT MOUNTING BASE 2 075580 1 FLANGE FUEL INLET 3 OE1006 1 ASSY REGULATOR 1.51-N.G.OR LPV 4 039253 2 SCREW HHC M8.1.25 X 20 G8.8 5 022145 2 WASHER FLAT 5116 ZINC 6 022129 6 WASHER LOCK M8.5116 7 045771 2 NUT HEX M8.1.25 G8 YEL CHR 8 OA7040 1 BRACKET-RAD HOSE 9 032552 1 BARBED EL 90 5116 X 118 NPT 10 029032 1 HOSE 9132 ID 11" 11 OE1056 1 FUEL HOSE ASSM.NAT.GASIL.P.V. 12 029032 1 HOSE 9132 ID 7.5" 13 OA5547 1 COVER AIR CLEANER 14 048031C 4 CLAMP HOSE BAND 114 15 OD1509 1 DECAL INLET PRESSURE 16" OE0591 1 ADAPTER,CARB.TO AIR CLNR 17 059402 1 FILTER ELEMENT 18 037561 1 NUT WING 114-20 NYLK 19 OE1028 1 CARBURETOR ASSY.1.5L 20 059401 1 CARBURETOR GASKET 21** 091526 4 SCREW PPHM M5.0.8 X 12 ZNC 22** 049226 4 WASHER LOCK M5 23 026307 1 ELBOW 90D STREET 314 24 062522 1 STUD TH 114.20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 114.20 STEEL 26 022259 2 NUT HEX 5116.18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 OA6125 2 STUD 5116.18 X 1.25 F THR 29 OD8492W 1 DECAL EMISSION CTRL 1.5NG 2006(10-15KW NATURAL GAS) 30** OE1104 1 GASKET AIR CLEANER ADAPTER 31*' OE0668 1 0-RING 2.0281.38 X 1.50 X.06 32*" OE0590 1 VENTURI18MM 33** 005133 1 0-RING 29.82 X 2.62 34*' OE0665 1 SCREW THROTTLE PIN STOP 35" OE1108 1 THROTTLE ARM REWORK 36" 033138 1 SCREW HHM#10.32 X 518 37" 022152 1 WASHER LOCK#10 38" OE0645 1 LEVER THROTTLE STOP 39" 063463A 1 BARBED STR 318NPT X 112 WNS 40 OE1558 1 HOSE LPG&NAT GAS 112 ID(23"1-G) 41 057823 2 CLAMP HOSE#10.56.1.06 42 OE1111 1 PLATE,GAS REGULATOR MOUNTING 43 042907 2 SCREW HHC M8.1.25 X 16 G8.8 44 OC2454 2 SCREW TH-FRM M6.1 X 16 N WA ZIJS * SHOWN IN OTHER VIEW "INCLUDED IN ITEM 19(CARBURETOR ASY.) REVISION: G-7134-G DATE: 1/4/06 PAGE 2 OF 2 1360 153,54'7 BASE FOOTPRINT 53 106 19 NOTES- 12,09'1 14,17'1 10,75'1 ELECTRICAL TYP 1. STANDARD BLOCK HEATER REQUIRES 120V AC CONNECTION STUB-UP ___-_______________________________ ------------------------- -------------------- 2, CONNECTION POINTS FOR AC LOAD LEADS AND ENGINE AUTOMATIC AREA '� ° + START/STOP CONTROL WIRES PROVIDED IN CONTROL PANEL. 3. 12 VOLT NEGATIVE GROUND SYSTEM Emma BATTERY TRAY INSIDE DIMENSIONS: 162 x 220 16, 38' X 8, 66'1 4. 2. 0' I. D. FLEX EXHAUST, STANDARD WITH COMPARTMENT o 4HOHIM0654 UNITS, OPTIONAL WITHOUT lumam 125,75'1 5, MAIN LINE CIRCUIT BREAKER, 475 BASE 118,70'3 ° !o!2no FOOTPRINT WEIGHT DATA 616 UNIT: 390 kg 1860 lbs] 124,25'1 Li @TYP UNITS: Mm [INCHES] 0 ENGINE SERVICE CONNECTIONS BREHM iy O INLET LP VAPOR = 3/4' NPT COUPLING 89,5 INLET NATURAL GAS = 3/4' NPT COUPLING 13.52'3 015,06 12V BATTERY NOTE 1 207 OIL DRAIN = 1/4' NPT COUPLING 100.59'] SEE NOTE 3 473 18,15'1 EXHAUST OUTLET - 2' OD MUFFLER OUTLET (6 PLCS) 946 118,62'1 TYP TYP 137,24'1 TYP TOP VIEW 1722 759 [67,80'] 129'88"] NOTE 4 RADIATOR ACCESS CAP NOTE 5 ---------------------------------------- --- ------------ NOTE 2 0 f7� Q o 0 o i 0 917,6 a a 136,12'1 EIDE] --- n r I38 `Lt_ �- Ju/J 11.50'1�-� Ui 654 GROUNDING NATURAL GAS OR L,P, VAPOR 230 125,75'7 LUG (FARSIDE) CONNECTION 3/4' NPT 19,06'3 REAR VIEW WEATHER PROOF & ACOUSTIC (SHOWN WITH DOOR REMOVED) COMPARTMENTS 32 GRO ROUP 24� 33 23 1! 34 38 i 35 %76% I 36 I 75 �.i�� 65 I 64 39 �� i ,�A�� 0. O r s2 / r J IIi I 74 123 f \ .I 240 42 24 2431 � 7 41 37 44 63 .b 60 30 24 4551 I i 50 I 48 TO 49 66��� � �� WATERPUMP \ °Au 10 14 i I b�HARDWARE 24 I i 10 72 9 10 11 1% 47 t1 59 7,j57 6967 ` 58 53 1 24 ® 52 73 12 71 14 70 56 10 55 11 54 4 x`24\ � 1410 \ � � 1146 111/// i 5 6 N% 11 17 68 �i� Z.. 11 10 1 28 IK14 �"� 20 2 30 24 10 \ 19 1%\ ` 7 J 11 11 1% 0 , 2 727 46 21 8 � 15 IC 10 13 16 126 rio14 10 11 220 �12 r 17 11 23 24 EXPLODED VIEW: REVISION: G-6902-J 18 21 22 25 ENGINE COMMON PARTS DATE: 11/21/05 PAGE 1 OF 2 DRAWING#: OE1228 EXPLODED VIEW:ENGINE COMMON PARTS DRAWWG#:OE1228 GR®U? D APPLICABLE TO: ITEM PART# QTY. DESCWnON ITEM PART# QTY. DESCRIPTION 1 OA4531 1 ENGINE-1.5L 64 OA5275 1 V-BELT 318 X 32.118 1.5L 2 022473 6 WASHER FLAT 114 ZINC OA5586 1 V-BELT 318 X 28.9 1.5L 4 CA45310258 1 GASKET-EXHAUST MANIFOLD 65 OA4814 1 SPACER PULLEY 5 OA4355 1 MANIFOLD-EXHAUST 66 OA45310244 1 FILTER OIL 6 OE2632 1 HEAT SHIELD EXH 1.51- 67 OC1852 1 ADAPTER DRAIN OIL 7 022097 8 WASHER LOCK M6.114 68 0912970066 1 GROUND WIRE(STARTER) 8 022507 2 SCREW HHC 114.20 X 112 G5 69 070928 1 CLAMP HOSE-OIL DRAIN 9 052212 2 SCREW HHC M10.1.25 X 25 G8.8 70 069860C 1 HOSE ASM.-OIL DRAIN 10 046526 4 WASHER-LOCK-MIO 71 069811 1 CAP HEX 114NPT BRASS 11 022131 20 WASHER FLAT 318 ZINC 72 058443 2 SCREW CRIMPTITE 114.20 X 518 12 OC2499 2 STAMPING ENG FOOT 73 OF3856 1 GUARD CRANKSHAFT 1.5L 13 055993 1 SPACER.41 X.75 X.12 STLJZNC 74' 055934C 1 CLAMP VINYL.5 X.406 Z 14 045772 1 NUT HEX M10.1.5 G8 YEL CHR 75 OF9483 1 ASSY PCB WATERLEVEL SNSR INTFC 15 023586 2 SCREW SHC 5116.18 X 2 G8.8 NZ 16 020692 1 STARTER-12V 'CLAMP FOR WIRING HARNESS(NOT SHOWN) 17 OA7005 2 SPACER.56 X 1 X.37 STRNC 18 052243 1 SCREW HHC M10.1.5 X 60 G8.8 19 OA4772 1 ENGINE PLATE 20 070901 2 SLEEVE DOWEL BLHSG 21 051735 3 SCREW HHC M1D-1.5 X 70 G8.8 22 056768 3 SCREW HHC M10.1.5 X 9D G8 8 23 022145 12 WASHER FLAT 5116 ZINC 24 022129 19 WASHER LOCK M8-5116 25 022259 2 NUT HEX 5116.18 STEEL 26 052213 11 SCREW HHC M10.1.25 X 20 G8.8 27 047411 2 SCREW HHC M6.1.0 X 16 G8.8 28 052830 1 SCREW HHC M10.1.25 X 45 G8.8 30 045771 12 NUT HEX M8.1.25 G8 YEL CHR 31 058306 5 SCREW SHC M8.1.25 X 25 612.9 32 030795 2 SCREW HHC 5116.18 X 1 G5 33 OA2711A 1 ADAPTER-THERMOSTAT 34 048665 1 GASKETTHERMOSTAT 35 075885 1 THERMOSTAT 195 DEG 36 DA45310257 1 GASKET INLET MANIFOLD 37 OE1100 1 MANIFOLD INTAKE MACHINED 38 OE2507 1 PROBE,COOLANT LEVEL 318NPTF 39 OA6751 1 SW-TMP 245 DEG 318 NPT 40 034339 1 BARBED EL 90 318 NPT X 518 41 026925 1 PLUG STD PIPE 318 STEEL SQ HD 42 061012 1 PLUG STD PIPE 118 SCKT HD 43 039253 5 SCREW HHC M8.1.25 X 20 G8.8 44 OA5110 1 PIPE WATER-INLET 45 OA7006 1 O-RING 1.1116 X 1.5116 X 118 46 025507 2 WASHER SHAKEPROOF EXT 7116 STL 47 022500B 2 SPACER.41X.75X25STIZNC 48 OA8584 1 SWITCH OIL PRESSURE 49 036277 1 ELBOW 90D STREET 118 50 042574 1 ADAPTOR 118 NPTF TO 118.28 51 026073A 1 PLUG STD PIPE 114 STEEL SQ HD 52 OA6701 1 SCREW HHC MID-1.5 X 110 G8.8 53 039414 1 SCREW HHC M8.1.25 X 35 G8.8 54 OA5568 1 SCREW HHC M12.1.25 X 55 G8.8 55 051769 1 WASHER LOCK M12 56 OA4804 1 PULLEY-CRANKSHAFT(1800 RPM)BUILT PRIOR TO 11120102 OA4804A 1 PULLEY-CRANKSHAFT(1800 RPM)BUILT AFTER 11120102 OA4800 1 PULLEY-CRANKSHAFT(3600 RPM)BUILT PRIOR TO 11120102 OA4800A 1 PULLEY-CRANKSHAFT(3600 RPM)BUILT AFTER 11120102 57 OA5839 1 BRACKET-ALT SUPPRT 58 OA1354B 1 DC ALTERNATOR-12V 59 OA4839 1 ARM ADJUST ALTERNATOR 60 055816 4 SCREW HHC M6.1.0 X 70 G8.8 62 OE1936 1 FAN COOLING 15" 63 OA2628 1 PULLEY-FAN 95 DIA REVISION: G-6902-J DATE: 11/21/05 PAGE 2 OF 2 GROUP A 1 17 16 30 21 31 29 21 20 36 18 24--"7 19 32 23 26 To Blower y Housing 35 7 22 10 11 TO ENGINE ,b CRANKSHAFT 8 33 � 2 . 3 6 5 o ® 13 12 4 9 15 14 EXPLODED VIEW: REVISION: G-6148-H GENERATOR DATE: 8/10/05 PAGE 1 OF 2 DRAWING M OA9348 EXPLODED VIEW:GENERATOR DRAWING M OA9348 GROUP A APPLICABLE TO: 1.5L ITEM PART# QTY. DESCRIPTION 1 098671 1 ASSY ROTOR 1 OKW 098681 1 ASSY ROTOR 15KW 098675 1 ASSY ROTOR 20KW 098936 1 ASSY ROTOR 25KW 2 OA5336A 1 HOUSING BLOWER 3 OA1659 1 SCREEN AIR OUTLET 4 071912 4 SCREW PPHM M5.0.8 X 8 SS 5 049226 4 WASHER LOCK M5 6 051713 4 WASHER FLAT M5 7 022129 4 WASHER LOCK MB-5116 8 098672 1 ASSY STATOR 10KW A 098673 1 ASSY STATOR 10KW D 098674 1 ASSY STATOR 10KW GJK 098682 1 ASSY STATOR 15KW 1 PH A 098683 1 ASSY STATOR 15KW 3PH D 098684 1 ASSY STATOR 15KW 1PH GJK 098676 1 ASSY STATOR 20KW 1PH A 098677 1 ASSY STATOR 20KW 1PH D 098678 1 ASSY STATOR 20KW 1PH GJK 097620 1 ASSY STATOR 25KW 1 PH A 098937 1 ASSY STATOR 25KW 1 PH D 097621 1 ASSY STATOR 25KW 3PH D 9 OA5382 1 BEARING CARRIER REAR 10 075591 1 ASSY HOLDER BRUSH 11 075476 4 SCREW PPHM M4.0.7 X 16 12 OA5601A 1 COVER REAR BEARING 13 075554B 4 BOLT STATOR X 16"LG 14 OA9375 4 SCREW RHM#10.24 X 2 15 022152 4 WASHER LOCK#10 16 097146 1 FAN&RING GEAR ASSEM. 17 042558 1 KEY SQ 318 X 1 STEEL 18 OA5061 1 SPACER-FLEX PLATE 19 OA4989 1 PLATE FLEX 20 053557 1 SCREW HHC M12.1.75 X 40 G8.8 21 051769 6 WASHER LOCK M12 22 049541 4 SCREW HHC M10.1.5 X 35 G8.8 23 046526 4 WASHER LOCK M10 24 045772 4 NUT HEX M10.1.5 G8 YEL CHR 26' 087599 1 PLUG PLASTIC 318 NPT 27 077043E 1 FLEX CONDUIT 1"BLACK(NOT SHOWN) 28 022131 4 WASHER FLAT 318-M10 ZINC 29 072578 1 SPACER ROTOR SHAFT 30 OA7043 5 SCREW HHC M12.1.25 X 25 G8.8 31 049808 5 WASHER FLAT M12 32 058589 1 DECAL WARN ENG START 33 023365 4 WASHER SHAKEPROOF INT#8 35 OA8830 4 WASHER FLAT.34 ID X.75 OD 36 072080 1 DECAL DANGER STANBY UNITS •USED ON PRE-PACKAGED UNITS ONLY REVISION: G-6148-H DATE: 8/10/05 PAGE 2 OF 2 TO ENGINE BYPASS GROUP C ON INTAKE MANIFOLD 7 6 12 11 7 11 1 5 22 14 r 16 7 32 15 TO WATER INLET TUBE 12 �\\ 23 26 (MIDWAY UP ENGINE BLOCK) 13 9 �� 8 20 8 TO THERMOSTAT ADAPTER o I 32 UK � 14 (BOTTOM ONLY) 21 I g ��� 12 24 I ` 19 I 1 "N1 29 10 8 rte\ I � • 28 1 r �\ 10 17 � I �� TO BASE OF I / 30 2 l� ��� WATER INLET 28 31)/P ',,,TUBE(ON BLOCK) 27 ��\ 36 35 I 36 3 l� > �\33 34 14 \�> 1218 � 4 34 17 33 EXPLODED VIEW: RADIATOR 1.51-10-25KW REVISION: G-6150-L DATE: 8/3/05 PAGE 1 OF 2 DRAWING#:OE0769 EXPLODED VIEW:RADIATOR 1.51-10-25KW DRAWING#:OE0769 GROUP C APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 1 OD8657 1 SUPPORT RADIATOR 1.51.MITSU 2 OA5734 1 RADIATOR 1.51. 3 OA6237 1 VENTURI 1.51.MODINE 4' OA6238 1 GUARD FAN 1.5L MODINE 5 084918 1 HEATER ENGINE 050OW 120V 084918A 1 HEATER BLOCK 1000W 120V 6 05152ON 1 TUBING 518 ID X 12 7 048031C 4 CLAMP HOSE BAND 114 8 099502 4 CLAMP HOSE#24 61.06.2.00 9 083709 1 CLAMP WIRE HOSE.573-.551 10 052250 2 TAPE FOAM 1 X 1(12"LG) 11 047411 4 SCREW HHC M6.1.0 X 16 G8.8 12 022097 8 WASHER LOCK M6-114 13 049813 2 NUT HEX M6 X 1.0 G8 YEL CHR 14 022473 9 WASHER FLAT 114 ZINC 15 084427 1 BRACKET HEATER 16 05152OZ 1 TUBING 518 ID X 18"LG 17' 058443 6 SCREW CRIMPTITE 114.20 X 518 18 056892 4 SCREW CRIMPTITE 10.24 X 318 19 OA6284 1 HOSE-LOWER RADIATR 20 OA6258 1 HOSE-UPPER RADIATR 21 029032 1 HOSE 9132 ID(36"LG) 22 031669 4 BOLT CARR 114-20 X 1.314 JS500 23 060035 4 SPACER.41 X.75 X.87 STIZNC 24 022127 4 NUT HEX 114.20 STEEL 26 046627 1 CAP RADIATOR 27 OC7649 1 CLAMP HOSE.38-.87 28 OC2454 4 SCREW TH-FRM M64 X 16 N WA ZIJS 29 076749 1 TANK COOLANT RECOVERY 30 OE0726 1 BRACKET WATER BOTTLE 1.51.MIT 31 035461 1 BARBED STR 114 NPT X 318 32 OA7275 3 FOAM 1.5 X 1 ADH BAK 33 OA2111 2 SCREW SWAGE 10.32 X 5116 ZIYC 34 065852 2 SPRING CLIP HOLDER.37-.62 35 047290A 1 ASSY.RAD.DRAIN HOSE 36 050275 2 DECAL WARNING-FAN 'FAN GUARD KIT OE3596(NOT USED WITH LEVEL ONE GUARDING) REVISION: G-6150-L DATE: 8/3/05 PAGE 2 OF 2 10 GROUP F 9 g 7- � 6 `� 11 12 13 00000 00 b 3 3 5 4 3 2 1 0 0 O L EXPLODED VIEW: REVISION: G-6609-B MUFFLER,OPEN SET DATE: 10/14/05 PAGE 1 OF 2 DRAWING#:OE0773 EXPLODED VIEW:MUFFLER,OPEN SET DRAWING#:OE0773 GROUP F APPLICABLE TO: 1.51- ITEM PART# QTY. DESCRIPTION 1 OA4355 1 MANIFOLD EXHAUST 1.51. 2 OE2844 1 NIPPLE TOE 1.5 NPT X 5.5 BLK IRON 3 036434 3 BOLT U 5116-18 X 2.09 036449 3 SADDLE 21NCH 4 OE0109 1 PIPE EXHAUST 1.51-STNDRD&ACSTC 5 OC1318 1 FLEX PIPE EXHAUST 6 OD8657 1 SUPPORT RADIATOR 1.51-MITSU 7 027837 2 SCREW RHM 114.20 X 2.114 8 OD9437 1 MUFFLER 1.51.ACOUSTICBSTANDARD 9 060366 2 STRAP MUFFLER 6"DIA 10 039253 4 SCREW HHC M8-1.25 X 20 G8.8 11 022145 4 WASHER FLAT 5116 ZINC 12 022129 4 WASHER LOCK M8.5116 13 045771 4 NUT HEX M8.1.25 G8 YEL CHR REVISION: G-6609-B DATE: 10/14/05 PAGE 2 OF 2 0 0 0 0 - 0 O O O a � a a 0 O 0 R 00 a 8f C1 ® si O - � W A ' 0 6 ® o 14 O O O m a m � CD F 0 0 0 � o o �^� RE O €1 0-1: O A SS 0 O ~ O Ef � A . 0 EXPLODED VIEW:CONTROL PANEL GUARDIAN DRAWING#o OE0778 GROUP B APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 1 OD9322 1 PANEL BACK&BOTTOM GUARDIAN 2 OD9332 1 PANEL LH SIDE GUARDIAN&SPRN 3 OD9325A 1 PANEL FRONT CONTROL GUARDIAN WI SILKSC 4 OD9330 1 PANEL RH SIDE C-PANEL SML BRK 5 OC1457 1 HOURMETER 6 064009 1 LIGHT 12VDC.02A LED RED PILOT 7 032300 1 HOLDER FUSE 8 022676 1 FUSE 15A X AGC15 9 OE4494 1 SWITCH ROC DPDT ON-OFF-ON 10 082573 1 SWITCH ROCKER DPST 125V SPD 11 083048 1 ASSEMBLY REGULATOR POTTED 12 083264 1 TFMR ASM CMA 240112V 13 076009A 1 PP LOGIC ASM 50160HZ 14* OE0331 1 HARNESS CONTROL PANEL PP GUARDIAN 15 056739 1 RELAY SOLENOID 12VDC PNL MNT 16 049350 1 CIRCT BRK 4 X 1 ETA 46.500-P 17 047822 1 BLOCK TERM 20A 7 X 6 X 1100V 18 048766 1 BLOCK TERM 20A 2 X 6 X 1100V 19 057335 1 BLOCK TERM 20A 20 X 6 X 1100V 20 098647 1 ASSY L.C.ELECT GOV 21 OE1454 1 DECAL COST.CONNT.PRE-PACKI.51. 22 OE1459 1 DECAL TERMINAL STRIP PRE-PACK 23 072566 4 NUT SPACER.250 PCB 24 080882 4 SCREW PPH TAPPING#6 X 518 SS 25 OA8955 2 SCREW PHM M6-1.0 X 20MM 26 022097 3 WASHER LOCK M6.114 27 022473 2 WASHER FLAT 114-M6 ZINC 28 OC2212 10 SCREW PHTT M4-0.7 X 16 ZYC 29 023762 2 WASHER SHAKEPROOF EXT#10 STL 30 OC2267 14 SCREW HHTT M5.0.8 X 12 BP 31 023897 15 WASHER FLAT#10 ZINC 32 OC2454 4 SCREW TH-FRM M6-1X16 N WA ZIJS 33 054199 1 DECAL HIGH VOLTAGE 34 081988 1 DECAL EXERCISE INFO 35 OE2514 1 STRAIGHT WIRE CONNECTOR 1 112" 36 OA1354A 1 REGULATOR-DC ALT 37 074908 4 SCREW HHTT M5.0.8 X 10 BP 38 020911 4 SCREW PPHM M5-0.8 X 30 ZINC 39 051713 5 WASHER FLAT M5 40 049226 5 WASHER LOCK M5 41 051716 5 NUT HEX M5.0.8 G8 YEL CHR 42 036261 4 RIVET POP.125 X.129-.1331#30 43 OD9334 1 PANEL,TOP 44 061979 1 BUS BAR 45 022237 1 WASHER LOCK 318 46 022241 1 NUT HEX 318.16 STEEL 47 057073 1 JUNCTION BLOCK 318.16 48 055440 1 SCREW HHC M5.0.8 X 25 G8.8 49 OD8671 1 HINGE CONTINUOUS 1.51.CNTL PNL 50 0912970080 1 WIRE ASSEMBLY 51 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR 52 033121 1 SCREW HHC#10-32 X 112 53 026850 1 WASHER SHAKEPROOF EXT 114 STL 54 022158 1 NUT HEX#10-32 STEEL 55 022152 1 WASHERLOCK#10 56 OA3968 1 CAPACITOR FILTER ASY 57 OC2323 2 SCREW PHTT#6-32 X 518 ZYC 58 OE3783 1 DECAL WARNING REMOVE FUSE *NOT SHOWN REVISION: G-2938-G DATE: 5/6/04 PAGE 2 OF 2 5 4 3 2 ° ITEM(13)NEOPRENE COATING ° ° 1 ° ° 14 7 10 WIRE HARNESS 15 SECURE WIRE HARNESS °� WITH TIE WRAP AS SHOWN. 12 7 9 °A° 16 17 8 J 18 / o j 10 7 INTAKE MANIFOLD CARBURETOR ARM 6 (REF.) (REF.) e EXPLODED VIEW:GOVERNOR ASSEMBLY DRAWING#:OE1331 GROUP D APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 1 098290 1 ASM MOTOR STEPPER 2 098941A 1 HOUSING GOVERNOR CONNECTOR 3 098958A REF CONNECTOR INTERFACE ASSEMBLY 4 098942A 1 COVER CONNECTOR HOUSING 5 098225 2 SCREW FHM#2 X 518 SELF TAP 6 043146 3 SCREW HHC M6.1.0 X 10 G8.8 7 022097 5 WASHER LOCK M6.114 8 084543A 1 SCREW PHM M3.0.5 X 12MM 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX#10-32 NYL INS 11 OE1326 1 ASSY.CARBURETOR LINKAGE ROD 12 OA7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 10 TIE WRAP 7.4"X.19"BLK UL 15 022507 2 SCREW HHC 114.20 X 112 G5 16 022473 2 WASHER FLAT 114 ZINC 17 064526 1 SCREW TAP HWH#6.25 X 318 ZINC 18 OE1694 1 SPRING,ANTI LASH REVISION:F-9532-B DATE: 3/17/03 PAGE 2 OF 2 CAP TS1-14 229 229 EC-9 13 13 EC-10 RED 183 EC-11 14 14 14 HM 0 EC-12 0 BLACK 14 SHOWN IN + EC-7 56 56 LL13J 15A OFF POSITION 13 EC EC-8 SA 1a EC-6 85 85 239 15C 0 EC-3 15C N C EC-4 4 85 14 239 178 15C EC-5 FED 4 0 56 229 178 SWl 15A 225A 15 4 4 F1 15 FL 1761 13 2 5 7 D 11 9 10 15E��-15A0 VR m 12 15C 15C 15 13 162 1 n PCB E 176 176 BLUE ¢S15 5 04 194 194 4 3 23 23 6 — 6 6 B A 17 16 14 15 225A BLUE 178 S16183 S16 S15 T1 T2 RED 5 5 I RED CB2 T2 T1 TS2 6 2 2 X162 0 0 FDP 2 WIRE START FOR STANDARD FAS] m GENERAC TRANSFER r SWITCH CONNECTION 11 22 33 44 S15 m m m m 316 ffl (�')m DIE BLUE WIRE F FOR L-L SYSTEMS MS YELLOW WIRE FOR RE L-L SYSTENB � INSULATE UNUSED WIRE ORANGE TO GCU YELLOW GOV ALTERNATE TRi BROWN ACTUATOR (RED) (BLUE) BLACK 7TR aucK 224 5 BLACK I 1.,s2`,�J � LEGEND JI 7AA TRi CB1 T1 T2 N1 N2 23 194 N AR -ALTERNATOR ROTOR GCU -GOVERNOR CONTROL UNIT I2 Et 00 E2 AS -ALTERNATOR STATOR HM -HOURMETER I CAP -CAPACITOR PCB -CIRCUIT BOARD CONTROLLER (BLACK) (BLACK) CUSTOMER CONNECTION CB1,2-CIRCUIT BREAKERS SA -SUPRESSIONASSEMBLY PREPACKAGE DPE -EXCITATION WINDING SW1 -AUTO/OFF/MANUAL SWITCH TRANSFER SWITCH 120/240V 1-PHASE EC -ENGINE CONNECTION SW2 -SET EXERCISE SWITCH CONNECTION TS3 F -FUSE 15 AMPS TR1 -TRANSFORMER,UTILITY SENSING F1 -FUSE 7 5 AMPS IN LINE TS1,2,3-TERMINAL BOARDS FL -LIGHT FAULT INDICATOR VR -VOLTAGE REGULATOR GROUP G -------------------------------------------------- I I I I I I I I I WLS LOS I DIS I DC—VR 1 2 3 4 5 cc WTS FS 48 0 49 13 14 14 13 16 85 I 13 I 56 85 0 0 RED 0 0 I I 3 —85 85 I CONTROL 5 —85 I PANEL o CONNECTION 6 —56 0 0 14 8 —o 0 0 I I 9 —13 GRDI-0- 10 o I •00000 DEUTSCH 10 —14 0000�• 11 —14-- 12j 1412 —14 6 DC—A 49 I I 48 I RED I LEGEND SM = I I I CC — CONTROL CONTACTOR 12—V. BLACK DIS — DISTRIBUTOR DCA — DC ALTERNATOR PBATTjERY GRD EH — ENGINE HEATER FS — FUEL SOLENOID GRD — GROUND LOS — LOW OIL PRESSURE SWITCH TO SM - STARTER MOTOR ELECTRONIC GOVERNOR I WTS — WATER TEMPERATURE SWITCH ACTUATOR I WLS — WATER LEVEL SENSOR GOVERNOR CONTROLLER ACTUATOR I CONNECTOR I I EH TO 120V/1 5A —BLACK— UTILITY FED —WHITE CIRCUIT —GREEN I I I I N❑TE1 I I I ENGINE HEATERS ARE NOT AVAILABLE ON HOME STAND—BY UNITS, I I L————————————————————————————————————————————————--J WIRING-DIAGRAM REVISION:G-4604-B ENGINE 1.51,MITSU DATE:1/21/05 DRAWING#:OE0343