Owner's Manual: Stationary Emergency Generator
Owner's Manual: Stationary Emergency Generator
Owner's Manual: Stationary Emergency Generator
2.4L
nNOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT
APPLICATIONS. 22/27kW Models
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST
FUMES! OUTDOOR INSTALLATION ONLY! EPA Certified
nSAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential
hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this
equipment.
INTRODUCTION
This symbol points out potential fire hazard.
Thank you for purchasing this model of the stationary emergency
generator product line. This symbol points out potential electrical shock hazard.
Every effort was expended to make sure that the information and
instructions in this manual were both accurate and current at the The operator is responsible for proper and safe use of the equip-
time the manual was written. However, the manufacturer reserves ment. The manufacturer strongly recommends that the operator
the right to change, alter or otherwise improve this product(s) at read this Owner's Manual and thoroughly understand all instruc-
any time without prior notice. tions before using this equipment. The manufacturer also strongly
recommends instructing other users to properly start and operate
READ THIS MANUAL THOROUGHLY the unit. This prepares them if they need to operate the equipment
in an emergency.
If any portion of this manual is not understood, contact the nearest
Service Dealer for starting, operating and servicing procedures. For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by a Service
Throughout this publication, and on tags and decals affixed to the Dealer or other competent, qualified electrician or installation
generator, DANGER, WARNING, CAUTION and NOTE blocks are technician who is familiar with applicable codes, standards and
used to alert personnel to special instructions about a particular regulations. The operator also must comply with all such codes,
service or operation that may be hazardous if performed incor- standards and regulations.
rectly or carelessly. Observe them carefully. Their definitions are
as follows:
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety checks, to
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF make sure that all maintenance for safe operation is performed
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. promptly, and to have the equipment checked periodically by a
Service Dealer. Normal maintenance service and replacement of
parts are the responsibility of the owner/operator and, as such,
Indicates a hazardous situation or action which, if not are not considered defects in materials or workmanship within the
avoided, could result in death or serious injury. terms of the warranty. Individual operating habits and usage con-
tribute to the need for maintenance service.
Proper maintenance and care of the generator ensure a minimum
Indicates a hazardous situation or action which, if not number of problems and keep operating expenses at a minimum.
avoided, could result in minor or moderate injury. See a Service Dealer for service aids and accessories.
NOTE:
Operating instructions presented in this manual assume that the
Notes contain additional information important to a procedure generator electric system has been installed by a Service Dealer or
and will be found within the regular text body of this manual.
other competent, qualified contractor. Installation of this equipment
These safety warnings cannot eliminate the hazards that they is not a do-it-yourself project.
indicate. Common sense and strict compliance with the special
instructions while performing the service are essential to prevent- HOW TO OBTAIN SERVICE
ing accidents.
When the generator requires servicing or repairs, simply contact
Four commonly used safety symbols accompany the DANGER, a Service Dealer for assistance. Service technicians are factory-
WARNING and CAUTION blocks. The type of information each trained and are capable of handling all service needs.
indicates is as follows:
When contacting a dealer about parts and service, always supply
This symbol points out important safety information that,
n if not followed, could endanger personal safety and/or
property of others.
the complete Model Number, Serial Number and Type Code (where
applicable) from the DATA LABEL that is affixed to the unit.
This symbol points out potential explosion hazard.
SAFETY RULES The engine exhaust fumes contain carbon monoxide gas, which
Study these SAFETY RULES carefully before installing, operating can be DEADLY. This dangerous gas, if breathed in sufficient
or servicing this equipment. Become familiar with this Owners concentrations, can cause unconsciousness or even death. For
Manual and with the unit. The generator can operate safely, effi- that reason, adequate ventilation must be provided. This should
ciently and reliably only if it is properly installed, operated and be considered prior to installing the generator. The unit should
maintained. Many accidents are caused by failing to follow simple be positioned to direct exhaust gasses safely away from any
and fundamental rules or precautions. building where people, animals, etc., will not be harmed. Any
exhaust stacks that ship loose with the unit must be installed
The manufacturer cannot anticipate every possible circumstance properly per the manufacturer's instruction, and in strict compli-
that might involve a hazard. The warnings in this manual, and on ance with applicable codes and standards.
tags and decals affixed to the unit are, therefore, not all inclusive. Keep hands, feet, clothing, etc., away from drive belts, fans,
If a procedure, work method or operating technique is used that and other moving or hot parts. Never remove any drive belt or
the manufacturer does not specifically recommend, ensure that it fan guard while the unit is operating.
is safe for others. Also make sure the procedure, work method or
Adequate, unobstructed flow of cooling and ventilating air is
operating technique utilized does not render the generator unsafe.
critical in any room or building housing the generator to prevent
buildup of explosive gases and to ensure correct generator
operation. Do not alter the installation or permit even partial
nDespite the safe design of this generator,
operating this equipment imprudently, neglect-
ing its maintenance or being careless can cause
blockage of ventilation provisions, as this can seriously affect
safe operation of the generator.
possible injury or death. Permit only respon- Keep the area around the generator clean and uncluttered.
sible and capable persons to install, operate or Remove any materials that could become hazardous.
maintain this equipment. When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
these machines. Ensure all steps are taken to
Potentially lethal voltages are generated by
fatigued.
render the machine safe before attempting to Inspect the generator regularly, and promptly repair or replace
work on the generator. all worn, damaged or defective parts using only factory-
approved parts.
nParts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
Before performing any maintenance on the generator, discon-
nect its battery cables to prevent accidental start-up. Disconnect
the cable from the battery post indicated by a NEGATIVE, NEG
GENERAL HAZARDS or () first. Reconnect that cable last.
Never use the generator or any of its parts as a step. Stepping
For safety reasons, the manufacturer recommends that this on the unit can stress and break parts, and may result in dan-
equipment be installed, serviced and repaired by a Service gerous operating conditions from leaking exhaust gases, fuel
Dealer or other competent, qualified electrician or installation leakage, oil leakage, etc.
technician who is familiar with applicable codes, standards
and regulations. The operator also must comply with all such
codes, standards and regulations.
ELECTRICAL HAZARDS
Installation, operation, servicing and repair of this (and related) All stationary emergency generators covered by this manual
equipment must always comply with applicable codes, stan- produce dangerous electrical voltages and can cause fatal
dards, laws and regulations. Adhere strictly to local, state and electrical shock. Utility power delivers extremely high and dan-
national electrical and building codes. Comply with regulations gerous voltages to the transfer switch as well as the generator.
the Occupational Safety and Health Administration (OSHA) has Avoid contact with bare wires, terminals, connections, etc.,
established. Also, ensure that the generator is installed, operat- on the generator as well as the transfer switch, if applicable.
ed and serviced in accordance with the manufacturers instruc- Ensure all appropriate covers, guards and barriers are in place
tions and recommendations. Following installation, do nothing before operating the generator. If work must be done around
that might render the unit unsafe or in noncompliance with the an operating unit, stand on an insulated, dry surface to reduce
aforementioned codes, standards, laws and regulations. shock hazard.
Do not handle any kind of electrical device while stand-
ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
Data Label
ENGINE OIL RECOMMENDATIONS nDo not remove the radiator pressure cap while
the engine is hot or serious burns from boiling
The unit has been filled with 5W-30 engine oil at the factory. Use
liquid or steam could result.
a high-quality detergent oil classified For Service SJ or SH.
Detergent oils keep the engine cleaner and reduce carbon deposits.
When changing the engine oil, be sure to use 5W-30 engine oil nEthylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the
(synthetic oil is recommended). radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
nAny attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
antifreeze even though it is poisonous to them.
NOTE:
For temperatures below 32 F, it is strongly recommended to
use the optional Cold Weather Start Kit (part number listed in
the Specification Section). The oil grade for temperatures below
32 F is 5W-30 synthetic oil.
WEATHER AND MAINTENANCE KITS 8. Install the previously removed NG jet into the jet keeper port
on the side of the regulator housing.
To keep the generator running at its peak, the following kits are
9. Install the previously removed black pipe onto the outlet
offered:
port of the demand regulator. Use pipe sealant on the pipe
Cold Weather Kit threads.
~ Recommended for climates with temperatures below 32 F. 10. Reverse steps 1-4 in this procedure to reactivate the demand
Extreme Cold Weather Kit regulator.
~ Recommended Block Heater Kit for protection in tempera- 11. Follow the instructions in the Control Panel section.
tures below 32 F.
Scheduled Maintenance Kit
~ Kit includes the recommended parts to maintain the genera-
tor. Refer to the Service Schedule for regular maintenance
intervals.
nSerious injury, including death, or damage may
occur if not configured properly. Please consult
an Authorized Dealer with any questions.
For additional information, or to order any of these kits, please
contact an Authorized Service Dealer or Customer Service Figure 6.1 Reconfigure the Fuel System
Representative.
FUEL SYSTEM
1. Turn the main gas supply off and disconnect the battery.
2. Remove the carburetor fuel hose from the outlet port of the CONTROL PANEL
demand regulator (see Figure 6.1).
The FUEL TYPE must be reconfigured in the control panel to final-
3. Disconnect the power wires from the fuel solenoid located ize the conversion process. To access the fuel selection menu,
on top of the regulator assembly by removing the screw on select EDIT from the main control panel menu. Scroll through the
the front of the connector and pulling the connector forward, prompts until FUEL TYPE is displayed. Press ENTER to select this
away from the solenoid body. field, then toggle the proper fuel type and press ENTER again to
4. Loosen the spring clamp on the small fuel enrichment line and accept. The fuel conversion is now complete.
remove the hose from the hose barb.
5. Remove the black pipe assembly from the outlet port of the
demand regulator. The solenoid assembly may need to be
6.
removed before performing this operation (Figure 6.1).
Remove the NG fuel jet (loosen counter clockwise) from the nWhenever the Generator's Fuel Regulator is
converted from one Fuel type to the other,
make sure to configure the Control Panel for
outlet port.
7. Remove the LP fuel jet (loosen counter clockwise) from the jet the correct Fuel type.
keeper port on the side of the regulator housing. Install this jet
into the outlet port in the regulator casting.
NOTE:
The jet sizes are stamped on the individual jets. The larger jet
size is used for running on NG.
L-L
S6 S4
00 (NEUTRAL)
S5
S3 S2
E3 L-N E2
E1
S1
S4
S7
L-L
S12 S10
S9 S11 S8
S6 S5
S3 S2
E3 L-N E2
E2
E3 E2
S3 S2 S2 S6
L-N
INTERNAL
Figure 7.5 Stator Power Winding CONNECTIONS
E1
S7 S1
S5 S3
L-L E1 S1 S4 E3
S10 S4
L-N
S12 S5
00 (NEUTRAL)
S9 S6 S11 S2
Figure 7.8 Stator Power Winding
E3 E2 Connections - 3-phase, 120/240V (12 Lead)
S3 S8
L-N
E2
S2 S12
Figure 7.6 Stator Power Winding
Connections - 3-phase, 346/600V (6 Lead)
E1
S5 S9
S1
INTERNAL L-L
CONNECTIONS S8 S6
L-L S3
S11
S6 S4
00 (NEUTRAL) E1 S1 S10 E3
S5
L-N
00 (NEUTRAL)
S3 S2
E3 L-N E2
CONTROL PANEL INTERFACE Upon power up, this controller will go through a system self test
which will check for the presence of utility voltage on the DC
circuits. This is done to prevent damage if the installer mistakenly
USING THE AUTO/OFF/MANUAL SWITCH connects AC utility power sense wires into the DC terminal block.
If utility voltage is detected, the controller will display a warning
message and lock out the generator, preventing damage to the
controller. Power to the controller must be removed to clear this
nWith the switch set to AUTO, the engine may
crank and start at any time without warning.
Such automatic starting occurs when utility
warning.
Utility voltage must be turned on and present at the N1 and N2
power source voltage droops below a preset terminals inside the generator control panel for this test to be
level or during the normal exercise cycle. To performed and pass.
prevent possible injury that might be caused
by such sudden starts, always set the switch NOTE:
to OFF and remove the fuse before work- DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT
ing on or around the generator or transfer WIRES IS NOT WARRANTABLE!
switch. Then, place a DO NOT OPERATE
tag on the generator panel and on the trans- This test will be performed each time the controller is powered
fer switch. up.
1. AUTO Position Selecting this switch activates fully auto- Next, the user must enter the minimum settings to operate. These
matic system operation. It also allows the unit to automati- settings are current date and time and exercise day and time. The
cally start and exercise the engine every seven days with the maintenance intervals will be initialized (i.e. started) the first time
setting of the exercise timer (see the Setting the Exercise the clock is set. If the clock is never set at power up, the mainte-
Timer section). nance intervals will be reset every time power is applied.
2. OFF Position This switch position shuts down the engine. If a subsequent power loss (loss of battery power) occurs the
This position also prevents automatic operation. Installation assistant will operate upon power restoration. The self
3. MANUAL Position Set the switch to MANUAL to crank test routine will be run and then the customer will be required to
and start the engine. Transfer to standby power will not occur re-enter the time and date, as this is not retained during a power
unless there is a utility failure. loss. The unit will not require re-activation.
ACTIVATION CHART
CHOOSE LANGUAGE TROUBLESHOOTING
Display Reads: Use ARROW keys to scroll to desired lan- If the wrong language is chosen, it can be
guage. Press ENTER to select. changed later using the edit menu.
Language
- English +
Escape Enter
Display Reads: Press ENTER to begin the activation pro- If ESCAPE is pressed instead of ENTER,
cess. your generator will only run in manual mode
Activate me (ENT) or (for test purposes) and NOT ACTIVATED will
ESC to run in manual be displayed. You will need to reconnect the
battery and begin with Step 1.
Escape Enter
Display Reads: Activation is complete when all digits are What happens if Wrong Passcode Try
entered above and your screen shows this Again appears?
SELECT HOUR (0-23) display. Re-enter the activation code. If a second
- 6 + Follow the controller prompts to continue attempt is unsuccessful, check the number
setting the time function. Refer to your against the code given on activategen.com.
Escape Enter
Owners Manual with questions. If it is correct and the generator will not
accept it, contact 1-888-9ACTIVATE (922-
8482).
INSTALLATION ASSISTANT If utility is still lost after the line interrupt period, run the engine
up to normal RPM and transfer the load. At this time the con-
Interconnect System Self Test Feature (follow the on-screen
troller will exit the exercise routine and assume full automatic
prompts).
operation.
Upon power up, this controller will go through a system self test
which will check for the presence of utility voltage on the DC
circuits. This is done to prevent damage if the installer mistakenly
USER ADJUSTABLE SETTINGS
connects AC utility power sense wires into the DC terminal block. Factory Minimum Maximum
If utility voltage is detected, the controller will display a warning Setting Increment
Default Setting Setting
message and lock out the generator, preventing damage to the
controller. Power to the controller must be removed to clear this Exercise 23:59
2 pm 00:00 (12 am) 1 min
warning. time (11:59 pm)
MAIN MENU
ACTIVATION
ESC
CONTRAST
ALARM LOG RUN LOG STATE DISPLAY COMMAND VERSIONS
INPUTS OUTPUTS DISPLAYS QT TEST
LANGUAGE
ESC
8-7
ENGINE TIME/DATE
HOURS
Press the ESCAPE key
ESC
Control Panel
GENERATOR RESET
Use the ENTER key
ENTER to select items or FREQUENCY MAINTENANCE
enter data.
BATTERY
FUEL
VOLTAGE
SELECTION
HOURS UNDER
LOAD LINE INTERRUPT
DELAY
STATIONARY EMERGENCY
GENERATOR CONTROL AND
OPERATION nDo not crank the engine continuously for lon-
ger than 30 seconds, or the heat may
damage the starter motor.
Refer to the appropriate control panel operators manual for this
unit. Let engine stabilize and warm up.
Check all applicable instrument and gauge readings. When
certain that all readings are correct, move the transfer switch
OPERATING UNIT WITH MANUAL manual handle to the STANDBY (or EMERGENCY STANDBY)
position, i.e., load circuits supplied by the generator.
TRANSFER SWITCH Set the generators main line circuit breaker to its ON (or
If the Stationary Emergency Generator was installed in conjunction
with a transfer switch capable of manual operation only, the fol- CLOSED) position.
lowing procedure applies. A manually operated transfer switch is Load circuits are now powered by the generator.
one that will not provide automatic start-up and does not include
an intelligence circuit. RETRANSFER AND SHUTDOWN
For additional information, refer to the applicable control panel
ENGINE START-UP AND TRANSFER manual for this unit, as well as any literature pertaining to the
specific transfer switch.
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the To transfer the load back to the utility power source and shut down
specific transfer switch. the generator, follow these directions:
Set the generators main line circuit breaker to its OFF (or OPEN)
position.
Manually move the transfer switch handle to its UTILITY
nThe Maintenance Disconnect Switch and the
AUTO/OFF/MANUAL switches (if so equipped)
must be set properly, or the generator will
(NORMAL) position, i.e., load circuits connected to the utility.
Turn ON the utility power supply to the transfer switch, using
crank and start as soon as the utility power to the means provided (such as the utility power source main line
the transfer switch is turned off. Refer to appli- circuit breaker).
cable control panel and transfer switch manuals Let the generator run at no-load for a few minutes to stabilize
for more information. internal temperatures.
Shut down the generator.
nDo not proceed until certain that utility source
voltage is available to the transfer switch and
the transfer switch main contacts are set to OPERATING UNIT WITH AUTOMATIC
UTILITY.
TRANSFER SWITCH
power supplies to the transfer switch have been If the Stationary Emergency Generator has been installed with an
Do not attempt manual operation until all
automatic transfer switch, the engine may be started and stopped
positively turned off, or extremely dangerous - automatically or manually.
possibly lethal - electrical shock will result.
NOTE:
GENERAL MAINTENANCE Refer to the Service Schedule for engine oil and filter change fre-
quencies.
Drain the oil while the engine is still warm from running. This
Before working on the Stationary Emergency means warm up the engine, shut it down and drain immediately
Generator, ensure the following: as follows:
The AUTO/OFF/MANUAL switch is in the OFF position. 1. Remove the drain hose from its retaining clip or cut the zip-tie
The control panel fuse has been removed from the control securing the oil drain hose.
box. 2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil com-
The 120VAC supply to the battery charger is switched OFF. pletely into suitable container.
The negative battery cable has been removed. 3. When all oil has drained, install and tighten OIL DRAIN HOSE
CAP and secure drain hose with a new zip-tie, or place the
CHECK ENGINE OIL hose in its retaining clip.
Check engine crankcase oil level (Figure 10.1) according to the 4. Turn OIL FILTER (Figure 10.1) counterclockwise and remove.
Service Schedule. Properly dispose of old filter.
5. Apply light coating of new engine oil to seal of new oil
Remove oil dipstick and wipe dry with a clean, lint-free cloth. filter.-Install FILTER and tighten by hand only. DO NOT OVER
Install oil dipstick, then remove again. TIGHTEN.
Oil should be between FULL and ADD marks. 6. Remove OIL FILL CAP and add recommended oil. Crankcase
If oil level is below the dipstick ADD mark, remove oil fill cap-. oil capacity is listed in the "Specifications" section.
Add the recommended oil to bring oil level up to the FULL
mark. DO NOT FILL ABOVE THE FULL MARK. See Engine Oil
Recommendations for recommended oils.
Figure 10.1 - Oil Dipstick and Oil Fill Cap nAfter refilling the crankcase with oil, always
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK ADD
MARK.
7. Start engine and check for oil leaks.
Oil Fill Cap 8. Shut OFF engine and wait 10 minutes for the oil to settle down
into the oil pan. Recheck oil level on dipstick. DO NOT fill
above the dipstick "FULL" mark.
9. Dispose of used oil at a proper collection center.
COOLING INTAKE/OUTLET
Air intake and outlet openings in the generator compartment must
be open and unobstructed for continued proper operation. This
includes such obstructions as high grass, weeds, brush, leaves
and snow.
Oil
Dipstick Without sufficient cooling and ventilating air flow, the engine/gen-
erator quickly overheats, which causes it to shut down. (See the
installation diagram.)
extremely
The exhaust system parts from this product get
Oil Filter hot and remains hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.
CHANGING ENGINE OIL
INSPECT COOLING SYSTEM
Inspect engine cooling system. See the Service Schedule.
Check hoses for damage, deterioration, leaks, etc. Correct any
nHot oil may cause burns. Allow engine to cool
before draining oil. Avoid prolonged or repeat-
ed skin exposure with used oil. Thoroughly
discrepancies found.
Check hose clamps for tightness.
wash exposed areas with soap.
COOLANT CHANGE
Every year, have a service facility drain, flush and refill the cooling
system. See the Specifications and Service Schedule for cooling
system recommendations.
fuse.
nBetobattery
sure the AUTO/OFF/MANUAL switch is set
the OFF position, before connecting the
cables. If the switch is set to AUTO or
MANUAL, the generator can crank and start as
soon as the battery cables are connected.
SERVICE SCHEDULE
TROUBLESHOOTING GUIDE
PROBLEM CAUSE CORRECTION
Engine wont crank. 1. Control panel 7.5 amp fuse blown. 1. Replace fuse.*
2. Loose or corroded or defective 2. Tighten, clean or replace
battery cables. 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/turn on fuel valve.
2. Fuel solenoid (FS) is defective 2. Replace solenoid.*
3. Spark plugs defective. 3. Clean, regap or replace plugs.
Engine starts hard, runs rough. 1. Air cleaner plugged or damaged. 1. Clean or replace as needed.
2. Defective spark plugs. 2. Clean, regap or replace plugs.
3. Fuel pressure incorrect. 3. Confirm fuel pressure to regulator is as
recommended in SPECIFICATIONS.*
4. Insufficient fuel supply. 4. Confirm fuel pressure to regualtor is as
recommended in SPECIFICATIONS.*
5. Fuel system set to wrong fuel type. 5. Reconfigure the fuel system. (See
RECONFIGURING THE FUEL SYSTEM in
manual.*
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.*
No AC output from generator. 1. Main line circuit breaker is tripped/open. 1. Reset to ON/CLOSED.
2. Generator internal failure. 2. *
3. Thermal circuit breaker open. 3. Auto-reset - Wait 5 min. and attempt restart.
As the engine purchaser/owner you are responsible for the following. 1.) The engine must be installed and configured in
accordance to the installation specifications. 2.) The completion of all maintenance requirements listed in your Owners
Manual. 3.) Any engine setting adjustment must be done in accordance and consistent with the instructions in the Owners
Manual. 4.) Any emission control system or component must be maintained and operated appropriately in order to ensure
proper operation of the engine and control system to minimize emissions at all times.
Generac may deny any, or all Emission Control System Warranty coverage or responsibility of the engine, or an emission
control system or component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or
improper maintenance, or the use of counterfeit and/or gray market parts not made, supplied or approved by Generac.
Warranty service/scheduled maintenance can be arranged by contacting your selling dealer or an Authorized Warranty
Service dealer. The purchaser/owner shall be responsible for any expenses or other charges incurred for service calls and/or
transportation of the product to/from the inspection or repair facilities. The purchaser/owner shall be responsible for any and/
or all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs.
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac), are pleased to
explain your recordkeeping requirements for compliance with Subpart JJJJ Standards of Performance for Stationary Spark
Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine
purchaser/owner who operates and maintains their certified emergency stationary engine and emission control system
according to applicable emission related guidelines as specified in this Owners Manual you are required to meet the fol-
lowing notification and recordkeeping requirements to demonstrate compliance. 1.) Maintain documentation that the engine
is certified to meet emission standards. 2.) Recordkeeping of maintenance conducted. 3.) Recordkeeping of the provision
allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel solely dur-
ing emergency operations provided the engine is not certified to operate on propane. 4.) Meet all compliance notifications
submitted to the purchaser/owner and maintain all supporting documentation. 5.) Recordkeeping of hours of operation,
including what classified the operation as emergency and how many hours are spent for non-emergency operation. For
emergency engines greater than or equal to 130 HP, recordkeeping of hours of operation begins January 1, 2011. For emer-
gency engines less than 130 HP, recordkeeping of hours of operation begins January 1, 2009; Engines are equipped with
non-resettable hour meters to facilitate recordkeeping.
Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/ reporting
requirements. Your permit to construct and/or operate the engine may be contingent upon compliance with those require-
ments. Check with your local Air Quality Management or Air Pollution Control District for specific requirements.
Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readi-
ness testing, provided that the tests are recommended by Federal, State or local government, Generac, or the insurance com-
pany associated with the engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year.
There is no time limit on the use of emergency stationary ICE in emergency situations. The purchaser/owner may petition the
Administrator for approval of additional hours to be used for maintenance checks and readiness testing, but a petition is not
required if the owner maintains records indicating that Federal, State, or local standards require maintenance and testing of
emergency ICE beyond 100 hours per year. Emergency stationary ICE may operate up to 50 hours per year in non-emergen-
cy situations, but those 50 hours are counted towards the 100 hours per year provided for maintenance and testing. The 50
hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply
power to an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/
owner of emergency engines, any operation other than emergency operation, maintenance and testing, and operation in non-
emergency situations for 50 hours per year, as permitted in this section is prohibited.
If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control sys-
tems in accordance with the specifications and guidelines in the Owners Manual, EPA will not require engine performance
testing. If not, your engine will be considered non-certified and you must demonstrate compliance according to Subpart JJJJ
Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of
Federal Regulations Title 40 Part 60.
Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment.
Inspection and replacement of an emissions related component is required to be done in accordance with the requirements
cited in the United States Environmental Protection Agency Warranty Statement or can be arranged by contacting your sell-
ing dealer or an Authorized Warranty Service dealer. Failing to follow these instructions when installing a certified engine in a
piece of nonroad equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean
Air Act.
EmsnWrnty001 Rev. C 05/10 13-2
Stationary Emergency Generator
Notes
1 0G9009 1 RTR-104-22AD1 HI EFF
0G9011 1 RTR-104-27AD2 HI EFF
0G9341 1 RTR-104-22GD1 HI EFF
0G9342 1 RTR-104-27GD2 HI EFF
2 0G8318A 1 HOUSING BLOWER MACHINED 2.4L
3 0G8366 1 BLOWER HOUSING SCREEN
4 020746 3 SCREW PPHM M5-0.8 X 8 ZINC
5 049226 3 WASHER LOCK M5
6 051713 3 WASHER FLAT M5
7 022129 4 WASHER LOCK M8-5/16
8 0G9008 1 STR-104-22AD1 HI EFF
0G9010 1 STR-104-27AD1 HI EFF
0G9339 1 STR-104-22GD1 HI EFF
0G9340 1 STR-104-27GD1 HI EFF
9 0A5382A 1 BEARING CARRIER REAR LG PILOT
10 075591 1 ASSY HOLDER BRUSH
11 051787 4 SCREW HHC M4-0.7 X 16 G8.8
12 0A5601A 1 COVER REAR BEARING
13 0G8827 4 STUD M8-1.25 475 LONG (27KW)
0G8827A 4 STUD M8-1.25 418 LONG (22KW)
14 0A9375 4 SCREW RHM #10-24 X 2
15 022152 4 WASHER LOCK #10
16 0G8311 1 FLYWHEEL & RINGGEAR ASSY 2.4L
17 042558 1 KEY SQ 3/8 X 1 STEEL
(1) 18 051756 4 SCREW HHC M10-1.5 X 20 C8.8
19 0G8364 1 PLATE FLEX 2.4L 10" ALT
(1) 20 053607 1 SCREW HHC M12-1.75 X 35 G8.8
21 051769 1 WASHER LOCK M12
22 023365 4 WASHER SHAKEPROOF INT #8
(1) 23 0G0114 7 SCREW HHC M12-1.25 X 15 C10.9
24 072578 1 SPACER ROTOR SHAFT
25 0D8427 4 WASHER LOCK M10 RIBBED ZINC
26 0A8830 4 WASHER FLAT .34 ID X .75 OD
27 029333A 7 TIE WRAP UL 7.4"X .19" BLK (NOT SHOWN)
28 063076 7 WASHER FLAT .531ID X 1.062OD
29 045771 4 NUT HEX M8-1.25 G8 CLEAR ZINC
30 077043A 1 CONDUIT FLEX .38"ID ( 18 LG)
31 077043C 1 CONDUIT FLEX .75"ID ( 18 LG) (NOT SHOWN)
REVISION: -A-
DATE: 4/13/10
PAGE 2 OF 8
EXPLODED VIEW: CONNECTION BOX C1 CPL
DRAWING #: 0H7234 GROUP A
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
N 022145 4 WASHER FLAT 5/16-M8 ZINC
P 045771 2 NUT HEX M8-1.25 G8 CLEAR ZINC
R 058306 2 SCREW SHC M8-1.25 X 25 C12.9
S 0F8451 2 LUG SLDLSS 300 MCM-6 AL/CU
REVISION: -A-
DATE: 4/13/10 PAGE 3 OF 8
EXPLODED VIEW: CONNECTION BOX C1 CPL
DRAWING #: 0H7234 GROUP A
APPLICABLE TO:
ITEM PART# QTY. DESCRIPTION
UL CIRCUIT BREAKER (CC 2P)
A 0H4745 1 CB 0100A 2P 240V E CC LL
B 0H6847 1 COVER CB E CC 2P C1 CONBOX
C 051716 2 NUT HEX M5-0.8 G8 CLEAR ZINC
D 0H4656 1 CIRCUIT BREAKER SUPPORT (CC)
E 038150 2 WASHER FLAT #8 ZINC
F 022264 2 WASHER LOCK #8-M4
G 022471 2 NUT HEX #8-32 STEEL
H 0C2454 10 SCREW HWHT M6-1 X 16 N WA Z/JS
J 053640 2 SCREW RHM #8-32 X 3-1/4
K 091526 2 SCREW PPHM M5-0.8 X 12 ZNC
L 023897 4 WASHER FLAT #10 ZINC
M 049226 2 WASHER LOCK M5
N 0H4698 1 INSULATOR CB 2P E TYPE CC
REVISION: -A-
DATE: 4/13/10 PAGE 5 OF 8
EXPLODED VIEW: CONNECTION BOX C1 CPL
DRAWING #: 0H7234 GROUP A
APPLICABLE TO:
REVISION: -A-
DATE: 4/13/10 PAGE 7 OF 8
EXPLODED VIEW: CONNECTION BOX C1 CPL
DRAWING #: 0H7234 GROUP A
APPLICABLE TO:
REGULATOR NOTES:
REGULATOR (I/N 11) AS SHOWN IN ILLUSTRATION IS SET UP FOR NATURAL GAS APPLICATION.
TO CONFIGURE REGULATOR FOR LP VAPOR, REFER TO THE RECONFIGURING THE FUEL SYSTEM SECTION OF THIS
MANUAL.
(2) SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING
GENERIC PARTS (NO COLOR).
MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER
TO AS400 BOM.
CUSTOMER: FOR CORRECT MATERIAL AND COLOR OF
REPLACEMENT PARTS REFER TO REPLACEMENT SHEET METAL
PARTS ORDERING GUIDE-0H7169 INCLUDED IN THE MANUAL OR
AVAILABLE ON THE GENERAC WEBSITE.