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Sida 1/96

Cover198 Rev. C 07/12 Part No. 0J0216



SECTION PAGE

INTRODUCTION .................................................................... 1-1

SAFETY RULES ....................................................................1-2

IDENTIFICATION RECORD ....................................................2-1

EQUIPMENT DESCRIPTION ..................................................3-1

Equipment Description ..........................................................3-1

Engine Oil Recommendations ................................................3-1

Coolant Recommendations ...................................................3-1

ENGINE PROTECTIVE DEVICES ............................................4-1

Engine Protective Devices .....................................................4-1

FUEL SYSTEMS ...................................................................5-1

SPECIFICATIONS ..................................................................6-1

GENERAL INFORMATION .....................................................7-1

Alternator AC Lead Connections ............................................7-1

Alternator Power Winding Connections ..................................7-1

CONTROL PANEL .................................................................8-1

Control Panel Interface ..........................................................8-1

Activate the Generator ...........................................................8-1

Display Interface Menus ........................................................8-1

Setting the Exercise Timer .....................................................8-3

User Adjustable Settings .......................................................8-3

Fuel Conversion ....................................................................8-3

Operation .............................................................................. 8-3

Auto Start .............................................................................8-4

Manual Start .........................................................................8-4

Alarm and Warning Messages ...............................................8-4

Common Alarm Relay ...........................................................8-6

Maintenance Alerts ...............................................................8-6

Menu System ........................................................................8-7

OPERATION .......................................................................... 9-1

Stationary Emergency Generator Control and Operation ......... 9-1

Operating Unit with Manual Transfer Switch ...........................9-1

Operating Unit with Automatic Transfer Switch ......................9-1

MAINTENANCE ................................................................... 10-1

Maintenance Performed by Authorized Service Dealers .......10-1

Cooling System...................................................................10-1

Checking Fluid Levels ..........................................................10-1

Maintenance Owner/Operator Can Perform .......................... 10-2

Miscellaneous Maintenance ................................................ 10-3

SERVICE SCHEDULE ..........................................................11-1

TROUBLESHOOTING ..........................................................12-1

Troubleshooting Guide .........................................................12-1

EMISSIONS WARRANTY ....................................................13-1

NOTES

EXPLODED VIEWS & PARTS LISTS

WIRING DIAGRAMS & SCHEMATICS

Content050 Rev. A 10/10

Table of Contents

INTRODUCTION

Thank you for purchasing this model of the stationary emergency

generator product line.

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. However, the manufacturer reserves

the right to change, alter or otherwise improve this product(s) at

any time without prior notice.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest

Service Dealer for starting, operating and servicing procedures.

Throughout this publication, and on tags and decals affixed to the

generator, DANGER, WARNING, CAUTION and NOTE blocks are

used to alert personnel to special instructions about a particular

service or operation that may be hazardous if performed incor-

rectly or carelessly. Observe them carefully. Their definitions are

as follows:

INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF

NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

Indicates a hazardous situation or action which, if not

avoided, could result in death or serious injury.

Indicates a hazardous situation or action which, if not

avoided, could result in minor or moderate injury.

NOTE:

Notes contain additional information important to a procedure

and will be found within the regular text body of this manual.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliance with the special

instructions while performing the service are essential to prevent-

ing accidents.

Four commonly used safety symbols accompany the DANGER,

WARNING and CAUTION blocks. The type of information each

indicates is as follows:

n This symbol points out important safety information that,

if not followed, could endanger personal 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 is responsible for proper and safe use of the equip-

ment. The manufacturer strongly recommends that the operator

read this Owner's Manual and thoroughly understand all instruc-

tions before using this equipment. The manufacturer also strongly

recommends instructing other users to properly start and operate

the unit. This prepares them if they need to operate the equipment

in an emergency.

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.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to

make sure that all maintenance for safe operation is performed

promptly, and to have the equipment checked periodically by a

Service Dealer. Normal maintenance service and replacement of

parts are the responsibility of the owner/operator and, as such,

are not considered defects in materials or workmanship within the

terms of the warranty. Individual operating habits and usage con-

tribute to the need for maintenance service.

Proper maintenance and care of the generator ensure a minimum

number of problems and keep operating expenses at a minimum.

See a Service Dealer for service aids and accessories.

Operating instructions presented in this manual assume that the

generator electric system has been installed by a Service Dealer or

other competent, qualified contractor. Installation of this equipment

is not a “do-it-yourself” project.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, simply contact

a Service Dealer for assistance. Service technicians are factory-

trained and are capable of handling all service needs.

When contacting a dealer about parts and service, always supply

the complete Model Number, Serial Number and Type Code (where

applicable) from the DATA LABEL that is affixed to the unit.

1-1

Safety004 Rev. F 05/10

Safety Instructions

n 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.

SAFETY RULES

Study these SAFETY RULES carefully before installing, operating

or servicing this equipment. Become familiar with this Owner’s

Manual and with the unit. The generator can operate safely, effi-

ciently and reliably 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 warnings in this manual, and on

tags and decals affixed to the unit are, therefore, not all inclusive.

If a procedure, work method or operating technique is used that

the manufacturer 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.

n 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 respon-

sible 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.

n 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, stan-

dards, laws and regulations. Adhere strictly to local, state and

national electrical and building codes. Comply with regulations

the Occupational Safety and Health Administration (OSHA) has

established. Also, ensure that the generator is installed, operat-

ed and serviced in accordance with the manufacturer’s instruc-

tions 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 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. 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 compli-

ance 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 operating.

Adequate, unobstructed flow of cooling and ventilating air is •

critical in any room or building housing 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 seriously 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.

Before performing any maintenance on the generator, discon-•

nect 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 dan-

gerous operating conditions from leaking exhaust gases, fuel

leakage, oil leakage, etc.

ELECTRICAL HAZARDS

All stationary emergency generators covered by this manual •

produce dangerous electrical voltages and can cause fatal

electrical shock. Utility power delivers extremely high and dan-

gerous voltages to the transfer switch as well as the 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 generator. 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 stand-•

ing in water, while barefoot, or while hands or feet are wet.

DANGEROUS ELECTRICAL SHOCK MAY RESULT.

1-2

Safety004 Rev. F 05/10

Safety Instructions

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.

Stationary Emergency Generator Model and Serial

Number

2-1

General Information

 Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.

 Do not use any chromate base rust inhibitor

with ethylene glycol base anti-freeze or chro-

mium hydroxide (“green slime”) forms and will

cause overheating. Engines that have been

operated with a chromate base rust inhibitor

must be chemically cleaned before adding eth-

ylene glycol base anti-freeze. Using any high

silicate anti-freeze boosters or additives will

also cause overheating. The manufacturer also

recommends that any soluble oil inhibitor is

NOT used for this equipment.

 Do not remove the radiator pressure cap while

the engine is hot or serious burns from boiling

liquid or steam could result.

 Ethylene glycol base antifreeze is poisonous.

Do not use mouth to siphon coolant from the

radiator, recovery bottle or any container. Wash

hands thoroughly after handling. Never store

used antifreeze in an open container because

animals are attracted to the smell and taste of

antifreeze even though it is poisonous to them.

3-1

Equip010 Rev. D 07/11

4-1

FUEL SYSTEM

5-1

Fuel System

Type......................................................................Synchronous

Total Harmonic Distortion < 3.5% ..............................................

Telephone Interference Factor (TIF) < 50 ..................................

Alternator Output Leads 1-phase ..................................... 4-wire

Alternator Output Leads 3-phase (150 kW) ..................... 6-wire

Alternator Output Leads 3-phase (100/130 kW) ............ 12-wire

Bearings ..................................................................Sealed Ball

Coupling

100/130 kW Gear Drive ...........................................................

150 kW Flexible Disk ...............................................................

Excitation System ......................................................Brushless

Generator Locked Rotor kVA Available @ Voltage Dip of 35%

100 kW 130 kW 150 kW

240 V, 1-phase

240 V, 3-phase

208 V, 3-phase

200 270 320

480 V, 3-phase 240 320 350

Refer to the Data Label on the generator for rated watts, amperes, frequency, volt-

age, phase and other pertinent information.

NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514,

SAE J1349, ISO3046 and DIN 6271 Standards. kW rating is based on LPG fuel

and may derate with natural gas.

Make Generac ...........................................................................

Model V-type .............................................................................

Cylinders and Arrangement ...................................................10

Displacement ............................................................... 6.8 Liter

Bore............................................................ 90.2 mm (3.55 in.)

Stroke ....................................................... 105.9 mm (4.17 in.)

Compression Ratio.......................................................... 9-to-1

Air Intake System Naturally Aspirated .........................................

Valve Seats ................................................................ Hardened

Lifter Type .................................................................. Hydraulic

Engine Parameters

Rated Synchronous rpm 60 Hz, See Data Label..........................

Exhaust System

Exhaust Flow at Rated Output 60Hz See Chart 1 .........................

Exhaust Temperature at Rated Output See Chart 1 ......................

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz See Chart 1 ......................................

kW Exhaust Flow

cfm Exhaust Temp °F Combustion Air

Flow cfm

100 888 960 262

130 1119 970 336

150 1535 1100 410

6-1

GenSpec089 Rev. C 11/15

Voltage 100 kW 130 kW 150 kW

Amps CB kW Amps CB kW Amps CB kW

120/240 V - 1 417 500 100 542 600 130 625 700 144

120/208 V - 3 347 400 100 451 500 130 520 600 150

120/240 V - 3 301 350 100 391 450 130 451 500 150

277/480 V - 3 150 175 100 195 225 130 225 250 150

Voltage 100 kW 130 kW 150 kW

Amps CB kW Amps CB kW Amps CB kW

120/240 V - 1 371 500 89 488 600 117 567 700 136

120/208 V - 3 326 400 94 423 500 122 493 600 142

120/240 V - 3 283 350 94 367 450 122 427 500 142

277/480 V - 3 141 175 94 183 225 122 214 250 142

Governor

Engine Lubrication System

Fuel Consumption - ft 3/hr (Natural Gas/LPV) @ 11 in

H20/68 °F

Voltage Regulator

Power Adjustment for Ambient Conditions

Controller Nexus ...................................................................

6-2

ALTERNATOR AC LEAD

CONNECTIONS

ALTERNATOR POWER WINDING

CONNECTIONS

E3 L - N

L - L

INTERNAL

CONNECTIONS

00 (NEUTRAL)

S12

S11

S10

E3 L - N

L - L

7-1

General Information

E3 E2

00 (NEUTRAL)

INTERNAL CONNECTIONS E1

L-L

L-N

S1 S1

S4 S4

S5 S2

E3 E2

L-L

L-N

S7 S1

S10 S4

S12

S11 S2

E3 L - N

L - L

INTERNAL

CONNECTIONS

00 (NEUTRAL)

0VAC

2VAC

208C

240C

240 VAC

120 VAC 120 VAC

240 VAC

S2 S12

S11

S10

E1 E3

208 VAC

7-2

General Information



8-1

8-2

ACTIVATION CHART

8-3

8-4

8-6

The Maintenance Disconnect Switch and the

AUTO/OFF/MANUAL switches (if so equipped)

must be set properly, or the generator will

crank and start as soon as the utility power to

the transfer switch is turned off. Refer to appli-

cable control panel and transfer switch manuals

for more information.

Do not proceed until certain that utility source

voltage is available to the transfer switch and

the transfer switch main contacts are set to

UTILITY.



Do not attempt manual operation until all

power supplies to the transfer switch have been

positively turned off, or extremely dangerous -

possibly lethal - electrical shock will result.



Transfer switch enclosure doors should be kept

closed and locked. Only authorized personnel

should be allowed access to the transfer switch

interior. Extremely high and dangerous voltages

are present in the transfer switch.

nDo not crank the engine continuously for lon-

ger than 30 seconds, or the heat may

damage the starter motor.

9-1



Oil Filter

Oil Fill

Oil

Dipstic



10-1

10-2

Air Filter





10-3

11-1

12-1

United States Environmental Protection Agency Warranty Statement

(Stationary Emergency Spark-Ignited Generators)

Warranty Rights, Obligations and Coverage

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission

Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or compo-

nent on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replace-

ment parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system may include parts

such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac will warrant

the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect, unapproved modifica-

tion, or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the date of sale to the ulti-

mate purchaser. For engines greater than or equal to 130 HP the warranty period is three years or 2500 hours of operation, whichever

comes first, from the date of the engine being placed into service. For high-cost warranted components, the Emission Control System war-

ranty is valid for 5 years or 3500 hours of operation, whichever comes ﬁrst.

Purchaser's/Owner's Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following: 1) The engine must be installed and conﬁgured in accordance to Gen-

erac's installation specifications. 2) The completion of all maintenance requirements listed in your Owner's Manual. 3) Any engine setting

adjustment must be done in accordance and consistent with the instructions in the Owner's Manual. 4) Any emission control system or com-

ponent must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize

emissions at all times.

Generac may deny any/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system or

component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of

counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting either

your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/owner shall

be responsible for any expenses or other charges incurred for service calls and/or tr spection or ansportation of the product to/from the in

repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being trans-

ported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System Warranty

related information, Generac Power Systems, Inc., PO. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www.generac.com.

Important Note

This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Gen-

erac pursuant to federal law. Note that this warranty shall not apply to 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). 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. Any

implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states

do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Emission Related Parts Include the Following (if so equipped)

*High-Cost Warranted Component

EmsnWrnty001 Revision F (04/15)

1) Fuel Metering System

1.1) Gasoline Carburetor Assembly and Internal Components

A) Fuel Filter, B) Carburetor, C) Fuel Pump

1.2) Carburetion Assembly and Its Components

A) Fuel Controller, B) Carburetor and Its Gaskets,

C) Mixer and Its Gaskets, D) Primary Gas Regulator,

E) Liquid Vaporizer

1.3) Fuel Regulator

2) Air Induction System Including A) Intake Pipe/Manifold,

B) Air Cleaner

3) Ignition System Including A) Spark Plug, B) Ignition Module,

C) Ignition Coil, D) Spark Plug Wires

4) Exhaust System

A) Catalyst Assembly*, B) Exhaust Manifold, C) Muffler,

D) Exhaust Pipe, E) Muffler Gasket

5) Crankcase Breather Assembly Including

A) Breather Connection Tube, B) PCV Valve

6) Oxygen Sensor

7) Diagnostic Emission-Control System

United States Environmental Protection Agency Compliance Requirements

(Stationary Emergency Spark-Ignited Generators)

Purchaser's/Owner's Record Keeping Responsibilities

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record

keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion

Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains

their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in

this Owner's Manual, you are required to meet the following notification and record keeping requirements to demonstrate compliance: 1)

Maintain documentation that the engine is certified to meet emission standards. 2) Record keeping of maintenance conducted. 3) Record

keeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel

solely during emergency operations provided the engine is not certified to operate on propane. 4) Meet all compliance notifications submitted

to the purchaser/owner and maintain all supporting documentation. 5) Record keeping of hours of operation, including what classified the

operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130

HP, record keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, record keeping of hours of oper-

ation begins January 1, 2009; engines are equipped with non-resettable hour meters to facilitate record keeping.

Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements.

Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air

Quality Management or Air Pollution Control District for specific requirements.

Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing,

provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the

engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emer-

gency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be

used for maintenance checks and readiness testing, but a petition t Federal, is not required if the owner maintains records indicating tha

State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may

operate up to 50 hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for

maintenance and testing.

The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to

an electric grid or otherwise supply power as part of a ﬁnancial arrangement with another entity. For purchaser/owner of emergency engines,

any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year,

as permitted in this section is prohibited.

If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance

to the speciﬁcations and guidelines in this Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be con-

sidered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Igni-

tion Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.

Emission-Related Installation Instructions

Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and

replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States

Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized

Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow t ified engine in a hese instructions when installing a cert

piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.

EmsnWrnty001 Revision F (04/15)