Generac Power Systems Portable Generator 004988 4 User Manual

Owner’s Manual  
Liquid-cooled, Prepackaged  
Standby Generators  
Model Number: 004988-4  
27kW NG, 30kW LP Vapor  
This manual should remain with the unit.  
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS  
SHOULD ATTEMPT INSTALLATION!!  
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Table of Contents  
Liquid-cooled 30 kW Generators  
INTRODUCTION ...............................................IFC  
SAFETY RULES....................................................2  
Section 3 OPERATION................................ 12  
3.1 Using a Standard “GTS” Transfer Switch ...........12  
3.2 Control Console Components..............................13  
3.3 Manual Transfer and Startup..............................14  
3.4 Engine Governor Adjustments ............................14  
3.5 Retransfer and Shutdown ...................................14  
3.6 Automatic Operation ...........................................14  
3.7 Weekly Exercise Cycle .........................................15  
Section 4 — MAINTENANCE........................... 15  
Section 1 — GENERAL INFORMATION............. 4  
1.1 Generator..............................................................4  
1.2 Transfer Switch.....................................................4  
1.3 Automatic System Operation.................................4  
1.4 Generator AC Connection Systems........................4  
1.5 Main Circuit Breaker.............................................4  
1.6 Generator Fuel System..........................................5  
1.7 Engine Protective Devices......................................5  
1.8 Unpacking.............................................................6  
1.9 Lifting the Generator.............................................6  
1.10 Specifications........................................................7  
1.11 Fuel Consumption.................................................7  
1.12 Reconfiguring the Fuel System ..............................7  
1.13 Torque Specifications............................................8  
1.14 Engine Oil Recommendations ...............................8  
1.15 Coolant Recommendations....................................8  
1.16 Before Installation.................................................8  
Section 2 — INSTALLATION............................. 8  
2.1 Standby Generator Installation .............................8  
2.2 Generator Location ...............................................9  
2.3 Generator Mounting and Support .........................9  
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  
4.1 Maintenance Performed by Authorized  
Service Facilities..................................................15  
4.2 Cooling System....................................................15  
4.3 Overload Protection for Engine DC  
Electrical System.................................................16  
4.4 Checking Fluid Levels .........................................16  
4.5 Maintenance Owner/Operator  
Can Perform........................................................16  
4.6 Miscellaneous Maintenance.................................18  
4.7 Scheduled Maintenance.......................................20  
Section 5 — TROUBLESHOOTING ................. 23  
Section 6 — NOTES........................................ 24  
Section 7 — INTALLATION DIAGRAM............ 25  
Section 8 — ELECTRICAL DATA.................... 26  
Section 9 — EXPLODED VIEWS AND  
PARTS LISTS ............................. 30  
Section 10 — WARRANTY .................Back Cover  
1
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IMPORTANT SAFETY INSTRUCTIONS  
Liquid-cooled 30 kW Generators  
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe  
operation be copied and posted in potential hazard areas. Safety should be stressed to all  
operators, potential operators, and service and repair technicians for this equipment.  
SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be   
followed during installation and maintenance of the generator and batteries.  
WARNING:  
GENERAL HAZARDS  
The engine exhaust from this product  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
For safety reasons, The manufacturer recommends  
that this equipment be installed, serviced and repaired  
by an Authorized Service Dealer or other competent,  
qualified electrician or installation technician who is  
familiar with applicable codes, standards and regula-  
tions. The operator also must comply with all such  
codes, standards and regulations.  
• Installation, operation, servicing and repair of this  
(and related) equipment must always comply with  
applicable codes, standards, laws and regulations.  
Adhere strictly to local, state and national electri-  
cal and building codes. Comply with regulations  
the Occupational Safety and Health Administration  
(OSHA) has established. Also, ensure that the genera-  
tor is installed, operated and serviced in accordance  
with the manufacturer’s instructions and recommen-  
dations. Following installation, do nothing that might  
render the unit unsafe or in noncompliance with the  
aforementioned codes, standards, laws and regula-  
tions.  
• The engine exhaust fumes contain carbon monoxide  
gas, which can be DEADLY. This dangerous gas,  
if breathed in sufficient concentrations, can cause  
unconsciousness or even death. For that reason,  
adequate ventilation must be provided. Exhaust  
gases must be piped safely away from any building  
or enclosure that houses the generator to an area  
where people, animals, etc., will not be harmed. This  
exhaust system must be installed properly, in strict  
compliance with applicable codes and standards.  
• Keep hands, feet, clothing, etc., away from drive belts,  
fans, and other moving or hot parts. Never remove  
any drive belt or fan guard while the unit is operat-  
ing.  
• Adequate, unobstructed flow of cooling and ventilat-  
ing air is critical to prevent buildup of explosive gases  
and to ensure correct generator operation. Do not  
alter the installation or permit even partial blockage  
of ventilation provisions, as this can seriously affect  
safe operation of the generator.  
WARNING:  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
Study these SAFETY RULES carefully before installing,  
operating or servicing this equipment. Become familiar  
with this Owner’s Manual and with the unit. The gen-  
erator can operate safely, efficiently and reliably only if  
it is properly installed, operated and maintained. Many  
accidents are caused by failing to follow simple and fun-  
damental rules or precautions.  
The manufacturer-cannot-anticipate-every-possible-cir-  
cumstancethatmight-involve-a-hazard.-The-warnings-in  
this manual, and on tags and decals affixed to the unit  
are, therefore,-not-all-inclusive. If using a procedure,  
work method or operating technique that the manufac-  
turer does not specifically recommend, ensure that it  
is safe for others. Also make sure the procedure, work  
method or operating technique utilized does not render  
the generator unsafe.  
DANGER  
Despite the safe design of this generator,  
operating this equipment imprudently, neglecting  
its maintenance or being careless can cause  
possible injury or death. Permit only responsible  
and capable persons to install, operate or maintain  
this equipment.  
Potentially lethal voltages are generated by these  
machines. Ensure all steps are taken to render the  
machine safe before attempting to work on the  
generator.  
• Keep the area around the generator clean and unclut-  
tered. Remove any materials that could become haz-  
ardous.  
• When working on this equipment, remain alert at all  
times. Never work on the equipment when physically  
or mentally fatigued.  
Parts of the generator are rotating and/or hot dur-  
ing operation. Exercise care near running genera-  
tors.  
2
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IMPORTANT SAFETY INSTRUCTIONS  
Liquid-cooled 30 kW Generators  
• Inspect the generator regularly, and promptly repair • Generators installed with an automatic transfer  
or replace all worn, damaged or defective parts using  
switch will crank and start automatically when NOR-  
MAL (UTILITY) source voltage is removed or is below  
an acceptable preset level. To prevent such automatic  
start-up and possible injury to personnel, disable  
the generator’s automatic start circuit (disconnect  
battery cables, etc.) before working on or around the  
unit. Then, place a “Do Not Operate” tag on the gen-  
erator control panel and on the transfer switch.  
• In case of accident caused by electric shock, imme-  
diately shut down the source of electrical power. If  
this is not possible, attempt to free the victim from  
the live conductor. AVOID DIRECT CONTACT WITH  
THE VICTIM. Use a nonconducting implement, such  
as a dry rope or board, to free the victim from the live  
conductor. If the victim is unconscious, apply first aid  
and get immediate medical help.  
only factory-approved parts.  
• Before performing any maintenance on the generator,  
disconnect its battery cables to prevent accidental  
start-up. Disconnect the cable from the battery post  
indicated by a NEGATIVE, NEG or (–) first. Reconnect  
that cable last.  
• Never use the generator or any of its parts as a step.  
Stepping on the unit can stress and break parts, and  
may result in dangerous operating conditions from  
leaking exhaust gases, fuel leakage, oil leakage, etc.  
ELECTRICAL HAZARDS  
• All generators covered by this manual produce dan-  
gerous electrical voltages and can cause fatal electri-  
cal shock. Utility power delivers extremely high and  
dangerous voltages to the transfer switch as well as  
the standby generator. Avoid contact with bare wires,  
terminals, connections, etc., on the generator as well  
as the transfer switch, if applicable. Ensure all appro-  
priate covers, guards and barriers are in place before  
operating the generator. If work must be done around  
an operating unit, stand on an insulated, dry surface  
to reduce shock hazard.  
• Never wear jewelry when working on this equipment.  
Jewelry can conduct electricity resulting in electric  
shock, or may get caught in moving components  
causing injury.  
FIRE HAZARDS  
• Keep a fire extinguisher near the generator at all  
times. Do NOT use any carbon tetra-chloride type  
extinguisher. Its fumes are toxic, and the liquid can  
deteriorate wiring insulation. Keep the extinguisher  
properly charged and be familiar with its use. If there  
are any questions pertaining to fire extinguishers,  
consult the local fire department.  
• Do not handle any kind of electrical device while  
standing in water, while barefoot, or while hands or  
feet are wet. DANGEROUS ELECTRICAL SHOCK  
MAY RESULT.  
• If people must stand on metal or concrete while  
installing, operating, servicing, adjusting or repair-  
ing this equipment, place insulative mats over a dry  
wooden platform. Work on the equipment only while  
standing on such insulative mats.  
• The National Electrical Code (NEC), Article 250  
requires the frame and external electrically conduc-  
tive parts of the generator to be connected to an  
approved earth ground and/or grounding rods. This  
grounding will help prevent dangerous electrical  
shock that might be caused by a ground fault condi-  
tion in the generator set or by static electricity. Never  
disconnect the ground wire.  
• Wire gauge sizes of electrical wiring, cables and cord  
sets must be adequate to handle the maximum elec-  
trical current (ampacity) to which they will be sub-  
jected.  
• Before installing or servicing this (and related) equip-  
ment, make sure that all power voltage supplies are  
positively turned off at their source. Failure to do so  
will result in hazardous and possibly fatal electrical  
shock.  
• Connecting this unit to an electrical system normally  
supplied by an electric utility shall be by means of a  
transfer switch so as to isolate the generator electric  
system from the electric utility distribution system  
when the generator is operating. Failure to isolate the  
two electric system power sources from each other  
by such means will result in damage to the generator  
and may also result in injury or death to utility power  
workers due to backfeed of electrical energy.  
EXPLOSION HAZARDS  
• Properly ventilate any room or building housing the  
generator to prevent build-up of explosive gas.  
• Do not smoke around the generator. Wipe up any fuel  
or oil spills immediately. Ensure that no combustible  
materials are left in the generator compartment, or  
on or near the generator, as FIRE or EXPLOSION  
may result. Keep the area surrounding the generator  
clean and free from debris.  
• These generator sets may operate using one of  
several types of fuels. All fuel types are potentially  
FLAMMABLE and/or EXPLOSIVE and should be  
handled with care. Comply with all laws regulating  
the storage and handling of fuels. Inspect the unit’s  
fuel system frequently and correct any leaks imme-  
diately. Fuel supply lines must be properly installed,  
purged and leak tested according to applicable fuel-  
gas codes before placing this equipment into service.  
• Diesel fuels are highly FLAMMABLE. Gaseous fluids  
such as natural gas and liquid propane (LP) gas are  
extremely EXPLOSIVE. Natural gas is lighter than air,  
and LP gas is heavier than air; install leak detectors  
accordingly.  
3
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Section 1 - General Information  
Liquid-cooled 30 kW Generators  
1.1 GENERATOR  
1.3 AUTOMATIC SYSTEM OPERATION  
When this generator, along with a transfer switch, has  
been installed and interconnected, a circuit board  
in the generator panel constantly monitors UTILITY  
power source voltage. Should that voltage drop below  
a preset value, and remain at such a low state for  
a preset amount of time, the generator cranks and  
starts. After the generator starts, the transfer switch  
transfers load circuits so the generator can power  
them.  
This equipment is a liquid-cooled, engine-driven  
generator set. The generator is designed to supply  
electrical power that operates critical electrical loads  
during utility power failure. The unit has been facto-  
ry-installed in a weather resistant, all metal enclosure  
and is intended for outdoor installation only. Use  
this generator as a source of electrical power for the  
operation of 120 and/or 240VAC, single-phase loads.  
When UTILITY source voltage has been restored, the  
switch re-transfers back to the UTILITY source volt-  
age and the generator then shuts down.  
If this generator is used to power electrical load  
circuits normally powered by a UTILITY power  
source, it is required by code to install a trans-  
fer switch. The transfer switch must effectively  
isolate the electric system from the utility distri-  
bution system when the generator is operating  
(NEC 701). Failure to isolate an electrical system  
by such means results in damage to the genera-  
tor and may also result in injury or even death  
to utility power workers due to backfeed of  
electrical energy.  
Please reference the transfer switch manual for spe-  
cific information.  
1.4 GENERATOR AC CONNECTION  
SYSTEMS  
The generator was shipped from the factory with its  
stator AC output leads connected in a single-phase,  
three-wire generator AC connection system (Figure  
1.1). The stator assembly in this system consists of  
a pair of stationary windings, with two leads brought  
out of each winding. Each single winding can sup-  
ply 120VAC, 60 Hertz. When the two windings are  
connected in series, a 240VAC, 60 Hertz AC output  
results. Typically the two HOT leads in the circuit  
are wires 11 and 44. The NEUTRAL leads are the  
junction of Wires 22 and 33. The NEUTRAL is not  
grounded.  
1.2 TRANSFER SWITCH  
This generator system may include a matched auto-  
matic transfer switch which is intended to be used  
in conjunction with the generator. It is supplied in  
a NEMA 3R enclosure. The NEMA 3R enclosure is  
weather proof and can be used indoors or outdoors.  
Follow these rules:  
• Install the transfer switch on a firm, sturdy sup-  
porting structure.  
Figure 1.1 - Generator AC Connection System  
To prevent switch distortion, level the switch if  
necessary. This can be done by placing washers  
between the switch enclosure and the mounting  
surface.  
• Never install the switch where water or any corro-  
sive substance might drip onto the enclosure.  
• Protect the switch at all times against excessive  
moisture, dust, dirt, lint, construction grit and cor-  
rosive vapors.  
If a transfer switch is not included, one may be pur-  
chased separately from an Authorized Dealer.  
1.5 MAIN CIRCUIT BREAKER  
The generator’s main circuit breaker is included with  
the unit as shipped from the factory. The breaker for  
each unit is described in Figure 1.2.  
Figure 1.2 - Main Circuit Breaker  
Model  
004988-4  
Rating  
27,000 NG  
30,000 LP  
Phase  
Actual Current  
112.5  
C/B Rating*  
Circuit Breaker  
150A QN2  
1
1
150  
150  
125.0  
150A QN2  
* Amp Rating of C/B structured under model.  
4
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Section 1 - General Information  
Liquid-cooled 30 kW Generators  
Figure 1.4 - Low Oil Pressure Switch  
1.6 GENERATOR FUEL SYSTEM  
The unit has been factory tested and adjusted using a  
natural gas fuel system. If propane (LP) gas is neces-  
sary, contact an authorized service dealer.  
Fuel pressure for a natural gas set up should be five  
inches to 14 inches of water column (0.18 to 0.5  
psi) at all load ranges.  
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.  
NOTE:  
The Low Oil Pressure, High Coolant Temperature  
and Low Coolant Level are not monitored for the  
first 10 seconds of engine run time.  
Gaseous fuels such as natural and LP (propane)  
1.7.2 HIGH COOLANT TEMPERATURE  
SWITCH  
gas are highly explosive. Even the slightest  
spark can ignite such fuels and cause an explo-  
sion. No leakage of fuel is permitted. Natural  
gas, which is lighter than air, tends to collect in  
high areas. LP gas is heavier than air and tends  
to settle in low areas.  
This normally open (N.O.) thermostatic switch has  
sensing tip which is immersed in captive coolant.  
Should coolant temperature exceed about 230°F  
(110°C), the switch contacts close. This causes the  
engine to shut down automatically and turns on  
the high coolant temperature/low coolant level LED  
(Figure 1.5).  
1.7 ENGINE PROTECTIVE DEVICES  
The engine has several safety switches which cause  
the engine to automatically shut down under the  
following conditions: low oil pressure, high coolant  
temperature, engine overspeed, low coolant level or  
overcrank (Figure 1.3).  
Figure 1.5- High Coolant Temperature Switch  
Figure 1.3 - Engine Protective Devices  
LOW COOLANT  
LEVEL SWITCH  
LOW OIL  
PRESURE  
SWITCH  
HIGH  
COOLANT  
TEMPERATURE  
SWITCH  
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 automatical-  
ly shuts down and turns on the high coolant tempera-  
ture/low coolant level LED (Figure 1.6 on page 6).  
1.7.1 LOW OIL PRESSURE SWITCH  
This switch is normally-closed (N.C.) but is held open  
by engine oil pressure during engine running. Should  
operating oil pressure drop below about 8-10 psi (55-  
68 kPa), the switch contacts close, the engine shuts  
down automatically, and the low oil pressure LED is  
turned ON (Figure 1.4).  
5
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Section 1 — General Information  
Liquid-cooled 30 kW Generators  
Figure 1.6 - Low Coolant Level Sensor  
1.7.7 LOW BATTERY  
The engine control board continually monitors the  
battery voltage and turns on the low battery LED  
if the battery voltage falls below 11.0 VDC for one  
minute. Low battery voltage is a non-latching alarm,  
which will automatically clear if the battery voltage  
rises above 11.0 VDC.  
The control system will not attempt to start the  
engine if there is a low battery condition, however, if  
the engine is already running when the low battery  
condition occurs, the engine will continue to run as  
long as possible.  
Battery voltage is NOT monitored during the crank  
cycle.  
1.7.4 OVERSPEED SHUTDOWN  
1.7.8 ALARM RESET  
The engine control board receives AC frequency sig-  
nals from an engine run winding in the alternator.  
Should AC frequency exceed about 72 Hertz for three  
seconds or 75 Hertz instantaniously, the engine shuts  
down and the overspeed LED turns on. Should AC  
frequency exceed about 72 Hertz, circuit board action  
will automatically shutdown the engine (Figure 1.7).  
If the engine control board shuts down the genera-  
tor for any of the above reasons, the engine remains  
stopped until the alarm is cleared by placing the  
AUTO/OFF/MANUAL switch into the OFF position.  
1.7.9 DC FUSES  
These fuses are located on the front panel of the con-  
trol system. They protect the panel wiring and com-  
ponents from damaging overload. Always remove the  
15 amp main fuse before working on the generator.  
The unit will not start or crank if this fuse is blown.  
Replace the fuse with one of the same size, type, and  
rating (main AGC-15, battery charger AG4).  
Figure 1.7 - Printed Circuit Board Assembly  
R44  
LED1  
C27  
Q2  
C9  
J2  
C26  
U7  
C4  
D10  
C21  
1.8 UNPACKING  
C30  
C2  
1.8.1 UNPACKING PRECAUTIONS  
RL1  
RL2  
R1  
R48  
D17  
Handle shipping cartons and crates with care. Use  
care to avoid damage from dropping, bumping, colli-  
sion, etc. Store and unpack cartons with the proper  
side up, as noted on the shipping carton.  
R49  
U1  
J1  
L3  
D19  
R E V 9 0 . 6 E 0 4 B #  
1.8.2 INSPECTION  
1.7.5 RPM SENSOR LOSS  
After unpacking, carefully inspect the generator for  
any damage that may have occurred during ship-  
ment. If loss or damage is noted at the time of deliv-  
ery, have the person(s) making delivery note all dam-  
age on the freight bill or affix their signature under  
the consignor’s memo of loss or damage.  
If the engine control board does not receive a proper  
rpm signal from the starter during cranking or run-  
ning, it shuts down the engine on rpm sensor loss  
and flash the overspeed LED.  
1.7.6 OVERCRANK SHUTDOWN  
1.9 LIFTING THE GENERATOR  
The engine control board uses a cyclic cranking pro-  
cess when attempting to start the engine. The first  
crank cycle is a 15-second crank followed by a seven-  
second rest. This is followed by five more crank  
cycles each with a seven-second crank followed by a  
seven-second rest.  
When lifting or hoisting equipment is used, be  
careful not to touch overhead power lines. The  
generators weight of more than 900 pounds  
requires proper tools, equipment, and qualified  
personnel to be used in all phases of handling  
and unpacking.  
If the engine fails to start after all six attempts, the  
start attempt is stopped and the overcrank LED’s  
illuminated.  
6
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Section 1 — General Information  
Liquid-cooled 30 kW Generators  
Fuel pressure for a natural gas set up should be five  
inches to 14 inches of water column (0.18 to 0.5  
psi) at all load ranges.  
1.10 SPECIFICATIONS  
1.10.1 GENERATOR SPECIFICATIONS  
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.  
Single-phase  
Model  
004988-4  
Rated Max. Cont.  
27 (NG), 30 (LP)  
AC Power Output (kW)  
Rated voltage (volts)  
No. of Rotor Poles  
Driven Speed of Rotor  
Rotor Excitation System  
Type of Stator  
1.12 RECONFIGURING THE FUEL  
120/240  
4
1800  
SYSTEM  
NOTE:  
Direct excited brush type  
4 Wire  
All models are configured for natural gas from the  
factory.  
Rotor/Stator Insulation  
Class F/H  
To reconfigure the fuel system from NG to LP vapor,  
follow these steps:  
1.10.2 ENGINE SPECIFICATIONS  
1. Turn the main gas supply off.  
Make........................................................................................................Ford  
Displacement.................................................................................... 3.0 liters  
Cylinder Arrangement ...............................................................................V-6  
Valve Arrangement................................................................Overhead Valve  
Firing Order ..................................................................................1-4-2-5-3-6  
Number of Main Bearings ............................................................................4  
Compression Ratio.............................................................................9.3 to 1  
No. of Teeth on Flywheel..........................................................................164  
Ignition Timing at 1800 rpm...............................................30 degrees BTDC  
Spark Plug Gap...................................................................0.042-0.046 inch  
Recommended Spark Plugs  
2. Remove the carburetor fuel hose from the outlet  
port (Port 1) of the demand regulator (Figure  
1.8).  
3. Remove the brass hose fitting from the outlet port  
(Port 1) of the demand regulator.  
4. Remove pipe plug from Port 2.  
5. Install brass hose fitting into Port 2.  
6. Install pipe plug into Port 1.  
7. Connect carburetor gas hose to brass fitting.  
8. Tighten all clamps and plugs.  
9. Make sure fuel supply is of the proper pressure  
and type for configuration.  
Motor Craft ..........................................................................AG, SF 32PGM  
Oil Pressure.....................................................................................40-50 psi  
Crankcase Oil Capacity.........................................5.0 U.S. quarts (4.7 liters)  
Recommended Engine Oil ..........................................................SAE 5W-20  
Type of Cooling System .................................. Pressurized, closed recovery  
Cooling Fan ................................................................................Pusher Type  
Cooling System Capacity .................................. 3.0 U.S. gallons (11.4 liters)  
Recommended Coolant.............................................Use a 50-50 mixture of  
ethylene glycol base and de-ionized water.  
10. Reverse the procedure to convert back to natural  
gas.  
Figure 1.8 — Reconfigure the Fuel System  
Port 1  
Port 2  
FUEL HOSE  
FUEL HOSE  
BRASS HOSE  
FITTING  
BRASS HOSE  
FITTING  
PLUG  
PLUG  
OUT  
PORT 1  
OUT  
PORT 2  
HOUSING  
PORTS  
HOUSING  
PORTS  
1.11 FUEL CONSUMPTION  
Natural Gas:  
% of Load  
3
25%  
3.1  
50%  
5.9  
75%  
8.5  
100%  
11.0  
m /hr  
3
ft /hr  
110.3  
209.0  
299.5  
387.0  
LP Vapor:  
% of Load  
25%  
1.3  
50%  
2.4  
75%  
3.5  
100%  
4.5  
3
m /hr  
3
NG FUEL SYSTEM  
LP FUEL SYSTEM  
ft /hr  
45.6  
86.4  
123.8  
160.0  
NOTE:  
NOTE:  
Port 1 is for NG only and Port 2 is for LP vapor  
only. No provision for dual fuel has been made.  
Fuel consumption is given at rated maximum  
continuous power output when using natural gas  
rated at 1000 Btu per cubic foot. LP gas is rated at  
2520 Btu per cubic foot. Actual fuel consumption  
obtained may vary depending on such variables as  
applied load, ambient temperature, engine condi-  
tions and other environmental factors.  
DANGER  
Serious injury or damage may occur if not con-  
figured properly. Please consult an Authorized  
Service Dealer with any questions.  
7
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Section 2 — Installation  
Liquid-cooled 30 kW Generators  
The generator’s rated wattage/amperage capacity  
must be adequate to handle all electrical loads that  
the unit will power. The critical (essential) loads may  
need to be grouped together and wired into a sepa-  
rate “emergency” distribution panel.  
1.13 TORQUE SPECIFICATIONS  
Cylinder Head............................................ 15 (+ 90° + 90°) ft.lb.  
Intake Manifold ................................................................13 ft.lb.  
Exhaust Manifold .............................................................13 ft.lb.  
This generator can be installed in conjunction with  
an engineered “GTS” type transfer switch, if neces-  
sary.  
1.14 ENGINE OIL RECOMMENDATIONS  
The unit has been filled with 5W-20 engine oil at the  
factory. Use a high-quality detergent oil classified “For  
Service CC, SD, SE, SF.” Detergent oils keep the engine  
cleaner and reduce carbon deposits. Use oil having  
the following SAE viscosity rating, based on the ambi-  
ent temperature range anticipated before the next oil  
change:  
The standard transfer switch has no sensing or con-  
trolling circuit boards. Instead, the generator control  
console houses a “Printed Circuit Board Assembly”,  
which controls all phases of operation, including  
engine start up and load transfer.  
Temperature  
Above 80° F (27° C)  
32° to 80° F (-1° to 27° C)  
Below 32° F (0° C)  
Oil Grade (Recommended)  
SAE 5W-20  
SAE 5W-20  
2.1 STANDBY GENERATOR  
INSTALLATION  
SAE 5W-20  
DANGER  
NOTE:  
Connecting this generator to an electrical system  
normally supplied by an electric utility shall be  
Synthetic oil is highly recommended in any element  
with temperatures above 90° F or below 30° F.  
by means of a transfer switch, so as to isolate  
the electric system from the utility distribution  
system when the generator is operating. Failure  
to isolate the electric system by these means  
will result in damage to the generator and may  
also result in injury or death to utility workers  
due to backfeed of electrical energy.  
Any attempt to crank or start the engine before it  
has been properly serviced with the recommend-  
ed oil may result in an engine failure.  
If an open bottom is used, the engine-generator  
is to be installed over non-combustible materi-  
als and should be located such that combustible  
materials are not capable of accumulating under  
the generator set.  
1.15 COOLANT RECOMMENDATIONS  
Use a mixture of half low silicate ethylene glycol base  
anti-freeze and half de-ionized water. Cooling system  
capacity is about 12 U.S. quarts (11.4 liters). Use only  
de-ionized water and only low silicate anti-freeze. If  
desired, add a high quality rust inhibitor to the rec-  
ommended coolant mixture. When adding coolant,  
always add the recommended 50-50 mixture.  
Only qualified, competent installation contractors  
or electricians thoroughly familiar with applicable  
codes, standards and regulations should install this  
standby electric power system. The installation must  
comply strictly with all codes, standards and regula-  
tions pertaining to the installation.  
Do not use any chromate base rust inhibitor  
with ethylene glycol base anti-freeze or chro-  
miumhydroxide (“green slime”) forms and will  
cause overheating. Engines that have been oper-  
ated with a chromate base rust inhibitor must  
be chemically cleaned before adding ethylene  
glycol base anti-freeze. Using any high silicate  
anti-freeze boosters or additives will also cause  
overheating. It is also recommend that any solu-  
ble oil inhibitor is NOT USED for this equipment.  
After the system has been installed, do nothing  
that might render the installation in noncompli-  
ance with such codes, standards and regulations.  
2.1.1 NFPA STANDARDS  
The following published standards booklets pertain-  
ing to standby electric systems are available form  
the National Fire Protection Association (NFPA),  
Batterymarch Park, Quincy, MA 02269:  
1.16 BEFORE INSTALLATION  
Before installing this equipment, check the ratings  
of both the generator and the transfer switch. Read  
“Emergency Isolation Method” and “Total Circuit  
Isolation Method” in Sections 2.5 and 2.6.  
NOTE:  
It is essential to use the latest version of any stan-  
dard to ensure correct and current information.  
8
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Section 2 — Installation  
Liquid-cooled 30 kW Generators  
• NFPA No. 37, STATIONARY COMBUSTION  
ENGINES AND GAS TURBINES.  
• NFPA No. 76A, ESSENTIAL ELECTRICAL  
SYSTEMS FOR HEALTH CARE FACILITIES.  
• NFPA No. 220, STANDARD TYPES OF BUILDING  
CONSTRUCTION  
• Where strong prevailing winds blow from one  
direction, face the generator air inlet openings into  
the prevailing winds.  
• Install the generator as close as possible to the  
transfer switch. This reduces the length of wiring  
and conduit.  
• Install the generator as close as possible to  
the fuel supply, to reduce the length of piping.  
HOWEVER, REMEMBER THAT LAWS OR CODES  
MAY REGULATE THE DISTANCE.  
• NFPA No. 68, GUIDE FOR EXPLOSION VENTING  
• NFPA No. 70, NATIONAL ELECTRICAL CODE.  
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE  
LIQUIDS CODE.  
• NFPA No. 10, INSTALLATION, MAINTENANCE AND  
2.3 GENERATOR MOUNTING AND  
USE OF PORTABLE FIRE EXTINGUISHERS.  
SUPPORT  
2.1.2 OTHER PUBLISHED STANDARDS  
Retain the generator compartment to a concrete slab  
with 1/4-inch masonry type anchor bolts. Be sure the  
bolts are long enough to retain the compartment. The  
slab should be at least six inches thick and should  
extend beyond the enclosure to a distance of at least  
three inches on all sides. See Section 6 for generator  
major dimensions.  
In addition to NFPA standards, the following informa-  
tion pertaining to the installation and use of standby  
electric systems is available:  
NOTE:  
It is essential to use the latest version of any stan-  
dard to ensure correct and current information.  
• Article X, NATIONAL BUILDING CODE, available  
from the American Insurance Association, 85 John  
Street, New York, N.Y. 10038.  
• AGRICULTURAL WIRING HANDBOOK, obtainable  
from the Food and Energy Council, 909 University  
Avenue, Columbia, MO, 65201.  
2.4 BASIC STANDBY ELECTRIC  
SYSTEM  
Figure 2.1 shows a schematic diagram of a basic  
standby electric system. Both the UTILITY power  
supply and the STANDBY (GENERATOR) output are  
connected to an approved transfer switch. The trans-  
fer switch is required by electrical code and serves  
the following functions:  
• ASAE  
EP-364.2,  
INSTALLATION  
AND  
MAINTENANCE OF FARM STANDBY ELECTRIC  
POWER, available from the American Society  
of Agricultural Engineers, 2950 Niles Road, St.  
Joseph, MI 49085.  
• Allows the LOAD circuits to be connected to only  
one power supply at a time.  
• A52.1, AMERICAN NATIONAL STANDARD  
FOR CHIMNEYS, FIREPLACES AND VENTING  
SYSTEMS, available from the American National  
Standard Institute, 1430 Broadway, New York, N.Y.  
10018.  
• Prevents electrical backfeed between the generator  
and the UTILITY power circuits.  
Notice that both the STANDBY and the UTILITY  
power supplies to the transfer switch are protected  
against overload by a main line circuit breaker.  
Figure 2.1 – Basic Standby Electric System  
2.2 GENERATOR LOCATION  
Install the generator set, in its protective enclosure  
outdoors, where adequate cooling and ventilating air  
always is available. Consider these factors:  
• Install the unit where air inlet and outlet open-  
ings will not become obstructed by leaves, grass,  
snow, etc. If prevailing winds will cause blowing or  
drifting, consider using a windbreak to protect the  
unit.  
• Install the generator on high ground where water  
levels will not rise and endanger it.  
• This genset must be installed on a level surface.  
The base frame must be level within 1/2 inch all  
around.  
• Allow sufficient room on all sides of the generator  
for maintenance and servicing. A good rule is to  
allow five feet of space on all sides.  
9
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Section 2 — Installation  
Liquid-cooled 30 kW Generators  
Figure 2.2 – Generator Grounding Lug (typical)  
2.5 EMERGENCY CIRCUIT ISOLATION  
METHOD  
This prevents overloading the generator by keeping  
electrical loads below the wattage/amperage capacity  
of the generator. If the generator can only power criti-  
cal loads, within it’s wattage/amperage capacity, dur-  
ing utility power outages, use the emergency circuit  
isolation method.  
GROUNDING  
LUG  
Critical electrical loads are grouped together and  
wired into a separate “Emergency Distribution Panel.”  
Load circuits powered by that panel are within the  
wattage/amperage capacity of the generator set. The  
transfer switch must meet the following require-  
ments:  
DANGER  
• It must have an ampere rating equal to the total  
amperage rating of the emergency distribution  
panel circuit.  
• Have it installed between the building’s main dis-  
tribution panel and the emergency distribution  
panel.  
Do not connect the ground wire to any pipe  
that carries a flammable or explosive substance  
– FIRE or an EXPLOSION may result.  
Proper grounding helps protect personnel against  
electrical shock in the event of a ground fault condi-  
tion in the generator or in connected electrical devic-  
es. In addition, grounding helps dissipate static elec-  
tricity that often builds up in ungrounded devices.  
2.6 TOTAL CIRCUIT ISOLATION  
METHOD  
When a generator capable of powering all electrical  
loads in the circuit is to be installed, use the “Total  
Circuit Isolation Method.” It is possible for the gen-  
erator to be overloaded when this isolation method is  
employed. The following apply to the transfer switch  
in this type of system.  
2.8 GENERATOR AC NEUTRAL  
CONNECTIONS  
The manufacturer uses an UNGROUNDED AC neu-  
tral. Grounding is recommended only at the main  
service entrance. If the neutral wire is grounded and  
one of the phase loads becomes grounded, the exces-  
sive current opens the load circuit breaker or col-  
lapses the generator field. The actual result depends  
on the electrical characteristics of the particular  
installed generator.  
• Ampere rating of the transfer switch must equal  
the ampere rating of the normal incoming utility  
service.  
• The transfer switch is installed between the util-  
ity service entrance and the building distribution  
panel.  
2.7 GROUNDING THE GENERATOR  
The National Electrical Code requires the frame and  
external electrically conductive parts of this equip-  
ment to be properly connected to an approved earth  
ground and/or grounding rods. For that purpose, a  
GROUND LUG (Figure 2.2) is provided on the gen-  
erator mounting base. Consult a qualified electrician  
for grounding requirements in the area. Grounding  
procedures must meet local regulations.  
Failure to connect the generator neutral proper-  
ly will result in unbalanced line-to-neutral volt-  
ages. Resulting high voltages will cause equip-  
ment damage.  
2.9 TRANSFER SWITCH SIGNAL  
CONNECTIONS  
2.9.1 PRE-PACKAGED ATS  
If the generator is to be installed with a pre-packaged  
(non-control board based) transfer switch, it is nec-  
essary to connect the control wires to the generator  
and set position two of the four-position dip switch  
to OFF.  
Setting switch two to OFF allows the control PCB to  
perform the ATS control functions.  
10  
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Section 2 — Installation  
Liquid-cooled 30 kW Generators  
Control system interconnections consist of N1 and  
N2, and leads 23 and 194. Control system intercon-  
nection leads must be run in a conduit that is sepa-  
rate from the AC power lead. Recommended wire  
gauge sizes for this wiring depends on the length of  
the wire, as recommended below:  
Battery electrolyte fluid is an extremely caus-  
tic sulfuric acid solution that can cause severe  
burns. Do not permit fluid to contact eyes, skin,  
clothing, painted surfaces, etc. Wear protective  
goggles, protective clothing and gloves when  
handling a battery. If fluid is spilled, flush the  
affected area immediately with clear water.  
MAXIMUM WIRE LENGTH  
RECOMMENDED WIRE  
SIZE  
Spilled electrolyte is to be washed down with  
an acid neutralizing agent. A common practice  
is to use a solution of one pound (500 grams)  
bicarbonate of soda to one gallon (4 liters) of  
water. The bicarbonate of soda solution is to be  
added until the evidence of reaction (foaming)  
has ceased. The resulting liquid is to be flushed  
with water and the area dried.  
460 feet (140m)  
No. 18 AWG.  
No. 16 AWG.  
No. 14 AWG.  
No. 12 AWG.  
461 to 730 feet (223m)  
731 to 1,160 feet (354m)  
1,161 to 1,850 feet (565m)  
2.9.2 GTS-TYPE ATS  
If the generator is to be installed with an automatic  
transfer switch, such as an engineered GTS-type  
switch, it is necessary to connect the two-wire start  
control system.  
Do not dispose of the battery in a fire. The  
battery is capable of exploding.  
Connect the two-wire start signal from the automatic  
transfer switch to the automatic start connection,  
which is located in the middle, on the bottom, inside  
the control panel. Match wires 178 and 183 in the  
transfer 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. (See  
Section 3.1 for further explanation.)  
Do not open or mutilate the battery. Released  
electrolyte can be toxic and harmful to the skin  
and eyes.  
The battery represents a risk of high short circuit  
current. When working on the battery, always  
remove watches, rings or other metal objects,  
and only use tools that have insulated handles.  
When replacing batteries, use the same number  
and type of battery. The recommended batteries are  
Group 26, 12V negative ground 525 CCA/75 AH mini-  
mum capacity, or Group 27F, 12V negative ground  
600 CCA/90 AH minimum capacity. All batteries  
must be at 100 percent state-of-charge before they  
are installed on the generator.  
2.10 BATTERY INSTALLATION  
DANGER  
Standby generators installed with automatic  
transfer switches will crank and start automati-  
cally when NORMAL (UTILITY) source voltage is  
removed or is below an acceptable preset level.  
To prevent such automatic start-up and possible  
injury to personnel, ensure that the 15A and  
4A fuses are removed from the control console,  
the AUTO/OFF/MANUAL switch is set to OFF,  
and the utility supply to the battery charger is  
removed before removing or connecting battery  
cables.  
When using maintenance-free batteries, it is not  
necessary to check the specific gravity or electrolyte  
level. Have these procedures performed at the inter-  
vals specified in Section 4, “Maintenance.” A nega-  
tive ground system is used. Battery connections are  
shown on the wiring diagrams. Make sure all batter-  
ies are correctly connected and terminals are tight.  
Observe battery polarity when connecting batteries to  
the generator set.  
Storage batteries give off explosive hydrogen  
gas. This gas can form an explosive mixture  
NOTE:  
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.  
Damage will result if the battery connections are  
made in reverse.  
2.11 PREPARATION BEFORE START-UP  
The instructions in this section assume that the  
standby generator has been properly installed, ser-  
viced, tested, adjusted and otherwise prepared for  
use by a competent, qualified installation contractor.  
Be sure to read the “Safety Rules” on Pages 2 and 3,  
as well as all other safety information in this manual,  
before attempting to operate this (and related) equip-  
ment.  
11  
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Section 3 — Operation  
Liquid-cooled 30 kW Generators  
2.11.1 PRIOR TO INITIAL START-UP  
2.11.6 BELT TENSION  
Check-the engine-fan belt tension and condition prior  
to placing the unit into service and at recommended  
intervals. Belt tension is correct when a force of  
approximately 22 pounds (10 kg), applied midway  
between pulleys, deflects the belt about 3/8- to 5/8-  
inch (10 to 16 mm).  
Prior to initially starting the generator, it must  
be properly prepared for use. Any attempt to  
crank or start the engine before it has been  
properly serviced with the recommended types  
and quantities of engine fluids (oil, coolant, fuel,  
etc.) may result in an engine failure.  
2.11.7 ELECTRICAL SYSTEM  
Before starting the generator for the first time, the  
installer must complete the following procedures. For  
follow-up maintenance information and/or service  
intervals, please refer to Section 4, “Maintenance.”  
Make sure the generator is properly connected to an  
approved earth ground and/or ground rod.  
Make sure the generator battery is fully charged,  
properly installed and interconnected, and ready for  
use.  
2.11.2 TRANSFER SWITCH  
Check to ensure that there are no loose electrical con-  
nections. Restrain any loose wires to keep them clear  
of any moving generator set components.  
If this generator is used to supply power to any elec-  
trical system normally powered by an electric utility,  
the National Electrical Code requires that a transfer  
switch be installed. The transfer switch prevents elec-  
trical backfeed between two different electrical sys-  
tems (for additional information, see the applicable  
transfer switch manual for this unit). The transfer  
switch, as well as the generator and other standby  
components, must be properly located and mounted  
in strict compliance with applicable codes, standards  
and regulations.  
3.1 USING AN ENGINEERED “GTS”  
TRANSFER SWITCH  
When required, the pre-packaged standby generator  
can be installed with an engineered “GTS” type auto-  
matic transfer switch.  
In this application, the GTS is responsible for utility  
sensing, weekly exercising, and load transferring.  
2.11.3 FUEL SYSTEM  
Position two of the four-position dip switch is used to  
turn over this control to the GTS.  
Make sure the fuel supply system to the generator (a)  
delivers the correct fuel at the correct pressure and (b)  
is properly purged and leak tested according to code.  
No fuel leakage is permitted. See “Specifications”  
(Section 1.10) for more information.  
Pos2 ON — GTS Application  
• The generator’s control board will NOT monitor  
utility.  
• The control board will NOT perform a weekly  
exercise. (The five red LEDs will not flash in this  
mode.)  
2.11.4 GENERATOR SET LUBRICATION  
Check the engine crankcase oil level before operating  
and add oil to the proper level – the dipstick “FULL”  
mark. Never operate the engine with the oil level  
below the dipstick ADD” mark. See “Specifications”  
(Section 1.10) and “Engine Oil Recommendations”  
(Section 1.14).  
• The control board will NOT activate the transfer  
output.  
• The control board WILL monitor all engine condi-  
tions and shut down on all the faults listed in this  
document.  
Pos2 OFF — ATS Application  
NOTE:  
• The generator’s control board will perform all of  
the automatic features listed in this document.  
• The two-wire start connections should NOT be  
used.  
This engine is shipped from the manufacturer  
with 5W-20 oil. This oil should be changed after  
30 hours of operation.  
2.11.5 ENGINE COOLANT  
GTS Mode Operation  
When in GTS mode, the generator’s control board  
will respond as follows based on the AUTO/OFF/  
MANUAL switch position.  
Have the engine cooling system properly filled with  
the recommended coolant mixture. Check the system  
for leaks and other problems. See “Specifications”  
(Section 1.10) and “Coolant” (Section 1.15).  
OFF — The generator will not start and run in this  
position.  
12  
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Section 3 - Operation  
Liquid-cooled 30 kW Generators  
MANUAL — The control board will start and run  
the generator whenever the switch is in the manual  
position.  
DANGER  
With switch set to AUTO, engine can crank and  
AUTO — The control board will monitor the two-  
wire start circuit. When a two-wire start is issued the  
control board will immediately start and run the gen-  
erator. Whe the two-wire start is removed the control  
board will immediately stop the generator.  
start suddenly without warning. Such automatic  
start up normally occurs when utility source  
voltage drops below a pre-set level. To prevent  
possible injury that might be caused by such  
sudden starts, set AUTO/OFF/MANUAL switch  
to OFF before working on or around the unit.  
Then, place a “DO NOT OPERATE” tag on control  
console.  
NOTE:  
If the generator is installed in conjunction with an  
engineered GTS type transfer switch, refer to the  
applicable transfer switch manual for exact oper-  
ating parameters and timing sequences.  
3.2.2 FAULT INDICATOR LED  
This LED goes ON when one or more of the following  
engine faults occurs and when engine shuts down.  
3.2 CONTROL CONSOLE  
• Low Oil Pressure  
COMPONENTS  
• Overcrank  
• Low Battery  
The components of a home standby generator control  
console (Figure 3.1) are as follows:  
• Overspeed/RPM Sensor Loss  
• High Coolant Temperature/Low Coolant Level  
See Section 1.7 for further explanation of engine pro-  
tection functions.  
3.2.1 AUTO/OFF/MANUAL SWITCH  
Use this three-position switch as follows:  
• Set the switch to AUTO for fully automatic opera-  
tion. See Automatic Operation” (Section 3.6).  
• Set switch to MANUAL position to crank and start  
the generator engine.  
• Set switch to OFF position to shut down an operat-  
ing engine. With OFF selected, operation will not  
be possible.  
3.2.3 15 AMP FUSE  
Fuse protects the control console’s DC control circuit  
against electrical overload. If the fuse has melted  
open because of an overload, engine cranking and  
startup cannot occur. If the fuse needs to be replaced,  
use only an identical 15-amp replacement fuse. (Type  
AGC)  
Figure 3.1 - Home Standby Generator Panel  
3.2.4 4.0 AMP INLINE FUSE  
LED INDICATORS:  
FLASHING GREEN LED  
This fuse protects the battery charger against electri-  
cal overload. If the fuse needs to be replaced, use only  
an identical 4 amp replacement fuse (type AG).  
=
=
NO UTILITY SENSE  
EXERCISER NOT SET  
5
FLASHING RED LED'S  
(IN AUTO MODE ONLY) SOLID GREEN LED  
RED LED'S INDIVIDUAL FAULT  
=
SYSTEM READY, UTILITY POWER ON  
=
(SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS)  
OVER CRANK  
RED LED  
E
E
NOTE:  
AUTO  
OFF  
This fuse will not remove the + battery input  
power from the PCB when it opens. This means  
the exercise timer will not be reset.  
OFF  
ON  
SET  
EXECISER  
TIME  
SET  
EXERCISE  
TIME  
MANUAL  
GREEN LED  
TO SET EXERCISER TIME  
1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.  
0E7194  
3.2.5 SET EXERCISE TIME SWITCH  
SWITCH  
This switch allows programming the generator to  
start and exercise automatically. See Weekly Exercise  
Cycle.”  
AUTO/OFF/MANUAL  
SWITCH  
4A FUSE  
BATTERY  
CHARGER  
15A FUSE  
3.2.6 SYSTEM READY LED  
MAIN  
The System Ready LED (green) has two main pro-  
poses. First, the LED will be ON when the AUTO/  
OFF/MANUAL switch is in the AUTO position, utility  
is present, and there are no system alarms. This ON  
state indicates the system is fully ready for automatic  
operation.  
POWER  
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Section 3 — Operation  
Liquid-cooled 30 kW Generators  
The system ready LED will be OFF when the switch  
is in the manual or OFF positions.  
Figure 3.2 — Engine Governor Adjustment  
R44  
The system ready LED is also used to indicate the  
presence of utility sensing at the PCB when the switch  
is either in the AUTO or MANUAL modes. The LED  
will flash at the rate of 1/2 second on, 1/2 second off  
if the utility sensing level is below the transfer back  
threshold.  
LED1  
C27  
Q2  
C9  
J2  
C26  
U7  
C4  
D10  
C21  
This secondary function is only available with dip  
switch two in the OFF position (standard ATS appli-  
cation).  
C30  
C2  
RL1  
RL2  
R1  
R48  
D17  
3.3 MANUAL TRANSFER AND  
R49  
START-UP  
U1  
To transfer electrical loads to the Standby  
(EMERGENCY) power source side and start the  
engine manually, refer to the Owner’s Manual of the  
particular transfer switch.  
J1  
L3  
D19  
0
DIP SWITCH  
DIFFERENTIAL  
STABILITY  
POSITION 1  
50/60 HZ  
POSITION 2  
GTS/ATS Select  
ON = GTS  
4
3
2
1
UNUSED  
ON = 50 HZ  
GTS/ATS  
OFF = ATS (standard mode)  
OFF = 60 HZ  
50/60 HZ  
3.4 ENGINE GOVERNOR  
ADJUSTMENTS  
3.5 RETRANSFER AND SHUTDOWN  
When utility power source voltage has been restored,  
electrical loads may be transferred back to that  
source and the generator can be shut down as fol-  
lows:  
Engine speed governing is also controlled by the  
engine control board. Connector J2 on the engine  
control board interfaces with a governor driver mod-  
ule and the Bosch throttle body. The engine gover-  
nor has been set by the factory during final testing  
of the generator and, in most cases, should not be  
adjusted.  
Verify that UTILITY power supply voltage to the  
transfer switch has been positively turned OFF,  
using whatever means provided (such as utility  
main line circuit breaker).  
If, however, adjustments are necessary, or a new  
engine control board is installed in the generator, the  
following procedure should be followed (Figure 3.2):  
• Set the generator’s main circuit breaker to its OFF  
or OPEN position.  
1. Set all three potentiometers (pots) fully counter-  
clockwise.  
2. Under no load condition, increase the GAIN pot  
as much as possible without causing instability.  
3. Apply 1/4, 1/2, 3/4 and full load to the unit.  
Decrease the GAIN pot if there is instability at any  
load point.  
4. Under full load condition, increase the stability  
pot until the unit returns to 60 Hertz (or 50 Hertz  
in 50 Hertz applications).  
5. Reduce load to 3/4, 1/2, 1/4 and no load. Decrease  
the stability pot if there is instability at any load  
point.  
6. Adjust differential pot to make the recovery to  
load changes even faster and minimize load  
change undershoot and overshoot. If it is set too  
high it may introduce oscillations at some load.  
It can be set to zero (full CCW) if a small amount  
causes oscillations at some load.  
• Let the generator engine run at no-load for a few  
minutes, to stabilize internal unit temperatures.  
• On the generator console, set the AUTO/OFF/  
MANUAL switch to OFF. Wait for engine to come to  
a complete stop.  
For transfer to utility position, refer to the Owner’s  
Manual of the particular transfer switch.  
Turn on the UTILITY power supply to the transfer  
switch, using whatever means provided (such as  
a utility main line circuit breaker). The UTILITY  
power source now powers the loads.  
3.6 AUTOMATIC OPERATION  
To set the system for fully automatic operation, pro-  
ceed as follows:  
• Check that load circuits are connected to the  
utility power supply.  
• Set the AUTO/OFF/MANUAL switch to its AUTO  
position.  
• Set the generator main circuit breaker to its ON or  
CLOSED position.  
14  
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Section 4 — Maintenance  
Liquid-cooled 30 kW Generators  
3.7 WEEKLY EXERCISE CYCLE  
4.1 MAINTENANCE PERFORMED BY  
AUTHORIZED SERVICE FACILITIES  
The engine control board will start and run the gen-  
erator once every seven days for approximately 12  
minutes. If utility should fail during this exercise  
period, the engine control board will transfer the load  
to the generator output and continue to run until util-  
ity returns.  
EVERY THREE MONTHS  
1. Check battery state of charge and condition.  
2. Inspect and test fuel system.  
3. Check transfer switch.  
4. Inspect exhaust system.  
5. Check engine ignition system.  
6. Check fan belts.  
On the day, and at the time of day chosen for the  
generator to exercise, set the weekly exercise cycle  
as follows:  
1. Place the AUTO/OFF/MANUAL switch in the  
AUTO position.  
ONCE EVERY SIX MONTHS  
2. Press and hold the “Set Exercise” switch for three  
seconds, then release.  
1. Test Engine Safety Devices (low oil pressure, low  
coolant level, high coolant temperature).  
At this time all five red LEDs will flash for approxi-  
mately 10 seconds, then the engine will start and run  
for it’s 12 minute exercise period, then shut down.  
The generator will now start and run each week at  
the same time.  
ONCE ANNUALLY  
1. Test engine governor. Adjust or repair, if needed.  
2. Clean, inspect generator.  
3. Flush cooling system.  
If DC power to the control board is lost, the weekly  
exercise setting will be lost. This is indicated by all  
five red LEDs continually flashing. In this state the  
generator will still start and run in manual mode, or  
automatically start and run if UTILITY is lost while in  
Auto mode, but it will not perform a weekly exercise  
cycle.  
FIRST 100 OPERATING HOURS  
1. Change engine oil and oil filter. (After initial  
change, service engine oil and filter at 150 operat-  
ing hours or 6 months, whichever comes first.)  
2. Retorque cylinder head. (See Torque Specs,  
Section 1.13.)  
If a failure occurs while running in this mode, the five  
red LEDs will stop flashing, the individual fault LED  
will turn on and the engine will shut down. Once the  
AUTO/OFF/MANUAL switch has been switch to OFF,  
the individual fault LED will turn OFF and the five  
red LEDs will begin flashing to show exercise has still  
not been set.  
3. Retorque intake and exhaust manifold. (See  
Torque Specs, Section 1.13.)  
EVERY 500 OPERATING HOURS  
1. Service air cleaner.  
2. Check starter.  
3. Check engine DC alternator.  
Figure 3.2 - “Set Exercise” Switch  
4.2 COOLING SYSTEM  
Air intake and outlet openings in the generator com-  
partment must be open and unobstructed for contin-  
ued proper operation. This includes such obstruc-  
tions as high grass, weeds, brush, leaves and snow.  
FUSE  
FUSE  
4A  
BAT.  
CHARGER  
15A  
MAIN  
Without sufficient cooling and ventilating air flow, the  
engine/generator quickly overheats, which causes it  
to shut down. (See Section 6 for installation drawings  
and vent locations.)  
AUTO  
OFF  
OFF  
ON  
The exhaust system parts from this product get  
extremely hot and remain hot after shutdown.  
SET  
EXERCISE  
TIME  
MANUAL  
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.  
15  
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Section 4 — Maintenance  
Liquid-cooled 30 kW Generators  
4.4.3 ENGINE COOLANT  
4.3 OVERLOAD PROTECTION FOR  
Check coolant level in coolant recovery bottle. See  
Specifications, Section 1.10.  
ENGINE DC ELECTRICAL SYSTEM  
Engine cranking, start up and running are controlled  
by a solid state Engine Controller circuit board.  
Battery voltage is delivered to that circuit board via  
a 15 amp fuse. These overcurrent protection devices  
will open if the circuit is overloaded.  
• 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.  
If a circuit breaker opens or a fuse element  
melts, find the cause of the overload before  
resetting the circuit breaker or replacing the  
fuse.  
4.5 MAINTENANCE OWNER/  
OPERATOR CAN PERFORM  
4.4 CHECKING FLUID LEVELS  
4.5.1 CHECK ENGINE OIL LEVEL  
4.4.1 CHECK ENGINE OIL  
Refer to “Checking Fluid Levels” in Section 4.4.  
Check engine crankcase oil level (Figure 4.1) at least  
every 20 hours of operation, or prior to use.  
4.5.2 CHECK BATTERY  
• Remove oil dipstick and wipe dry with a clean, lint-  
free cloth.  
• Check battery fluid level each week as outlined  
under “Check Fluid Levels”.  
• Check battery cables for condition, tightness, cor-  
rosion or damage. Clean, tighten or replace as  
necessary.  
• Install oil dipstick, then remove again.  
• Oil should be between FULL and ADD marks.  
• If oil level is below the dipstick ADD mark, remove  
oil fill cap. Add the recommended oil to bring oil  
level up to the FULL mark. DO NOT FILL ABOVE  
THE “FULLMARK. See Section 1.14 for recom-  
mended oils.  
4.5.3 EXERCISE SYSTEM  
Start the generator engine at least once every seven  
days and let it run at least 20 minutes. See Section  
3.6, “Weekly Exercise Cycle”.  
Figure 4.1 - Oil Dipstick and Oil Fill Cap  
4.5.4 INSPECT COOLING SYSTEM  
OIL  
DIPSTICK  
• Inspect engine cooling system at least once each  
month.  
• Check hoses for damage, deterioration, leaks, etc.  
Correct any discrepancies found.  
• Check hose clamps for tightness.  
OIL  
FILL  
4.5.5 CHECK ENGINE COOLANT LEVEL  
See “Checking Fluid Levels” in Section 4.4.  
4.5.6 PERFORM VISUAL INSPECTION  
Complete a thorough visual inspection of the entire  
engine-generator monthly. Look for obvious damage,  
loose, missing or corroded nuts, bolts and other fas-  
teners. Look for fuel, oil or coolant leaks.  
4.4.2 BATTERY FLUID  
4.5.7 INSPECT EXHAUST SYSTEM  
Check battery electrolyte fluid at least once weekly.  
Fluid should cover separators in all battery cells. If  
fluid level is low, add distilled water to cover tops of  
separators. DO NOT USE TAP WATER IN BATTERY.  
Inspect the exhaust system at least once every three  
months. Check all exhaust system pipes, mufflers,  
clamps, etc. for condition, tightness, leaks, security,  
damage.  
16  
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Section 4 — Maintenance  
Liquid-cooled 30 kW Generators  
Figure 4.2 - Oil Filter  
4.5.8 CHECK FAN BELT  
• Inspect fan belts every three months. Replace any  
damaged, deteriorated, worn or otherwise defec-  
tive belt.  
• Check fan belt tension. Thumb pressure, exerted  
midway between pulleys, should deflect about 3/8  
to 5/8 inch. Adjust belt tension as required.  
4.5.9 INSPECT ENGINE GOVERNOR  
Visually inspect electronic governor.  
DANGER  
Do not attempt to adjust the governor. Only  
qualified service facilities should adjust the  
OIL FILTER  
governor. Excessively high operating speeds  
are dangerous and increase the risk of personal  
injury. Low speeds impose a heavy load on the  
engine when adequate engine power is not  
available and may shorten engine life. Correct  
rated frequency and voltage are supplied only  
at the proper governed speed. Some connected  
electrical load devices may be damaged by incor-  
rect frequency and/or voltage. Only qualified  
service technicians should adjust the governed  
speed.  
After refilling the crankcase with oil, always  
check oil level on dipstick. NEVER OPERATE  
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”  
MARK.  
7. Start engine and check for oil leaks.  
4.5.11 CHANGING THE ENGINE AIR CLEANER  
To replace the engine air cleaner, (part number  
059402), remove the air cleaner cover and replace  
the air filter making sure it is positioned properly  
before reattaching the cover (Figure 4.3).  
4.5.10 CHANGING ENGINE OIL  
Refer to maintenance performed by authorized ser-  
vice facilities for engine oil and filter change frequen-  
cies.  
Figure 4.3 – Engine Air Cleaner  
Drain the oil while the engine is still warm from run-  
ning. This means warm up the engine, shut it down  
and drain immediately as follows:  
1. Remove OIL DRAIN HOSE from its retaining  
clip.  
2. Loosen and remove OIL DRAIN HOSE CAP. Drain  
oil completely into suitable container.  
3. When all oil has drained, install and tighten OIL  
DRAIN HOSE CAP, and re-install into its retaining  
clip.  
4. Turn OIL FILTER (Figure 4.2) counterclockwise  
and remove. Dispose of old filter.  
5. Apply light coating of new engine oil to seal of new  
oil filter.-Install FILTER and tighten by hand only.  
DO NOT OVERTIGHTEN.  
6. Remove OIL FILL CAP. Add recommended oil (see  
SPECIFICATIONS). DO NOT FILL ABOVE THE  
DIPSTICK “FULLMARK. Crankcase oil capacity  
is 4.0 U.S. quarts (3.8 liters).  
See the “Service Schedule,” Section 6, for air cleaner  
maintenance.  
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Section 4 — Maintenance  
Liquid-cooled 30 kW Generators  
Finally, have the insulation resistance of stator and  
rotor windings checked. If insulation resistances are  
excessively low, the generator may require drying.  
4.5.12 SPARK PLUGS  
Reset the spark plug gap or replace the spark plugs  
as necessary. See Section 6.  
1. Clean the area around the base of the spark plugs  
to keep dirt and debris out of the engine. Clean  
by scraping or washing using a wire brush and  
commercial solvent. Do not blast the spark plugs  
to clean.  
2. Remove the spark plugs and check the condition.  
Replace the spark plugs if worn or if reuse is  
questionable. See the “Service Schedule,” Section  
6, for recommended inspection.  
4.6.2 BATTERY  
All lead-acid storage batteries discharge when not in  
use. Refer to specific instructions and warnings that  
accompany the battery. If such information is not  
available, observe the following precautions when  
handling a battery:  
• DO NOT use jumper cables and a booster battery  
to crank or start the generator engine.  
3. Check the spark plug gap using a wire feeler  
gauge. Adjust the gap to 1.06-1.16 mm (0.042-  
0.046 inch) by carefully bending the ground elec-  
trode (Figure 4.4).  
• DO NOT recharge a weak battery while it is  
installed in the generator. Remove battery from  
generator and recharge in a well-ventilated area,  
away from fuel vapors, sparks, heat or flames.  
• Battery electrolyte fluid is an extremely caustic  
sulfuric solution that can cause severe burns. DO  
NOT permit fluid to contact eyes, skin, clothing,  
painted surfaces, wiring insulation, etc. If any bat-  
tery fluid is spilled, flush the affected area with  
clear water immediately.  
Figure 4.4 – Setting the Spark Plug Gap  
SET PLUG GAP AT 1.06-1.16 mm  
(0.042-0.046 inch)  
• Always wear safety glasses, rubber apron and  
gloves when handling a battery.  
• Batteries give off explosive hydrogen gas while  
charging. The gas can form an explosive mixture  
around the battery for several hours after charging.  
Any spark, heat or flames can ignite the gas and  
cause an explosion which can shatter the battery,  
causing blindness or other serious injury.  
4.5.13 COOLANT CHANGE  
4.6.3 BATTERY MAINTENANCE  
Everyyear,haveAuthorizedServiceFacilitydrain,flush  
and refill the cooling system. See SPECIFICATIONS  
(Section 1.10) for cooling system recommendations.  
The battery should be inspected per the “Service  
Schedule,” Section 6. The following procedure should  
be followed for inspection:  
1. Inspect the battery posts and cables for tightness  
and corrosion. Tighten and clean as necessary.  
2. Check the battery fluid level of unsealed batteries  
and, if necessary, fill with DISTILLED WATER  
ONLY. DO NOT USE TAP WATER IN BATTER-  
IES.  
3. Have the state of charge and condition checked.  
This should be done with an automotive-type bat-  
tery hydrometer.  
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-  
erator windings have an adverse effect on insulation  
resistance.  
Periodically clean generator exterior surfaces. A soft  
brush may be used to loosen caked on dirt. Use a  
vacuum system or dry, low pressure air to remove  
any accumulations of dirt. The generator is housed  
inside an all-weather enclosure, clean the enclosure  
with a soft, damp cloth or sponge and water.  
Once each year, have the generator cleaned and  
inspected by an Authorized Service Dealer. That  
dealer will use dry, low pressure air to clean internal  
windings. Parts inside the control console should be  
cleaned and inspected at this time as well.  
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Section 4 — Maintenance  
Liquid-cooled 30 kW Generators  
4.6.4 BATTERY REPLACEMENT  
DANGER  
When replacing batteries, use the same number and  
the type of battery that follows:  
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.  
BCI Group No.  
26/26R  
CCA  
525 @ 0 deg. F  
27  
600 @ 0 deg. F  
NOTE:  
The BCI number should be located directly  
on the battery.  
Battery electrolyte fluid is an extremely caus-  
tic sulfuric acid solution that can cause severe  
burns. Do not permit fluid to contact eyes, skin,  
clothing, painted surfaces, etc. Wear protective  
goggles, protective clothing and gloves when  
handling a battery. If the fluid is spilled, flush  
the affected area immediately with clear water.  
PERIODIC REPLACEMENT PARTS  
Part Number  
Part Name  
Oil Filter  
# 0E7180  
# 046627  
# 0C8127  
# 0E7079  
Radiator Cap  
Air Cleaner  
Spark Plug  
Spilled electrolyte is to be washed down with  
an acid neutralizing agent. A common practice  
is to use a solution of one pound (500 grams)  
bicarbonate of soda to one gallon (4 liters) of  
water. The bicarbonate of soda solution is to be  
added until the evidence of reaction (foaming)  
has ceased. The resulting liquid is to be flushed  
with water and the area dried.  
Do not use any jumper cables or booster battery  
to crank and start the generator engine. If the  
battery has completely discharged, remove it  
from the generator for recharging.  
Ensure that the 15A and 4A fuses are removed  
from the control console, the AUTO/OFF/  
MANUAL switch is set to OFF, and the utility  
supply to the battery charger is removed before  
removing or connecting battery cables. If the  
switch is set to AUTO or MANUAL, the genera-  
tor can crank and start as soon as the battery  
cables are connected.  
Be sure the UTILITY power supply to the battery  
charger is turned off, or sparking may occur at  
the battery posts as the cables are attached and  
cause an explosion.  
19  
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Section 4 — Maintenance  
Liquid-cooled 30 kW Generators  
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 applica-  
tion. Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to  
determine 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 ensure 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 15A and 4A fuses.  
• Turn off the battery charger.  
• 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 ensure 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 ensure it is ready to operate and carry the load when required,  
and to identify any potential problem areas.  
Performed semi-annually or following 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 ensure 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.  
20  
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Section 4 — Maintenance  
Liquid-cooled 30 kW Generators  
Maintenance  
Tasks  
Level 1  
Recom-  
mended  
Level 2  
Required  
Level 3  
Required  
Level 4  
Task  
Task  
Task  
Task  
Comp.  
Comp. to be done Comp. to be done Comp.  
Required  
to be done (Date-  
3 months/  
Break-in  
30 hrs.  
(Date-  
Initials)  
Semi-  
annually/  
50 hrs.  
(Date-  
Initials)  
to be done (Date-  
Annually/ Initials)  
100 hrs.  
monthly/  
10 hrs.  
Initials)  
1. Disable the unit from  
operating per the first page  
warning.  
2. Check the engine oil level.  
Adjust as necessary.  
3. Check the engine coolant  
level. Adjust as necessary.  
4. Check the engine coolant  
thermal protection level.  
Correct as necessary.  
5. Check the natural gas  
delivery system on gas  
engine driven units.  
Tighten connections as  
necessary.  
6. Check the air inlets and  
outlets for debris. Clean as  
necessary.  
7. Check the battery  
electrolyte level if  
accessible. Adjust as  
necessary.  
8. Check the battery posts,  
cables, and charger for  
loose connections,  
corrosion, and proper  
operation. Correct as  
necessary.  
9. Check the unit wiring for  
loose connections,  
corrosion, and damage.  
Correct as necessary.  
10. Check the engine  
accessory drive belts for  
wear, weather cracking,  
and damage. Replace as  
necessary.  
11. Visually inspect the unit  
looking for leaks, wear or  
damage, loose connections  
or components, and  
corrosion. Correct as  
necessary.  
12. Test the engine and  
transfer switch safety  
devices. Correct and/or  
adjust as necessary.  
21  
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Section 4 — Maintenance  
Liquid-cooled 30 kW Generators  
Maintenance  
Tasks  
Level 1  
Recom-  
mended  
Level 2  
Required  
Level 3  
Required  
Level 4  
Task  
Task  
Task  
Task  
Comp.  
Comp. to be done Comp. to be done Comp.  
Required  
to be done (Date-  
3 months/  
Break-in  
30 hrs.  
(Date-  
Initials)  
Semi-  
annually/  
50 hrs.  
(Date-  
Initials)  
to be done (Date-  
Annually/ Initials)  
100 hrs.  
monthly/  
10 hrs.  
Initials)  
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  
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,  
loose connections or  
components, and abnormal  
operating conditions.  
Correct as necessary.  
15. Change the engine oil.  
16. Replace the engine oil  
filter(s).  
17. Replace the engine air  
filter(s).  
18. Replace the engine fuel  
filter(s) on diesel engine  
driven units and re-prime  
the fuel system.  
19. Check the engine spark  
plugs on gas engine driven  
units. Clean and re-gap or  
replace as necessary.  
20. Perform a 5 minute no-load  
operational run of the unit  
looking for any post service  
problems.  
21. Return the unit to standby  
setup for operation when  
required.  
22  
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Section 5 — Troubleshooting  
Liquid-cooled 30 kW Generators  
TROUBLESHOOTING POINTS  
PROBLEM  
CAUSE  
CORRECTION  
Engine won’t crank.  
1. 15 amp fuse blown.  
2. Loose or corroded or defective  
battery cables.  
1. Replace fuse.  
2. Tighten, clean or replace  
battery cables as necessary.  
3. Replace contactor.  
3. Defective starter contactor.  
4. Defective starter motor.  
5. Dead or Defective Battery.  
6. 4 amp fuse blown.  
4. Replace starter motor.  
5. Remove, change or replace battery.  
6. Replace fuse.  
Engine cranks, but won't start  
1. Out of fuel.  
1. Replenish fuel.  
2. Replace solenoid.  
3. Reconnect wire.  
2. Fuel solenoid (FS) is defective  
3. Open Wire #14 from Engine Control  
circuit board.  
4. Spark plugs defective.  
4. Clean, regap or replace plugs.  
1. Clean or replace as needed.  
Engine starts hard, runs rough.  
Engine starts, then shuts down.  
1. Flame arrestor (air cleaner) plugged or  
damaged.  
2. Plugged fuel line.  
2. Unclog fuel line.  
3. Clean, regap or replace plugs.  
3. Defective spark plugs.  
1. Engine oil level is low.  
2. Engine is overheated.  
1. Check oil and add oil as needed.  
2. Check cooling system for leaks.  
3. Replace switch.  
3. Defective Low Oil Pressure Switch  
4. Defective Coolant Temperature Switch  
5. Defective Control Module circuit board.  
6. Coolant Level is Low.  
4. Replace switch.  
5. Replace board.  
6. Repair leak - Add coolant.  
7. Replace Switch.  
7. Defective Low Coolant Level Switch  
AUTO/OFF/MANUAL Switch at,  
OFF engine continues to run  
1. Defective AUTO/OFF/MANUAL switch  
2. Open/disconnected wire #15A between  
AUTO/OFF/MANUAL switch and Control  
Module circuit board.  
1. Replace switch.  
2. Reconnect/close wire.  
3. Defective Control Module circuit board  
3. Replace board.  
No AC output from generator.  
1. Check main line circuit breaker.  
2. Check circuit breaker & fuses.  
3. Transfer switch set to NORMAL position  
4. Generator internal failure.  
1. Reset to ON or CLOSED.  
2. Reset and replace, if necessary.  
3. Set to GENERATOR position.  
4. Contact an Authorized facility.  
5. Auto-reset - Wait 5 min. and  
attempt restart.  
5. Thermal circuit breaker open.  
23  
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Section 6 - Notes  
Liquid-cooled 30 kW Generators  
24  
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Section 7 — Installation Diagram  
Liquid-cooled 30 kW Generators  
Installation Diagram — Drawing No. 0E8695  
25  
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Section 8 - Electrical Data  
Liquid-cooled 30 kW Generators  
Wiring Diagram — Engine — Drawing No. 0E6199-F  
2
NOTE:  
SIZE (AWG)  
CB2  
162  
ALL WIRES ARE 18 AWG 300  
VOLT UL LISTED UNLESS  
OTHERWISE NOTED AS SHOWN:  
1
162  
11  
4
16  
AVR  
0
0
2
4
5
TB1  
0
0
0
55  
14  
44  
6
14  
14  
225  
224  
D1  
4
4
TR2  
55  
0
OA  
225A  
224A  
0
13A  
0
239  
15A  
15  
TR1  
178  
178  
8
1
2
7
4
5
1b  
2b  
1
1
1a  
2a  
85  
3
6
BC1  
0
1
15  
RL1  
F2  
F1  
0
0
2
13A  
13  
13  
3
4
14  
0A  
13  
11  
44  
14  
5
14A  
15A  
15E  
14  
6
1
16  
16  
7
4
8
2
5
1
2
3
4
5
6
11  
9
6
224  
225  
239  
10  
11  
12  
6
IC  
CB1  
55  
66  
44  
BA  
44  
11  
22  
33  
6
NB  
6
6
NEUTRAL  
23  
66  
23  
66  
TRANSFER SWITCH  
CUSTOMER CONNECTION  
LEGEND {CONT.]:  
LEGEND:  
AVR -  
BA -  
F2 -  
FUSE, B/C (4A AGC TYPE)  
AUTOMATIC VOLTAGE REGULATOR  
BRUSH ASSEMLY (GENERATOR)  
BATTERY CHARGER  
ICT -  
INTERCONNECT. TERMINAL BLOCK  
NEUTRAL BLOCK  
NB -  
RL1 -  
SW1 -  
SW2 -  
TB1 -  
TR1 -  
TR2 -  
B/C -  
RELAY 1  
BC1 -  
CB1 -  
CB2 -  
D1 -  
BULKHEAD CONNECTOR 1 (ENGINE)  
CIRCUIT BREAKER (OUTPUT)  
CIRCUIT BREAKER (EXCITATION)  
DIODE [FIELD BOOST]  
AUTO/OFF/MANUAL SWITCH  
SET EXERCISER SWITCH  
TERMINAL BLOCK 1  
TRANSFORMER 1 (56 VA 240/16 VAC)  
TRANSFORMER 2 (6 VA 240/16 VAC)  
F1 -  
FUSE, BAT. POWER (15A AGC TYPE)  
26  
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Section 8 - Electrical Data  
Liquid-cooled 30 kW Generators  
Wiring Diagram — Engine — Drawing No. 0E6199-F  
NOTE:  
SIZE (AWG)  
PCB J2  
1
DEG  
0
765  
767  
ALL WIRES ARE 18 AWG 300  
VOLT UL LISTED UNLESS  
OTHERWISE NOTED AS SHOWN:  
1
2
765  
769  
766  
768  
0
2
16  
3
4
5
6
7
8
766  
14  
3
4
CC  
JB  
766  
765  
767  
770  
771  
768  
767  
769  
5
6
16  
16  
16  
14  
14  
14  
N/C  
14  
7
8
9
10  
11  
12  
PCB J1  
10  
1
56  
86  
16  
10  
4
2
13  
13  
3
4
15A  
23  
BAT  
GOV  
5
224  
0
-
771  
767  
765  
770  
N/C  
766  
1
2
3
4
5
6
4
4
6
7
SM  
4
8
239  
0
9
10  
11  
12  
13  
14  
15E  
85  
10  
10  
13  
0
14A  
225  
66  
0
ALT  
16  
16  
16  
16  
14  
14  
0
IM  
16  
0
0
4
C1  
1
449  
449  
1
2
0
0
2
5
3
3
0
0A  
0
0A  
0
GND1  
14  
0
4
16  
IC  
5
13  
16  
6
14A  
15A  
15E  
14  
0
14  
3
2
1
7
5
FS  
8
9
10  
11  
12  
224  
225  
239  
85  
85  
BLK  
RED  
HCT  
WLS  
0
C
86  
0
0
23  
66  
23  
66  
LEGEND:  
ALT -  
LEGEND [CONT.]:  
D.C. CHARGE ALTERNATOR  
12VDC BATTERY  
HCT -  
IC -  
HIGH COOLANT TEMP SWITCH  
IGNITION COIL  
BAT -  
C1 -  
CONNECTOR 1 (ENGINE)  
STARTER CONTACTOR  
DRIVER ELEC. GOVERNOR  
FUEL SOLENOID  
IM -  
IGNITION MODULE (ON DISTRIBUTOR)  
JUNCTION 1 (ON PCB)  
CC -  
J-1 -  
DEG -  
FS -  
J-2 -  
JUNCTION 2 (ON PCB)  
JB -  
JUNCTION BLOCK (RUN POWER)  
LOW OIL PRESSURE SWITCH  
STARTER MOTOR  
GND1-  
GND2-  
GOV -  
GROUND (SENSING/LOW AMP)  
GROUND (POWER/HIGH AMP)  
ELEC. GOVERNOR ACTUATOR  
LOS -  
SM -  
WLS -  
COOLANT LEVEL SWITCH  
27  
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Section 8 - Electrical Data  
Liquid-cooled 30 kW Generators  
Electrical Schematic — Engine — Drawing No. 0E6200-B  
LEGEND:  
AR -  
ALTERNATOR ROTOR  
LEGEND {CONT.]:  
AS -  
ALTERNATOR STATOR  
F1 -  
FUSE, BAT. POWER (15A AGC TYPE)  
FUSE, B/C (4A AGC TYPE)  
TERMINAL BLOCK, INTERCONNECT.  
NEUTRAL BLOCK  
AVR -  
BA -  
AUTOMATIC VOLTAGE REGULATOR  
BRUSH ASSEMLY (GENERATOR)  
BATTERY CHARGER  
F2 -  
ICT -  
NB -  
RL1 -  
SW1 -  
SW2 -  
TR1 -  
TR2 -  
B/C -  
BCW -  
CB1 -  
CB2 -  
D1 -  
BATTERY CHARGE WINDING  
CIRCUIT BREAKER (OUTPUT)  
CIRCUIT BREAKER (EXCITATION)  
DIODE [FIELD BOOST]  
RELAY 1  
SWITCH, AUTO/OFF/MANUAL  
SWITCH, SET EXERCISER  
TRANSFORMER 1 (56 VA 240/16 VAC)  
TRANSFORMER 2 (6 VA 240/16 VAC)  
DPE -  
DISPLACED PHASE EXCITATION  
66  
0
0
14A  
14  
15  
15  
14  
14  
66  
F2  
1
3
A  
0A  
1
3  
1
3  
1
2
AR  
2 3  
1
5
15  
15  
4
4
6
5
4
66  
2
3  
2
1
224A  
224  
225  
225A  
6
2
2
162  
0
0
1
2
DPE  
11  
44  
0
0A  
1
3  
14A  
15A  
15E  
14  
224  
225  
2
39  
3
4
5
6
7
8
9
10  
11  
12  
SW2  
1
N1  
N2  
2
2
3  
1
9
4  
1
83  
17
8  
2a  
15  
15A  
17
8  
AS  
E1  
33  
44  
1
2
4
5
CB1  
15  
2
39  
3
6
1
9
4  
SW1  
IN OFF POSITION  
SHOWN  
00  
E
3  
1
83  
17
8  
NB  
CUSTOMER CONNECTION  
120/240V 1-PHASE  
TRANSFER SWITCH  
CONNECTION  
28  
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Section 8 - Electrical Data  
Liquid-cooled 30 kW Generators  
Electrical Schematic — Engine — Drawing No. 0E6200-B  
0
0
8
6  
WLS  
HCT  
0
LOS  
8
5  
14  
0
56  
16  
0
12V BATTERY  
1
3  
CC  
) +  
(-)  
RED  
BLACK  
1
3  
SC  
1
3  
16  
PCB  
56  
86  
J1-1  
14  
J1-2  
J1-3  
J1-4  
J1-5  
J1-6  
J1-7  
J1-8  
J1-9  
15A  
23  
14  
44
9  
224  
0
IC  
6
0
J2-1  
J2-2  
J2-3  
J2-4  
J2-5  
J2-6  
J2-7  
J2-8  
767  
765  
769  
766  
768  
0
239  
6
1
3
4
5
15E  
85  
J1-10  
J1-11  
J1-12  
J1-13  
J1-14  
2
IM  
14A  
225  
66  
N/C  
14  
DEG  
0
765  
1
2
766  
14  
3
4
5
6
7
8
9
GOV  
1
771  
2
767  
765  
770  
N/C  
766  
766  
765  
767  
770  
771  
768  
767  
769  
3
4
5
6
66  
2
3  
10  
11  
12  
1
2
0
0
3
4
5
6
7
8
9
10  
11  
12  
0
0A  
1
3  
14A  
15A  
15E  
14  
224  
225  
2
39  
LEGEND:  
ALT -  
LEGEND [CONT.]:  
D.C. CHARGE ALTERNATOR  
CONNECTOR 1 (ENGINE)  
CRANKING CONTACTOR  
DRIVER ELEC. GOVERNOR  
SOLENOID FUEL  
IC -  
IGNITION COIL  
C1 -  
IM -  
IGNITION MODULE (ON DISTRIBUTOR)  
SWITCH LOW OIL PRESSURE  
CONTACTOR, STARTER MOTOR  
STARTER MOTOR  
CC -  
LOS -  
SC -  
SM -  
WLS -  
DEG -  
FS -  
GOV -  
HCT -  
ELEC. GOVERNOR ACTUATOR  
SWITCH, HIGH COOLANT TEMP  
SENSOR, COOLANT LEVEL  
29  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Mounting Base — Drawing No. 0E6266-F  
30  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Mounting Base — Drawing No. 0E6266-F  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0E5822  
052860  
052251  
052257  
052252  
052259  
052891  
0536210213  
074906  
047411  
055414  
026850  
022097  
022473  
049813  
0A1694  
052213  
025507  
027482  
022129  
045771  
051756  
046526  
022131  
055934M  
077483  
058665  
038804D  
038805AA  
021991  
049814  
046526  
022131  
075763  
050331  
050331A  
0A4010  
052858  
061902  
059473  
049820  
1
4
BASEFRAME, WELDMENT 3.0L FORD  
NUT FLANGED HEX M12-1.75  
DAMPENER VIBRATION 40 BLUE  
SPACER .49 X .62 X 1.87 PWDR/ZNC  
DAMPENER VIBRATION  
3
4
4
4
5
4
6
4
WASHER FLAT M12  
7
4
SCREW HHC M12-1.75 X 80 G8.8  
ASSY GRNDWIRE 11"/3/8 & 5/16 LUG  
SCREW HHTT M6-1.0 X 20 BP  
SCREW HHC M6-1.0 X 16 BP  
LUG SLDLSS #2-#8 X 17/64 CU  
WASHER SHAKEPROOF EXT 1/4 STL  
WASHER LOCK M6-1/4  
8
1
9
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
20  
21  
22  
23 *  
24 *  
25 *  
26 *  
30  
1
1
2
1
2
WASHER FLAT M6-1/4 ZINC  
NUT HEX M6 -1.0 G8 YEL CHR  
1-1/2" BUTTON PLUG  
1
4
1
SCREW HHC M10-1.25 X 20 G8.8  
WASHER SHAKEPROOF EXT 7/16 STL  
WASHER SHAKEPROOF EXT 5/16 STL  
WASHER LOCK M8-5/16  
3
2
1
1
NUT HEX M8-1.25 G8 YEL CHR  
SCREW HHC M10-1.5 X 20 G8.8  
WASHER LOCK M10  
1
1
1
WASHER FLAT 3/8-M10 ZINC  
CLAMP VINYL .75 X .343 Z  
BATT 12VDC 75-AH 26  
1
REF.  
REF.  
1
BATT 12VDC 90-AH 27F  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
CABLE BATT RED #4 X 20.00  
CABLE BATT BLK #4 X 30"  
EARTH STRAP  
1
1
1
SCREW HHC M10-1.5 X 25 G8.8  
WASHER LOCK M10  
WASHER FLAT 3/8 ZINC  
2
1
1
BOOT BATTERY CABLE  
1
BATTERY POST COVER BACLK -  
BATTERY POST COVER RED +  
SCREW HHC M8-1.25 X 60 G8.8 FT  
NUT TOP LOCK FL M8-1.25  
HOLD DOWN BATTERY  
1
2
2
1
1
HOLD DOWN BATTERY  
NUT HEX LOCK M8-1.25 NY INS  
2
* NOT SHOWN-USED TO HOLD DOWN I/N 32  
31  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Enclosure — Drawing No. 0F1142-B  
32  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Enclosure — Drawing No. 0F1142-B  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0E8411  
0E8042  
0E8041  
0C2454  
0E8402  
0E7808  
0E7809  
0E8387  
0E6986  
0F5552  
089961  
0A2115  
0E8404  
0D2538A  
0D2538  
078115  
022097  
022473  
0E7570  
0E7571  
070015  
0E7662  
0D2537A  
0D2537  
0D2023  
0E7869  
0E8001  
0F5551  
0E8406  
0D3037A  
0C7781  
0E7794  
0E8052  
0D3037  
0E8007  
0E8008  
0F1130  
0E8055  
026850  
0912970063  
0912970064  
049813  
0E8665  
0E7829U  
0E7829N  
0E7829T  
0E7829S  
0E7829R  
0E7829P  
0E8441  
0E7829A  
0E7829B  
043116  
1
1
1
62  
1
1
1
1
2
1
2
4
1
1
1
8
12  
12  
2
4
4
4
1
1
3
2
1
1
1
1
2
1
1
1
1
1
1
1
4
2
2
2
1
2
2
1
1
2
4
1
1
2
8
INTAKE DUCT HSB  
DUCT DISCHARGE RH FRONT  
DUCT DISCHARGE LH FRONT  
SCREW TH-FRM M6-1 X 16 N WA Z/JS  
BAFFLE REAR BOTTOM  
3
4
5
6
POST CORNER LH REAR  
POST CORNER RH REAR  
BAFFLE REAR TOP  
7
8
9
DOOR COMPARTMENT SIDE  
SUPPORT R/H SIDE  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50 *  
51  
52  
53  
FOAM STRIP 3/4" WIDE X 3/16" THK (40" LG)  
WASHER NYLON .257  
BRACKET STIFFENER RH FRONT  
HINGE LIFT OFF TYPE B KNUCKLE  
HINGE LIFT OFF TYPE B PIN  
WASHER SELF LOCKING DOME  
WASHER LOCK M6-1/4  
WASHER FLAT 1/4-M6 ZINC  
GAS SPRING  
BALL STUD GAS SPRING MOUNT  
NUT HEX 5/16-18 LOCK  
SCREW WING M6-1.00 X 25  
HINGE LIFT OFF TYPE A KNUCKLE  
HINGE LIFT OFF TYPE A PIN  
GASKET CLIP-ON SELF GRIPPING (84" LG)  
BRACKET STIFFENING BACK  
MUFFLER BOX  
ROOF, W/SHOCK MOUNT  
BRACE FRONT TOP  
LATCH 1/4 TURN NONLOCKING  
PAWL DOOR HSB  
SUPPORT LH SIDE  
MUFFLER BOX TOP  
LATCH QUARTER TURN LOCKING  
POST CORNER LH FRONT  
POST CORNER RH FRONT  
BRACE, FRONT BOT 3.0L FD STEEL  
DUCT DISCHARGE MID FRONT  
WASHER SHAKEPROOF EXT 1/4 STL  
ASSY WIRE 14AWG 7.5 #0 GRN/YEL  
ASSY WIRE 14AWG 7.5 #0 GRN/YEL  
NUT HEX M6 X 1.0 G8 YEL CHR  
BRACKET STIFFENER LH FRONT  
AI BRACE PANEL  
AI ROOF PANEL 2  
AI SUPPORT RH PANEL  
AI SUPPORT LH PANEL  
AI CORNER POST PANEL 2  
AI CORNER POST PANEL 1  
KIT INSULATION 3.0L HSB  
AI ROOF PANEL 1  
AI DOOR PANEL  
SCREW HHC M6-1.0 X 12 G8.8  
* ALL ITEMS NOTATED WITH "AI" ARE COMPONENTS OF 0E8441  
33  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Control Panel — Drawing No. 0E7118-K  
34  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Control Panel — Drawing No. 0E7118-K  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
0E7195  
0E7196  
0E7197  
0E7193  
0E7194  
0E4494  
082573  
032300  
022676  
067682B  
060015  
054199  
0C2657  
099076  
040213  
0E9668  
067680  
0E6875A  
0E6881 *  
0C5139 *  
0C5142 *  
1
CONTROL BOX HSB  
37  
38  
39  
0C1127  
0A1441B  
0E7128  
1
1
1
DECAL AVR COVER  
COVER PLATE, AVR  
1
COVER FRONT PANEL HSB  
COVER TOP PANEL HSB  
DECAL WARNINGS HSB  
DECAL CONTROLS HSB  
SWITCH ROC DPDT ON-OFF-ON  
SWITCH ROCKER DPST 125V SPD  
HOLDER FUSE  
3
1
HARNESS CNTRL PNL (NOT  
SHOWN)  
4
1
5
1
40  
41  
42  
0E7358  
074908  
0C5141  
8
6
1
SCREW PPPH HI-LO #4-24 X 3/8  
SCREW HHTT M5-0.8 X 10 BP  
CONN DEUTSCH GASKET 8/12 POS  
DT  
6
1
7
1
8
2
9
1
FUSE 15A X AGC15  
43  
44  
45  
46  
47  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
0C2699  
0C2323  
022155  
0C2265  
022264  
020911  
066849  
022152  
023897  
051716  
090388  
042568  
022097  
022473  
0441140187  
070370  
023762  
11  
4
SCREW PHTT #6-32 X 3/8 ZYC  
SCREW PHTT #6-32 X 5/8 ZYC  
WASHER LOCK #6  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
1
FUSE 4A SLO BLO GLASS  
FITTING CONDUIT 90D 3/8"  
DECAL DANGER HIGH VOLTAGE  
TRANSFRMR 16V 6VA  
1
15  
4
1
1
SCREW PHTT M4-0.7 X 12 ZYC  
WASHER LOCK #8-M4  
4
1
TRANSFORMER 16V 56VA  
PCB SUPPORT SNAP-IN 1/4"  
ASSY PCB HSB CONTROLLER  
ASSY VOLTAGE REGULATOR 60HZ  
RELAY 12VDC C FORM W/DIODE  
SOCKET RELAY  
2
SCREW PPHM M5-0.8 X 30 ZINC  
SCREW HHTT M5-0.8 X 16  
WASHER LOCK #10  
2
2
1
4
1
3
WASHER FLAT #10 ZINC  
NUT HEX M5-0.8 G8 YEL CHR  
SCREW HHTT M6-1.0 X 12 ZINC  
SCREW HHC M6-1.0 X 20 G8.8  
WASHER LOCK M6-1/4  
WASHER FLAT 1/4-M6 ZINC  
WIRE ASSY 3" X (2) 3/16" TABS  
WASHER MICA .203  
1
2
REF.  
REF.  
REF.  
2
CONN DEUTSCH RECEPT GY/FLN  
CONN DEUTSCH RECEPT WDGE  
BLKHD  
4
8
6
22  
23  
24  
0E3161  
054450  
0D5070A  
1
1
1
ASSY BOSCH GOV DRIVER  
CIRCT BRK 5.5 X 1 ETA 46-500-P  
ASSY 2A 12V UL BATTERY  
CHARGER  
2
2
1
WASHER SHAKEPROOF EXT #10  
STL  
HEATSINK  
25  
26  
27  
0E2514  
0A9457  
0E7539  
1
1
1
FITTING CONDUIT STR 1-1/2"  
DECAL NEUTRAL  
61  
62  
63  
64  
65  
66  
67  
68  
69  
055444  
030468  
049939  
022158  
022985  
038750  
0A2115  
0C2454  
0F6146  
1
1
1
1
1
2
4
4
1
WASHER STEP NYLON .20  
RECTIFIER MSC 12A 600V 1N1206R  
NUT HEX #10-32 STEEL  
WASHER FLAT #6 ZINC  
SCREW HHC M6-1.0 X 30 G8.8  
WASHER NYLON .257  
DECALCUSTOMER CNNCTN XFER  
SW  
28  
29  
30  
31  
046357 *  
0D3719B  
057073  
REF.  
BLOCK TERM 20A 6 X 6 X 1100V  
DECAL CUSTOMER CNNCTN  
JUNCTION BLOCK 3/8-16  
CB 0150A2P240V S QN2 LL  
CB 0200A2P240V S QN2 LL  
BASE QN CIRCUIT BREAKER  
DECAL TB1 HSB CONTROL PANEL  
BLOCK TERM 20A 6 X 3 X 1100V  
BRACKET CB 221.5 X 102  
DECAL WARNING ELECTRICAL  
SHOCK  
1
1
0E7283  
0E3628  
0E3664  
0E7539A  
0D4698 *  
0E7252  
0C1229  
1
SCREW THF M6-1 X 16 N WA Z/JS  
HANG TAG 2 WIRE START (NOT  
SHOWN)  
1
32  
33  
34  
35  
36  
1
1
REF.  
1
* ITEMS INCLUDED AS PART OF I/N 39  
1
35  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Engine — Drawing No. 0F6836-B  
36  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Engine — Drawing No. 0F6836-B  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
0E6201  
0E8824  
0E8963  
1
2
1
ENGINE 3.0L FORD (FD) (MAKE)  
STAMPING ENG FOOT 3.0L FORD  
PULLEY CRANKSHAFT 3.0L FORD  
RD  
47  
48  
49  
50  
51  
53  
54  
55  
56  
049808  
051430  
045773  
0E6203C  
0E6679  
049226  
091526  
093278  
0F7000  
4
4
3
1
2
7
3
4
1
WASHER FLAT M12  
WASHER SHAKEPROOF INT 1/2  
NUT HEX M12-1.75 G8 YEL CHR  
COIL IGNITION 3.0L FORD  
BRACKET IGN COIL 3.0L FORD  
WASHER LOCK M5  
4
5
6
7
8
0E9020  
0A1232  
0A7801B  
0A5610  
0E6308  
1
1
1
1
1
BRACKET DC ALT 3.0L FORD  
D.C. ALTERNATOR ASSY  
PULLEY POLY-V 82 OD.  
SCREW PPHM M5-0.8 X 12 ZNC  
SCREW HHTT M5-0.8 X 25 BP  
HARN ENGINE 3.0L FORD HSB CAR  
(NOT SHOWN)  
BRACKET ALTERNATOR  
PULLEY WATERPUMP 3.0L FORD  
(RD)  
9 **  
0E7804  
1
HARN IGNITION 3.0L FORD (NOT  
SHOWN)  
57  
58  
60  
61  
62  
0E7163  
0E5527  
0E7202  
085296  
0E6203D  
2
2
2
6
1
GASKET EXHAUST 3.0L FORD  
MANIFOLD EXHAUST 3.0L FORD  
HEAT SHIELD 260 X 80 HOT  
SCREW HHC 1/4-20 X 1/2 SS  
WIRE SET 3.0L FORD (NOT  
SHOWN)  
10  
11  
12  
14  
15  
0D3488F  
0E7996  
0E8006  
0A6751  
0E0561  
1
1
1
1
1
BELT SERPENTINE 38.35  
CLUTCH COOLING FAN FORD  
FAN 18" 7 BLADE STEEL ECS  
SWITCH HI-TEMP 245D X 3/8NPT  
ASSY WATER LEVEL SENSOR C/E  
PL  
63  
64  
057772  
057765  
055596  
069860C  
057822  
069811  
061012  
065852  
0A2111  
057073  
066849  
022152  
0E7880  
1
1
1
1
2
1
1
1
1
1
2
2
2
WASHER NYLON .565  
ADAPTER M14-1.50 X 3/8 NPT  
BARBED STR 3/8NPT X 3/8  
HOSE OIL DRAIN ASSY 21"  
CLAMP HOSE #8 .53-1.00  
CAP HEX 1/4 NPT BRASS  
PLUG STD PIPE 1/8 SOCKET HEAD  
SPRING CLIP HOLDER .37-.62  
SCREW SWAGE 10-32 X 5/16 Z/YC  
JUNCTION BLOCK 3/8-16  
SCREW HHTT M5-0.8 X 16  
WASHER LOCK #10  
077043H  
1
CONDUIT FLEX .25"ID (6"LG) (NOT  
SHOWN)  
65  
66  
16  
17  
0E6729  
0E6703  
1
1
STARTER DELCO-REMY 12V  
COVER FLYWHEEL ACCESS 3.0L  
HSB  
67  
68  
69  
18  
19  
20  
21  
0E6667  
0E5048  
035579  
0A8584  
1
1
1
1
ENGINE ADAPTER 3L FORD  
FLEXPLATE 3.0L FORD  
70 *  
71 *  
72  
BUSHING REDUCER 1/4 TO 1/8  
SWITCH OIL PRESSURE 10PSI  
2POL  
73  
74  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
083896  
084929  
055597  
0F6151  
057823  
056739  
047411  
022097  
022473  
047411  
040976  
022129  
022145  
045771  
049814  
049821  
059980  
0D5417  
046526  
022131  
059982  
098780  
051769  
6
6
WASHER LOCK 1/4-M6 SS  
WASHER FLAT 1/4 SS  
75  
CLIP SPARK PLUG 3P  
SCREWMOUNT (NOT SHOWN)  
CLIP SPARK PLUG 2P  
1
SCREW HHC M12-1.75 X 85 G8.8  
CAP RUBBER  
76  
77  
0E7880A  
0E7880B  
4
1
1
SCREWMOUNT (NOT SHOWN)  
CLIP SPARK PLUG 3P FREEHANG  
(NOT SHOWN)  
1
CLAMP HOSE #10 .56-1.06  
RELAY SOLENOID 12VDC PNL MNT  
SCREW HHC M6-1.0 X 16 G8.8  
WASHER LOCK M6-1/4  
1
6
78  
79  
055934C  
027482  
1
1
CLAMP VINYL .5 X .406 Z  
WASHER SHAKEPROOF EXT 5/16  
STL  
6
6
WASHER FLAT 1/4-M6 ZINC  
SCREW HHC M6-1.0 X 16 G8.8  
SCREW SHC M8-1.25 X 20 G12.9  
WASHER LOCK M8-5/16  
WASHER FLAT 5/16-M8 ZINC  
NUT HEX M8-1.25 G8 YEL CHR  
SCREW HHC M10-1.5 X 25 G8.8  
SCREW SHC M8-1.25 X 30 G12.9  
SCREW HHC M10-1.5 X 25 G10.9  
SCREW HHC M10-1.0 X 25 G10.9  
WASHER LOCK M10  
4
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
0E8940  
0A7387  
022097  
022473  
055934H  
0F5966  
022985  
036261  
0F6658  
0F6809  
1
2
4
4
2
1
3
3
1
1
SPACER FLEXPLATE HSB  
SCREW HHC M10-1.5 X 40 G10.9  
WASHER LOCK M6-1/4  
8
28  
22  
1
WASHER FLAT 1/4-M6 ZINC  
CLAMP VINYL .62 X .406 Z  
REFLECTIVE HEAT SHIELD 3.0L FD  
WASHER FLAT #6 ZINC  
6
16  
4
RIVET POP .125 X .275 SS  
COVER EGR  
ADAPTER, WATER PUMP  
REF.  
18  
11  
4
WASHER FLAT 3/8-M10 ZINC  
SCREW SHC M12-1.75 X 45 G10.9  
SCREW HHC M12-1.75 X 65 G8.8  
WASHER LOCK M12  
* NOT SHOWN-USED TO HOLD OIL DRAIN ASSEMBLY.  
** NOT SHOWN  
2
3
37  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Radiator — Drawing No. 0F6848-B  
38  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Radiator — Drawing No. 0F6848-B  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0E9947  
0E6340  
0E8531  
0E6398  
0F6630  
080713  
076749  
049814  
022131  
046526  
045772  
035685  
0E8562  
058443  
0C2454  
048031C  
029032  
046627  
069811  
065852  
0A2111  
052250  
035461  
0C7649  
069860C  
0F6746  
0F6631  
0F6657  
055934N  
092079  
022097  
047411  
1
1
2
1
1
1
1
4
8
4
4
6
1
4
9
1
1
1
1
1
1
2
1
1
1
1
1
2
2
2
2
2
RADIATOR R-IN,L-OUT 658X489X49  
VENTURI 3.0L FORD HSB  
SIDE SUPPORT RADIATOR HSB  
TUBE LOWER RAD 3.0L FORD HSB  
HOSE RADIATOR UPPER  
3
4
5
6
BRACKET COOLANT TANK  
TANK COOLANT RECOVERY  
SCREW HHC M10-1.5 X 25 G8.8  
WASHER FLAT 3/8-M10 ZINC  
WASHER LOCK M10  
7
8
9
10  
11  
12  
13  
14  
15  
17  
18  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
35  
NUT HEX M10-1.5 G8 YEL CHR  
CLAMP HOSE #28 1.32-2.25  
FAN GUARD HSB  
SCREW CRIMPTITE 1/4-20 X 5/8  
SCREW TH-FRM M6-1 X 16 N WA Z/JS  
CLAMP HOSE BAND 1/4  
HOSE 9/32 ID (30" LG)  
CAP RADIATOR  
CAP HEX 1/4 NPT BRASS  
SPRING CLIP HOLDER .37-.62  
SCREW SWAGE 10-32 X 5/16 Z/YC  
TAPE FOAM 1 X 1 (27" LG)  
BARBED STR 1/4 NPT X 3/8  
CLAMP HOSE .38-.87  
HOSE OIL DRAIN ASSY 21"  
TUBE UPPER COOLANT C4 3.0L  
HOSE RADIATOR ENGINE  
SUPPORT TUBE RADIATOR  
CLAMP VINYL 1.31 X .281 Z  
SCREW HHTT M6-1.0 X 25 BP  
WASHER LOCK M6-1/4  
SCREW HHC M6-1.0 X 16 G8.8  
39  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Fuel System — Drawing No. 0F6849-A  
40  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Fuel System — Drawing No. 0F6849-A  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1 *  
2
---------  
1
1
1
2
2
4
2
2
2
1
1
1
2
1
1
1
1
1
1
1
1
4
8
4
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
WELDMENT MOUNTING BASE  
FLANGE FUEL INLET  
075580  
0E7691  
039253  
022145  
022129  
045771  
042907  
0C2454  
026307  
0E1056  
0E6584  
057823  
059194  
044117  
0D1509  
050279  
0E6123  
0E6586  
0E4395  
057753B  
047487  
022097  
051751  
035685  
0C7649  
047290  
047290  
0A4121  
0E6609  
049099  
055934M  
047411  
022097  
O22473  
0E9295A  
0E6382A  
0E7121  
0E6376A  
0F2119  
3
ASSY REGULATOR 3.0L NG OR LPV  
SCREW HHC M8-1.25 X 20 G8.8  
WASHER FLAT 5/16 ZINC  
4
5
6
WASHER LOCK M8-5/16  
7
NUT HEX M8-1.25 G8 YEL CHR  
SCREW HHC M8-1.25 X 16 G8.8  
SCREW TH-FRM M6-1 X 16 N WA Z/JS  
ELBOW 90D STREET 3/4  
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35 **  
36 **  
37 **  
38 **  
39  
40  
41  
42  
43  
FUEL HOSE ASSY NAT.GAS/L.P.V.  
BRACKET REGULATOR 3.0L FORD HSB  
CLAMP HOSE #10 .56 - 1.06  
HOSE 5/8 ID LPG & NG (20" LG)  
BARBED STR 3/8 NPT X 5/8  
DECAL INLET PRESSURE  
DECAL FUEL INLET NG  
INTAKE ADAPTER 3.0L FORD-BOSCH  
GASKET BOSCH 32  
ACTUATOR BOSCH 32 GOVERNOR  
HOSE 1.5 ID X 2 LG 20R4  
SCREW SHC M6-1.0 X 18 G12.9  
WASHER LOCK M6-1/4  
SCREW HHC M6-1.0 X 50 G8.8  
CLAMP HOSE #28 1.32-2.25  
CLAMP HOSE .38-.87  
HOSE 3/8 ID SINGLE BRAID (305mm [22"] LONG)  
HOSE 3/8 ID SINGLE BRAID (432mm [13"] LONG)  
VALVE PCV  
GROMMET ROCKER COVER 3.0LFORD  
BARBED EL 90 3/8 X 3/8 PLST  
CLAMP VINYL .75 X .343 Z  
SCREW HHC M6-1.0 X 16 G8.8  
WASHER LOCK M6-1/4  
WASHER FLAT 1/4-M6 ZINC  
ASSY THROTTLE 27MM  
VENTURI HOLDER W/32MM ACTUATOR  
O-RING 47.625 ID X 2.38 WIDTH  
VENTURI, 27 ID THROTTLE W/CHOK  
O-RING 45.63 ID X 2.62 WIDTH  
* SHOWN IN OTHER VIEW  
** NOT SHOWN-USED TO HOLD #31 IN PLACE  
41  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Alternator — Drawing No. 0F5092-B  
42  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Alternator — Drawing No. 0F5092-B  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
0F1659A  
0F1657A  
0F1655A  
0F5073A  
0E7413A  
0F1660A  
0F1658A  
0F1656A  
0F5074A  
0E7412A  
0E5706  
1
1
ROTOR 390 15KW 1P DIRECT HSB (2.5L FORD)  
ROTOR 390 20KW 1P DIRECT HSB (2.5L FORD)  
ROTOR 390 25KW 1P DIRECT HSB (2.5L FORD)  
ROTOR 390__30AD1 HSB TECUM  
RTR 390 40KW 1P DIRECT HSB  
1
1
1
2
1
STR 390 15AD HSB (382MM LONG) (2.5L FORD)  
STR 390 20AD HSB (382MM LONG) (2.5L FORD)  
STR 390 25AD HSB (382MM LONG) (2.5L FORD)  
STR-390__30AD1 HSB TECUM  
1
1
1
1
STR-390--40AD HSB (433MM LONG)  
REAR BEARING CARRIER 390/DRCT  
FLEXPLATE 3.0L FORD  
3
4
1
0E5048  
REF  
REF  
REF  
1
0E5048B  
0E5048A  
0E6668  
FLEXPLATE 2.5L FORD  
FLEXPLATE HSB 3.9L CHRYSLER  
FLYWHEEL ASSY 3.0L HSB LG GEAR  
REVCOR FAN 10.75 X 2 W/PRESS DIS  
WASHER LOCK M10  
5
6
7
8
9
0E6076  
046526  
051755  
1
8
4
SCREW HHC M10-1.5 X 16 G8.8  
04576100BK  
04576100BF  
043123  
4
STUD M14-2.0 X 490 G5 ZINC (3.0L FORD & 2.5L FORD)  
STUD M14-2.0 X 540 G5 ZINC  
WASHER LOCK M14  
4
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
4
051779  
0E7587  
4
NUT HEX M14-2.0 G8 YEL CHR  
1
ASSY BRUSH HOLDER 390/HSB  
WASHER SHAKEPROOF INT #8  
SCREW PPHM M4-0.7 X 25  
023365  
092980  
1
4
057192  
0A2602  
4
SCREW SHC M10-1.5 X 30 G12.9  
WASHER FLAT .688 ID X 3.25 OD  
KEY SQ 3/8 X 1 STEEL  
1
042558  
0A2601  
1
1
SCREW HHC M16-2.0 X 45 G8.8  
WASHER LOCK #8-M4  
022264  
038150  
4
4
WASHER FLAT #8 ZINC  
CONDUIT FLEX 1-1/4" (30" LG - 3.0L FORD & 3.9L CHRYSLER)  
CONDUIT FLEX 1-1/4" (18" LG - 2.5L FORD)  
077043F  
077043F  
1
1
ROTOR REPLACEMENT PARTS  
30  
31  
047248  
070892  
1
1
BALL BEARING-45 MM  
SLIP RING -MACHINED-  
43  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Exhaust — Drawing No. 0F0968-B  
21  
13  
2
11  
18  
17  
16  
1
19  
7
8
16  
16  
17  
6
18  
TO  
MANIFOLD  
19  
8
TO  
COMPARTMENT  
10  
15  
20  
16  
17  
3
10  
17  
20  
5
9
TO  
MANIFOLD  
12  
13  
14  
3
4
12  
9
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
0F0738  
0F6258  
044149  
0F1008  
0F1009  
039288  
0E5914  
1
1
2
1
1
1
1
MUFFLER 7"X9"-(2)2"IN/2.5"OUT  
PIPE MUFFLER OUT  
12  
13  
14  
15  
16  
17  
18  
19  
0E8816  
085917  
0D2611  
039253  
022145  
022129  
045771  
0C2454  
2
8
4
2
4
7
3
4
EXHAUST FLANGE 2" PIPE  
WASHER LOCK 3/8 SS  
GASKET EXHAUST RING  
EXHAUST PIPE LH 3.0L HSB  
EXHAUST PIPE RH 3.0L HSB  
SCREW HHC M8-1.25 X 55 G8.8  
BRACKET MUFFLER 3.0L FORD  
HSB  
SCREW HHC 3/8-16 X 1-3/4 SS  
SCREW HHC M8-1.25 X 20 G8.8  
WASHER FLAT 5/16-M8 ZINC  
WASHER LOCK M8-5/16  
NUT HEX M8-1.25 G8 YEL CHR  
SCREW TH-FRM M6-1 X 16 N WA  
Z/JS  
8
9
0E8726  
0E0170  
036797  
080762  
2
2
2
1
STRAP MUFFLER  
EXHAUST BLANKET 750MM  
BOLT U 5/16-18 X 2.25  
BOLT U 3/8-16 X 2.62  
20  
21  
022259  
022241  
4
2
NUT HEX 5/16-18 STEEL  
NUT HEX 3/8-16 STEEL  
10  
11  
44  
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Section 9 - Exploded Views and Parts  
Liquid-cooled 30 kW Generators  
Air Cleaner — Drawing No. 0F6850-A  
1
2
3
4
5
6
7
8
9
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
0E5193  
0E0519A  
049226  
049815  
0C8127  
022127  
062974  
0A5547  
037561  
1
1
4
4
1
1
1
1
1
PLATE AIR CLEANER ADAPTER  
ADAPTER CARBURETOR W/PVC CONN  
WASHER LOCK M5  
SCREW HHC M5-0.8 X 16 G8.8  
ELEMENT AIR CLEANER  
NUT HEX 1/4-20 STEEL  
STUD TH 1/4-20 X 4-1/2 G2 ZNC  
COVER - AIR CLEANER  
NUT WING 1/4-20 NYLK  
45  
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Section 10 – Warranty  
Liquid-cooled 30 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. 0F6866  
Revision 0 (07/26/05)  
Printed in U.S.A.  
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