background image

 1 

0F3137 

PAN CB CONN BOX 

0F3188 

STAND RH CONTROL 

0F3189 

STAND LH CONTROL 

023484N 

BUSHING SNAP SB-2.5-31 

0F6366B 

1  

XFMR DUAL 120V/16V (FOR 120/240V & 277/480V UNITS) 

 

0F6366A 

XFMR DUAL 104V/16V (FOR 120/208V UNITS) 

043180 

2  

WASHER FLAT M4 

022264 

2  

WASHER LOCK #8-M4 

0C3990 

2  

SCREW PHTT M4-0.7 X 10 ZYC 

  (1) 9 

057701 

REF 

BLOCK TERM 20A 8 X 6 X 1100V 

10 

022155 

WASHER LOCK #6 

11 

0C2428 

SCREW PHTT #6-32 X 1/2 ZYC 

12 

0F3824 

DECAL UTIL SENSE/CUST CONN 

13 

0A9457 

DECAL NEUTRAL 

14 

057073 

JUNCTION BLOCK 3/8-16 

 (2) 15 

0D5466 

REF 

BUS BAR NEUTRAL BLOCK 390 

 (2) 16 

0A7822 

REF 

LUG SLDLSS 600/250-1/0 X 1/4-28 

17 

022237 

WASHER LOCK 3/8 

18 

022241 

NUT HEX 3/8-16 STEEL 

19 

049226 

WASHER LOCK M5 

20 

0C2266 

SCREW PHTT M5-0.8 X 16 ZYC 

21 

0C2454 

SCREW THF M6-1 X 16 N WA Z/JS 

23 

022473 

WASHER FLAT 1/4-M6 ZINC 

24 

022097 

WASHER LOCK M6-1/4 

 (1) 26 

0D4698 

REF 

BLOCK TERM 20A 6 X 3 X 1100V 

27 

0F4464 

DECAL CUST CONN 120V UTILITY 

28 

025433 

LUG SLDLSS #6-14 X 13/64 CU 

29 

024469 

SCREW HHTT #10-32 X 3/8 CZ 

30 

067210A 

DECAL GROUND LUG 

31 

0D6029 

SCREW HHTT M6-1.0 X 16 ZYC 

32 

081008 

GROMMET 1.25 X .25 X .75 

33 

077043J 

CONDUIT FLEX 2.0" ID (36” LG) 

34 

051713 

WASHER FLAT M5 

35 

0F6156 

PLATE WIRE SNGL GALV 

36 

029289 

TAPE ELEC 1/2 FOAM (AS REQ’D) 

37 

047411 

SCREW HHC M6-1.0 X 16 G8.8 

(3) 39 

0G0770 

HARNESS, TRANSFORMER ADAPTER 

(4) 40 

0G5952 

ASSY PCB IGN MOD 4.2L 

(4) 41 

036943 

SCREW PPHM #10/32 X 2   

(4) 42 

023897 

WASHER FLAT #10 ZINC 

(4) 43 

022152 

WASHER LOCK #10   

(4) 44 

022158 

NUT HEX #10-32 STEEL    

(4) 45 

0C2454 

SCREW THF M6-1 X 16 N WA Z/JS   

(4) 46 

055934D 

CLAMP VINYL 1.06 X .406 Z 

47 

0F6145 

A/R 

SEAL WEATHER .45"DIA 

 

 

 

 

1) 

 

UL CIRCUIT BREAKER (ED) 

0F3328 

COVER ED CB SHORT STND 

0D5552 

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 

0F0492 

INSULATOR CB S (ED-3P) 

048927 

SCREW RHM #10-32 X 4-1/2 

023897 

WASHER FLAT #10 ZINC 

022152 

WASHER LOCK #10 

022158 

NUT HEX #10-32 STEEL 

0C2454 

SCREW THF M6-1 X 16 N WA Z/JS 

029289 

TAPE ELEC 1/2 FOAM (AS REQ’D) 

0F1733 

DECAL CUSTOMER CONNECT INSIDE 

 

 

 

 

2) 

 

UL CIRCUIT BREAKER (FD) 

0F3138 

COVER CB CONN BOX 

0D5572 

CB 0150A 3P 600V S FD6 LL 

 

0D5573 

CB 0175A 3P 600V S FD6 LL 

 

0D5574 

CB 0200A 3P 600V S FD6 LL 

 

0D5575 

CB 0225A 3P 600V S FD6 LL 

 

0D5576 

CB 0250A 3P 600V S FD6 LL 

0F0199 

INSULATOR CB FD FRAME 30MIL 

081320 

SCREW SHC 1/4-20 X 4.5 G8.8 NZ 

022473 

WASHER FLAT 1/4-M6 ZINC 

022097 

WASHER LOCK M6-1/4 

022127 

NUT HEX 1/4-20 STEEL 

0C2454 

SCREW THF M6-1 X 16 N WA Z/JS 

029289 

TAPE ELEC 1/2 FOAM (AS REQ’D) 

0F1733 

DECAL CUSTOMER CONNECT INSIDE 

3) 

 

UL CIRCUIT BREAKER (JD+LD) 

0F3329 

COVER JD/LD CB SHRT STAND 

0D5577 

CB 0300A 3P 600V S JD6 LL 

0F2353 

INSULATOR CIRCUIT BR. JD/LD 

022770 

SCREW RHM 1/4-20 X 3 

022473 

WASHER FLAT 1/4-M6 ZINC 

022097 

WASHER LOCK M6-1/4 

022127 

NUT HEX 1/4-20 STEEL 

0C2454 

SCREW THF M6-1 X 16 N WA Z/JS 

029289 

TAPE ELEC 1/2 FOAM (AS REQ’D) 

0F1733 

DECAL CUSTOMER CONNECT INSIDE 

 

 

 

 

4) 

 

UL CIRCUIT BREAKER (QN) 

0F8135 

COVER QN FRM CB 

0E7283 

CB 0150A 2P 240V S QN2 LL 

 

0E7284 

CB 0175A 2P S QN2 LL 240V 

0E3664 

BASE, QN CIRCUIT BREAKER 

074908 

SCREW HHTT M5-0.8 X 10 BP 

0F8140 

COVER QN CB DISH 

036261 

RIVET POP .125 X .275 SS 

0C2454 

11 

SCREW THF M6-1X16 N WA Z/JS 

029289 

TAPE ELEC 1/2 FOAM (AS REQ’D) 

0F1733 

DECAL CUSTOMER CONNECT INSIDE 

 

 

 

 

 

 

 

 

 

 

(1)  ITEM INCLUDED WITH HARNESS 

 

 

(2)  ITEM INCLUDED WITH 0D5464B 

 

 

(3)  ITEM USED WITH EARLY MODEL 208V  UNITS ONLY 

 

 

(4)  ITEMS USED ON 4.2L MODELS ONLY. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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...

Page 54: ......

Page 55: ......

Page 56: ......

Page 57: ......

Page 58: ......

Page 59: ......

Page 60: ......

Page 61: ......

Page 62: ......

Page 63: ......

Page 64: ......

Page 65: ......

Page 66: ......

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...

Reviews: