.6L 20/25/30 kW Models Serial Number STANDBY GENERATOR OWNER'S MANUAL A new standard of reliability Not intended for use in critical life support applications. —CAUTION— ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! This manual should remain with the unit. Cover113 Rev. A 04/07 Catalog Number OMASPES025-1 Part No.
Standby Generator Sets Table of Contents SECTION PAGE SAFETY RULES ................................................ 1-1 OPERATION ...........................................................9-1 INTRODUCTION .....................................................1-3 Read this Manual Thoroughly ...................................1-3 Operation and Maintenance ......................................1-3 How to Obtain Service ..............................................1-3 IDENTIFICATION RECORD .................
Standby Generator Sets Important Safety Instructions 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.
Standby Generator Sets Important Safety Instructions • 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 personnel, 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.
Standby Generator Sets Important Safety Instructions INTRODUCTION symbol points out potential explosion This hazard. Thank you for purchasing this model of the standby generator set product line. This symbol points out potential fire hazard. symbol points out potential electrical shock This hazard. Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written.
Standby Generator Sets General Information IDENTIFICATION RECORD 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. DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator.
EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers.
Standby Generator Sets Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm.
FUEL SYSTEM FUEL REQUIREMENTS The standby generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (PV) fuel system The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the unit. Recommended fuels should have a Btu content of at least 1,000 Btus per cubic foot for natural gas; or at least 2,520 Btus per cubic foot for LP gas.
Standby Generator Sets Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ...................................................................... Gear Oil Filter .............................................................Full Flow, Cartridge Crankcase Oil Capacity ....................................................4 U.S. qts. GENERATOR Type ............................................................................. Synchronous Rotor Insulation .................................
Utility In CONTROL PANEL NEUTRAL TO ALTERNATOR GENERATOR CONNECTION BOX Gen N1 N2 23 194 183 178 NEUTRAL N1 N2 23 194 186 CIRCUIT BREAKER 178 Load Out GROUND To Generator Control Panel FRAME RAIL Ground Level Concrete Slab STUB-UP AREA See Install Dwg for Dimensions COLD WEATHER KIT NOTE: For cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes: The jet sizes are stamped on the individual jets. The larger jet size is used for running on NG.
Standby Generator Sets General Information GENERATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING CONNECTIONS See “Voltage Codes”. This generator may be rated at any one of three voltages, either single-phase or three-phase. The electrical wires in the unit’s AC connection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. If there are any questions regarding lead connection, refer to the wiring diagrams at the back of this manual.
Standby Generator Sets Installation PRIOR TO INITIAL START-UP INSTALLATION Refer to the separate “Installation Guide” supplied with the unit. to initially starting the generator, it must Prior be properly prepared for use. Any attempt to PREPARATION BEFORE START-UP The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor.
Standby Generator Sets Installation • Open 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 pressure. It must be as listed in the Specifications. • Insert the fuse into the control panel. • Move the AUTO/OFF/MANUAL switch to the manual position. The engine should now crank and start. • Check voltage at the generator terminals.
GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator’s manual for this unit. OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the generator was installed in conjunction with a transfer switch capable of manual operation only, the following procedure applies. A manually operated transfer switch is one that will not provide automatic start-up and does not include an intelligence circuit.
Standby Generator Sets Maintenance MAINTENANCE PERFORMED BY SERVICE FACILITIES COOLING SYSTEM Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow. working on the generator, ensure the fol Before lowing: Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See the installation diagram.
Figure 10.
CHANGING ENGINE OIL Refer to maintenance performed by service facilities for engine oil and filter change frequencies. Drain the oil while the engine is still warm from running. 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.
Standby Generator Sets Maintenance MISCELLANEOUS MAINTENANCE 3. Have the state of charge and condition checked. This should be done with an automotive-type battery hydrometer. CLEANING THE GENERATOR DANGER Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance. Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt.
Standby Generator Sets Service Schedule SERVICE SCHEDULE 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 application.
Standby Generator Sets Service Schedule Maintenance Tasks Level 1 Recommended to be done monthly 10 Hrs. Level 2 Task Comp. (DateInitials) Required to be done 3 months/ Break-in 30 Hrs. 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.
Standby Generator Sets Service Schedule Maintenance Tasks Level 1 RecomTask mended Comp. to be done (Datemonthly In itials) 10 Hrs. Level 2 Required to be done 3 months/ Break-in 30 Hrs. 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.
Standby Generator Sets Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 5 amp fuse blown. 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor.* 4. Replace starter motor.* 5. Remove, change or replace battery. 6. Replace fuse.* Engine cranks but won't start 1.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 (1) 23 24 25 26 27 28 0G4827 0G2927 0G2827 0G3451C 0G0820A 0G4452 020746 049226 051713 022129 0G4825 0G4826 0G2926 0G3682 0G5584 0G3685 0G2826 0G3683 0G6573 0G3686 0G3452C 0G3684 0G3687 0G5909 0G6103 0A5382A 075591 051787 0A5601A 075554B 075554E 0A9375 022152 0G4196 042558 049814 0G0965B 053607 051769 023365 0F3353 072578 0G3787 0A8830 077043E 0G2070 1 1 1 1 1 1 4 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 4 4 4 4 1 1 4 1 1 1 4 6 1 10 4 1 1 ASSY
1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 0G3343 027482 070936 070936C 039253 022145 022129 045771 071956 051730 021991 026850 049813 055414 047411 022097 022473 1 2 2 2 8 12 12 4 4 4 1 1 1 1 1 1 5 MOUNTING BASE 1.6L 2007 C1 WASHER SHAKEPROOF EXT 5/16 STL DAMPENER VIBRATION VIB. ISO. 70-75 DURO SCREW HHC M8-1.25 X 20 G8.8 WASHER FLAT 5/16 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 YEL CHR WASHER FLAT M8 SCREW HHC M8-1.25 X 60 G8.8 EARTH STRAP WASHER SHAKEPROOF EXT 1/4 STL NUT HEX M6 X 1.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0F3408C 0F3411 025507 059980 046526 077483 050331A 050331 038805J 038804M 045771 022131 027482 0F3976 0C2454 022145 1 1 1 1 1 REF REF REF 1 1 REF 1 1 1 4 REF BATTERY TRAY, C1 & C2 STRAP BATTERY RETAINMENT WASHER SHAKEPROOF EXT 7/16 STL SCREW HHC M10-1.5 X 25 G10.9 WASHER LOCK M10 BATTERY 12VDC 75-AH 26 BATTERY POST COVER RED + BATTERY POST COVER BLK CABLE BATTERY BLACK #1 X 30.00 CABLE BATTERY RED #1 X 21.00 NUT HEX M8-1.
1 2 3 4 5 6 7 8 9 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 54 55 56 57 58 59 60 61 62 0G0207 0G0834 0G0820 0E9747 0G0839 0G0781 0G0722 0G4059 0G4604 0G3424 0G4863 0G0786 0G4605 0F9617A 0A1354B 0G0823 0G4949 0G3900 0D2244M 036710 0C5479 059980 046526 022131 0G3922 0G0464 0G0465 052858 051735 0G3920 0A7387 039414 022129 022145 029333A 057821 045771 022507 022097 022473 090388 0A5768 0A6751 035579 0A8584 0C1852 070928 0
1 2 3 4 026812 075580 0G1397A 0G1397B 039253 2 1 1 1 2 ELBOW 90D 3/4 NPT FLANGE FUEL INLET FUEL REG. REWORK 1.6L 3600 '07 (3600RPM) FUEL REG. REWORK 1.6L 1800 '07 (1800RPM) SCREW HHC M8-1.25 X 20 G8.
(1) 1 (1) 2 (2) 3 (1) 4 (1) 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 0G3337 0G3336 077992 0G3341 0G3335 0F4487A 022127 022097 022473 0C2454 0F5048D 0F5049 0F8869D 089961 078115 0G4029 0G4029A 0F3890 0E3257 0912970090 0G4029B 0F3890B 1 1 16 2 1 1 1 1 1 16 2 2 1 1 18 2 1 5 4 2 1 4 ROOF 1.6L C1 REAR INTAKE WRAP 1.6L C1 NUT HEX LOCK M6-1.0 SS NY INS RIGHT SIDE DOOR 1.6L C1 FRONT DISCHARGE WRAP 1.
Standby Generator Sets Notes
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