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• Before performing any maintenance on the gen-

erator, 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 con-
ditions from leaking exhaust gases, fuel leakage, 
oil leakage, etc.

 ELECTRICAL HAZARDS 

• All generators covered by this manual produce 

dangerous electrical voltages and can cause fatal 
electrical 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 appropriate covers, guards 
and barriers are in place before operating the gen-
erator. If work must be done around an operating 
unit, stand on an insulated, dry surface to reduce 
shock hazard.

• 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 personnel 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) requires the 

frame and external electrically conductive parts 
of the generator to be connected to an approved 
earth ground. This grounding will help prevent 
dangerous electrical shock that might be caused 
by a ground fault condition 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 maxi-
mum electrical current (ampacity) to which they 
will be subjected.

• Before installing or servicing this (and related) 

equipment, make sure that all power voltage 
supplies are positively turned off at their source. 
Failure to do so will result in hazardous and pos-
sibly fatal electrical shock.

• Connecting this unit to an electrical system nor-

mally 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 operat-
ing. 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.

• Generators installed with an automatic transfer 

switch will crank and start automatically when 
normal (utility) source voltage is removed or is 
below an acceptable preset level. To prevent such 
automatic start-up and possible injury to person-
nel, disable the generator’s automatic start circuit 
(battery cables, etc.) before working on or around 
the unit. Then, place a “Do Not Operate” tag on 
the generator 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 imple-
ment, such as a dry rope or board, to free the vic-
tim from the live conductor. If the victim is uncon-
scious, apply first aid and get immediate medical 
help.

• Never wear jewelry when working on this equip-

ment. Jewelry can conduct electricity resulting in 
electric shock, or may get caught in moving com-
ponents 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 extin-
guisher properly charged and be familiar with its 
use. If there are any questions pertaining to fire 
extinguishers, consult the local fire department.

 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 com-
bustible materials are left in the generator com-
partment, or on or near the generator, as FIRE or 
EXPLOSION may result. Keep the area surround-
ing 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 regulat-
ing the storage and handling of fuels. Inspect the 
unit’s fuel system frequently and correct any leaks 
immediately. Fuel supply lines must be prop-
erly installed, purged and leak tested according to 
applicable fuel-gas codes before placing this equip-
ment 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.

1-2

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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