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Study these SAFETY RULES carefully before install-
ing, operating or servicing this equipment. Become 
familiar with this Owner’s Manual and with the unit. 
The generator can operate safely, efficiently and reli-
ably only if it is properly installed, operated and 
maintained. Many accidents are caused by failing to 
follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible 
circumstance that might involve a hazard. The warn-
ings in this manual, and on tags and decals affixed 
to the unit are, therefore, not all inclusive. If a pro-
cedure, work method or operating technique is used 
that the manufacturer does not specifically recom-
mend, ensure that it is safe for others. Also make 
sure the procedure, work method or operating tech-
nique utilized does not render the generator unsafe.

DANGER

  Despite the safe design of this generator, 

operating this equipment imprudently, neglect-
ing its maintenance or being careless can cause 
possible injury or death. Permit only responsible 
and capable persons to install, operate or main-
tain this equipment.

  Potentially lethal voltages are generated by 

these machines. Ensure all steps are taken to 
render the machine safe before attempting to 
work on the generator.

  Parts of the generator are rotating and/or hot 

during operation. Exercise care near running 
generators. 

 GENERAL HAZARDS 

•  For safety reasons, the manufacturer recommends 

that this equipment be installed, serviced and 
repaired by a Service Dealer or other competent, 
qualified electrician or installation technician who 
is familiar with applicable codes, standards and 
regulations. 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 
generator is installed, operated and serviced in 
accordance with the manufacturer’s instructions 
and recommendations. Following installation, do 
nothing that might render the unit unsafe or in 
noncompliance with the aforementioned codes, 
standards, laws and regulations.

• The engine exhaust fumes contain carbon mon-

oxide 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. 
This should be considered prior to installing the 
generator. The unit should be positioned to direct 
exhaust gasses safely away from any building 
where people, animals, etc., will not be harmed. 
Any exhaust stacks that ship loose with the unit 
must be installed properly per the manufacturer's 
instruction, and in strict compliance with appli-
cable 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 operating.

•  Adequate, unobstructed flow of cooling and venti-

lating air is critical in any room or building hous-
ing the generator to prevent buildup of explosive 
gases and to ensure correct generator operation. 
Do not alter the installation or permit even partial 
blockage of ventilation provisions, as this can seri-
ously affect safe operation of the generator.

• Keep the area around the generator clean and 

uncluttered. Remove any materials that could 
become hazardous.

• When working on this equipment, remain alert 

at all times. Never work on the equipment when 
physically or mentally fatigued.

• Inspect the generator regularly, and promptly 

repair or replace all worn, damaged or defective 
parts using only factory-approved parts.

  SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation 

be copied and posted in potential hazard areas. Safety should be stressed to all operators, 
potential operators, and service and repair technicians for this equipment.

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth 

defects or other reproductive harm.

WARNING:

This product contains or emits chemicals

known to the state of California to cause

cancer, birth defects or other reproductive harm.

WARNING:

1-1

Standby Generator Sets

Important Safety Instructions

Safety004  Re

v. B  08/07

Summary of Contents for 2.4L 35kW

Page 1: ...liability Serial Number 2 4L 35 45kW Models Not intended for use in critical life support applications ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDO...

Page 2: ...8 1 Start up Checklist 8 2 Preparation for Start up 8 2 Start up Inspection 8 2 OPERATION 9 1 Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch 9 1 Engine Start up and Tr...

Page 3: ...the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations...

Page 4: ...s will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch wil...

Page 5: ...l safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator...

Page 6: ...factor etc NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Generator...

Page 7: ...properly serviced with the recom mended oil may result in an engine failure NOTE For temperatures below 32 F it is strongly recom mended to use the optional Cold Weather Start Kit part number listed...

Page 8: ...st be turned to OFF and then back to AUTO OVERCRANK SHUTDOWN After a prespecified duration of cranking this func tion ends the cranking if the engine has failed to start The overcrank LED will turn ON...

Page 9: ...not supply such a regulator It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutof...

Page 10: ...ency Regulation Isochronous Steady State Regulation 0 25 Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Spin on Cartridge Crankcase Oil Capacity 4 U S qts COOLING SYSTEM Type Pre...

Page 11: ...et port in the regulator casting NOTE The jet sizes are stamped on the individual jets The larger jet size is used for running on NG 8 Install the previously removed NG jet into the jet keeper port on...

Page 12: ...e between each circuit breaker ter minal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator 3 PHASE ALTERNATORS Y...

Page 13: ...roduced in the alternator power windings These windings were connected at the factory to the main circuit breaker with a Delta configuration as shown in Figures 7 5 The rated voltage between circuit b...

Page 14: ...e dipstick ADD mark See Specifications and Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with break in oil This oil should be changed after 30 hours of operation PRIOR T...

Page 15: ...the valve to the engine fuel line Bleed the fuel system of air necessary for long fuel lines Open the generator main line circuit breaker Connect a manometer to the gas line and record the static pre...

Page 16: ...ansfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the standby generator s main line circuit break er to its OFF or OPEN position Start the gener...

Page 17: ...e 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 Without suf...

Page 18: ...rmation see the respective sec tions in the Control Panel Technical Manual that is supplied with the unit INSPECT COOLING SYSTEM Inspect engine cooling system See Maintenance Schedule Check hoses for...

Page 19: ...for oil leaks CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the co...

Page 20: ...CE The battery should be inspected per the Scheduled Maintenance section The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Ti...

Page 21: ...etup for normal operation when required 2 A wear in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem area...

Page 22: ...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 for leaks and correct pressure on...

Page 23: ...ve clearance lash Adjust as necessary 12 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 13 Test the engine and transfer s...

Page 24: ...h for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 19 Perform an engine oil analysis send a sample to a lab for results Cha...

Page 25: ...ded in SPECIFICATIONS Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Swi...

Page 26: ...Standby Generator Sets Notes...

Page 27: ...Standby Generator Sets Notes...

Page 28: ...Standby Generator Sets Notes...

Page 29: ...Standby Generator Sets Notes...

Page 30: ......

Page 31: ...ORT STND C 0D5552 1 CB 0050A 3P 480V S ED4 LL 0D5553 CB 0060A 3P 480V S ED4 LL 0D5554 CB 0070A 3P 480V S ED4 LL 0D5556 CB 0090A 3P 480V S ED4 LL 0D9693 CB 0125A 3P 480V S ED4 LL D 0F0492 1 INSULATOR C...

Page 32: ......

Page 33: ...APTOR 1 W W CB 2 TERMINAL COVER CB X 0G3259 1 DECAL TERMINAL SHOCK HZD BI 7 UL CIRCUIT BREAKER 400AF A 0F4187 1 COVER CB C2 C4 400AF C 0F4166 REF CIRCUIT BREAKERS 400A FRAME D 0F1733 1 DECAL CUSTOMER...

Page 34: ......

Page 35: ...L 0G6565 1 STR 390 35GD1 CPL 0G6566 1 STR 390 35KD1 CPL 0G6567 1 STR 390 35JD1 CPL 0H0201 1 STR 2390 60JD2 CPL 3 0C9708 REF INSTR HYPOT TEST NOT SHOWN 4 SEE ENGINE EV REF ENGINE ADAPTER 5 SEE ENGINE E...

Page 36: ......

Page 37: ...3 18X12 7X382 27 0F6305A 1 SEAL COVER 3 18X12 7X283 28 0F5886 3 SCREW HHPM M5 0 8 X 12 29 051713 12 WASHER FLAT M5 30 049226 12 WASHER LOCK M5 31 0F5752F 1 RES WW 15R 5 25W QK CONN 32 0F5884 2 SCREW...

Page 38: ......

Page 39: ...4 13 022097 1 WASHER LOCK M6 1 4 14 022473 2 WASHER FLAT M6 1 4 ZINC 15 049813 1 NUT HEX M6 1 0 G8 YEL CHR 16 022261 1 WASHER SHAKEPROOF INT 3 8 17 0F9597A 1 SUPPORT LH ENGINE 2 4L 18 045764 1 SCREW...

Page 40: ......

Page 41: ...FLAT 3 8 M10 ZINC 7 050331A REF BATTERY POST COVER RED 8 050331 REF BATTERY POST COVER BLACK 9 038805Y 1 CABLE BATTERY BLACK 1 X 18 00 10 03880400AE 1 CABLE BATT RED 1 X 18 00 11 045771 REF NUT HEX M8...

Page 42: ......

Page 43: ...4 049815 4 SCREW HHC M5 0 8 X 16 G8 8 5 022127 1 NUT HEX 1 4 20 STEEL 1 6 062974 1 STUD TH 1 4 20 X 4 1 2 G2 ZNC 7 0G0190 1 PLATE AIR CLEANER TOP 2 4L 8 037561 1 NUT WING 1 4 20 NYLK 1 APPLY MEDIUM ST...

Page 44: ......

Page 45: ...10 WASHER FLAT 1 4 M6 ZINC 32 043116 4 SCREW HHC M6 1 0 X 12 G8 8 33 026073A 2 PLUG STD PIPE 1 4 STEEL SQ HD 34 052243 1 SCREW HHC M10 1 5 X 60 G8 8 35 0A8258 1 SCREW HHC M8 1 25 X 25 G10 9 1 36 0G06...

Page 46: ......

Page 47: ...LOCK 1 2 34 022196 1 NUT HEX 1 2 13 STEEL 35 0F8651 9 SCREW HHFC M8 1 25 X 20 W M6 36 070015 1 NUT HEX LOCK 5 16 18 NY INS SS 37 0F9867 1 SHAFT FAN DRIVE 38 0F2461 1 RETAINER BEARING 39 022145 16 WASH...

Page 48: ......

Page 49: ...AID 18 LG 32 057823 2 CLAMP HOSE 10 56 1 06 RECONFIGURING THE FUEL SYSTEM Note All models are configured to run on natural gas from the factory To reconfigure the fuel system from NG to LP follow thes...

Page 50: ......

Page 51: ...LDMENT 11 044149 1 GASKET EXHAUST RING 12 085917 2 WASHER LOCK 3 8 SS 13 0D2611 2 SCREW HHC 3 8 16 X 1 3 4 SS 14 0E8816 1 EXHAUST FLANGE 2 PIPE 15 049721 4 SCREW HHC M6 1 0 X 35 G8 8 BLK 16 022097 4 W...

Page 52: ......

Page 53: ...ON SPLITTER 28 0G5892C 2 INSULATION SPLITTER 29 0F4051C 2 INSULATION DUCT 30 0F3890B 4 RETAINER INSULATION 820 31 0F4051B 2 INSULATION DUCT SIDES 32 0F3890 4 RETAINER INSULATION 450 33 078115A 6 WASHE...

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Page 67: ...B 0C2454 3 SCREW THF M6 1 X 16 N WA Z JS 3 C4 UNITS A 0F9832A 1 SHIELD CONTROL STAND C4 B 0C2454 3 SCREW THF M6 1 X 16 N WA Z JS 4 C5 UNITS A 0F9832C 1 SHIELD CONTROL STAND C5 0F9832D 1 SHIELD CONTROL...

Page 68: ...Morris St D Indianapolis IN 46231 Printed in U S A Edition Date 10 07 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Catalog N...

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