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DS-07-2494Inspection Worksheet Miami Shores Village 10050 N.E. 2nd Avenue Miami Shores, FL Phone: (305)795 -2204 Fax: (305)756 -8972 Inspection Date: 04/07/2008 Inspector: Grande, Claudio Owner: LARA, RALPH Job Address: 921 99 Street NE Miami Shores Village, FL Project: <NONE> Contractor: ALL YEAR ELECTRIC INC Permit Type: Driveways /Sidewalks /Slabs Inspection Type: Final Work Classification: New Block: Phone Number Parcel Number 1132060340240 Lot: Phone: (954)566 -4644 Building Department Comments NEW GENERATOR 0 ® ®® Passed Inspector Comments cc Failed Correction Needed Re- Inspection Fee ($75) No Additional Inspections can be scheduled re- inspection fee is paid. until Friday, April 4, 2008 Page 2 of 2 Miami Shores Village Building Department 10050 .NE 2 Ave, Miami Shores, Fl 33138 Tel: (305)795 -2204 • Fax; (305)756 -8972 RECEIPT PERMIT #; �S 01 OLVI 8 DATE: Feb I, —re- A (.s lc tae 1 fa Contractor o Owner o A clad y� )ticked v sets f plans and �+h�r) S19 (WG' a vi d I Address: 01,21 arJ an Si- From the building department on this date in order to have corrections done to plans And/or get County stamps. I understand that the plans need to be brought back to Miami Shores Village Building Department to continue permitting process. Acknowledged PERMIT CLEARK INITIAL: RESUBMITTED DATE: 4 /z /() PERMIT CLEARK INITIAL: } 7z4A 7&?�D� vi_ViVrt BUILDING PERMIT APPLICATION FBC 2004 Miami Shores Village Building Department 10050 N.E.2nd Avenue, Miami Shores, Florida 33138 Tel: (305) 795.2204 Fax: (305) 756.8972 ^ter' .111 DEC 1 3 2007 Li B Y: Permit No. CIS(Tf -7494- Master Permit No. Permit Type (circle): wilding Electrical Plumbing �� . Roofing Owner's Name (Fee Simple Titleholder) r ( ' Lam/ Phone # Owner's Address 2-- c NF , S r(--- City �P4�i " State flog t°64-- Zip Tenant/Lessee Name Phone # Job Address (where the work is being done) City Miami Shores Village FOLIO / PARCEL # County Miami -Dade Zip 33 ( 38'' Is Building Historically Designated YES NO Contractor's Company Name A (t /Q4 7-7.- -e(e[ c_ Phone # <--/( " 5-4 6 r 6 f 4-4-,... j ,),,c, Contractor's Address c f r ,J-e_ City f 677-4 1.t t2Ic � r e State `--. ( ®ft--; Cl Zip *--504. Qualifier Name 7Z 4 .-r( ,../ ((e 8"Z_ Phone # 41, S —'Bi - 5-6 iii'-'144 `Y ' State Certificate or Registration No. e�j4-01 Q ®`3 Certificate of Competency No. 7 'I- e �s /vim ®6 Architect/Engineer's Name (if applicable) Value of Work For this Permit $ Phone # Type of Work: ❑Addition ['Alteration Describe Work: • 5 F (f -5 Square / Linear Footage Of Work: ew ❑ Repair/Replace ❑ Demolition 1L ******** * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ** Fees************* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ** Submittal Fee $ Permit Fee $ L0 t e--- • CCF $ CO /CC Notary $ 5 • Oo Training/Education Fee $ Technology Fee $ `3(Th Scanning $ Radon $ DPBR $ Zoning $ Bond $ Code Enforcement $ Double Fee $ Structural Review. $ Total Fee Now Due $ See Reverse side -+ Bonding Company's Name (if applicable) Bonding Company's Address City State Zip Mortgage Lender's Name (if applicable) Mortgage Lender's Address City State Zip Application is hereby made to obtain a permit to do the work and installations as indicated. I certify that.no work or installation has commenced prior to the issuance of a permit and that all work will be performed to meet the standards of all laws regulating construction in this jurisdiction. I understand that a separate permit must be secured for ELECTRICAL WORK, PLUMBING, SIGNS, WELLS, POOLS, FURNACES, BOILERS, HEATERS, TANKS and AIR CONDITIONERS, ETC OWNER'S AFFIDAVIT: I certify that all the foregoing information is accurate and that all work will be done in compliance with all applicable laws regulating construction and zoning. "WARNING TO OWNER: YOUR FAILURE TO RECORD A NOTICE OF COMMENCEMENT MAY RESULT IN YOUR PAYING TWICE FOR IMPROVEMENTS TO YOUR PROPERTY. IF YOU INTEND TO OBTAIN FINANCING, CONSULT WITH YOUR LENDER OR AN ATTORNEY BEFORE RECORDING YOUR , NOTICE OF COMMENCEMENT." Notice to Applicant: As a condition to the issuance of a building permit with an estimated value exceeding $2500, the applicant must promise in good faith that a copy of the notice of commencement and construction lien law brochure will be delivered to the person whose property is subject to attachment. Also, a certified copy of the recorded notice of commencement must be posted at the job site for the first inspection which occurs seven (7) days after the building permit is issued. In the absence of such posted notice, the inspection will not be approved and a reinspection fee will be charged. ,i Signature 1 • � it t{ -'A- / r _� Signature P E — n\4s, t Si afore Owner or Agent ontractor The foregoing instrument was acknowledged before me this ' 3 The foregoin instrument was acknowledged before me this 13 day oil ®c , 20 Oc by , day of 2O ?, by PALN, I_ .. 111. 1,iif who is personally known to me or who has produced who is personally known to me or who has produced As identification and who did take an oath. t/1. as identification and who did take an oath. NOTARY PUBLIC: j NOTA PUBLIC: Sign: Print: ej s4!�� • Christine Anderson • toy Commission r osd y Commiss'sDn DD322026 My Commis 11• Wits July 21, 2100S My Commission E : Q 21, 2008 t xpires My APPLICATION APPROVED BY: (Revised 02/08/06) Plans Examiner V Engineer Zoning Inspection Date: 05/19/2008 Inspector: Levrock, James Owner: LARA, RALPH Inspection Worksheet Miami Shores Village 10050 N.E. 2nd Avenue Miami Shores, FL Phone: (305)795 -2204 Fax: (305)756 -8972 2 .4944 Job Address: 921 99 Street NE Miami Shores Village, FL Project: <NONE> Block: Contractor: THE GREAT AMERICAN SERVICE MAN INC • Permit Type: Plumbing - Residential Inspection Type: Final Work Classification: Gas Phone Number Parcel Number 1132060340240 Lot: Phone: (954)321 -6198 Building Department Comments Friday, May 16, 2008 Page 1 of 2 ' 'I Pe E • ace ' ermi tor Comments TED AS REINSPECTION FOR INSP- 70025. Gas tanks are not at a minimum of5' from the rear property line as approved in ,. See approved survey. 4/2/08 JL Passed 1 Failed Correction Needed Re- Inspection Fee ($75) No Additional Inspections can be scheduled until re- inspection fee is paid . Friday, May 16, 2008 Page 1 of 2 • 2 g2 ib S Inspection Date: 04/02/2008 Inspector: Levrock, James Owner: LARA, RALPH Inspection Worksheet Miami Shores Village 10050 N.E. 2nd Avenue Miami Shores, FL as al_ iiter4 Phone: (305)795 -2204 Fax: (305)756 -8972 Job Address: 921 99 Street NE Miami Shores Village, FL Project: <NONE> Contractor: THE GREAT AMERICAN SERVICE MAN INC Permit Type: Plumbing - Residential Inspection Type: Final MI" Work Classification: Gas Phone Number Block: Parcel Number 1132060340240 Lot: Building Department Comments Tuesday, April 1, 2008 Page 1 of 2 Passed sp cto omments Failed Correction Needed Re- Inspection Fee ($75) No Additional Inspections can be scheduled re- inspection fee is paid . until Tuesday, April 1, 2008 Page 1 of 2 1jL 1 \WO DLL voovsklk- Miami Shores Village Building Department 10050 N.E.2nd Avenue, Miami Shores, Florida 33138 Tel: (305) 795.2204 Fax: (305) 756.8972 BUILDING PERMIT APPLICATION FBC 2004 Permit Type: Plumbing Owner's Name (Fee Simple Titleholder) A( Owner's Address q..2 ( Afe-- .4G[ DEC 13 20011 Permit No. G, Master Permit No. OS 01 ' 4 (AI 4-lki 14qt city Am„Ar 5,t( 5 State Zip ..i`0 ( 3) Tenant/Lessee Name Phone # E -MAIL: Job Address (where the work is being done) '`021 ,,J8- T / 5/' City Miami Shores Village County Miami -Dade Zip FOLIO / PARCEL # Phone # Is Building Historically Designated YES NO 2( Contractor's Company NameMi diglett4meirumoYth 4d , Contract--7-1/1//P- r's Address 33c1 . /„) 721) 721) City State FL e T7it d ,,ef - Zip Qualifier Name L( 77 F 1 t/1'U t'7 Phone # Phone # ( r 4/Ts' ✓ /T s State Certificate or Registration No. Certificate of Competency No. E -MAIL: Architect /Engineer's; Name (if applicable) Phone # Value of Work For tltis Permit $ rao 0 Type of Work: yP dAddition ElAlteration Describe Work: .c-1 S'�c t r r4(q-rc--5 Square / Linear Footage Of Work: 4w® 0 Repair /Replace 0 Demolition jet (/D K- 7237z47 414-e ******************************** **** Feesxxxx* xz******* *************** *******x *xxx *r.* Submittal Fee $ Permit Fee $ / 7d CCF $ '40 CO /CC JNotary $ ® Training /Education Fee $ Q' Technology Fee $. 4.30 Scanning $ 6.00 Radon $ DPBR $ Zoning $ Bond $ Code Enforcement $ Structural Review. $ Double Fee $ Total Fee Now Due $ !CIO- lb MAR 3 Z�o1 A:. See Reverse side. -4 Bonding Company's Name (if applicable) Bonding Company's Address City State Mortgage Lender's Name (if applicable) Mortgage Lender's Address City Zip State Zip Application is hereby made to obtain a permit to do the work and installations as indicated. I certify that no work or installation has commenced prior to the issuance of a permit and that all work will be performed to meet the standards of all laws regulating construction in this jurisdiction. I understand that a separate permit must be secured for ELECTRICAL WORK, PLUMBING, SIGNS, WELLS, POOLS, FURNACES, BOILERS, HEATERS, TANKS and AIR CONDITIONERS, ETC OWNER'S AFFIDAVIT: I certify that all the foregoing information is accurate and that all work will be done in compliance with all applicable laws regulating construction and zoning. "WARNING TO OWNER: YOUR FAILURE TO RECORD A NOTICE OF COMMENCEMENT MAY RESULT IN YOUR PAYING TWICE FOR IMPROVEMENTS TO YOUR PROPERTY. IF YOU INTEND TO OBTAIN FINANCING, CONSULT WITH YOUR LENDER OR AN ATTORNEY BEFORE RECORDING YOUR NOTICE OF COMMENCEMENT." Notice to Applicant: As a condition to the issuance of a building permit with an estimated value exceeding $2500, the applicant must promise in good faith that a copy of the notice of commencement and construction lien law brochure will be delivered to the person whose property is subject to attachment. Also, a certified copy of the recorded notice of commencement must be posted at the job site for the first inspection which occurs seven (7) days after the building permit is issued. In the absence of such posted notice, the inspection will not be approved and a reinspection fee will be charged. Owner or Agent The foregoing instrument was acknowledged before me this yy day of 2i. , 20 6��, by t( C 1 9 > rho is personally known to me who has produced As identification and who did take an oath. NOT Si Print: My Commis Christine E Anon • my Comma I r9228` � ilr l4 Jut 2'i. 20O6 Signature Contractor The foregoing instrument was ac o�wledgedbefore me is )\ day of �b`I , 200 , by �1 '4\\ ho is personally known to me> who has produced as identification and who did take an oath. NOTARY PUBLIC: \ \ Sign: N:, . '. .\ ,V „t.. _ 4 \*S, .ar+ \ Print: ^ zo1 [`e`;, My Commission Expires: %-.1,4\ Obi ._... yi in..f..1..4.1.yy.�yiiL_i_.F±4 = '+-*• K%' Ki;3;** Ii***:****'* ***** ***�[****YXYXYYf**IsYKKXY. APPLICATION APPROVED ssiorpor., (Revised 02/08/06) - KooblsU D0351870 Expires August 31, 2008 KK KY. Y. KKK ., KK Y.K*WIC HK "/ / Plans Examiner Engineer Zoning I42-1\o1 Miami Shores Village Building Department 10050 N.E.2nd Avenue, Miami Shores, Florida 33138 Tel: (305) 795.2204 Fax: (305) 756.8972 BUILDING PERMIT APPLIC;ATION FBC 2004 LIS • BY :_9_C_'mo_ooe_ Permit No. FLO1 -.249's • Master Permit No. 01, -?4G4 Permit Type: Electrical Owner's Name (Fee Simple Titleholder) f r, Cara_ Phone # Zip 3'50 Owner's Address 1aI City INAL CPI/ o ;State Tenant /Lessee Name E -MAIL: Job Address (where the work is being done) City Miami Shores Village Phone # FOLIO / PARCEL # County Miami -Dade Zip Is Building Historically Designated YES NO Contractor's Company Name A1` \I *COW ded C Contractor's Add ess 1 4S 11. , +Li ate,. City Oa Qualifier Name gay) State Certificate or Registration No E, MA A Q � l9 E -MAIL: State, Phone # I s4 -SG(.0 4644 Architect/Engineer's Name (if app icable) Zip Phone # Certificate of Competency No. Value of Work For this Permit $ Type of Work: ❑Add'tion ['Alteration Describe Work: Phone # Square / Linear Footage Of Work: ❑ Repair /Replace ❑ Demolition xr.xx xxxr. xr. xxx*x*xr.*xr.r.xxr.xxxxxxxa:aex Fees%X*'" YY'"wz' "''t'""""''"'"""''ww'w''"'""l w . .ww Submittal Fee $ Permit Fee $ 02-5 , 4' CCF $ VO CO /CC Technology Fee $ S' OA Zoning $ Notary $ Scanning $ �• OQ Bond $ Training /Education Fee $ Radon $ Structural Review. $ Q (oO DPBR $ Code Enforcement $ Double Fee $ Total Fee Now Due $ 036 '02.- See Reverse side -+ Bonding Company's Name (if applicable) Bonding Company's Address City State Zip Mortgage Lender's Name (if applicable) Mortgage Lender's Address City State Zip Application is hereby made to obtain a permit to do the work and installations as indicated. I certify that no work or installation has commenced prior to the issuance of a permit and that all work will be performed to meet the standards of all laws regulating construction in this jurisdiction. I understand that a separate permit must be secured for ELECTRICAL WORK, PLUMBING, SIGNS, WELLS, POOLS, FURNACES, BOILERS, HEATERS, TANKS and AIR CONDITIONERS, ETC OWNER'S AFFIDAVIT: 1 certify that all the foregoing information is accurate and that all work will be done in compliance with all applicable laws regulating construction and zoning. "WARNING TO OWNER: YOUR FAILURE TO RECORD A NOTICE OF' COMMENCEMENT MAY RESULT IN YOUR PAYING TWICE FOR IMPROVEMENTS TO YOUR PROPERTY. IF YOU INTEND TO OBTAIN FINANCING, CONSULT WITH YOUR LENDER OR AN ATTORNEY BEFORE RECORDING YOUR NOTICE OF COMMENCEMENT." Notice to Applicant: As a condition to the issuance of a building permit with an estimated value exceeding $2500, the applicant must promise in good faith that a copy of the notice of commencement and construction lien law brochure will be delivered to the person whose properly is subject to attachment. Also, a certified copy of the recorded notice of commencement must be posted at the job site for the first inspection which occurs seven (7) days after the buildin, permit is issued inspection will not be approved and a reinspection fee will be charged. Signature Owner or Agent The fore ing instrument was acknowledged before me this day of N ti'p 20e) , by C Y 1-171 , is personally known to me r who has produced As identification and who did take an oath. NOTARY PUBLIC: Sign: Print: 0 Signature . . ntractor The fore 'ng instrument was acknowledged before me this r%/ day of ,206i�,by I�PIU, r �kII 12, wJ o is personally known to me or who has produced as identification and who did take an oath. NOT ' / PUBLIC: Sign. Print: c i-h (SIVE p,a Christine E Anderson My Commission My Commission Expires: z My Commission DD322025 )6ta Christine E Anderson My Commission 00322026 ,yirresagsp riald`****t,r**** APPLICATION APPROVED BY: (Revised 02/08/06) n n.c r.'..-7CWXXXXY.Y.XY.Y.XY.Y.X 4141 V- AO-- %3,9 e - Plans Examiner Engineer Zoning 1 .. . MMENCEMEN7 f A R . ED COPY MUST BE POS DON '' =.JOB SITE AT TIME OF FIRST INSPECTION 1111111 1111111111 11111 11111 11111 y i 11 1111 1111 ®� 2008W:01.14536 PERM NO. J 1 Li 014 TAX FOL • NO. � e' `o� t� �� OR Bk 26209 P s� ?S i (1a9 RECORDED 02/11/2008 15:40=27 HARVEY RUVINv CLERK OF COURT STATE OF �'IDA: MIAMI -DADE COUNTY, FLORIDA COUNTY OF MIAMI = LAST PAGE THE UNDERSIGNED hereby gives notice that improvements will be made to certain real property, and in accordance with Chapter 713, Florida Statutes, the following information is provided in this Notice of Commencement. 1. Legal description of property and street/address: AA 1 444 I s .my e ($ c6-c ¶ riC )4-33 t "r 1 (A)z-11 FT- L071 g LK 17o 2. Description of improvement: 11-) STPIL. L Si 4N ±hy O E4u6f 1' 3. Owner(s) name and address: K 1 N l 4M 1 eye`s, Interest in property: Name and address of fee simple titleholder: N s7 C( ST -°r- 4. Contractor's name and address: ALL viLeThe 06c-roc r t-. ( & Ave- ? i cAubi l7- 3 ?3 Ott TATE OF FLORIDA, COUNTY OF 5. Surety: (Payment bond required by owner from contractor, if anyjRav CERTIFY that this is a true Name and address: original fled I Amount of bond $ 6. Lender's name and address: ■ADE yofthe nd, o it ,AD2I s S my and and Officio/ Seal. HARVEY RUVIN of Cir 7. Persons within the state of Florida designated by Owner upon who i notices or other documents may be served as provided by Section 713.13(1)(a)7., Florida Statutes, Name and address: 8. In addition to himself, Owners designates the following person(s) to receive a copy of the Lienor's Notice as provided in Section 713.13(1)(b), Florida Statutes. Name and address: 9. Expiration date of this Notice of Commencement: (the expiration date is 1 year from the date of recording unless a rent date is sp ified) Si nature of Owner a Print Owner's Name 4f 1'' 1 L 4 Prepared by 0A. Sw, t Sworn to and subscribed before me this 111 day of �e 6 , 20 psi ` Address: A 1 k eA Con t tAC Notary Public Ceteease,0"7-..—. 1-,--ii--- fill j 'Li AO -� Print Notary's Name .. t k_pt vA '1?-6.r--AP I- (, � 3,3(}� -� My commission expi Christine E Anderson 123.01-52 PAGE4 6/07 00` 1 moires July 21, 2008 Miami Shores Village 10050 N.E. 2nd Avenue Miami Shores, FL 33138 -0000 Phone: (305)795 -2204 Fax: (305)756-8972 Permit NO. DS -12 -07 -2494 Issue Date: Not Issued Expires: of Issued Folio Number:1132060340240 Owner's Name: RALPH LARA Owner's Phone: Job Address: 921 99 Street NE Total Square Feet: 12 Miami Shores Village, FL Total Job Valuation: $ 2,000.00 Contractor(s) Phone Primary Contractor • Planning and Zoning Criteria and Comments Approved: Yes Date Approved: 12/17/2007 : Yes Comments: MUST MAINTAIN A MINIMUM 10 FOOT SIDE YARD SETBACK ANDS FOOT REAR YARD SETBACK FOR PAD AND GENERATOR 9 A L L'L' V 9• AOPNALT N.07.90.40•E. 90.99• e▪ ar ItION PIPe 0,9°090 48"0. 90.9R' (H.) 11.0117. ) X x ac P x 41. 4'C. 1.00' 0.7'C•8.9tALL �_° 0.49'1. 44.9• • .9.9• It9?' • i4$ pe,I'tto •in 1.0•� • 04119$4. Jg�Ill .. • • I—V D •: - o D 9:49' 10.90' ,WALL. 11.00' I:7 I$ Is. J2 1 OTORY G.P.O. I?L9.No.q?I t 49.90• lair" 0 v a, I� pp pj 49.19• i• ••• •,p • • • •• ••• • • 19.00• 19.7 P O 999.9I• CH. ) 400.00• IV. ) N. 09.90.46 V. a -J x x _10.9fi� -_ • MT NAIL- 41.00' 4•.00' 0.99' • .11 !. (M..} 91.o'4 ). : , : = 9' C NC. WALK, !; • •• .• • • s •• • • • •• 40' 4 O P ALT P A V E H E N T/ i• • 14.b•�1'?9rw. 40.94' • N. e. 4th • •OTIMET e' tiy,) • • • • • •• • • •• • -•• • ••• • • • NOTEST osounnoorso wavaTOTUSAT»Iatae ocoro os. twIMOOKU a), Si DO ramoomoomounomoLoomailoomuosmoon • tos000OlOpWO»NOfi01. • TN O1 lLemoll OOLOOIELOW NiffinliallOWAIIO O_ BIS ANL • �pTA WA ANa iPARIT a COPOOMAILL MOO al ALO Oil MIS PLO NALI• tiTSTOINI PILO LOPLwCLOGN PO.OMMOLaPeBa • I» as E 4 MA Moo ROOM OIPL OaPAN1YO1I. C4 Z LA Ni+r. auNATIOI. oen •gpOMtia PIMA ROOM LAMP TILL PCOTAT AP. FOOMEDnDOA PA. F011ialialL Pea MOO. OILOOPOIL LP TANKS TO BE MINIMUM 10 Feet FROM BUILDING LEGEND: •aloci Pavans. • SAS .•.4P a A• AO ATPN. OOC LOA. 8. 031.0. na COWL aaa COOL OWN tool PONai, IUV*O M. ICNOONIROARAOCOaB uta Pull OOIMea00RaonUaa). APO LOGO MAUL A•COOIMOrA Oat A•MKL awowO. a GWAROCaeAlnOBOO•oa CENT•ALANOti[OM A COMM WOO BOOR OOpWTIL OciPOLL COeN;M=sumo mgO4 COATULOOSTOODNOLUNR. Oupi mg FOOL O 0.1'W. 400.0.0'f ft.) 994.9I't4.) e. SURVEYOR'S CERTIFICATE: somneonsn THAT AO OMIT • TAIO A SO Gomm TO A! HO PO on oosL000aoaealeaa•ostrnxsu vinoaNOausNaarol Oil OOnatIQIL Pao ANT OM =TM Olin flat UMW 1O00101. •TANOOLIP IRMnt•ATM ROOM MO SONO OP OM OILIM OAO N COMP= ODOPC /TORCA a uormoNa AS2OcTATE$7 WC. woa mnoto lLaunaa wain• 2 -250 GAL. LP TANKS ABOVEGROUND .4ntivv .GENE `jam NOTES co 6x°7.9 CT:51 C.11 LL O4 UR OAS PAO. PAO. PA PA a P.T. PAC PAO. ARAL OL) a- PILL Oa SA TM! TO. VOL MY Kv lioa MOASOOL •AMIOI@. MAMA O0FOARIKA•is8MC MOOPrdiela. POPOV, COOMicalift OAT 1100X MOW OWINALOOLPOROPT /o1NOY. MaOWCasioainYANAINRL MRCP MEL= CWhOIOL PEAMANI rtrP•NNCi ONIAMI1rt f•NM. •AaeuenlAls. Room. LOOOP•MAT. SOMA aOWaiPHT TOMMY. TOOL voila UP tASOMa a•DIMO► vain IMO WOO TOOL 200 AMP BREAKER Y 0 0 0 Z m z • 0 m O O NOT VALID UNLESS EMBOSSED WITH RAID VEAL OP ATTESTING REGISTERED LAND SURVEYOR REVISIONS DATE .. NAME: 1144 ADDRESS: Generator [ ] - Other: Size: /$ KW - SIZE: Gas Type: Natural [ ] LP [(47 Total Load:34 Of7BTU's = CFH Total Run: 25- Feet @ PSI (first stage) /1 w.c (second stage) Line Size: Pa` stage — inch - 2"El stage �' inch Material: Metallic pipe [ad-Polyethylene pipe [ SST [ ] 3/4' Wispvio54- (/AI r5 Process # 3 /N6CE VdrE 460iArat& !7ef✓,e . •• .•• • • •• • • • • • • •• • •• ••• •• • • • •• • • • • • • •. • • • .• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • .• • • •. ••• • ••.• • • • ••• • • • • ••• • • • • • • • • • ••• • • • • • • • • • •• •• • • • ••• • • • ••• • • • • • • •• • Alo ox. L3"af 3/t° a -,?So G,st�cr/ L P Ztrks LP GAS SYSTEM INSTALLED PER N F PA 54 and 58 By: The Great American Service Man 108 Chapter 6 • Pipe Sizing TABLE ,6.3(k) Polyethylene Plastic Pipe Note: All table entries are rounded to 3 significant digits. • • • • •• • • • • • • •• • • • • • • • • • • • •••• • • • • .0•• • • • • • • • • •• •• •• •• • • • • • 0000 • • • • •0•• • • • •• • •0• • • 2006 National Fuel Gas Code Handbook Gaq. Undiluted Propanl Inlet Pressue: 11.0 in. w c_ Pressure Drop: as in. w c. Specific Gravity: 1.50 _ Pipe Size (in.) Nominal OD: jh 3/4 . '' 1 P/4 Ph 2 Designation: SDR 9.33 SDR 11.0 SDR 11.00 SDR 10.00 SDR 11.00 SDR 11.00 Actual ID: 0.660 0.860 1.077 1.328 1.554 1.943 Length (ft) Capacity in Thousands of Btu per Hour 10 340 680 1,230 2,130 3,210 5,770 20 233 gk 844 1,460 2,210 3,970 0 187 375?" - 677 1,170 1,770 3,180 40 160 321 580 1,000 1,520 2,730 50 142 285 514 890 1,340 2,420 60 129 258 466 807 1,220 2,190 70 119 237 428 742 1,120 2,010 80 110 221 398 690 1,040 1,870 90 103 207 374 648 978 1,760 100 98 196 353 612 924 1,660 125 87 173 313 542 819 1,470 150 78 157 284 491 742 1,330 175 72 145 261 452 683 1,230 200 67 135 243 420 635 1,140 250 60 119 215 373 563 1,010 300 54 108 195 338 510 916 350 50 99 179 311 469 843 400 46 92 167 289 436 784 450 43 87 157 271 409 736 500 41 82 148 256 387 695 Note: All table entries are rounded to 3 significant digits. • • • • •• • • • • • • •• • • • • • • • • • • • •••• • • • • .0•• • • • • • • • • •• •• •• •• • • • • • 0000 • • • • •0•• • • • •• • •0• • • 2006 National Fuel Gas Code Handbook QUIETSOURCE 25 kW OPERATING DATA STANDBY 25 kW GENERATOR OUTPUT VOLTAGE/KW - 60Hz 120M40V, 1-phase, 1.0 pf NOW Rated AMP CB Size 25 104.2 125 MOTORSTAFMNG Maodmum at 35% irk voltage cfrp with standard ahematon 60 Hz 40 KVA FUEL — Natural Gas and LP Vapor Only Fuel consumption — 60 Hz N.G Re Au: LP ft3Jhr.(galJhr- for reference only) Exercise 25% Cycle Load 60 137 24 (.66) 55 (1.54) 50% Load 206 82 (225) 75% Load 275 110 (3.02) 100% Load 343 138 (3.76) / COOLING Coolant cape* Engine rgus gaL) Radiator 6t(US gaL) Coolant fbwhrdn. Heat rejection to coolant Cooling airfbw System IIL(US gal) 60 Hz lL(US gal) 00 Hz 6TWhr. 60 Hz mIminn. (dm) 11.4(3.0) 5.3 (1.4) 6.1 (1.6) 67.8 (17.9) 95,E 41 (1438) CO6IBUSTION AIR REOUIFIEMENTS Flow at rated power 60 Hz malnrdn. (dm) 1.9 (67.5) EXHAUST Eideatl=et rated oulpt60Hz *win. (thn) Maxreoonmerdedbrdcpnsswe Kpa049) Exhaust temp. at rated output °C (°F) Exhaust outlet size N.P.T. (female) 52 (183.6) 5.0 (10) 538 (1000) 1.5" ENGINE Rated at RPM HP at rated KW Futon speed BMEP (PSI) 60 Hz 60 Hz 60 Hz m/min. (ftlmin.) 60 Hz 1800 40 310 (1020) 125 POWER ADJUSTMENT FOR ANENT CONDITIONS Temperature -1.65% for every 10°F above - °F Afflude -3% for every 1000 ft above -ft 77 600 MIND OUTPUT fn dB(A) at 23 feat whh generator mending atfull bad In cB(A) at23 feet wtih generator operating at exeraSe 69 58 • • TRANSFER SWITCH SPECIRCATIONS ffso equ6ped No. of Poles Current Rating Voltage Utirgy Rage Monitor Enclosure - NEMA 3R Return to Utility Exerciser 15 minute weekly UL 1008 List Dimensions Weight 4 =0 (VAC) ( Rck-up Dropout (IfxW xD') 2 200 250 80% 60% Standard 15 seconds Standard Standard 20x15x7 35 1bs. • • • • • •• • • .••• • • • • •• •• • • • • • • • .. •• • • •• • • • • • •• • • • • ▪ • • • • •• •. • • • • •••• ••• • • • •• • •• • • • • • • • • •••• • • • •••• • •••• • ••• • • ••• •••• • • • •••• • ••••• A/G - UG PROPANE TANK • 3/16" COATED CABLE CoNercg1E V .. ... • • • • • • •..•..I •• :• .lei • A .TH .ANCHORS .. ... .. • • .. (2 ON EACH END) • . • • . . .. . . .. • • • • • • • • • • • • • • • • • • • • • • • • • • . • • .. .. . �4 .. • . ••. • • . • • • • • • • • • • • .. • • • ... • • • • • • • • ... • • • • • • • • • • • • • • .. .• • 0 .. • • ANCHORING SYSTEM LP GAS SYSTEM INSTALLED PER N F P A SS and 54 By: THE GREAT AMERICAN SERVICEMAN, INC. 05/13!'2006 09:04 9543464655 6 arlean Welding & Tank Co1runitted to Quality & Servi e n ALL AMERICAN WELDING TANKS MEET OR EXCEED ASME STANDARDS AMERIGAS POMPANO PAGE 01 DETAILLABFJ. (04UOl LIFTING%me WATER GALLON .CAPACITY 1990 Gal, t. 3400 Ibs. 1000 Gal. 1760 lbs. 949L Ibs. •325 Gal. 60" 697 Ibs. . 4831bs. 150 Gal. . :257 sibs • •• for average : tag vassolo may 4*. Calmat. iiiSwit & %$ d riato. . We mom tonight 10 dump aped without Orly notbat ., • • • • • American Welding & Tank Harsco •.•. ; • • The people you know, the •tatdt.7 u mot; Flehable Tanks for the LP Gas Indus: 1917. • • • • • •• P. O. Box 81170 Camp tt0i. PA 170014870 I Auld alhtroi Group...; 1.800 -56 -TANKS (1-13004684115:41. • • • Trinity LPG - Aboveground Underground Tank About Locations Partnerships Page 1 of 3 Contact Us CONTAIN S'S Aboveground Tank Aboveground /Underground Underground Tank Vertical Tank Domes. Lids, etc. Color Chart Storage Vessels Truck Tank Barrels Transport Barrels Chlorine Tanks Ammonia Tanks CO2 Vessels Custom Vessels Bulk Storage Tanks Concrete Pier Drawings Aboveground / Underground LPG Tank General Specifications Conforms to the latest edition and addenda of the ASME Code for Pressure Vessels, Section VIII Division I. Complies with NFPA 58 and is listed by Underwriters Laboratories, Inc. All tanks are pre - purged and ready to be filled. Rated at 250 psig from -200 degrees F. to 125 degrees F. All tanks may be evacuated to a full (14.7 psi) vacuum. Please read and understand all warranty and installation instructions before in tank. Vessel Finish: Coated with epoxy red powder. (Tanks coated with the epoxy p, be buried). For aboveground use, tanks may be coated with TGIC powder. Applicable federal, state or local regulations may contain specific requirement: protective coatings and cathodic protection. The purchaser and installer are re for compliance with such federal, state or local regulations. tomer Si' View Large All vessel dimensions are approximate. • • • • • • • .. • .. • • • • • • • • • • • .... • • • • .... • • • • • • • • • • • .. .. • • .... • • • • .... • • • .. • ... • • • • https : / /www.trinitylpg.com/products. asp? productid= Q6UJ9A0005CV &prodname= Trinit... 12/20/2006 Trinity LPG Aboveground Underground Tank Page 3 of 3 WATER CAPACITY I OUTSIDE DIAMETER HEAD TYPE OVERALL LENGTH OVERALL HEIGHT W/ LID & SHROUD ASSEMBLY LEG WIDTH LEG SPACING WEIGHT 8" 18" + + 3'- 101/4" 101/8" 3' -0" 2451bs. • + • 1122.4 mm 257.2 mm 914.4 mm 111.1 kg + 4' -5 3/4" 12 3/4" 3' -6" 472 Ibs. :++ +• 1363.7 mm 323.9 mm 1066.8 mm 214.1 kg 4' -5 3/4" 12 3/4" 4' -0 1/4" 588 Ibs. : + + + • 1363.7 mm 323.9 mm 1225.6 mm 266.7 kg 4' -11 5/8" 15" 5' -0" 871 Ibs. • 1514.5 mm 381.0 mm 1524.0 mm 395.1 kg + + • 40.96" Hemi. + 5' -3 1/4" 16 1/4" 9' -0" 1729 Ibs. 1040.4 mm + mm 1605.0 mm 412.8 mm 2743.2 mm 784.3 kg • • • • • • •• • • • • •• • • • • • • • •• • • • •••• • • • • • • •••• • • • •• • • • • • • • •• •• • • • • • • • • • • • •••• • • • • •••• • • • •• • ••• • • • https : / /www.trinitylpg.com/products .asp ?productid= Q6UJ9A0005C V &prodname= Trinit... 12/20/2006 Trinity LPG - Aboveground Underground Tank GAUGE SERVICE MU fIVALVE; e ANODE CONNECTION ILL ALVE Page 2 of 3 AWAL °PENING`ARtNGEMENT RELIEF VALVE NAME PI1TE • • • • • •••• • • • •• • " ••• • •• • • httns : / /www.trinitvlpg.comlproducts .asp ?productid= Q6UJ9A0005 CV &prodname= Trinit... 12/20/2006 is co Propane; Proper location of ASME and DOT propane containers per NFPA 58 •• s • • • •• TO/641 on r. 1. X11[ lag' (Note 3) elate 4) ;31; _ 'uA tC - gyvlt Q ...e_raggit,�../ Underground Container Containers Notes: 1.) Regardless of its size, any ASME tank filled on -site must be located so that the filling connection and fixed level gauge are at least 10 feet from external sources of ignition (Le, open flame, window A/C, compressor, etc), intake to direct vented gas appliance or intake to a mechanical ventilation system. 2.) May be reduced to a 10 feet minimum for a single container of 1200 gallons water capacity or less If It is located at least 25 feet from any other LP-Gas container of more than 125 gallons water capacity. 3.) Minimum distances from underground containers shall be measured from the relief valve and filling or level gauge vent connection at the container, except that no part of the underground container shall be less than 10 feet from a building of line of adjoining property which may be built upon. 4.) Where the container may be subject to abrasive action or physical damage due to vehicular traffic or other causes it must be either, (a) placed not less than 2 feet below grade; (b) otherwise protected against such physical damage. I lag CenrtafACC Compressor (bniion Source) Crawl Space Opening n 10ft !! +Qt ny 0 1"?' yi n , !e Waa%1 C p a11�rtons r apaoYY ,► Page 2 of 2 _ • • •• • .- • ' - we__ ta Def pmant By: ,.nbel4 Asociates 2000 • • • • • • •• • • 1,411, • • • Web site development graphics, and hosting by Ennelt Associates • • • • • • • • • • • • Web Dovetopmerd By: • • • • • • • • • • • • • • • Erin ell & Associates • • • • ••• • • • • it, ig2000 • • ••• • • • • • • • • • • • • ••• • • • • • • • •• •• • • ••• • • • ••• • • • • • • s • • • • • r •• s• ••• • • r// www. aaccn- nrn»sinp.cnm/Filea/lnnnfdnt html • GASCO Holding Inc. All Rights Reserved 02000 LP GAS SYSTEM INSTALLED PER N F P A 58 and 54 By: THE GREAT AMERICAN SERVICEMAN, I.�c. ASTVIE TANK & 420# CYLINDER ANCHORING SYSTEM. MINUTE -MAN EZ ONE STEP ANCHORING SYSTEM Securely anchors tanks and cylinders In flood prone areas. Deluxe anchors have compacting disks and stoballzing hoods. Iterr► # Description MME-Z4430 - 36- economy anchor MME -Z1594 38' deluxe anchor MME -21596 48' deluxe anchor MM2375 Stainless steel strapping (100") MM2365 Coated 2 strop siing MM2382 Plastic sheathing MM2O10 _ Bolfa /nufs MME -7x741 Adaptor MM2 730 Anc?rcx rive mochrne • • • • • •• • • • • •• • • • • • • • • • • • - • • i••• • • • • • • • • • • •• •• •• •• • • • • • • • • • • • •••• • • • • • •• • ••• • • • RTS Automatic Transfer Switch • • • .. • .. •. • • .. • •. • • •• •• ••• •: ••. • • • ••, ••• _Aria ALT: r- ,i. a��PSes A new standard' of reli ility iMT ") - (34- N. ,am i Shores Village APPROVED BY r -E f CE WITH ALL EDERAL RULES AND REGULATIONS ZONING DEPTTANMAJI BLDG DEPT A'falfifilFWANII SUBJECT TO; 01. STA I t AND COUNTY mace DENERAC® POWER SYSTEMS, INC. This manual should remain with the unit. SAFETY RULES Important Safety Instructions A Read the following information carefully before attempting to install, operate o� service this A equipment. Also read the instructions and information on tags, decals, and' labels that ntgy / ! \ • • be affixed to the transfer switch. Replace any decal or label that is no lone,- ereegible.• • • DANGER! Connection of a generator to an electrical system normally suphl e f by an electric • utility shall be byineanss f_suitable trap er;equtpment so -as to Isolate Oi electrtc•sysiem em when th nerator: ts- Aperating fA_ri Ie 7f}T f''ph 7F �equwed Standby Systems or Article 7Q2 Optional Standby Systems, as,applrcablej.' Site/ire tq e ectrze system-by-these means may result m damage o generator and nfdy Wstilt-tn ittj or death to utility workers due to backfeed of electrical energy. The manufacturer cannot anticipate every possible circumstance that might involve hazard. The-warn: : ` ings in this manual, : =and on tags and decals affixed = to the unit are, therefore, not all - inclusive. If using a procedure, work .rnethod -.or operating technique the manufacturer does not specifically recommend, ensure _that it is safe for others. Also make sure, the = procedure, work method or operating technique -uti- lized does not render the transfer switch unsafe. - rou Li s arid_on and decals_ g�-afi�lus_ pub � _ ==to he eral _ XANGER, = ,WARNING AUTION- and N01 Eblocks'aieuse<d to alert person neito special instruction about a particular operation that may' be hazardous if performed incorrectly or carelessly. Observe them : carefully- The definitions are as follows: DANGER A • • • ▪ •••• • • • • •••• This symbol points out ititpoi�tant safety jnfor. oration that, if not followed,-could eridtsige personal safety and /or property of others. ` r; - This symbol = points out potential' explosion .F hazard. This symbol points out potential fire hazard. • • • • After this heading, read instructions that, if not strictly complied with, will result in personal injury or property damage. WARNING After this heading, read instructions that, if not strictly complied with, may result in personal inju- ry or property damage. CAUTION After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and /or property. -NOTE: After this heading, read explanatory statements that require special emphasis. These safety warnings cannot, eliminate the hazards that they indicate. Common sense and strict compli- ance with the special instructions while performing the service are essential to preventing accidents. Four commonly used safety symbols accompany the DANGER. WARNING and CAUTION blocks. The type of information each indicates follows: Any AC generator that is used for backup, power a NORMAL (UTILITY) power source failure occifs,- must be isolated from the NORMAL ( UTILITY) power source by means of an approved transfer switch. Failure to properly isolate the NORMAL and STANDBY power sources from each other may result in injury or death to electric utility workers, due to backfeed of electrical energy. • Improper or unauthorized installation, operation, service or repair of the equipment is extremely dangerous and may result in death, serious per- sonal injury, or damage to equipment and /or per- sonal property. • Extremely high and dangerous power voltages are present inside an installed transfer switch. Any contact with high voltage terminals, contacts or wires will result in extremely hazardous, and pos- sibly LETHAL, electric shock. DO NOT WORK ON THE TRANSFER SWITCH_. UNTIL ALL POWER VOLTAGE SUPPLIES TO THE SWITCH HAVE - BEEN POSITIVELY TURNED OFF. • Competent, qualified personnel should install, operate and service this equipment. Adhere strictly to local, state and national electrical and building codes. When using this equipment, comply with regulations the National Electrical Code (NEC), CSA Standard; C22.1 Canadian Electric Code and Occupational Safety and Health Administration (OSHA) have established. • Never handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT. Table of Contents • Because jewelry conducts electricity, wearing it may cause dangerous electrical shock. Remove all jewelry (such as rings, watches, bracelets, etc.) __before working on -finis equipment. e _on�snPnt standing :an me£aT or conefe e7.- iaee_ insurative - " iimats aver " °a -€ ry -wood- ii- rm work : °on -this equipment only while standing on such insulative mats. • Never work on this equipment while physically or mentally Keep the transfer _switch- enclosure =dobr closed and bolted at all times. Only qualified personnel should_be- permitted access to the switch interior. • In case of an accident caused by electric shock, immediately shut down the source of electrical power. If -this is not possible, attempt to free the victuntrom the live conductor but-AVOID DIRECT -CONTAMDILI THE V1CT.IM Ilse a noncondurt - -sncch. as a rope E rxr -board, _to nee - e Ti re cf ttsr If the vic is unconscious apps first aid =aid -get immediate medical help. When an-automatic transfer switch is installed for„._ '__ a standby generator set, the generator engine may crank and start at any time without warning. To "avoid possible injury that might be caused by such sudden start -ups, the system's automatic start cir- cuit must be disabled before working on or around the generator or transfer switch. Turn the genera- tor's AUTO /OFF/MANUAL switch to OFF'. Turn the generator's main circuit breaker OFF. Then place a "DO NOT OPERATE" tag on the transfer switch and on the generator. Remove the Negative (Neg) or ( -) battery cable. TABLE OF CONTENTS • • • • Safety Rules • RA • selnside•Fjont Cover Section 1 - General Information .1;> „Introduction........._._ • •. i • •• • ••.•.• • SOAP ..' • 3 ` Transfer bv"fc,i 1.4 Transfer Switch Enclosure ....•...• • • 1.5 Safe Use Of Transfer Switch....• • • • Section 2- Installation �'..:e.. • 1 ` 1ntrodiction to Instal 2.2 Unpacking • .•.• • • ••••• -- • 2 •• 3 • 2.4 - Connecting Power Source anioad Lines..:.:: - 2 Pole Mechar isn - - Connecting Start Circuit wires: 2.6 Auxiliary Contacts Section 3 Operation -- 3.1 Functional Tests & Adjustments 3.2 Manual Operation 3.2.1 Close to Normal Source Side 5 3.2.2 Close to Emergency Source Side 5 3.2.3 Return to Normal Source Side 5 3.3 Voltage Checks 5 3.3.1 Utility Voltage Checks 5 3.3.2 Generator Voltage Checks 6 3.4 Generator Tests Under Load 7 Section 4 - Installation Diagram 8 Section 5 Electrical Data 9 Section 6 -- Exploded Views & Parts Lists 04 Section 7 - Warranty Back Cover 1 GENERAL INFORMATION Section 1 — General Information RTS "W" Type Transfer Switch 1.1 INTRODUCTION This manual has been prepared especially for the purpose of familiarizing personnel with the design, ..application, - :installation, operation and servicing of he- appliquipent:= Reacf~the.-manual carefully � fiTWvI11helpt_ t otherwise be caused by carelessness, incorrect appli- cation, or improper procedures. Every effort has been expended to make sure that the • • • • • • 1.3 TRANSFER SWITCH DATA LABEL • A DATA LABEL is permanetifl�raffixed•to the transfer• • • • switch enclosure. Use this .t;aasfer switck only with • the _specific limits shown_on.the•DATA .LABEL and •- onother.;decals,af el t i' i-T ed -tor' • — �sw�teli. -� �� ____ -►.� pi operiy:=s� - sa . =s•.. .F• P. .cc! .. rAA-0_0A - When requesting informatitri t t•ctrdering pArts for this • • equipment, make sure to iriclude•all infpitfi2dtion frdih• " the DATA LABEL. • •••• • contents of this manual •are -loth accurate and cur •+ • • • • Record :the Model mid Sere: = rsr,tr� i� -Ike space rent The "manufacturer, however; reserves the right provided below, for�futurereference '� -to change, alter or otherwise improve the product at __ time without prior notice • • 1.2 - EQUIPMENTDESCRIPTION The automatietransfer switch is used for transferrin critical` electrical loads from a - UTILITY (NORMAL) older 50riKe :hi an EM'ilt - MODEL # -she -- transfer --switch prevents electrical feedback. between the- UTILITY and EMERGENCY sources. For that- reason, electrical codes require a transfer switch in all standby electric system installations. When the transfer switch is connected to the engine generator control panel, the control panel constantly monitors the UTILITY voltage and controls the opera- tion of the transfer switch. Should the UTILITY voltage drop below a preset value, and remain at this low voltage for a preset amount of time; the generator cranks and starts. After the gen- erator starts, the transfer switch transfers the load circuits to the generator, the generator then supplies the loads. When UTILITY returns above a preset Ievel the load is transferred back to the UTILITY and the generator shuts down. SERIAL -# 2 1.4 TRANSFEI SWITCH-ENCLOSUR The stan dard switch enclosure is a National Electn.cal Manufacturer's Association - (NE ) and UL 3R type. UL and NEMA 3R type enclosures primarily provide a degree of protection against falling rain and sleet: undamaged by the forniation of ice on the enclosure. 1.5 SAFE USE OF TRANSFER SWITCH Before installing, operating or servicing this equip- ment, read the SAFETY RULES (inside front cover) carefully. Comply strictly with all SAFETY RULES to prevent accidents and/or damage to the equip- ment. The manufacturer recommends a copy of the SAFETY RULES are made and posted near the trans- fer switch. Also, be sure to read all instructions and information found on tags. labels and decals affixed to the equipment. Two publications that outline the safe use of transfer switches are the following: • NFPA 70: National Electrical-Code • UL 1008, STANDARD FOR SAFETY - AUTOMATIC TRANSFER SWITCHES NOTE: It is essential to use the latest version of any stan- dard to ensure correct and current information. Section 2 — Installation RTS "W" Type Transfer Switch • INSTALLATION 2.1 INTRODUCTION TO INSTALLATION ♦ 2.4.1 2 -POLE MECHA▪ AIJSM •. . • • • • • This equipment has been wired and tested at the These switches (Figure 2.I1 *art. used 'with. a sine factory. Installing the switch includes the following phase system, when the sifitte'r.ifiase NEUTRAL lima • • • -_procedures: _..... � - is to be connected to a' NewtealMug= ar>t1.i,Sjtpt.toaie ...... • txonnectiog,f t ity -auU -genet __ leads. • Connecting the load leads. • Connecting any auxiliary contact (if needed) • Installing/connecting any options -and accessories.. _Testing ftine.lons - 2.2 UNPACKING Carefully unpack the transfer switch. Inspect closely for any damage that might have occurred during ship- Anent. The purchaser must file with the carrier any _ claims for loss- or . damage incurred while_in transit. 01=k-that a ckingma terial,is.completely_removed typica122 PBfis 7fa-- seer till &thanis .1. (400 Amp.Sliown) • • • • •••• • ... • - €rely the ;57.1 terror t MS MOIJNTtNG Mounting dimensions for the transfer switch enclo- sure are in this manual. Enclosures are-typically wall- - — mounted. See the 'Mounting Dimensions" drawing. A CAUTION A Handle transfer switches carefully when install - ing. Do not drop the switch. Protect the switch against impact at all times, and against construc- tion grit and metal chips. Never install a transfer switch that has been damaged. Install the transfer switch as close as possible to the electrical loads that are to be connected to it. Mount the switch vertically to a rigid supporting structure. To prevent switch distortion, level all mounting points. If necessary, use washers behind mounting holes to level the unit. 2.4 CONNECTING POWER SOURCE AND LOAD LINES ® 2.4.2 3 -POLE MECHANISM These switches (Figure 2.2) are used with a three phase system, when the three phase NEUTRAL line is to be connected to a NEUTRAL lug and is not to be switched. Figure 2.2 — Typical 3 -Pole Transfer Mechanism (400 Amp Shown) /z\ Make sure to turn OFF both the UTILITY (Normal) and EMERGENCY (Standby generator) power supplies before trying to connect power source and load lines to the transfer switch. Supply voltages are extremely high and danger- ous. Contact with such high voltage power sup- ply lines causes extremely hazardous, possibly Lethal, electrical shock. Wiring diagrams and electrical schematics are pro- vided in this manual. Power source and load connec- tions are made at the transfer mechanism, inside the switch enclosure. 3 INSTALLATION Section 2 — Installation RTS "W" Type Transfer Switch Solderless, screw -type terminal lugs are standard. The conductor size range is as follows: Switch Rating Wire Range - _.. _ .00A - - __; . 1)--#t4 -600 ulCM ors= Standb 461 to 730 feet (223m); - Conductor sizes must be adequate to handle the max- imum current to which they will be subjected; based on the 75 °C column of tables, charts, etc. used to size conductors. The installation must comply fully with all-apphcable- codes .- standards -and regulations - Before connecting w firing cables to terminals, remove any surface oxides from the cable ends with a wire - brush. All power cables should enter the switch -next to transfer mechanism terminals. If ALUMINUM con- -ar -- dductors e' used, apply corrosion inhibitor to con- ..-__ -- -. _ - ductors Tighten terminal lugs to the torque values as noted on the decal,located on_the inside of the door meter tighten-in-0' Terminal lugs,=carefully wipe -away any rxceS.s-4Or- i hIhlt 'All_po uer cables should enter the switch next to transfer mechanism terminals. 2.5 CONNECTING•START CIR'Cltl.T • .. WIRES • • Control system interconneGtio?4s consist of. UTILI'''• . . : 1 and 2, and _leads 23 .,1194 ,: - dpntro1• systems... -_ .- ir�teFC= osiriect_finds =art - IS separate from he AC RRq50.0,c Rd P twire gauge sizes for this w ends he ens ett,ati *; len of the wire, as recommenced betow: • • MAXIMUM WIRE LENGTH : RgtpmmEND 'WIRE :• .. SIZE'. • _• _ 460 feet (140m) No_ -18- "AWG' Standb 461 to 730 feet (223m); - No. 16 AWG. 0 e - 731 to 1,160, feet (354m) No. 14 AWG. Closed 1,161 to 1,850 feet (565m) No. 12 AWG. 2.6 = AUXILIARY -CONTACT If desired. there are Ai diary ontaefs ors the trap s , - w itch. -to operate c :stot € accesso - . or atttrcr �.. gu=t', you er oiiT must l ncelyd terminal♦ See Figure 2 Contact operation is shown in the following chart: . ... • CAUTION A A Use a torque wrench to tighten the conductors, being sure not to overtighten, or damage to the switch base could occur. If undertightened, a loose connection would result, causing excess heat which could damage the switch base. Connect power source load conductors to clearly marked transfer mechanism terminal lugs as fol- lows 1. Connect UTILITY (NORMAL) power source cables to switch terminals Ni, N2, (N3). 2. Connect EMERGENCY (STANDBY) source power cables .to transfer switch terminals El, E2. (E3). 3. Connect customer LOAD leads to switch termi- nals Ti. T2. (T3). 4. Connect neutral conductors of UTILITY, EMERGENCY and customer LOAD to the neutral block. - Conductors must be properly supported. of approved insulative qualities, protected by approved conduit. and of the correct wire gauge size in accordance with applicable codes. Be sure to maintain proper electrical clearance between live metal parts and grounded metal. Allow at least 1/2 inch for 100 -400 amp circuits. NOTE: Auxiliary Contacts are rated 10 amps at 125 or 250 volts AC. DO NOT EXCEED THE RATED VOLTAGE AND CURRENT OF THE CONTACTS. Figure 2.3 - Auxiliary Contacts 300 -amp through 400 -amp Switches Auxiliary Contact (Actuated) Auxiliary Contact (Non - Actuated) 4 Side views shown in Utility position ,,— Switch Position- Standb C. . t. N. .il O•l 0 e - Closed -. -- Common to Normally Closed Closed Open NOTE: Auxiliary Contacts are rated 10 amps at 125 or 250 volts AC. DO NOT EXCEED THE RATED VOLTAGE AND CURRENT OF THE CONTACTS. Figure 2.3 - Auxiliary Contacts 300 -amp through 400 -amp Switches Auxiliary Contact (Actuated) Auxiliary Contact (Non - Actuated) 4 Side views shown in Utility position Section 3 - Operation 3.1 FUNCTIONAL TESTS AND ADJUSTMENTS RTS "W" Type Transfer Switch • 3.2.1 CLOSE TO NORMAL 3OURCCSIt1E Before proceeding, verify the. piti • on of the swi p tch . -- Following transfer switch. installation and intercon by observing window A' in .ire 3.1•on Rage 6. �f • • • ; • wmdo« 'A reads ON the •contaets are elt ti in-tl ne on In ect.#he- entireinstallation carefully. A • . •�• -if rtn l -pose ri, ro further :act is re -u irgd . ticorTipefent, "yea fi3�fietirrcran s�iottld respect - A reads "OFF • proceed unth�t n -� --The installati hould comply strictly: with all apple : _ . : _, .:.. -,, $_ .. ,. *.• -••• cable codes, standards, and regulations. When abso- Step 1: With the handle 4144441 jll41 `to the .actuating . lutely certain the installation is proper and correct, shaft, move handl: het tee direction of (I ... :. complete a functional test of the system. arrow on the switch over LtutiL.ft stops OPERATION • • • CAUTION Perform functional tests in the exact order pre- ' sented in this manual, or damage to the switch - could be done. — DO NOT FORCE. • Retase 144.4d1c slowj•' •' to allow :;She sp- in_g -in to switch bo?c relax ON" now appears = Window L.W and `OF'F appears in-Window--B". ♦ 3.2.2 CLOSE TO EMERGENCY SOURCE SIDE _Before proceeding,; verify the_posittnn of the switch by observing window "B in Fi urez 1 on' age _lf window "B reads "ON'.'; the contacts are closed, r h EMERGENC # TANDBY}p ri ito-T is required. if it .reads t s:pt < ' "> j t €tt -IMPORTAN Iefore proceeding with functional tests read and make sure-you understand all instructions andinformatinn in -this section. Also read the ionr =T taoii nd-jn'.1i fions o labeTs and decals affxed opens -oi aeeessones- t-be installed and review themaperat orr. p I: With -the _handle attached to the_ g shaft, move the handle in the direction of the arrow on the - switch cover.tntil it stops _JDO NOT FORCE. Release handle slowly to allow _ - the spring m the switch box to relax_ "OFF' now appears in Window "A' and "ON" appears - in Window ,.8,. A Do NOT manually transfer under Toad. Disconnect transfer switch from all power sourc- es by approved means, such as a main circuit breaker(s). A manual HANDLE is shipped with the transfer switch. Manual operation must be checked BEFORE the transfer switch is operated electrically. To check manual operation. proceed as follows: 1. Turn the generator's AUTO /OFF /MANUAL switch to OFF. 2. Turn OFF both UTILITY and EMERGENCY power supplies to the transfer switch, with whatever means provided (such as the main line circuit breakers). 3. Note position of transfer mechanism main con- tacts by observing display windows in W and "B- in Figure 3.1 on page 6 as follows: • Window "A' ON, Window "B" OFF - LOAD termi- nals (T1, T2, T3) are connected to utility termi- nals (N1, N2. N3). • Window "A OFF, Window "B" ON - LOAD termi- nals (T1, T2. T3) are connected to emergency terminals (El. E2, E3). A CAUTION ®► A Do not use excessive force when operating the transfer switch manually or the manual handle could be damaged. ♦ 3.2.3 RETURN TO NORMAL SOURCE SIDE Manually actuate switch to return Window A' to the "ON" position. 3.3 VOLTAGE CHECKS • 3.3.1 UTILITY VOLTAGE CHECKS I. Turn ON the UTILITY power supply to the trans- fer switch with whatever means provided (such as the UTILITY maim line circuit breaker). Q DANGER ,A, A PROCEED WITH CAUTION. THE TRANSFER SWITCH IS NOW ELECTRICALLY HOT. CONTACT WITH LIVE TERMINALS RESULTS IN EXTREMELY HAZARDOUS AND POSSIBLY FATAL ELECTRICAL SHOCK. 2. With an accurate AC voltmeter, check for correct voltage. Single -phase utility supply: Measure across ATS terminal lugs NI and N2; NI to NEUTRAL and N2 to NEUTRAL. Three -phase utility supply: Measure across ATS terminal lugs NI to N2, N2 to N3, and NI to N3. OPERATION Section 3 — Operation RTS "W" Type Transfer Switch Figure 3.1— Actuating Transfer Switch DANGER: Do NOT manually transfer under Toad. Disconnect transfer switch from all power sources by approved -means -such as amain:- circuit breaker(s) Detail of instructions 'prtnt'ed-o`n•transfersvrttch • • • • • •• • • • • • • •• • • • . • • •• • •. • • • i•..• . •••• ... _ • • • -S - • ••••• • --• s_ -1- ••••.• MANUAL CPE:=ATIO^t D.. 'l'T CF:,RATE THE SAATCI, IS UM:C? I.O.AI > 5E: kAwUAI 11,10,1 CV ,i A ^,CC C? -RA:! 11.- =ME i 040EC7I0I: r5:7,T: MAMA: -_ _- .(L;RATI ID 110 4 .- 6iR..C?tfry • •••• • •••• • • ••• • • • • • • UT tI Attach- handle '1 to actuating shaft. - Move handle down = then release slowly_ tQallow �niernaf spring .to`.relaz.` End View NOTE: Return handle to storage position in enclosure when finished with manual transfer Measure across ATS terminal lugs N1 to NEUTRAL, N2 to NEUTRAL, and N3 to NEUTRAL. 3. Three -phase only. Locate the 3 phase power monitor relay. Verify the following: 208 Vac system - LED Green and ON The factory setting is 80% of nominal voltage (208 Vac systems = 166 Vac dropout) 4. If the LED indicator is Red or not ON then it will be necessary to adjust the power monitor relay setting. Rotate the adjustment potentiometer in a counter - clockwise direction until the LED turns ON. At this point the 3 phase power monitor relay is the most sensitive to irregular power line con- ditions. NOTE: If the power monitor does not operate properly, check that all three voltages are present, and are of the correct voltage level and phase rotation. To change phase rotation, turn off the utility supply, interchange 2 of the utility power phases. ® DANGER -A A FAILURE TO TURN OFF THE UTILITY SUPPLY BEFORE WORKING ON THE UTILITY CONNEC- TIONS OF THE ATS WILL RESULT IN EXTREMELY DANGEROUS AND POSSIBLY FATAL ELECTRICAL SHOCK. 5:= When certain that UTILITY supply voltage s'cor- rect and compatible with transfer switch ratings, turn OFF the UTILITY supply to the transfer switch. ♦ 3.3.2 GENERATOR VOLTAGE CHECKS 1. On the generator panel, set the AUTO /OFF/ MANUAL switch to MANUAL position. The gen- erator should crank and start. 2. Let the generator stabilize and warm up at no- load for at least five minutes. 3. Set the generator's main circuit breaker (CB 1) to its ON or CLOSED position. Section 3 — Operation A DANGER A 4 PROCEED WITH CAUTION. GENERATOR OUTPUT VOLTAGE IS NOW BEING, DELIVERED .-Ti - TRANSFER SWITCH TERMII4ALS ONTACT_.z RTS "W" Type Transfer Switch OPERATION • • • • 3.4 GENERATOR TESr1S•UNRER LOAD ' . Set the generator's mAM x'Ifcuit 1 rea'Iter to $s OFF or OPEN position. • • Manually actuate the tit ?Ale" swiP,c i. wain con- tacts_totheir.emergency-.t by) Position ,iieler. _ to °ManualOpera-tior �a — _ _+ 0 startthe= generator; -S-tt eAf3I E3 /CVFAAAItlt31 - s¢ switch to MANUAL. Wlittelii4ine starts'. let it sta- . bilize for a few minutes • • •••• Turn the generator's niin,ci=cuit brea1 er to 44 .... ON or CLOSED position'The'gener"dt'dr naw ers ail LOAD circuits.-Cheek generator 5eratton _- under load as follows: Turn ON electrical loads to the full rated watt- age /amperage capacity of the generator. DO NOT OVERLOAD. With maximum rated -ioad_.applied,. _rhec volt ge and frequency across transfer swig -term- inals El nud-E2;LVoitage_`shouldti_ eater than 00 voas 208VAC , syster, €k- €xl (24OVA t mL tre e py s c be greater than-59 z Let the generator run under rated load for at least 30 minutes_ With "unit "running. listen for unusual noises, vibration, overheating, etc., that might indicate a problem. 5. When checkout under load is complete, set main circuit breaker of the generator to the OFF or OPEN position. 6. Let the generator run at no -load for several minutes. Then, shut down by setting the AUTO/ OFF/MANUAL switch to its OFF position. 7. Move the switch's main contacts back to the UTILITY position. For example, load connected to utility power supply. Refer to "Manual Operation ". Handle and operating lever of transfer switch should be in down position. 8. Turn on the utility power supply to transfer switch, using whatever means provided (such as a utility main line circuit breaker). The utility power source now powers the loads. 9. Set the generator's AUTO /OFF /MANUAL switch to its AUTO position. -The system is now set for fully automatic operation. -'WITH LIVE-TERNITNALS -LSULT5IN EXTREMELY -DANGEROUS AND 'POS5SIBLY-FATAL- ELECTRICAL ;— SHOCK. 4. With an accurate AC voltmeter and frequency meter. check the no -load, voltage and frequency. Single -phase generator supply: Measure across ATS terminal lugs El to�E2; E) _ _ to NEUTRAL and E2 to NEUTRAL. a. Frequency - .60-62 Hz b. Terminals E1 to E2 .......... ...:....:240 -246 VAC e. Terminals E1 to NEUTRAL. ...:.:120- 123 -VAC --_ d. Terminals E2 to NEUTRAL .....:....._120 -123 VAC - Three -phase generator - supply Measure across ATS ter nurai luga fJ to E2, E2 €rI Measure across AT'S terminal iu s E 1 to NEUTRAL, E2 to NEUTRAL and E3 to NEUTRAL a. Fre ueric ...60 -62 Hz b. Terminals E1 -E2, E2 -E3, EI -E3 ....208- 212VACor 470 -485 c. Terminals E1 -N. E2 -N, E3 -N 120:122VAC or 272 -282 It will also be necessary to verify that the phase rota- tion of the utility matches the phase rotation of the generator. This can be clone by using a phase rotation indicator. 4. • CAUTION A Failure to do so may result in damage to certain rotary equipment. 5. When certain that UTILITY supply voltage is cor- rect and compatible with transfer switch ratings, turn OFF the UTILITY supply to the transfer switch. 6. Set the generator's main circuit breaker (CBI) to its OFF or OPEN position. - 7. Set the Auto /Off/Manual switch to the OFF position to shut down the generator. NOTE: Do NOT proceed until generator AC output volt- age and frequency are correct and within stated limits. If the no -load voltage is correct but no- load frequency is incorrect, the engine governed speed probably requires adjustment. If no -load frequency is correct but voltage is not, the voltage regulator may require adjustment. 7 • INSTALLATION csi Section 4 — Installation Diagram RTS "W" Type Transfer Switch Installation Diagram - Drawing No. OF6401 • • • • • • • • ==- • • • • SO • • • • • • • • • • • • • • • • • - • - - ." • _ _ _ • • • • • • • • • • • • • • • • - • ■ ■ . _ .1, E 8 QT SERIES ENGINE GENERATOR CONNECTION PANEL —N1 N2- ,-23 194 UTILITY SUPPLY FROM; SERVICE DISCONNECT / SINGLE PHASE NEUTRAL BLOCK NEUTRAL BLOCK GROUND y r NOTE: 178 AND 183 CONNECTIONS ARE NOT USED IN THIS APPLICATION NOTE: E3, N3 AND T3 WIRES ARE ONLY USED ON 3 PHASE SYSTEMS U3 NOTE: POWER LEADS AND TRANSFER SWITCN'..' LEADS MUST DE RUN IN TWO DIFFERENT CONDUITS • • • •• • • • • • • • • • • ••• • j;i • • • • •, • • •• L v• .••ti•;1 • • • • •• •• • • • '.• • ♦ • CUSTOMER LOAD; (DISTRIBUTIQN PANEL) i;. ••• 1 • • • le • 1 • • • •I • • • • • • 0 tit m • 0I v a ••• ••• m • • • • m • • • • • y..1-- I g • ••• • • • • • • •• • • • • • • • • • • •• •• • ••• • • lfi , , , , , , , , , , ELECTRICAL DATA --► 4--- -• Section 5 — Electrical Data RTS "W" Type Transfer Switch Wiring Diagram /Schematic - 400 Amp, 120/240V, 2 -pole Switch — Drawing No. OD3819 -A LEGEND C - CONTACTOR ACTUATING COIL GTS - TRANSFER SWITCH CONTACTOR TR - RELAY, TRANSFER TS - TERMINAL STRIP (CUSTOMER CONNECTION) LS1,LS2,LS3 - LIMIT SWITCHES, ACTUATOR F1,F2 - FUSE 5A SENSING 10 NOTES: 23 ---® 23 194 -194 ALL CONTACTS SHOWN WITH TRANSFER SWITCH IN UTILITY POSITION. Section 5 — Electrical Data RTS "W" Type Transfer Switch Wiring Diagram /Schematic - 400 Amp, 120/240V, 2 -pole Switch — Drawing No. OD3819 -A N2A N2A N1A N1A • • • • • •• • • 1111s Isoti ELECTRICAL DATA • • • • •• • • • • • • • •• • • • •••• • • • • ♦ ••••s* • • •-• •• 0. .•ss • •4•••• • • • • • • •••• • • • •••• • • • • • • ••• • • • • . .• N1A N1A-- 126 E 23 - N1A 194 N2A N1A N1A 194 N1 N2 r 0® 23 1 0 194 0 0 rn TS 11 ELECTRICAL ~ DATA 1 ---► Section 5 — Electrical Data RTS "W" Type Transfer Switch Wiring Diagram /Schematic - 400 Amp, 120/280V, 3 -pole Switch - Drawing No. OD3818 -A TR PM • • • • • •• • • • •• • • • • • • • 000000 LEGEND C. - _CONTACTOR ACTUATING COIL GTS - TRANSFER SWITCH CONTACTOR PM - POWER MONITOR, 3 PHASE UTILITY TR - RELAY, TRANSFER TS - TERMINAL STRIP (CUSTOMER CONNECTION) LS1,LS2,LS3 - LIMIT SWITCHES, ACTUATOR F1,F2 - FUSE 5A SENSING 12 NOTES: 1.) ALL CONTACTS SHOWN WITH TRANSFER SWITCH IN UTILITY POSITION. 2.) FOR SINGLE PHASE OPERATION, ADD JUMPER WIRE FROM PM TERMINALS 1 TO 8. Section 5 - Electrical Data RTS "W" Type Transfer Switch Wiring Diagram /Schematic - 400 Amp, 120/280V, 3 -pole Switch — Drawing No. OD3818 -A N2A N2A — • • • 1 • • • • • 1 ELECTRICAL �~ DATA --► • • --r • • • • • • • •• • •• • • • N31• •. •• • N1B N1B • • • • N1 N2 • • _ •••••• •••••• • • • • • • •• •••• • ••••• ••• • • • • • 194 23 N1B N1B 205 = — El 23 194 N1B N1A N3 N2A 1 N3 N2A PM 23 °- N2A 194 N1B N2A N3 N1B N2A N2A N1 N2 j 0 0 ® ® F N � J ® 0 ®!® ®!® 0 0 TS 13 PARTS ,,rr�i STS (0) Section 6 — Exploded Views and Parts List RTS "W" Type Transfer Switch 400 A, 120/240V, 2 -pole Switch Assembly - Drawing No. 0F6274$ -C Section 6 — Exploded Views and Parts List ITEM PART NO. RTS "W" Type Transfer Switch 400 A, 120/240V, 2 -pole Switch Assembly - Drawing No. OF6274$ -C CITY. ESCRIPTION • • • • • •• • PARTS LISTS • • • 1 OD7294 2 0A7822 3 026902 4 -. 2C7907a u245z6 6 - 057329 #1 09038& 0A1495 13" 063617_. 14 047411 15 0A1661 16 OF4034 _0F5935 I8 0F5939 iS 008308 1 XFER SW -W 400A600V2P 6 LUG SLDLSS 600/250 - 1/0X1/4 -28 5 SCREW HHTT #8-32 X 1/4 CZ - COVER LUG 2R- 300/400AMP - SCREW RTF5 7.618 X3 /4 CZ 'LUG- SLDLSS 356 - #6 X 13/32 AL/CU �`w • •. • • ' • • •• • • 000000 • • • • •••.•. •.•• • • • • �.•._• • • •:.. • •••••• 7 027482 1 WASHER SHAKEPROOF EXT 5/16 STL 8 022097 9 WASHER LOCK M6 -1/4 9 008275 4 SCREW PPHM DSEMS M4 -7 X 10 ZNC 10 ** _ 002806 1 FUSEBLOCK 30A 600V 2 POS W /SQ 3- SCREW HHTT- M6 -1.0 X 12 ZINC:-.,„--< 6 SCREW HHTT M4 -0.7 X 10 BP = . RELAY PNL 12VDC DPDT 10A @240VA SCREW HHC M6 -1.0 X 16 G8.8 RIVET POP .156 X .675 AL ASSYTERMINAL BLOCK 300- 400A:___ RTS 3R ENCLOSURE 24X36X;10 - COVER, NEMA 3R XFER SWITCf:ENC-' DECAU-TERMINAL SHOCK FfAZARFT -- =DECAL TERMINALSTRIP WASHER NYLON - -- 22 0E8443 1 ` DECAL,SWITCH RATING 23 064101 6 NUT HEX FL WHIZ 3/8 -16 :24 0F5940 1 SUBPLATE - =- 25 .. 087680 1 NUT WING M6 -1.0 26 063378 4 HOLDER CABLE TIE 27 ' 064761 _ 4 TIE WRAP UL 5.6 X .10 NATL 28 063321 1 HANDLE XFER SWITCH 1 -400A 29 073590A 2 FUSE 5A X BUSS 30 OD3587 1 DECAL FUSE REPLACEMENT 31 067210A 1 DECAL GROUND LUG 32 0A9457 1 DECAL NEUTRAL 33 OD4545 1 DECAL MANUAL OPERATION 34 * OF6129 1 DECAL TEST SEQUENCE 3P TS 3R 35 081221 1 DECAL -UL LIST HSB 36 0A8261 6 SCREW HHC 114 -28 X 5/8 .625TH 37 022473 6 WASHER FLAT 1/4 -M6 ZINC 38 ** 048850 1 BLOCK TERM 20A 5 X 6 X 1100V 39 * ** "" OF6521 1 DECAL TRANSFER SWITCH RTS 40 022129 1 WASHER LOCK M8 -5/16 41 091472 1 DUCT WIRING 1 X 1.5 (24" LG) 42 091472A 1 COVER WIRE DUCT 1 tN (24" LG) 43 067989 2 NUT HEX FL WHIZ M8 -1.25 44 0F6273A 1 HARNESS,400A 2POLE 1PHASE" :- •••••• . • • • • •••• •••• * CENTER DECAL ON INSIDE OF THE COVER (ITEM #18) ** ITEMS INCLUDED WITH HARNESS * ** INSTALL ON FRONT OF THE COVER (ITEM #18) 15 PARTS /"C4 �� STS (:), Section 6 — Exploded Views and Parts List RTS "W" Type Transfer Switch 400 A, 120/208V, 3 -pole Switch Assembly - Drawing No. OF6276$ -C • smisirimunwrimmimmi■miiman®®®luRmoilmew� Mkt au !i.a 1 INE ` "' !� `-' I 16 Section 6 — Exploded Views and Parts List JTEM 1 PART NO. RTS "W" Type Transfer Switch 400 A, 120/208V, 3 -pole Switch Assembly - Drawing No. 0F6276S -C QTY. DESCRIPTION OD7295 0A7822 026902 - -= 1 XFER SW -W 400A600V3P LUG SLDLSS 600/250 - 1/0X1/4 -28 SCREW HHTT #8 -32 X 1/4 CZ C7907F -- _ 2 COVER LUG 3P 300 /400AMP —1.-5.--'-- 024526 =- -- - - -- t SCREWHNTT 5/16 -18X 3/4 CZ - ___ 6 — 057329 ° _ -'.. 7 - - LUG- SLDLSS 350- #6 X 13/32 AL/CCt'-=' 7 027482 1 WASHER SHAKEPROOF EXT 5/16 STL 8 022097 12 WASHER LOCK M6 -1/4 9 008275 4 SCREW PPHM DSEMS M4 -7 X 10 ZNC 10 ** OD2806 1 FUSEBLOCK 30A 600V 2 POS W /SQ 090388 3 SCREW HI-ITT M6 -1.O X 12 ZINC. 0A1495 6__ _ :_ SCREW HHTT M4 -0.7 -X 10 BP 063617 1 = RELAY PNL 12VDC DPDT 10A @240VA 047411 2 - " SCREW HHC M6 -1.0 X 16 G8.8 0A1661 2 RIVET POP .156 X .675 AL 0F4034 1 t; ASSY TERMINAL BLOCK 300 -400A 0F5935 _- �: 1 y _,;; RTS 3R ENCLOSURE 24X36X10 - -_ 0F5939 - 1 COVER NEMA 3R XFER SWITCH EN 00830/3-f=±" - _ _._- DECAL TERMINAL SHOCK FtAZN DECAL TERMINAL STRIP 616a 6 WASHER-NYLON_ 0F5569 1 DECAL SWITCH RATING 064101 6 NUT HEX FL WHIZ 3/8 -16 OF5940 -'- 1 = SUBPLATE 087680 1 `. NUT WING M6 -1.0 063378 6 HOLDER CABLE TIE 064761 - . - 6' TIE WRAP UL 5.6 X .10 NATL 28 063321 1 HANDLE XFER SWITCH 1 -400A. 29 073590A 2 FUSE 5A X BUSS 30 OD3587 1 DECAL FUSE REPLACEMENT 31 067210A 1 DECAL GROUND LUG 32 0A9457 1 DECAL NEUTRAL 33 OD4545 1 DECAL MANUAL OPERATION 34 0F6129 1 DECAL TEST SEQUENCE 3P TS 3R 35 081221 1 DECAL -UL LIST HSB 36 0A2284 2 SCREW SWAGE #8 -32 X 1/2 ZYC 37 063306 1 POWER MONITOR 3 -PHASE 160 -240V 38 ** 066972 1 SOCKET RELAY OCTAL 8P 300V -10A 39 * ** '= OF6521 1 DECAL TRANSFER SWITCH RTS 40 022129 1 WASHER LOCK M8 -5/16 41 091472 1 DUCT WIRING 1 X 1.5 (24" LG) 42 091472A 1 COVER WIRE DUCT 1 IN (24" LG) 43 067989 2 NUT HEX FL WHIZ M8 -1.25 44 0A8261 9 SCREW HHC 1/4 -28 X 5/8 .625TH 45 022473 9 WASHER FLAT 1/4 -M6 ZINC 46 ** 048850 1 BLOCK TERM 20A 5 X 6 X 1100V 47 OF62736 1 HARNESS 400A 3POLE 3PHASE • • • • • • PARTS � ■l�j USTS • • • • - • • • • • •• • • • • • • •..••• • • • • • • •••• •••• ••••• - • • • • * CENTER DECAL ON INSIDE OF THE COVER (ITEM #18) ** ITEMS INCLUDED WITH HARNESS * ** INSTALL ON FRONT OF THE COVER (ITEM #18) 1 7 Section 7 — Warranty RTS 'V" Type Transfer Switch • • GENERAC POWER SYSTEMS STANDARD TWO -YEAR LIMITED jWM 1ANTY FOR GENERAC TRANSFER SWITCH SYSTEMS ** :.• • • • •• • •• NOTE: ALL UNITS MUST HAVE A START -UP INSPECTION PERFORMED BY AN AUTHORIZEp•Q:CDikRAC DEADER • • For a period of two (2) years or two thousand (2,000) hours of operation from the date of sale, which ever occurs first, Genera• ovnerSystenl:4 V! 1p�4 at its • • • option, repair or replace any.part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authh4iz8 f rtified G1enerac Power • • • •' Systems Dealer, or branch thereof, is found to be-defective under normal use and service, in accordance with the warranty schse Ii I �Ct forth brtow -- • Pauip r •• •. ment that the purchaser /owner_:claims to be defective must be examined by the nearest Authorized /Certified Generac Power tyssemseealer, a442'1i rtreteof.� • • •ate This warranty applies only to Generac Power Systems Transfer Switch used in "Standby" applications, as Generac Power Syfttms inc. has definedTransfer Switch applications, provided said generator has been initially installed and/or inspected on -site by an Authorized /Certified G*tlia: 4wer Systems Dealer, or • branch thereof. Scheduled maintenance, as outlined by the generator owner's manual, must be performed by an Authorized/Certified lienerac PEu/2tS4stems Dealer, or branch thereof. This will verify service has been performed on the unit throughout the warranty period. This warranty is limited to and.avileble only or Liquid - cooled units. r • • • • • ••• • • WARRANTY SCHEDULE •. YEAR ONE — One hundred percent (100%) coverage on mileage, labor, and parts listed. • ALL COMPONENTS YEAR TWO — One hundred percent (100 %) coverage on parts listed. • ALL COMPONENTS — PARTS ONLY Guidelines: • • Travel allowance is Itmited to 300 miles maximum, and 7.5 hours maximum (per occurrence), round trip, to the nearest authorized Generac Service Facility, and only applies to permanently wired and mounted units. • Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized /Certified Generac Power Systems Dealer, or branch thereof. • A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the generator set. If a Non Generac PowesSystetils, Inc. Transfer Switch is substituted for use and directly causes damage to the generator set,-no-warranty coverage shall apply. ---- -- •All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, Procedures and Flat Rate Manual. • Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable. • Unit enclosure is only covered during the first year of the warranty provision. • Use of Non - Generac replacement part(s) will void the warranty in its entirety. • Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty typ rovision. THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING: 1. Any unit built/manufactured prior to July 1, 2004. 2. Costs of normal maintenance (Le. tune -ups, associated part(s), adjustments, loose/leaking clamps, installation and start -up). 3. Any failure caused by contaminated fuels, oils, coolants /antifreeze or lack of proper fuels, oils or coolants /antifreeze. 4. Units sold, rated or used for "Prime Power ", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems has defined Prime Power, Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition and warranty. 5. Failures caused by any external cause or act of God such as, but not limited to, collision, fire, theft, freezing. vandalism. riot or wars, Lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust. 6. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing. 7. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing. 8. 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). 9. Damage related to rodent and/or insect infestation. 10. Failure due to misapplication, misrepresentation, or bi -fuel conversion. 11. Telephone, - facsimile, cellular phone, satellite, Internet, or any other communication expenses. 12. Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.). 13. Overtime, holiday, or emergency labor. 14. Modes of transportation deemed abnormal (refer to Generac Power Systems Warranty. Policies, Procedures and Flat Rate Manual). 15. Steel enclosures that are rusting due to improper installation, location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised. 16. Any and all expenses incurred investigating performance complaints unless defective Generac materials and /or workmanship were the direct cause of the problem. 17. Starting batteries. fuses, light bulbs. engine fluids, and overnight freight cost for replacement part(s). THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an mplied warranty lasts, so the above limitation may not apply to purchaser /owner. GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser /owner. Purchaser /owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser /owner specific legal rights. Purchaser /owner also may have other rights that vary from state to state. Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 531 87 Ph: (262] 544 -481 1 • Fax: (262] 544 -4851 Bulletin 0166260SBY / Printed in U.S.A. 6.04 Part No. OF6351 Revision B (1 1/18/05) Printed in U.S.A. EXISTING METER 200AMP GRADE r EXISTING PANEL "A" CIRCUIT BREAKER 200AMP 120V/240V EXISTING GROUNDING \/ X/ \/ \/ X/ <.&X/ , FROM FPL }}} gis DEC 1 2 2007 Lj Y: .. ................. (3)3/0 THW CU. (1)#4 GR 2" C. 200AMP T/S (3)3/0 THW CU. (1)#4 GR 2" C. (DI zI fat 1 0 fX I CD I #2 GROUNDING 1- AUTOMATIC TRANSFER SWITCH (3)3/0 THW CU. (1)#4 GR 2" C. . T 1\kami Shores Vill.FcP APPROVED FY - ... 41 7,--,,l,tu,ors ImE:p: DC; DEPT SUaJECT TO CCM --,.'.';TF P '7.-, cou,NTY "I'di i )‘ Au, 11 I yr V ANCE \ NI IT-1 ALL FEDERAL RULES AND REGULA7ONS EXISTING PANEL 200AMP NOTE: ADD SIGN ON SERVICE STANDBY GENERATOR MAY ENERGIZE AT ANY TIME GENERATOR 25 KW • • • • • • • • • • • • • • • • • • • • • • • • 410. 7. — 0" MSL • • ICONC. FOUNDATION] • • • \17-X \If Xy-X/TXTX7X,/ \c/ \v X/ \<„, x„, \v \<„, ,„<„, X/ X,/ X/W X," X/ -X/ --XTX/S.,y X/A- X,/ X, • • • A //A A /A A J./\; A A 7/> A /2/. /./ A A A A A /2/. A ././A A A \A /A A A EXISTING GROUNDING = EXISTING - GROUNDING ROD. ■ Nov -1 2 2007 Jorge A. Pomerantz, P.E. FL. LIC. # 55326 VALID FOR (1) JOB ONLY VALID WITH RAISED ENGINEER SEAL SWIM • • • • /i!Si • •0W8g • ,f1g.e6 • • 44an .4141 • • •• • • • • • • • 1 • • •• • • • • • • • • • • • • • • REVISIONS DATE ELECTRICAL GENERATOR JOB NUMBER 1107-002 SHEET 1 of 4 • SKETCH OF SURVEY BEARING NOTE: Bearings shown hereon are based upon an assumed meridian. N•89-5925 W. is assumed to be parallel with N.E. 99th Street as shown hereon. FLOOD ZONE INFORMATION: Community No.: 120652 Panel No.: 0093, Suffix G Flood Zone: X (Outside 500 Year Flood Plain.) lU .Ir 4.81 °98'48 "E. I0G.49'(M.) 1---- f:-:6.. IOG.90'(8.) 9oc? =. „y� 0 -n 0 •" M O 04 ••U 5, 0 J CO NORTH SCALE : t" 20' 4^ 0.egK a pp I04. GO' CO.) 01.91' ?5'W 10G.97' (M.) J� WALL 4/ \SET FENCE PIE 0.I'9•- 0.99 3 v 7.0' WALL.CONC. ANG FENCE 60.9'0.- O z 15' A L L ' Y 1' 49PNALT N.01•90'48 "E. 10.11' N . ' 4 " . 90. 99' (M. 41.91' 4'C. L. P. 11 .0 (8. ) F O.7'C.e .WALL •` ?b•1' \\ II 9?' • ' BArmeaue •. a N • • ' C O N C . 1.71' • . O 14'. WALL • 90.G'N.Z 0.99'C. LEGAL DESCRIPTION: Lot 15 and the West 41 feet of Lot 16, Block 170, 'SECTION NO. 8 OF MIAMI SHORES', according to the Plat thereof as recorded In Plat Book 14, Page 33 of the Public Records of Dade County, Florida. TYPE OF SURVE aJ1(J19'4 PREPARED FOR: 1,449,4 O21 N- 490'S•,Mt111'11 0YLEC„pl LEITER & ASSOCIATES. INC. LAND DEVELOPMENT CONSULTANTS CIVIL ENGINEERS - LAND SURVEYORS LAND PLANNERS - ENVIRONMENTAL 190 N. N. 076Th 3T.. SUITE 403. MIAMI. FLORIDA 33069 PNONC OADE (3051 652 -0033 500655) (309) 004 -5202 1.70' G.10 • 9.49' II. • JJ. 18.90 .41.00' 19.00' 0.7'G.P�. /WALL 11.00' 49.10' E• 1.42 0 0.1'9.- 0.6.9.3• 11.7e 10.98' ••c•O v :e. a •E 8: ✓ 0 41.11' 41.00' 0 • ' x x 10.56' 9ET NAIL - DI9C J li 0.10' • V.'!" ,.25;'ttl:•:= 90•y9 M.111.o'ca.):: 9' CONC. WALK -1 F 0 I2 A9 PA LT PAVEMENT/ N. E:. 'I 71 h 9TCIEET (7o' ruin) N.81 °91' ?9 "W. 10.11' r) 911.11'(30.) 1 400.00'(8.) 4.01.90'40 "E. 0.� ENCE 0.I'W. LEGEND: = •ASPHALT. • BRICK PAVERS C::73 . CORCIWTE 1 111 -x- •CHApitUYR FOWL . 5.25 •ELEVATKNL - l_ --,22Y ROWVERMIAAR ACCESS W2 Z 2 - PLUS OR WWII MORE OR LEE. 053 al A. -ARC W/Orn00641L AU • AM COH5R10NER UNIT. LV). Q PR /IS - ASPHALT. OO BURL .04(0wa !'S'I t CORD -CONCRETE RCA •NWwM00 0MY RECORDS. A. - CENTRAL AWILE IMAM 4- AE •CATCH BASIN. CSWNL • CONCRETE BLACK WALL 0 O CAS. • CONCR01 BLOCK 2 SWICCO. C.0CL • COASTAL COWL CONTROL UNE 4' C.I.P. •CRAW UAL PENCE Cut •CLEAR. • coat •CONBTRUCT20,L 0 CEPT. •DEPARTMENT. 2 • • DADS COUNTY RE0AROI. Z EL •S WV. •ELEVATION EMC. FA.O.T. P.P. LL LP. (0y M.H. 0.0.) P.O.0. P.O.0 •ORO/CAC/WS • PO/10A 0EPTOF TRANSPORTAWOU •MOH10 F0000. •POMO. •WARD POST. •' • • BUEI•06S •LKWT POLL • MEASURES . NUMBER. .00FICIAI. RECORDS BOOR . PORT OFBEOWNWO. • PO W T OF OOMMENCF0ENf. O .0 - PLAT LOON RC 4 PT. - POW, OP CURVATURE PONT OF TANGENCY. 022 - PORT OR COMPOONOCURVATURL PAC • PORT OPREVERSSCUPIVATURL PAM •PERMANENTR 05%407CE1.10NWIENr. 014 - REC000. R. •MOVE EQUALS 4114 •RANOL RES. •RESIDENCE LOW •MGM-0P.3AY. SEC •9ECIIDIL L F. •SCUMS FEET. TWP. - TOwx3gP. 000. •TYPICAL W.L • WATERLINE (MOW OROUNDI. WAL •WATERMETER W.V. -WATER YAWL R E V 1 S 1 O N S: • DATE: .000 ORDER: DESCRIPTION: F.E P5. DATE: A1 I 1473 ORDER: L -II Oct JOB FILE NO.: F. B. PG. NOTES: 14 ELEVATIONS WREN SOWN REM 1.2 MR NORMAL 0E0001C VERNAL ONnANN SVJI.) E( 03000401.040 MACE NO ATT 'TTU LOCARf00TDO6 AMOR FOUNDATIONS DURESS CITIER WI80 NORD} 04 THE LANDS SHOWN HEREON NAVE NOT SEEN AE•TRACTSD SY T/SS 50040501.0030 WARM/ OF INTEREST STONER PARTIES. SUCH A0 EASEA5T5, RNNLIS- 0R•WAY9: RSSEMATiONB. ETC- 14 71115 SURVEY WAS PREPARED FOR Al10 PAW= We PARTYANCOR PAR)106 SOICATEDHEREON AND IE 40TTRAN5FERAEW OR ASSONASLL LI A11.1RON PIPES MO NAM A =CS, SEr WIMP ARK SLR CHAR /DISC YSIH LL SISAL SURVEYOR'S CERTIFICATE: TR WNW GERM: THAT MS /SURVEY • TRUE AND CORRECT TO THE OW OF OUR 0010•1200E AHD B1IAF 03 R ECENRY SURVEYED AND DRAWN WIDER OUR CRECTMNL PAD TUT TO SURVEY 10E05 005 'MNSNM 0ELl94CAL STANDARDS. AS BET SOUTH BYNE FLORIDA STAR BOARD OP LAND SURVEYORS R COPIER 10304• FLORIDA AOA•1•TRATIVE COOS.P1WE1UNT TO SECTION 472014 FLORIDA STATURES ER & ASSOCIATES. INC. •Y: TOWS FL MTO SURVEYOR WPM. STATE OP ROMDA DA1t 4/W 1430 NOT VALID UNLESS EMBOSSED WITH RAISED SEAL OF ATTESTING REGISTERED LAND SURVEYOR CONTRACTOR NOTE: 1. MINIMUM 5' -0" SETBACK FROM ALL PROPERTY LINES 2. MINIMUM 10' -0" DISTANCE FROM ANY WINDOW OR DOOR 3. MINIMUM 3' -0" DISTANCE FROM ANY WALL 4. MINIMUM 15' -0" DISTANCE GENERATOR FROM LPG OR NG 5. PROVIDE VENT FOR REGULATORS WITH SCREEN MIN. 5' FROM SOURCE OF IGNITION SHEET 1 OF 1 2 -250 GAL. LP TANKS SEE NOTES 25 KW GENERATOR SEE NOTES -200 AMP BREAKER METER • • • • • • • • • •••• • • •••• • • •• •• • • • • • • • • • • •• • h1 1 o q i NOV 1 2 2007 Jorge A. Pomerantz, P.E. FL. LIC. # 55326 VALID FOR (1) JOB ONLY VALID WITH RAISED ENGINEER SEAL w < 0 ZW� 0 Lr.. LL ui re �O W = Q Z _, J • 2 -4 H a-•7 c (0 u) 0 MINN • • REVISIONS DATE .1• •• • • • • • •• ••• • 4 • 4 • 4 • ELECTRICAL GENERATOR 1 Z gm 1 yN 6 a" JOB NUMBER 1107 -002 SHEET 2 of 4 • •• • •• ••• • •• ••• • ••• • 200 amp Int.Electrical Panel General Panel Information Panel Type Mounting Interior Surface Voltage 120 / 240 Wire A.I.C. Rating 3 -Wire IOk Min Panel Identification Panel "A" Manuf / Type U.L. Approved Phase 1 Cirkt. P / Brk. Cond. 1 2/40 3 5 2/30 7 9 2/30 11 13 2/30 15 17 1/20 19 1/20 21 1/20 23 1/15 25 1/15 27 1/15 29 31 33 35 37 30 41 Wire Circuit Nam e kva kva kva @ 100% Circuit Nam e Cond. Wire 8 COOK TOP 8,000 8,000 AC #1 8 10 WATER HEATER #1 5,000 5,000 OVEN 10 12 SMALL APPL. 2,000 1,500 5 VIALL APPL. 12 10 DRYER 7,000 1,500 DISH WASHER 12 DISPOSAL 12 12 FREEZER 1,500 SMALL APPL. 12 12 WASHER 12 12 DEN LIGHTING 14 14 KITCHEN MASTER BED 14 14 MASTER BATH 14 14 14 14 14 14 12 10 P / Brk. Cirkt. 2/40 2 4 2/30 6 8 1/20 10 12 1/20 14 1/20 16 1/20 18 1/20 20 1/15 22 1/15 24 1/15 26 1/15 28 1/15 30 1/15 32 1/15 34 1/20 36 38 2/30 40 42 Sub -Total ( kva ) Total @ 100% General Lighting Load Total Load ( kva ) 1st 10,000 of Sub -Total @ 100 Remainder @ 40% Load Added @ 100% From Above Total Load ( kva ) Divided by Total Required Service (amps) 39,500 12,004 51,504 10,000 16,602 0 26,602 240 110.84 General Lighting sq ft. 3 watts per sq ft Sub -Total Ceiling Fans @ .15 kw Each Exhaust Fans @.08 kw each High Hats @ .07kw each 4,000 3 Am nt. 12,000 11 1.65 5 0.4 28 1.96 Total 4.01 • • • • • •• • •..• • • •.•• • • •• • •• • • • • • • • • • • •• • 92001 wn 22 00? Jorg omerantz, P.E. FL. LIC. # 55326 VALID FOR (1) JOB ONLY VALID WITH RAISED ENGINEER SEAL 0 c to +J c 0 • h :444 • O p m U Iggh . _ . • • • • • REVISIONS •• DATE ELECTRICAL GENERATOR 1 im g gQ JOB NUMBER 1107 -002 SHEET 3 of 4 • • • • • • • • • • • • •• • •••• • GENERAL ELECTRIC NOTES 1. ALL WORK IS TO BE INSTALLED IN ACCORDANCE WITH THE FLORIDA BUILDING CODE 2004, CHAPTER 27, ALSO COMPLY WITH ALL NEC, 6NFPA70, LOCAL CODES, STANDARDS AND REQUIREMENTS OF THE BUILDING OFFICIALS. 2. ALL WORK SHALL BE INSTALLED IN A NEAT AND ORDELY MANNER PAYING PARTICULAR ATTENTION TO THE SUPPORTING OF CONDUCTORS, JUNCTION/TERMINATION BOXES, AND PANELS WHICH MUST BE SUPPORTED FROM STRUCTURAL ELEMENTS. ALL EQUIPMENT AND MATERIAL MUST BE NEW. 3. THE ELECTRICAL CONTRACTOR MUST APPLY, PAY FOR AND SECURE AND ELECTRICAL BUILDING PERMIT BEFORE COMMENCING ANY WORK. 4. SUBMITTALS SHALL BE DELIVERED TO THE ARCHITECT & ENGINEER FOR REVIEW AND ALLOW 2 WEEKS FOR RETURN PRIOR TO ORDERING. THE ELECTRICAL CONTRACTOR MUST SUBMIT DETAILED INFORMATION FOR THE FOLLOWING ELECTRICAL SYSTEM COMPONENTS: a) ELECTRICAL PANNELS AND DISCONNECTS b) LIGHTING FIXTURES c) ELECTRICAL DEVICES d) CONDUCTORS 5. THE FOLLOWING CONDUCTORS AND RACEWAYS SHALL BE INSTALLED: a) ABOVE GROUND CONCEALED BY FINISHED BUILDING ELEMENTS SHALL BE NEC APPROVED ELECTRICAL WIRING SUPPORTED AS REQUIRED. b) EXTERIOR SURFACE MOUNTED RACEWAYS SHALL BE RIGID METALLIC CONDUIT OR SCHEDULE 80 PVC PIPE WITH THREADED FITTINGS. c) EXTERIOR CONNECTIONS TO PUMPS AND MOTORS SHALL BE LIQUID TIGHT FLEXIBLE SONDUIT. d) SCHEDULE 40 PVC OR ELECTRICAL NONMETALLIC TUBING RACEWAYS SHALL BE USED FOR ALL UNDERGROUND SERVICE. ALL CONDUCTORS ARE TO BE COPPER WITH 90 DEGREE C RATED INSULATION TYPE THHN. EXTERIOR RACEWAYS, BOXES, COVER PLATES, ETC. SHALL BE WEATHERPROOF CONSTRUCTION. e) fl 6. CIRCUIT BREAKER PANELBOARDS SHALL BE INCLUDED AS INDICATED IN THE PANEL SCHEDULES. INCLUDE CIRCUIT BREAKERS WHERE "SPARE" IS INDICATED. INTERIOR PANEL BOARDS SHALL BE SURFACE MOUNTED SQUARE D TYPE NQOD PANEL BOARDS OR EQUAL IN NEMA TYPE 1 ENCLOSURE OR EQUAL PRODUCTS BY ITE OR GE. ALL PANELS BOARDS SHALL BE THE PROCDUCT OF ONE MANUFACTURER. 7. THE FOLLOWING DEVICES SHALL BE USED: a) ALL DEVICES SHALL BE RATED FOR THE RATING OF THE CIRCUIT BREAKER SERVING SUCH DEVICES; 30 AMP BREAKERS SHALL SERVE 30 AMP DEVICES, 20 AMP BREAKERS SHALL SERVE 20 AMP DEVICES. b) EXTERIOR DEVICES SHALL BE ENCLOSED IN WEATHERPROOF ENCLOSURES. c) COORDINATE THE EXACT CONFIGURATION OF SPECIAL DEVICES WITH THE ACTUAL EQUIPMENT BEING SUPPLIED. d) PROVIDE GFI DEVICES AS INDICATED. e) PROVIDE AFCI DEVICES IN ALL DEBROOMS. f) SMOKE DETECTORS SHALL BE INTERCONNECTED AND HAVE BATTERY BACK -UP. g) DIMMERS SHALL BE RATED NO LESS THAN THE LOAD THEY SERVE. h) DISCONNECT SWITCHES SHALL BE SQUARE D, GENERAL DUTY CLASS 3130, OR EQUAL ITE OR GE PRODUCT. PROVIDE TYPE 3R ENCLOSURE FOR EXTERIOR SERVICE AND TYPE 1 ENCLOSURE FOR INTERIOR SERVICE. i) STANDARD DEVICES ARE AS FOLLOWS (PASS & SEYMOUR OR EQUAL): • 20a SWITHCES - 20AC SERIES • 20A RECEPTACLES - 5350 SERIES • COVER PLATES - STANDARD WHITE 8. JUNCTION BOXES SHALL BE METAL BOXES WITH ADDITIONAL STRUCTURAL SUPPORT FOR USE IN CEILING. 9. THE ELECTRICAL CONTRACTOR SHALL INCLUDE ALL ITEMS NECESSARY TO PROVIDE A COMPLETE AND CODE ACCEPTABLE OPERATING ELECTRICAL SYSTEM. 10. THE ELECTRICAL CONTRACTOR SHALL VISIT THE SITE AND FAMILIARIZE HIMSELF WITH ALL EXISTING CONDITIONS BEFORE SUBMITTING A BID FOR CONSTRUCTION. 11. THE CONTRACTOR SHALL PAY FOR ALL, FEES, TAXES, TESTING, INSURANCE, AND SCAFFOLDING SUPPORTING MEANS, ETC. AS REQUIRED. 12. PROVIDE SEPARATE GROUND AND NEUTRAL WIRES FOR ALL ISOLATD CIRCUITS. 13. PROVIDE A #6 SOLID GREEN INSULATED GROUND WIRE FROM A COLD WATER PIPE TO THE TELEPHONE /CABLE TV ENTRANCE POINT. BOND COLD WATER PIPE AT WATER HEATER. 14. SHORT CIRCUIT CURRENT RATINGS SHALL BE COORDINATED WITH THE EQUIPMENT MANUFACTURER TO ENSURE THE ALL FAULKTS WILL TRIP THE OVERCURRENT DEVICE CLOSEST TO THE FAULT. ALL CURRENT DEVICES SHALL HAVE A MINIMUM SHORT CIRCUIT RATING OF 10,000 AIC. 15. COORDINATE THE EXACT REQUIREMENTS OF THE SERVICE WITH FLORIDA POWER AND LIGHT. 16. PROVIDE ALL FUSES AND THERMAL OVERLOAD DEVICES FOR OPERATION OF ALL ELECTRICAL & MECHANICAL EQUIPMENT. 17. "PROVIDE" MEANS TO FURNISH AND INSTALL ALL ITEMS NECESSARY FOR COMPLETE OPERATION AND CODE COMPLIANCE. 18. THE ELECTRICAL CONTRACTOR SHALL PROVIDE A WRITTEN GUARANTEE FOR ALL WORK AND EQUIPMENT FOR A PERIOD OF ONE YEAR FROM THE DATE OF THE CERTIFICTE OF OCCUPANCY AND SHALL REPLACE ALL DEFECTIVE MATERIALS AND CORRECT ALL PROBLEMS AT NO COST TO THE OWNER. 19. ALL LIGHTING FIXTURES SHALL COMPLY WITH THE FLORIDA ENERGY CODE LATEST EDITION. 20. INCLUDE PATCHING AND SEALING ALL WALLS, FLOORS, CEILING, ETC. PENETRATED BY INSTALLATION OF ELECTRICAL WORK. ALL HOLES AND CRACKS SHALL BE SEALED TO PREVENT THE PASSAGE OF AIR, INSECTS, WATER, FIRE, ETC. 21. INCLUDE FINAL CLEANING OF ALL ELECTRICAL EQUIPMENT. PROVIDE TYPED SCHEDULES FOR EACH ELECTRICAL PANEL. TOUCH -UP SCRATCHED PAINTED SURFACES W /MANUFACTURER'S RECOMMENDED PAINT. LABEL ALL DISCONNECTS AND PANELS W /PERMANENTLY ENGRAVED PLASTIC NAMEPLATES, MECHANICALLY ATTACHED. 22. CONTRACTOR SHALL VERIFY ALL DIMENSION AND CONDITIONS ON THE SITE PRIOR TO COMMENCING TO WORK AND NOTIFY THIS ENGINEER IF ANY DISCREPANCY OCCURS. 23. THE DRAWINGS ARE INTENDED TO SHOW THE GENERAL ARRANGEMENT, DESIGN, AND EXTENT OF THE WORK AND ARE PARTLY DIAGRAMMATIC. THEY ARE NOT INTENDED TO BE SCALED FOR ROUGHIN -IN MEASUREMENTS, OR TO SERVE AS SHOP DRAWINGS OR PORTIONS THEREOF. 24. ENGINEER SEAL AFFIXED HERETO VALIDATES ELECTRICAL DESIGN AS SHOWN ONLY. USE OF THIS SPECIFICATION BY THE CONTRACTOR, INC., ET. AL. INDEMNIFIES AND HOLDS HARMLESS THIS ENGINEER FOR ALL COSTA AND DAMAGES INCLUDING LEGAL FEES AND APPELLATE FEES RESULTING FROM MATERIAL FABRICATION, SYSTEM ERECTION, AND CONSTRUCTION PRACTICES BEYOND THAT WHICH IS CALLED FOR BY LOCAL, STATE AND FEDERAL CODES AND FROM DEVIATIONS OF THIS PLAN. 25. EXCEPT AS EXPRESSLY PROVIDED IN THIS CERTIFICATION, NO ADDITIONAL CERTIFICATIONS OR AFFIRMATIONS ARE INTENDED. 26. THIS DRAWING SHALL NOT BE USED FOR PERMIT WITHOUT THE SIGNATURE, DARE AND RAISED SEAL. 27. THE ENGINEER SHALL IS NOT RESPONSIBLE OR LIABLE IN ANY WAY FOR ERRONEOUS OR INACCURATE DATA OR FIELD MEASUREMENTS PROVIDED TO THIS ENGINEER. • • • • • •• • • •••. • • •••• • • •• •• • • • • • • • • • • •• • NOV 1 2 2Q0? Jorge A. Pomerantz, P.E. FL. LIC. # 55326 VALID FOR (1) JOB ONLY VALID WITH RAISED ENGINEER SEAL W < ZW13' Q -J Cn LL ". O) ec ec W Q Z N ui c� Q ON W E • •s+ • •4so a u ° gd oo H • er@ yaLL • 96284 REVISIONS DATE ••• 10 -25 -07 ELECTRICAL GENERATOR gm JOB NUMBER 1107 -002 SHEET 4 of 4 • • • ••• • •••• • ••• • •• • •• • • • • • .6L• • ...25 • • •••••• • • Models::005324 -0 • •06532S -0 ECTTO C VMf IAN ('H gal j F AND R'=A,)La. IC)NS A new standard of reliability E: ....... .... /\ Not intended for use in critical life support applications. /A - 0 CAUTION a - ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! 09Zt`JO'°N ued This manual should remain with the unit. 90150 V t:SOJ AO3 SECTION PAGE SAFETY RULES 1 -1 INTRODUCTION 1 -3 Read this Manual Thoroughly 1 -3 Operation and Maintenance 1 -3 How to Obtain Service 1 -3 IDENTIFICATION RECORD 2 -1 Data Label 2 -1 EQUIPMENT DESCRIPTION 3 -1 Equipment Description 3 -1 Engine Oil Recommendations 3 -1 Coolant Recommendations 3 -1 ENGINE PROTECTIVE DEVICES 4 -1 High Coolant Temperature Switch 4 -1 Low Coolant Level Sensor 4 -1 Low Oil Pressure Switch 4 -1 Overcrank Shutdown 4-1 Overspeed Shutdown 4 -1 RPM Sensor Loss Shutdown 4-1 DC Fuse 4 -1 FUEL SYSTEMS 5-1 Fuel Requirements 5 -1 Natural Gas Fuel System 5 -1 Propane Vapor Withdrawal Fuel System 5 -1 LP Fuel System 5 -1 SPECIFICATIONS 6 -1 Generator 6 -1 Engine 6 -1 Cooling System 6-1 Fuel System 6 -1 Electrical System 6 -1 Cold Weather Kit 6 -2 Reconfiguring the Fuel System 6 -2 GENERAL INFORMATION 7 -1 Generator AC Lead Connections 7 -1 Four -lead, Single -phase Stator 7 -1 Alternator Power Winding Connections 7 -1 3 -phase Alternators 7 -1 INSTALLATION 8 -1 Installation 8-1 Preparation Before Start -up 8-1 Transfer Switch 8-1 Fuel System 8-1 Generator Set Lubrication 8-1 Prior to Initial Start-up 8 -1 Engine Coolant 8-1 Belt Tension 8-1 Electrical System 8-1 Initial Inspection for QT Genset Start-up 8-1 Start -up Checklist 8-2 Preparation for Start-up 8-2 Start -up Inspection 8 -2 .. • • •• . • • • • .. • • • • • OPERATION • 9-; Generator Control and Operas :1 •• a vs • s R A 9 Operating Unit with Manual T:lsf� •Switch • • 9 -1 • • Engine Start-up and Transfer,' r v• • a i• b • 9 -1 Retransfer and Shutdown... . 9-1 Operating Unit with Automatic:TrSn4er Switgb.. 9 -1 MAINTENANCE .• a • •.•.•.a ...10-1 Maintenance Performed by Authorized •. • • • Service Facilities • r;,...10 -1 Every Three Months 10 -1 Once Every Six Months 10-1 Once Annually 10 -1 First 100 Operating Hours 10-1 Every 500 Operating Hours 10 -1 Every 800 Operating Hours 10 -1 Exhaust Manifold Procedure 10 -1 Intake Manifold Procedure 10 -1 Cylinder Head Procedure 10 -1 Cooling System 10 -2 Overload Protection for Engine DC Electrical System 10 -2 Checking Fluid Levels 10 -2 Check Engine Oil 10-2 Battery Fluid 10 -2 Engine Coolant 10 -2 Maintenance Owner /Operator Can Perform 10-3 Check Engine Oil Level 10-3 Check Battery 10 -3 Exercise System 10 -3 Inspect Cooling System 10 -3 Check Engine Coolant Level 10 -3 Perform Visual Inspection 10 -3 Inspect Exhaust System 10 -3 Check Fan Belt 10 -3 Inspect Engine Governor 10-3 Changing Engine 011 10-3 Changing the Engine Air Cleaner 10 -3 Spark Plugs 10 -4 Coolant Change 10-4 Miscellaneous Maintenance 10 -4 Cleaning the Generator 104 Battery 10-4 Battery Maintenance 10-4 Battery Replacement 10-5 SERVICE SCHEDULE 11 -1 TROUBLESHOOTING 12 -1 Troubleshooting Guide 12 -1 NOTES EXPLODED VIEWS & PARTS LISTS WIRING DIAGRAMS & SCHEMATICS • • • • • • WARRANTY 50!60 0 %eH 400Woiu00 • Standby Generator Sets. mportant Safety Instruction •• • • •• • • • -. • •••• • • • • • SAVE THESE INSTRUCTIONS - The manufacturer suggests that thes4,„Gitles for scdfe A. . operation be copied and posted in potential hazard areas. Safety should '6patfessec; tb•Qtl •••• operators, potential operators, and service and repair technicians for this ggjpgrcent.: • • • • • • • •• •• •• •• The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other re, roductive harm. RN 1 This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. 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 Qi 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. 0 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. A Parts of the generator are rotating and /or hot during operation. Exercise care near running generators. 1 -1 Q GENERAL BAZARDS A • For safety reasons, the manufacturer i 8frunend% that this equipment be: inst'ajled, s&Mded and repaired by an Authorized'Serdice DcM; or othef competent, qualified electrician or installati!+rti tech- nician who is familiar with applicable codes, stan- dards and regulations. The operator also must comply with all such codes, standards and regula- tions. • 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 monox- ide 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. Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people, animals, etc., will not be harmed. This exhaust system must be installed properly, in strict compliance with applicable codes and stan- dards. • 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. SO/90 0 Aati too ARES • • • Standby Generator Sets portant Safety Instructions- • 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 Qy • 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. SOBO ova too ken 1 -2 • .• •• • •• • • • • • •• •••• •� • • Generators installed with an automatic transfel switch will crank and st'aff'automStigalry whefi • normal (utility) source vdltMe is removed or YS•; • • • below an acceptable pre preSetvelici. To jiteyeOt such•••• automatic start -up and possible injury•to•persorr• • • •• • nel, disable the generatos'a•ansttmatic start circuit • (battery cables, etc.) before working ota•as around...: • the unit. Then, place a ;Do Not OptGat,a' tag og • the generator control p %l• and on, a tjansfr • • • ; 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. ® ARE HAZARDS A • 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. A EXPLOSION HAZARDS A • 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 units 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. • Standby Generator Sets Important Safety Instructions. INTRODUCTION Thank you for purchasing this model of the standby generator set 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, con- tact the nearest Authorized Service Dealer for start- ing, 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 person- nel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows: DANGER After this heading, read instructions that, if not strictly complied with, will result in personal injury or property damage. ® WARNING After this heading, read instructions that, if not strictly complied with, may result in personal injury or property damage. • CAUTION After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and /or property. NOTE: After this heading, read explanatory statements that require special emphasis. These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compli- ance with the special instructions while performing the service are essential to preventing accidents. , Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows: 0 This symbol points out important safety infor- mation that, if not followed, could endanger personal safety and /or property of others. This symbol points out potential explosion hazard. 1 -3 • • • •. • .. . • • • • .. • •• • • • ® This symbol points out potential fir: ji ijd. • •••• • & This symbol points out potential electricaLshock. :..• hazard. ' • The operator is responsible ter proper and safe use • of the equipment. The manefacturer strongly reconi- • .... mends that the operator read this Owners. Manual and thoroughly understant. ail ;nstrue&ipnse befoa using this equipment. The manufacturer a1 strong ly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency. • • ® 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 an Authorized 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 contribute 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 an Authorized Service Dealer for service aids and accessories. Operating instructions presented in this manual assume that the standby electric system has been installed by an Authorized Service Dealer or other competent, qualified contractor. Installation of this equipment is not a "do- it- yourself" project. 4. HOW TO OBTAIN SERVICE When the generator requires servicing or repairs, simply contact an Authorized Service Dealer for assistance. Service technicians are factory- trained and are capable of handling all service needs. When contacting an Authorized Service Dealer or the factory about parts and service, always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit. AUTHORIZED SERVICE DEALER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER, please call this number: 1 -800- 333 -1322 or locate us on the web at: www.generac.com snreo o Aoti loo Anus • GENERAL INFORMATION andby Generator Sel eneral °Information IDENTIFICATION RECORD ® DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator. The data label, which can be found attached to the gen- erator's lower connection box, lists the units serial number and its rated voltage. amps. wattage capacity, phase, frequency, rpm. power factor, etc. • • • • • •• • NOTE': For actual information rely gd to this: •past lcular • • • • • model, please refer to the Manual Drawing Listing' • • located at the end of this Rare, or •tb the data label affixed to the unit. • • • + Generator Model and 4eril '!lumber • • • This number is the key to ngmesoxs engii3 &'ping and manufacturing details pertaining t3 your'.i$ir. $1wayy supply this number when requesting service. "order- ing parts or seeking information. • (GENERAL INFORMATION • • •• • • • • • •• • • • • • • Data Label MODEL RATED KW GENERATOR SET DATA RATED VOLTAGE POWER FACTOR I HERTZ ENGINE RPM I 1 PRODUCTION DATE ALTERNATOR SUBTRANSIENT REACTANCE ALTERNATOR TRANSIENT REACTANCE CLASS ROTOR STATOR WINDING INSULATION AT 25 °C AMBIENT SERIAL RATED KVA MADE IN USA RATED AMPS PHASE ALT RPM GENERAC POWER SYSTEMS, INC. WAUKESHA, WI 2 -1 • So(n v'Aet! ZOO'' PI • GENERAL INFORMATION tandby Generator Sets, uipment Description EQUIPMENT DESCRIPTION This equipment is a revolving field, alternating cur- rent generator set. It is powered by a gaseous fueled engine operating at 1800 rpni 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. The unit comes complete with a sound attenuated enclosure, internally mounted muffler, control console, main- line circuit breaker, battery charger, and protective alarms as explained in the following paragraph. All AC connections, including the power leads from the alternator, 120 volt battery charger input and control connections to the transfer switch are avail- able in the main connection box. The generator incorporates the following generator features: • Rotor and Stator insulation is CIass F rated as defined by NEMA MG1 -32.6, NEMA MG1 -1.66. The generator is self ventilated and drip -proof con- structed. • The voltage waveform deviation, total harmonic content of the AC waveform and telephone influ- ence factor have been evaluated and are acceptable according to NEMA MG 1 -32. ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W-40 engine oil at the factory. Use a high - quality detergent oil classified "For Service CC, SD, SE, SF." Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change: Temperature Oil Grade (Recommended) SAE 30W or 15W-40 Above 80° F (27° C) 32° to 80° F (0° to 27° C) SAE 20W -20 or 15W-40 Below 32° F (0° C) See Note CAUTION A 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. NOTE: For temperatures below 32° F, it is strongly recom- mended to use the optional Cold Weather Start Kit (part number listed in the Specification Section). The oil grade for temperatures below 32° F is 5W- 30 synthetic oil. 3-1 • • • •• • •• • • • • •• COOLANT RECOMMEt WAtION,S • • •• • • • • Use a mixture of half IoW' •s3l4cdte et leh@• glycol • • base anti - freeze and deioniz“ I•i er. Cooling §ystenn• capacity is listed in the specihs. Ustgrilydeion- ized water and only low silicy p i i- freeze. IL desired, add a high quality rust inhatItoPtqthe recommended coolant mixture. When adding coolantr hays add the recommended 50 -50 milct use.: CAUTION A 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 oper- ated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene 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. ••• • • •• • • ••• • • • • •• DANGER` A Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result. A 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. somo o •mod zooamb • andbyGenerator Sets rme Protective Devices ENGINE PROTECTIVE DEVICES 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 tempera- ture, oil pressure or rpm. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low the coolant temperature is too high, the coolant level is too low, or the engine is running too fast. NOTE: Engine protective switches and sensors are men- tioned here for the reader's convenience. Also refer to the applicable control panel manual for additional automatic engine shutdown informa- tion. • HIGH COOLANT TEMPERATURE SWITCH This switches contacts close if the temperature should exceed approximately 140° C (284° F). initiating an engine shutdown. The generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level. • LOW COOLANT LEVEL SENSOR Should the engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shut- down. To prevent such overheating. the engine has a low coolant level sensor. If the level of engine coolant drops below the level of the low coolant level sensor, the engine automatically shuts down. • LOW OIL PRESSURE SWITCH This switch has normally closed contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure drop below the 8 psi range, switch contacts close, and the engine shuts down. The unit should not be restarted until oil is added, and the AUTO /OFF/MANUAL switch must be turned to OFF and then back to AUTO. OVERCRANK SHUTDOWNI After a prespecified duratioiiA4, gfankIr 'this func- tion ends the cranking if tj. ,Fpgine his faded to start. The overcrank LED will t 1'ON. 'Piro OFF the AUTO /OFF/MANUAL switch„Wlistern switchback to • • AUTO to reset the generator'corol boards • • • • • • 4-1 • • • • NOTE: • • •••• ' • If the fault is not corrected,'ihe bverct *ature will continue to activate. Approximate Crank Cycle limes • 15 seconds ON • 7 seconds OFF • 7 seconds ON • 7 seconds OFF • Repeat for 45 seconds Approximately 90 seconds total. • OVERSPEED SHUTDOWN A speed circuit controls engine cranking. start-up, operation and shutdown. Engine speed signals are delivered to the circuit board whenever the unit is running. Should the engine overspeed above a safe, preset value, the circuit board initiates an automatic engine shutdown. Contact the nearest Authorized Dealer if this failure occurs. • O RPM SENSOR LOSS SHUTDOWN If the speed signal to the control panel is lost. engine shutdown will occur. • DC FUSE This fuse is located inside of the control panel. It protects the panel wiring and components from damaging overload. Always remove this fuse before commencing work on the generator. The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rating. (See the exploded views and parts lists at the end of this manual for replacement part number.) 50190 0 ali 100nwd6u3 • 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. Ask the fuel supplier for the Btu content of the fuel. Required fuel pressure for natural gas is 5 inches to 14 inches water column (0.18 to 0.5 psi); and for liquid propane, 5 inches to 14 inches of water column (0.18 to 0.5 psi). NOTE: Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below five inches water column for natural gas or 5 inches water column for propane vapor for all load ranges. NOTE: It is the responsibility of the installer to make sure that only the correct recommended fuel is sup- plied to the generator fuel system. Thereafter, the owner /operator must make certain that only the proper fuel is supplied. • NATURAL GAS FUEL SYSTEM Natural gas is supplied in its vapor state. In most cases, the gas distribution company provides piping from the main gas distribution line to the standby generator site. The following information applies to natural gas fuel systems. • Gas pressure in a building is usually regulated by national, state and Local codes. • To reduce gas pressure to a safe level before the gas enters a building, a primary regulator is needed. The natural gas supplier may or may 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 shutoff sole- noid should not exceed approximately 14 inches water column (0.5 psi). Optimum pressure at the fuel shutoff solenoid is 11 inches water column (0.4 psi). 5 -1 • • • • • • •• • • •• • • • • •••s,•• • •• • • • PROPANE VAPOR WITHDItAL FUEL•SYSTERI� • ••••• This type of system utilizes i41,e y0ors farmed •above • the liquid fuel in the supplyt, ky •Appro 1ma rely 10 .:..• to 20 percent of the tank capAtris nee id f or fuel expansion from the liquid 42 style. vapor sttate. The vapor withdrawal system is senerally best suited for smaller engines that require less Tii� •Pnstallef • should be aware of the followlng: . • • • • • • • The natural gas and LP gas systems are Am11ar. However, the natural gas system delivers gas at a pressure of approximately five inches water col- umn to the carburetor. • When ambient temperatures are low and engine fuel consumption is high, the vapor withdrawal system may not function efficiently. • Ambient temperatures around the supply tank must be high enough to sustain adequate vaporiza- tion, or the system will not deliver the needed fuel volume. • In addition to the cooling effects of ambient air, the vaporization process itself provides an additional cooling effect. • • • • LP FUEL SYSTEM LP is supplied as a liquid in pressure tanks. It is usually made up of propane, butane, or a mixture of the two gases. Propane tends to vaporize readily even at temperatures as low as -20° F ( -29° C). However, butane reverts to its liquid state when temperatures drop below 32° F (0° C). LP in a liquid withdrawal system must be converted to its gaseous state before it is introduced into the engine carburetor. A vaporizer- converter is generally used to accomplish this. In such a converter, heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state. SO/80 vaaii t00sASlanA andby Generator Saeciftcatron� • • • • • • • • • SPECIFICATIONS • GENERATOR Type Synchronous Rotor Insulation Class F Stator Insulation Class F Total Harmonic Distortion < 5% Alternator Output Leads 3 -phase 4 -wire Bearings Sealed Ball Coupling Flexible Disc Load Capacity (Standby Rating) 25kW* * NOTE Generator rating and performance in accordance with IS08528 -5, BS5514, SAE J1349, IS03046 and DIN 6271 Standards. KW rating Is based on LPG fuel and may derate with natural gas. Excitation System Direct Generator Output Voltage/kW - 60 Hz kW Amp CB Size 120/240V, 1- phase, 1.0 pf 25 104 125 120/208V, 3- phase, 0.8 pf 25 87 100 Generator Locked Rotor KVA Available @ Voltage Dip of 35% Single -phase or 208 3 -phase 34 KVA ® ENGINE Make Generac Model In Line Cylinders and Arrangement 4 Displacement 1.6 Liter Bore 3.15 in. Stroke 3.13 in. Compression Ratio 9.75 -to -1 Air Intake System Naturally Aspirated Valve Seats Replaceable Lifter Type Hydraulic Engine Parameters Rated Synchronous RPM 60 Hz, 3600 HP at rated kW 45 Hz Exhaust System Exhaust Flow at Rated Output 60 Hz 249 cfm Exhaust Temperature at Rated Output 1015° F Combustion Air Requirements (Natural Gas) Flow at rated power, 60 Hz 90 cfm Governor Type Electronic Frequency Regulation lsochronous Steady State Regulation t .25% Adjustments: Speed Selectable Engine Lubrication System Type of Oil Pump Oil Filter Crankcase Oil Capacity 6-1 • COOLING SYSTEM Type Water Pump Fan Speed Fan Diameter Fan Mode • •• • • • • • • •• • • • • • •••• • ••4 • : ear • • • • • Full Flew, c,artridge • 4.U. t. qts. •••••• • w •• • •• • • - • • •• •• • • • • • • • • • •• • dosed •Belt Driven • • • • • :2550 • 15 inches Pusher Air Flow (inlet air including alternator and combustion air) 1528 ft3/min. Coolant Capacity 2.0 U.S. gal. Heat Rejection to Coolant 117,000 Btu/h Maximum Operating Air Temp. on Radiator 60° C (150° F) Maximum Ambient Temperature 50° C (140° F) • FUEL SYSTEM Type of Fuel Natural Gas, Propane Vapor Carburetor Down Draft Secondary Fuel Regulator Standard Fuel Shut -off Solenoid Standard Operating Fuel Pressure 5 in. -14 in. Water Column Fuel Consumption ft3/hr (Natural Gas/LPV) Exercise 25% 50% 75% 100% Cycle Load Load Load Load 60/24 161/64 253/101 345/138 437/175 • ELECTRICAL SYSTEM Battery Charge Alternator Static Battery Charger Recommended Battery System Voltage 12V, 15 Amp 2 Amp Group 26, 525CCA 12 Volts .• • Voltage Regulator Type Electronic Sensing Single -phase Regulation t 1% Features V/F Adjustable, Adjustable Voltage and Gain LED Indicators Power Adjustment for Ambient Conditions Temperature Deration 3% for every 10° C above °C 25 1.65% for every 10° above °F 77 Altitude Deration 1 °I° for every 100 m above m 182 3% for every 1000 ft. above ft. 600 Controller R -200 son O'^ati acc•dSUeO • GENERATOR CONNECTION BOX 0 000000 CONTROL PANEL Figure 1 — Interconnections TO ALTERNATOR Ground Level I STUB UP AREA Concrete Slab See Install Dwg for Dimensions • COLD WEATHER KIT For cold climates, optional cold weather kit (part number OF6148) is recommended. The kit includes: • Battery Warmer • 4" Junction Box with hardware • 6 qt. pack 5W -30 synthetic oil (engine) O RECONFIGURING THE FUEL SYSTEM NOTE: All models are configured for natural gas or LP vapor from the factory. To reconfigure the fuel system from NG to LP follow these steps: 1. Turn the main gas supply off. 2. Remove the carburetor fuel hose from the outlet port (Port 1) of the demand regulator (Figure 6.2). 3. Remove the brass hose fitting from the outlet port (Port 1) of the demand regulator. 4. Remove pipe plug from Port 2. 5. Install brass hose fitting into Port 2. 6. Install pipe plug into Port 1. 7. Connect carburetor gas hose to brass fitting. 8. Tighten all clamps and plugs. 9. Make sure fuel supply is of the proper pressure and type for configuration. 90/tr0 0 vN ZZOcedSueD 6-2 Transfer Switch • •..• • • •..• • • • • • • • • • • ••••• • • •• • •. • 4- #14 GA WIRES TO GENERATOR CONNECTION BOX • • TO GENERATOR CONNECTION BOX To Generator Control Panel CIRCUIT BREAKER SIZE KW VOLTS / AMPS LUG SIZE 25 240 1 0 125 #4 to 1/0 25 208 3 0 100 #4 to 1/0 10. Reverse the procedure to convert back to natural gas. 11. The Dip switch inside the control panel must be in the LP or NG position when switching to differ- ent fuels. Figure 6.2 — Reconfigure the Fuel System Pon 1 Port2 NG FUEL SYSTEM LP FUEL SYSTEM PLUG NOTE: Port 1 is for NG only and Port 2 is for LP vapor only. No provision for dual fuel has been made. A DANGER Serious injury or damage may occur if not con- figured properly. Please consult an Authorized Dealer with any questions. • • GENERAL INFORMATION andby Generator Se eneral Information_ . �. GENERAL INFORMATION GENERATOR AC LEAD 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 con- nection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. If there are any questions regard- ing lead connection, refer to the wiring diagrams at the back of this manual. Voltage codes apply to the type of stator assembly installed on a particular generator. A FOUR -LEAD. SINGLE -PHASE STATOR Four -lead generators (see Figure 7.1) are designed to supply electrical loads with voltage code "A" (240V, 1- phase, 60 Hz). Electrical power is produced in the stator power windings. These windings were con- nected at the factory to the main circuit breaker as shown in Figure 7.1. The rated voltage 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 44 E3 I I I 1 1 1 r 120 VOLTS VOLTS 1 I NEUTRAL I 1 120 VOLTS 1 11 E1 CIRCUIT BREAKER i • • • • • •• • ALTERNATOR POWER WI.NOI 1G CONNECTIONS • •• • • • • • •• •••• • • • • •••• • ♦ 3 -PHASE ALTERNATORS •; INSTALLATION Refer to the separate "Installation Guide QT Product Line" supplied with the unit. PREPARATION BEFORE START-UP The instructions in this section assume that the standby generator has been properly installed, ser- viced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor. Be sure to read the "Safety Rules ", as well as all other safety information in this manual, before attempting to operate this (and related) equipment. Before starting the generator for the first time, the installer must complete the following procedures. For follow -up maintenance information and/or service intervals, please refer to the "Maintenance" section and the "Service Schedule". • TRANSFER SWITCH If this generator is used to supply power to any elec- trical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents elec- trical backfeed between two different electrical sys- tems. (For additional information, see the applicable transfer switch manual for this unit.) The transfer switch, as well as the generator and other standby components, must be properly located and mounted in strict compliance with applicable codes, standards and regulations. • FUEL SYSTEM Make sure the fuel supply system to the genera- tor (a) delivers the correct fuel at the correct pres- sure and (b) is properly purged and leak tested according to code. No fuel leakage is permitted. See "Specifications" for more information. ® GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper level — the dipstick "FULL" mark. Never operate the engine with the oil level below the 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. Check the oil level in the generator gearbox (if so equipped) prior to initial use and at the intervals indicated by the "Service Schedule." The recom- mended oil is SAE 90 gear lubricant. Also, if the engine is equipped with a mechanical gov- ernor, make sure the governor is properly lubricated with clean engine oil. • ▪ • • •• • • PRIOR TO INITIAL STARTUP • CAUTION • • •• • • • • • •• • • • • • • • • • • • ••••• A Prior to initially starting the generator, itfnust; be properly prepared for use.•AfiP attemitttd• crank or start the engine bettlee,it has been properly serviced with the rgcomnlendeci'ypt and quantities of engine flujds (dij, coolarit,•fFuel, • etc.) may result in an engine failui. •••• • ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See "Specifications" and "Coolant" sections. • BELT TENSION Check -the engine -fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of approximately 22 pounds (10 kg), applied midway between pulleys, deflects the belt about 3/8- to 5/8- inch (10 to 16 mm). • ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground. Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use. Check to ensure that there are no loose electrical con- nections. Restrain any loose wires to keep them clear of any moving generator set components. INITIAL INSPECTION FOR QT GENSET STARTU P Inspect for the following. • Freight Damage. • Manuals present. • Fluid Levels ( OiI, coolant, battery, Gear Drive). • Correct fuel piping. • Correct muffler installation for QT50, QT70, QT 100 - QT 150. • Adequate air flow, clearances and ventilation per installation drawings and applicable codes. • Correct AC and DC wire size, connections and grounding. Control and communication wiring to/ from the transfer switch must be run in a separate conduit from the AC power leads. • Battery charger connection to 120 VAC. • Communication wires connected between transfer switch and generator (HTS only). • Unit secured to pad. 8-1 9040 Eras 10011E15u1 • • • • • • • START -UP CHECKLIST A WARNING A Before working on the generator, ensure the fol- lowing: • The AUTO /OFF/MANUAL switch is in the OFF position. • The 120VAC supply to the battery charger is switched OFF. • PREPARATION FOR START -UP • Ensure that the 120VAC circuit breaker to the bat- tery charger is open. • Remove the fuse from the the control panel. For the H -100 and R- series: Open the front door of the control box and remove the 15 Amp ATO fuse in the lower left -hand corner of the control box. • Connect the battery cables to the battery. Attach negative battery cable last. • Close the 120VAC circuit breaker to the battery charger. • Measure the voltage at the battery before and after the charger is turned on. • Verify all AC electrical connections are tight at the circuit breaker and transfer switch. • Visually inspect entire area looking for loose paper, plastic wrappings. leaves. etc. • Check all hoses clamps fittings for Ieaks or dam- age. • Check all electrical plugs throughout the genera- tor. Ensure each plug is seated correctly and fully inserted into its receptacle. • Verify the AUTO /OFF/MANUAL switch is in OFF position. • 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 MAN- UAL position. The engine should now crank and start. 9M0 a *MU iDOPISUI 8 -2 • • • •. • • •• . • • • • • Check voltage at the generatoi itgim�nals. : • • For 3 -phase units, check pha ee•rotatioi at the transfer switch terminals. 'PYle. .4etneratvi• •please rotation must match the utlliVal a se rotation. • • Check for coolant, fuel, oil, a�a'Pe1cjiaust • Close the generators main ling,4;94it breakel. • Turn the generator set off. : • •••• • Connect the UTILITY supply to the •tr,a1S'fer • switch. • • • Set the AUTO /OFF/MANUAL switch to AUTO...: • Disconnect utility power before the transfer switch. Engine should start, transfer to load. Run at least 15 minutes on generator power. Make certain all 3 -phase loads are functioning correctly (correct phase rotation). • Reconnect Utility power Transfer switch will transfer back to Utility and engine will shut down within the given time parameters set up for the specific transfer switch and controller. • Install all covers, access plates and door panels. • Put the Owners Manual in a safe and accessible place. • Make certain the AUTO / OFF/MANUAL switch is in the AUTO position. • START -UP INSPECTION When a start-up is performed by an Authorized Service Dealer, a standard three -part form titled "Start -up Inspection for Standby Power Systems" (part no. 067377), should be completed by the instal- lation technician or engineer. See page 1 -3 for infor- mation on locating the nearest Authorized Service Dealer. The installer should complete the form and disseminate copies as follows: • White copy: Mail to Generac Warranty Department, P.O. Box 340, 211 Murphy Dr., Eagle, WI 53119- 2062. • Pink Copy: For service file of installing dealer. • Yellow Copy: For the customer's records. • • • • • • • •• • • • 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. • ENGINE START -UP AND TRANSFER For additional information, refer to the applicable control panel manual for this unit, as well as any lit- erature pertaining to the specific transfer switch. A A DANGER A 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 applicable control panel and transfer switch manuals for more information. A 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 posi- tively turned off, or extremely dangerous - pos- sibly lethal - electrical shock will result. 0 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. In order to transfer load from the utility source to the generator, follow these directions: • Turn OFF or disconnect the utility power circuit to the transfer switch, using the means provided (such as the utility source main line circuit break- er). • Set the transfer 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 generator. 9-1 • • • • •• • • CAUTION • A • • • 0 Do not crank the engine continuously fo;ionger than 30 seconds, or the heath• . • • damage the starter motor. •• •• •• •• • Let engine stabilize and warm;flp;•; • • Check all applicable instrumEnt acid gat C' ings. When certain that all rgadifigs are eerrect, move the transfer switch matflial• handle •to its STANDBY (GENERATOR) position, i.e., loabvir- cuits supplied by the generator. • Set the standby generator's main line circuit break- er to its ON (or CLOSED) position. • Load circuits are now powered by the standby generator. • RETRANSFER AND SHUTDOWN For additional information, refer to the applicable control panel manual for this unit, as well as any lit- erature pertaining to the specific transfer switch. To transfer the load back to the utility power source and shut down the generator, follow these direc- tions: • Set the standby generator's main line circuit break- er to its OFF (or OPEN) position. • Manually move the transfer switch handle to its UTILITY (NORMAL) position, i.e., load circuits connected to the utility. • Turn ON the utility power supply to the transfer switch, using the means provided (such as the util- ity power source main line circuit breaker). • Let the generator run at no -load for a few minutes to stabilize internal temperatures. • Shut down the generator. • •• • • • • • .• • OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If the generator has been installed with an automatic transfer switch, such as an RTS, HTS, or GTS -type transfer switch, the engine may be started and stopped automatically or manually. NOTE: Refer to the applicable manual for your trans- fer switch and to "Transfer Switch Start Signal Connections ". In addition, please note the dangers under "Engine Start-up and Transfer." so/so ova towo MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A WARNING A Before working on the generator, ensure the fol- lowing: • The AUTO /OFF/MANUAL switch is in the OFF position. • The 15A fuse has been removed from the con- trol box. • The 120VAC supply to the battery charger is switched OFF. • EVERY THREE MONTHS 1. Check battery condition. 2. Inspect and test fuel system. 3. Check transfer switch. 4. Inspect exhaust system. 5. Check engine ignition system. 6. Check fan belts. • ONCE EVERY SIX MONTHS 1. Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature). • ONCE ANNUALLY 1. Test engine governor; adjust or repair, if needed. 2. Clean, inspect generator. 3. Flush cooling system. • FIRST 30 OPERATING HOURS 1. Change engine 'break -in" oil and filter. • FIRST 100 OPERATING HOURS 1. Change engine oil and oil filter. After initial change, service engine oil and filter at 100 operat- ing hours or six months, whichever comes first. 2. Retorque cylinder head. 3. Retorque intake and exhaust manifold. • EVERY S00 OPERATING HOURS 1. Service air cleaner. 2. Check starter. 3. Check engine DC alternator. • EVERY 800 OPERATING HOURS 1. Retorque cylinder head. 2. Retorque intake and exhaust manifold. 3. Check engine compression. 4. Check valve clearance. COOLING SYSTEM • • • • •• • • • •• • • • • • •• • Air intake and outlet openings in•tgenerator cpm- partment must be open and uno'bstiv ted fcrdd8tin- ued proper operation. This in 1i .such gbstrytc- tions as high grass. weeds, bru44,9ca0es antlartry. Without sufficient cooling and vctitiltalttong air flow, the engine /generator quickly overheats, which causes it to shut down. (See the installation raml.•.. • •• • ••• • • WARNING AL • • • • • • • • • • • •• ® The exhaust system parts from this product get extremely hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system. OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via a 15 amp fuse. These overcurrent protection devices will open if the circuit is overloaded. A CAUTION If a circuit breaker opens or a fuse element melts, find the cause of the overload before resetting the circuit breaker or replacing the fuse. CHECKING FLUID LEVELS • CHECK ENGINE OIL Check engine crankcase oil level (Figure 10.1) at least every 20 hours of operation, or prior to use. • Remove oil dipstick and wipe dry with a clean, lint - free cloth. • Install oil dipstick, then remove again. • Oil should be between FULL and ADD marks. • If oil level is below the dipstick ADD mark, remove oil fill cap -. Add the recommended oil to bring oil level up to the FULL mark. DO NOT FILL ABOVE THE "FULL" MARK. See "Engine Oil Recommen- dations" for recommended oils. 10 -1 9 0 0 ? Uau! u •• • • • Figure 10.1 - Oil Dipstick and Oil Fill Cap OIL FILL CAP OIL DIPSTICK O BATTERY FLUID Check battery electrolyte fluid based on the Maintenance Schedule. Fluid should cover separa- tors in all battery cells. If fluid level is low, add dis- tilled water to cover tops of separators. DO NOT USE TAP WATER IN BATTERY. ® ENGINE COOLANT Check coolant level in coolant recovery bottle. See Specifications. • Add recommended coolant mixture as necessary. • Periodically remove radiator pressure cap (only when engine has cooled down) to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact an Authorized Service Dealer. Inspect cooling system and coolant recov- ery system for leaks. MAINTENANCE OWNER/ OPERATOR CAN PERFORM • CHECK ENGINE OIL LEVEL Refer to "Checking Fluid Levels ". • CHECK BATTERY • See "Checking Fluid Levels ". • Check battery cables for condition, tightness, cor- rosion or damage. Clean, tighten or replace as necessary. SOIi'O 0 AH uo a eaN 1 0-2 • EXERCISE SYSTEM • • • •• • •• • • • • • • • •• • Start the generator engine at 1eas4 once evory seven days and let it run at 'least 20 nldnntes. Sol stretkly Exercise Cycle ". • • • • •• •• • INSPECT COOLING SYSTEM • • • Inspect engine cooling system. Sie "Maintenance Schedule ". • • • • Check hoses for damage, deterioration, leaks etc. •Correct any discrepancies found. • Check hose clamps for tightness. • • • • • •• •• • • CHECK ENGINE COOLANT LEVEL See "Checking Fluid Levels ". • PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine - generator monthly. Look for obvious damage, loose, missing or corroded nuts. bolts and other fas- teners. Look for fuel, oil or coolant leaks. • INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months. Check all exhaust system pipes. mufflers, clamps, etc. for condition, tightness, leaks, security, damage. • CHECK FAN BELT • Inspect fan belts every, three months. Replace any damaged, deteriorated, worn or otherwise defec- tive belt. • Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 of an inch. Adjust belt tension as required. • INSPECT ENGINE OVERNOR Visually inspect electronic governor. DANGER A A Do not attempt to adjust the governor. Only qualified service facilities should adjust the governor. Excessively high operating speeds are dangerous and increase the risk of personal injury. Low speeds impose a heavy Toad on the engine when adequate engine power is not available and may shorten engine life. Correct rated frequency and voltage are supplied only at the proper governed speed. Some connected electrical load devices may be damaged by incor- rect frequency and /or voltage. Only qualified service technicians should adjust the governed speed. • • • • • • • • MAINTENANCE Standby Generator Sets Maintenance MAINTENANCE • ® CHANGING ENGINE OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies. Drain the oil while the engine is still warm from run- ning. 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. Turn OIL FILTER (Figure 10.2) counterclockwise and remove. Properly dispose of old filter. Figure 10.2 — Oil Filter 5. Apply light coating of new engine oil to seal of new oil filter. - Install FILTER and tighten by hand only. DO NOT OVER TIGHTEN. 6. Remove OIL FILL CAR Add recommended oil (see SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK "FULL" MARK. Crankcase oil capacity is 4.0 U.S. quarts (3.8 liters). CAUTION After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK "ADD" MARK. 7. Start engine and check for oil leaks. ® CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner, (part number 059402), simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover (Figure 10.3). See the "Service Schedule," for air cleaner mainte- nance. • • • • • • •• • •• • • • • Figure 10.3 - Engine Air 'leaner• • • Air Cleaner • • • ® SPARK PLUGS (Doors Removed for Clarity) • • •• • • • • • •• Reset the spark plug gap or replace the spark plugs as necessary (Figure 10.4). 1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean. 2. Remove the spark plugs and check the condition. Replace the spark plugs if worn or if reuse is questionable. See the "Service Schedule," Section 6, for recommended inspection. 3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.5 -0.6 mm (0.020 -0.025 inch) by carefully bending the ground electrode (Figure 10.4). Figure 10.4 — Setting the Spark Plug Gap SET PLUG GAP AT 0.5 - 0.6 mm (0.020 - 0.025 inch) 10 -3 ® COOLANT CHANGE Every year, have an Authorized Service Facility drain, flush and refill the cooling system. See "Specifications" for cooling system recommendations. 901170 0108 1101u!eW • : •• •• + 1 • •• — _Lh'`� i `4a. • . 1 + 7 ® SPARK PLUGS (Doors Removed for Clarity) • • •• • • • • • •• Reset the spark plug gap or replace the spark plugs as necessary (Figure 10.4). 1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean. 2. Remove the spark plugs and check the condition. Replace the spark plugs if worn or if reuse is questionable. See the "Service Schedule," Section 6, for recommended inspection. 3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.5 -0.6 mm (0.020 -0.025 inch) by carefully bending the ground electrode (Figure 10.4). Figure 10.4 — Setting the Spark Plug Gap SET PLUG GAP AT 0.5 - 0.6 mm (0.020 - 0.025 inch) 10 -3 ® COOLANT CHANGE Every year, have an Authorized Service Facility drain, flush and refill the cooling system. See "Specifications" for cooling system recommendations. 901170 0108 1101u!eW MISCELLANEOUS MAINTENANCE ® CLEANING THE GENERATOR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal gen- erator windings have an adverse effect on insulation resistance. Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dry, low pressure air to remove any accumulations of dirt. The generator is housed inside an all- weather enclosure, clean the enclosure with a soft, damp cloth or sponge and water. Once each year have the generator cleaned and inspected by an Authorized Service Dealer. That dealer will use dry, low pressure air to clean internal windings. Parts inside the control console should be cleaned and inspected at this time as well. Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low, the generator may require drying. 4. BATTERY All lead -acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery. If such information is not available, observe the following precautions when handling a battery: • DO NOT use Jumper cables and a booster battery to crank or start the generator engine. • DO NOT recharge a weak battery while it is installed in the generator. Remove battery from generator and recharge in a well - ventilated area, away from fuel vapors, sparks, heat or flames. • Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns. DO NOT permit fluid to contact eyes, skin, clothing, painted surfaces, . wiring insulation, etc. If any bat- tery fluid is spilled, flush the affected area with clear water immediately. • Always wear safety glasses, rubber apron and gloves when handling a battery. • Batteries give off explosive hydrogen gas while charging. The gas can form an explosive mixture around the battery for several hours after charging. Any spark, heat or flames can ignite the gas and cause an explosion which can shatter the battery, causing blindness or other serious injury. ® BATTERY MAINTENANCE The battery should be inspected per Section 4.7, Scheduled Maintenance. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. 2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES. 90/40 0 %iaH l'omen 1 0-4 • • • • • • • • • 3. Have the state of charge anc ecaftltion eheeleed. This should be done with an atitntotive -type bat- tery hydrometer. ••••• • • • • •• • • ••• • • DANGER • • • • • AStorage batteries give off of l si °ve hydrogei gas. This gas can form an explosive mixture' around the battery for several hours aftePtRArg- ing. The slightest spark can igniSSahe gas'9Atl cause an explosion. Such an d'RploSion cAASjiat ter the battery and cause blindness or other •• injury. Any area that houses a storage battery must be properly ventilated. Do not allow smok- ing, open flame, sparks or any spark producing tools or equipment near the battery. Di Battery electrolyte fluid is an extremely corro- sive sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid is spilled, flush the affected area immediately with clear water. Do not use any jumper cables or booster battery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging. WARNING A Be sure the AUTO /OFF /MANUAL switch is set to the OFF position, before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected. A Be sure the 120VAC power supply to the battery is turned OFF, or sparking may occur at the bat- tery posts as the cables are attached and cause an explosion. BATTERY REPLACEMENT When replacing batteries, use the same number and the type of battery that follows: BCI Group No. CCA 26 525 @Odeg.F NOTE: The BCI number should be located directly on the battery. 4 REPAIR PARTS The Iatter portion of this manual consists of exploded views, parts lists and electrical data pertaining to this generator set. The parts lists consist of (a) an item number, (b) a part number, (c) the quantity required, and (d) a description of the part. The item number corresponds to an identical number on the exploded view drawing. • • • • • ••••• • • • • • •••••• • • • tandby GeneratorSel Service Schedule{ ILLAINTEKANCE SERVICE SCHEDULE The following is a recommended maintenance schedule for small standby and reside established intervals in•the schedule are the maximum recommended when the unit is application. They will need to be decreased (performed more frequently) if the unit is tion. Use calendar time or accumulated run time, from the previous maintenance inte required maintenance interval. • • • ntial • neratoc. sets. The uttstrir average service esed•in a severe applicar rvaTrty determine The next •••• • • • •• •• Service Maintenance Interval Information: The various service maintenance intervals are designated by interval numbers as follow$: • • • • • •• • •• • • • • •••• • • • •• • •• • 1 An early inspection of the generator set to insure it is ready to operate when required tdidentLfyanX potew. •••• tial problem areas. • • • Performed monthly this requires approximately .5 man -hours per unit to complete. This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning: To prevent injury, perform the following steps in the order indicated before starting any maintenance: • Disable the generator set from starting and/or connecting to the load by setting the control panel AUTO /OFF/MANUAL switch to the OFF position. • Remove the 5 amp and 15 amp control panel fuses. • Turn off the battery charger (turn OFF utility supply to ATS). • Remove the negative battery cable. The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits. Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required. 2 A break -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 areas. Performed ONLY ONCE following the first three months, or 30 run time hours of operation after purchase of the unit and requires approximately 2.5 man-hours per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Deafer. 3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed semi - annually this requires approximately 1.5 man -hours per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer. 4 A mid -level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed annually this requires approximately 4.0 man -hours per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer. 1 1 -1 5021 9 ma ZOOP43SNS Maintenance Tasks Level 1 Recom- mended to be done monthly Hrs. Task Comp. (Date- Initials) Level 2 Required to be done 3 months/ Break -in 30 Hrs. Task Comp. (Date- Initials) Level 3 Required to be done Semi- annually 50 Hrs. : • Task • , Comp „„ (Date • , • Initial51, , ••■ tevel•4 • • • • Required lo be done ,Annually • j00 Hrs. ••• • • • •Task • Comp. • •(Date -: • • Initials), ,• 1. Disable the unit from operating per the first page warning. • • • II •••I • • • • • . • • • •: • • • • • • • 2. Check the engine oil level. Adjust as necessary. • • • v. _ __ ■ • • • • 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. Tighten connections as necessary. 6. Check the air inlets and outlets for debris. Clean as necessary. 7. Check the battery electrolyte level if accessible. Adjust as necessa . � 8. Check the battery posts, cables, and charger for loose connections, corrosion, and proper operation. Correct as necessary. 9. Check the unit wiring for loose connections, corrosion, and damage. Correct as necessary. 10. Check the engine accessory drive belts for wear, weather cracking, and damage. Replace as necessary. 11. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary. 12. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary. 9Ogl 9'AGEI MOPLIOSAIS 1 1 -2 •••• • • • •••• •••• • ••• • • ••• •••• • • • •••• • •••- • y Generator Se ervice Schedule` .. Maintenance Tasks Level 1 Recom- mended to be done monthly 10 Hrs. Task Comp. (Date- In itials) Level 2 Required to be done 3 months/ Break -in 30 Hrs. Task Comp. (Date- Initials) Level 3 Required to be done Semi- annually 50 Hrs. • , Task •• Comp• . • I 'i (Date -to Initials)... -••• f evel 4• • :'• Ttequire'd be done :�rtnually • 00 Hrs. • • • • 'Task 'comp. •1 ' (Date- :I • initials) _ 1 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. • • • •••••• • • • • • • • • • • • • • • •••• •••• • • • • • • • •• •, ' • •. (t 14. Start and exercise the unit at full rated load (use a load bank if the site load is not enough) for at least 2 hours looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary. • 15. Change the engine oil. 16. Replace the engine oil filter(s). c.' 17. Replace the engine air filter(s). 18. Replace the engine fuel filters) on diesel engine driven units and re -prime the fuel system. G- 19. Check the engine spark plugs on gas engine driven units. Clean and re -gap or replace as necessary. 20. Perform a 5 minute no -load operational run of the unit looking for any post service problems. 21. Return the unit to standby setup for operation when required. 1 1 -3 SO2t 8 AaH ZOORPSAIS •••• • • • •••• • •••• • • • ••• •••• • • • •••• • •••• • TROUBLESHOOTING GUIDE PROBLEM CAUSE • .•• • CORRECTION - • • • • ' •• • • Engine won't crank. 1. 15 amp fuse blown. 1. Replace fuse. • • • 2. Loose or corroded or defective 2. Tighten, clean or replan* • • • battery cables. battery cables as necessary. • • 3. Defective starter contactor. 3. Replace contactoV. • ,.• • • • • • • • • • • 4. Defective starter motor. 4. Replace starter mgpAr..*. • • 5. Dead or Defective Battery. 5. Remove, change 4' rep ac: battery.•••• • • 6. 5 amp fuse blown. 6. Replace fuse.* • • • • • • • • • • • • .. Engine cranks but won't start 1. Out of fuel. • 1. Replenish fuel. • • • 2. Fuel solenoid (FS) is defective 2. Replace solenoid? 3. Open Wire #14A from Engine Control circuit board. 3. Reconnect wire. 4. Spark plugs defective. 4. Clean, regap or replace plugs. 5. Door on tank not closed. 5. Close door on tank. Engine starts hard, runs rough. 1. Flame arrestor (air cleaner) plugged or damaged. 1. Clean or replace as needed. 2. Plugged fuel line. 2. Unclog fuel line. 3. Defective spark plugs. 3. Clean, regap or replace plugs. 4. Fuel pressure incorrect. 4. Confirm fuel pressure to regulator is as recommended 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 Switch 3. Replace switch.* 4. Defective Coolant Temperature Switch 4. Replace switch.* 5. Defective Control Module circuit board. 5. Replace board.* 6. Coolant Level is Low. 6. Repair leak - Add coolant. 7. Defective Low Coolant Level Switch 7. Replace Switch.* AUTO /OFF/MANUAL Switch at OFF, engine continues to run 1. Defective AUTO /OFF/MANUAL switch 2. Open/disconnected wire #15A between 1. Replace switch.* 2. Reconnect/close wire. AUTO /OFF /MANUAL switch and Control Module circuit board. 3. Defective Control Module circuit board 3. Replace board.* No AC output from generator. 1. Check main line circuit breaker. 1. Reset to ON or CLOSED. 2. Check circuit breaker & fuses. 2. Reset and replace, If necessary. 3. Transfer switch set to NORMAL position 3. Set to GENERATOR position. 4. Generator intemal failure. 4. * 5. Thermal circuit breaker open. 5. Auto -reset - Wait 5 min. and attempt restart. *Contact the nearest Authorized Dealer for assistance. 1 2 -1 SO/BO 0'Na 10010111.1 ••. • • • • ••. • • •••• • ••• • • • • .• • •• •••. • • • •• • • • • • • • .. • 0000 • • .. • • 00 • • • Ir • • • • • • • • • • 0. 00 .. .. • • • • • • 0000 • • • • • .. • wwww .0. • • • • • • • • . . • • • • .0 • .. • • • .. 0000 • • • • • . • • • • • 00 00 00 00 • • • • • • • • • 4100. • • 410.. i • • . . 00 • 000 • • • • • • • •• • •. • • • • • • . • • • •••• • •, - - - • • • • • • • .. •• •• • • • • • • • • •••• . • • •11100 . • • • •• • ••• • • • • 24 L N. : • • l` e 12 r. c. 6\ 26 16 r 14 15 / 8 9 40 13 I// 25 aei r ;► ti 1 e \ ` ■ r • . \\ lam''`✓" \\ 1 38 / /' 32 / / • GROUP A , 23 <\ 24 293q<\ \ � 28 7 16 eC272 17 16 39 DATE: 3/24/06 6 �• G6 • `r •f •• \ s• /' 18 PAGE 1 OF 2 •• ••• • • • • • •• • • •• ••• • •• • • • • • • • • • •• 24 • • • • • • ...... • • • • • • • • • • • • • • • • • •• • • •• ••• • ••• • • • EXPLODED VIEW: CONNECTION BOX SPL PARTS DL4 II. • is 04433 • • • • • • • • • • • •• •• • • • •• •• ••• • • • ••• • • EXPLODED VIEW: CONNECTION BOX SPL PARTS ,DRAWING #: 0G0433 APPLICABLE TO: ITEM PART # QTY. DESCRIPTION 1 OF7135 1 BREAKER TRAY BACK/BOTTOM 2 0F7022 1 SUPPORT CONTROL PANEL SIDE RH 3 OF7021 1 SUPPORT CONTROL PANEL SIDE LH 4 OF7260 1 COVER CIRCUIT BREAKER 2P 0E7136 1 COVER CIRCUIT BREAKER 3P 5 OF6156 1 PLATE WIRE SNGL GALV 6 0F4464 1 DECAL CUST CONN 120V UTILITY 7 OD4698 REF BLOCK TERM 20A 6 X 3 X 1100V 8 OF3824 1 DECAL UTIL SENSE/CUST CONN 9 057701 REF BLOCK TERM 20A 8 X 6 X 1100V 10 OF6146 1 HANG TAG 2 WIRE START (NOT SHOWN) 12 081008 1 GROMMET 1.25 X .25 X .75 13 0C2267 2 SCREW HHTT M5-0.8 X 12 BP 14 049226 2 WASHER LOCK M5 15 051713 2 WASHER FLAT M5 16 0C2212 11 SCREW PHTT M4-0.7 X 16 ZYC 17 022264 11 WASHER LOCK #8-M4 18 OF6366A 1 XFMR DUAL 104V /16V (3 PHASE) OF6366B 1 XFMR DUAL 120V /16V (1 PHASE) 19 022241 1 NUT HEX 3/8-16 STEEL 20 022237 1 WASHER LOCK 3/8 21 057329 1 LUG SLDLSS 35046 X 13/32 AUCU 22 057073 1 JUNCTION BLOCK 3/8-16 23 023484J 1 BUSHING SNAP SB- 2000 -26 24 0E3257 15 SCREW HWHTF M6-1.0 X 16 25 0E7890 REF BRKT CB MTG BACK 2P 0E6002 REF MTG TRACK BQ SIEMENS CB 313 26 0A2077 REF CB 0125A 2P 240V S BQ2 LL (2 POLE) 040532 REF CB 0100A 3P 240V S BQ3 LL (3 POLE) 27 052619 REF SCREW HHC M5 -0.8 X 20 G8.8 (NOT SHOWN) 28 023897 REF WASHER FLAT #10 ZINC (NOT SHOWN) 29 049226 REF WASHER LOCK M5 (NOT SHOWN) 30 051716 REF NUT HEX M5 -0.8 G8 CLEAR ZINC (NOT SHOWN) 31 025433 1 LUG SLDLSS 46-14 X 13/64 CU 32 0A1354A 1 REGULATOR - DC ALT 33 0E3257 REF SCREW HWHTF M6-1.0 X 16 34 022473 REF WASHER FLAT 1 /4-M6 ZINC 35 022097 REF WASHER LOCK M6-1/4 36 067210A 1 DECAL GROUND LUG 37 OF7194 REF BRACKET PANEL SUPPORT 1.5L C1 38 057593 1 CABLE TIE MOUNT BLACK 39 0F1733 1 DECAL CUSTOMER CONNECT INSIDE 40 023762 1 WASHER SHAKEPROOF EXT 410 STL GROUP A • • • • • • • • • •• • •• • • • • • • • •• • • • • 0006 • • • • • 0000 • • • • • • • • • • •• •• •• •• • • • • • • • • •••• • • • • 0000 • • • • • •• • ••• • • • • • •• DATE: 3/24/06 PAGE 2 OF 2 17 TO BLOWER HOUSING 16 . 30 28 4 29 2�� / / .'' 19 23 �� Y�_+ '' 18 GROUP A 21 20 <' 26 287'N7 7 10 22 ' * 11 31 . 13 REVISION: G- 6501 -A DATE: 3/15/06 PAGE 1 OF 2 12 TO ENGINE CRANKSHAFT 1'3 •• • • .�• •. . ••• • . •• • • • • • • • • • • • • • • . • .... • .• • • • • • • . . •. E VIA5DED VIEW: ALT COMMON PARTS •: • • : Dr #: OGD463 • • • • • UWI11i� • • • • • •• •• • • • •• •• ••• • • • ••• • • EXPLODED VIEW: ALT COMMON PARTS DRAWING #: OG0463 APPLICABLE TO: ITEM PART # QTY. DESCRIPTION 1 098936 1 ASSY RTR 25KW 2PH 2 060820 1 HOUSING BLOWER MACHINED 1.6L 3 061019 1 GUARD BLOWER HOUSING 1.6L 4 020746 4 SCREW PPHM M5-0.8 X 8 ZINC 5 049226 4 WASHER LOCK M5 6 051713 4 WASHER FLAT M5 7 022129 4 WASHER LOCK M8-5116 8 061317 1 ASSY STATOR 25KW 1PH D 061316 1 ASSY STATOR 25KW 3PH D 9 0A5382 1 BEARING CARRIER REAR 10 075591 1 ASSY HOLDER BRUSH 11 051787 4 SCREW HHC M4-0.7 X 16 G8.8 12 0A5601A 1 COVER REAR BEARING 13 0755548 4 BOLT STATOR X 16" LG 14 0A9375 4 SCREW RHM #10-24 X 2 15 022152 4 WASHER LOCK #10 16 OG0430 1 FLYWHEEL & RING GEAR ASSY 1.6L 17 042558 1 KEY SQ 318 X 1 STEEL 18 061452 1 PLATE SPACER 1.61 19 OG0965 1 PLATE FLEX 1.6L 20 053557 1 SCREW HHC M12 -1.75 X 40 G8.8 21 051769 1 WASHER LOCK M12 22 049541 4 SCREW HHC M10-1.5 X 35 G8.8 23 046526 4 WASHER LOCK M10 24 045772 4 NUT HEX M10-1.5 G8 YEL CHR 26 0A8830 4 WASHER FLAT .34 ID X .75 OD 27 077043E 1 FLEX CONDUIT 1" BLACK (NOT SHOWN) 28 022131 10 WASHER FLAT 3/8 -M10 ZINC 29 072578 1 SPACER ROTOR SHAFT 30' OF3353 6 SCREW HHC M10.1.0 X 20 G10.9 31 023365 4 WASHER SHAKEPROOF INT #8 APPLY LOCTITE 242 TO I/N 30 BEFORE THREADING INTO CRANKSHAFT. REVISION: G- 6501 -A DATE: 3/16/06 GROUP A • • • • • •• • • •••• • • •••y • • •• •• • • • •• • • • • • •• • • • • • • • • • •• •• • • • • • ••■• • • • • • • • • •••• •• • ••• • • • •• PAGE 2 OF 2 • • • • • • • • • •.••. • • • • • 000000 • • GROUP B , DETAIL 'A' NOTE - COVER ALL OPEN FASTENER HOLES REVISION: G- 8000 -B DATE: 4/28/06 PAGE 1 OF 2 SEE DETAIL 'A' • •• ••• • • • • • •• • • • 0 00 OOOO 0. • • • • •, • • • • •• •• •• •• • • • •• • • • • ••• ••e ••• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • EXP O13ED VIEW: R -200 3600 RPM 1.61. DI A•WENOt 0G1f91D • • • ••• • • • • • • • • . • •• •• • • • • ••• •• •.• • • • ••• • • EXPLODED VIEW: R -200 3600 RPM 1.6L , DRAWING #: 0G1291D APPLICABLE TO: ITEM PART # QTY. DESCRIPTION COMPONENTS INCLUDED IN OG1291E 1 OF1823A 1 ENCL I-ISB CONTROL PANEL 2 OF3078 1 COVER CONTROL PANEL 3 OF2606 1 HINGE CONTINUOUS H -PANEL 4 036261 6 RIVET POP .125 X .275 SS 5 043181 4 SCREW PHM M3-0.5 X 10MM 6 052777 7 WASHER FLAT M3 7 0613036 1 ASSY PCB CPL2 CTRLR 3600 RPM 8 OF1262 4 HOLDER FUSE WICKMANN 178.6150 9 OF1263 1 ADPTR RH SIDE WICKMAN 178.6191 10 OF1264 1 ADPTR LH SIDE WICKMAN 178.6192 11 0F1725C 1 ASSY PCB 2AMP 12V UL BAIT CHGR 12 067680 1 ASSY VOLTAGE REGULATOR60HZ. 13 0E6875A 2 RELAY 12VDC C FORMW/DIODE 14 055911 1 BLOCK TERM 20A 12 X 6 X 1100V 15 OF5459 1 DECAL CPL CONTROL PANEL FUSES 18 OF5462 1 DECAL CPL 3.9L TB1 19 0A5062J 4 SPACER 9.5H 3.21D 20 029673 1 DIO BRIDGE 25A 600V 21 049350 1 CIRCT BRK 4 X 1 ETA 46.5001' 22 OF1958 1 PLATE HARNESS CLAMP 23 082573 1 SWITCH RKR DPST 125V SPD 24 0E4494 1 SWITCH RKR DPDT ON -OFF -ON 25 OF3215 1 DECAL CONTROL HSB 26 OF6305 2 SEAL COVER 3.18 X 12.7 X 382 27 0F6305A 1 SEAL COVER 3.18 X 1Z7 X 283 28 OF5886 3 SCREW HHPM M5-0.8 X 12 29 051713 14 WASHER FLAT M5 30 049226 14 WASHER LOCK M5 31 0F5752F 1 RES WW 15R 5% 25W QK CONN 32 OF5884 2 SCREW PHTT M33 -0.6 X 10 33 OF5896 2 SCREW PHTT M3.5 -0.6 X 16 34 0C2265 4 SCREW PI-ITT M4-0.7 X 12 ZYC 35 OC3990 2 SCREW PI-ITT M4-0.7 X 10 ZYC 36 091526 8 SCREW PPHM M5-0.8 X 12 ZNC 37 051716 7 NUT HEX M5-0.8 G8 CLEAR ZINC 43 043182 7 WASHER LOCK M3 44 051714 7 NUT HEX M3-0.5 G8 YEL CHR 45 OF3192 1 SUPPORT ANGLE PCB 46 0E7403C 1 FUSE ATO TYPE 15 AMP (BLUE) 47 OF9785 1 HARN 3600RPM R200 CONTROL PNL (NOT SHOWN) 48 OF2627 1 PLATE COVER H PANEL COMPONENTS INSTALLED PER THIS DRAWING A 056739 1 RELAY SOLENOID 12VDC PNL MNT B 022287 2 SCREW HHC 1/4-20 X 3/4 G5 C 022473 4 WASHER FLAT 1/4-M6 ZINC D 022097 2 WASHER LOCK M6-1/4 E 022127 2 NUT HEX 1/4-20 STEEL F OF6145 AIR SEALWEATHER.45 "DIA REVISION: G- 8000 -B DATE: 4/28/06 GROUP B • • • • • •• • •••••• • •••••• •••• • • •••• •••••• • • •• •• • • • • • •••• • • • • • • •• • • • • • •• • • • • • • • • •• •• • • • • •• • ••• . • • •• PAGE 2 OF 2 • • • • • •••••• • • • • ••••• • � • •••••• • • •••••• • • TO BASE OF WATER INLET TUBE(ON BLOCK) 23 GROUP C f 2 J 28 '� // '"/ 27 .`. 9 ` i' �. . �)Ti 18 <7), 8 DATE: 3/20/06 36 11 41 14 TO O^0 28 17 37 20 TO THERMOSTAT ADAPTER 14157 16 MOUNT TO ENGINE PAGE 1 OF 2 15 16 MOUNTING • • FRAME REF. • . • . • • • ►� • . • 66° • • • • • • • • • • • • • • • • •• • • • • • • EXPLODED /4E%! COOLING SYSTEM 1.6L C1 • • • • D$W\1 1N #: OGOA29 • • • • • •.. • • • • • • • • • • • • • • • • • •. • •• • • • • • ••• • • EXPLODED VIEW: COOLING SYSTEM 1.6L C1 DRAWING #: 0G0429 APPLICABLE TO: ITEM PART # QTY. DESCRIPTION 1 OF7211 1 SUPPORT RADIATOR LH SIDE 2 060760 1 VENTURI 16" DIA FAN 3 OF7210 1 SUPPORT RADIATOR RH SIDE 4 0E9837B 1 RADIATOR 1.6L CHY 5 0F0230B 1 FAN COOL 16" DIA 8 BLADE 6 046526 5 WASHER LOCK M10 7 060910 1 LOWER RADIATOR HOSE 1.6L 8 099502 4 CLAMP HOSE #24 B1.06-2.00 9 069860C 1 HOSE OIL DRAIN ASSY 21° 10 055596 1 BARBED STR 318 NPT X 3/8 11 060908 1 UPPER RADIATOR HOSE 1.6L 12 046627 1 CAP RADIATOR 13 052250 2 TAPE FOAM 1 X 1(24" LG) 14 022473 10 WASHER FLAT 114 -M6 ZINC 15 022097 12 WASHER LOCK M6-1/4 16 008566 8 SCREW HHFC M6-1.0 X 20 G8.8 17 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR 18 0C2454 28 SCREW THE M6-1 X 16 N WA ZIJS 19 042568 4 SCREW HHC M6-1.0 X 20 G8.8 20 060932 1 GUARD FAN LH C1 21 060933 1 GUARD FAN RH C1 22 007649 1 CLAMP HOSE .38 -.87 23 OF7320 1 BLOCK OFF UPPER 24 OF1433 1 BRACKET 2.5L FORD WATER BOTTLE 25 076749 1 TANK COOLANT RECOVERY 26 048031C 2 CLAMP HOSE BAND 1/4 27 029032 1 HOSE 9/32 ID (43" LG) 28 050275 3 DECAL WARNING -FAN 29 022131 1 WASHER FLAT 318 -M10 ZINC 30 029107 1 GROMMET 718 X 3/16 X 518 31 060568 1 ASSY FAN BEARING SUPPORT 32 OG0405 1 BRACKET FAN ALT ADAPTER 1.6L 33 059980 1 SCREW HHC M10 -1.5 X 25 G10.9 34 051756 4 SCREW HHC M10-1.5 X 20 G8.8 35 029333A 1 TIE WRAP UL 7.4" X .19" BLK 36' 042907 4 SCREW HHC M8 -1.25 X 16 G8.8 37 026850 4 WASHER SHAKEPROOF EXT 1/4 STL 38 0A2628 1 PULLEY - FAN 95 DIA 39 0E2507 1 PROBE COOLANT LEVEL 318 NPTF 40 055934K 2 CLAMP VINYL 1.62 X .343 Z 41 0E3257 2 SCREW HWHTF M6-1.0 X 16 • APPLY LOCTITE 242 TO IIN 36 BEFORE THREADING INTO UN 31. DATE: 3/20/06 GROUP C • . • • • • •• • •••••• • OOO 4" ••.. • e•.••• • • •• •• • • • • • •••• • • • • •••. • • • •• • ••• • • • •• • • • •• • • • • • •• • • • • • • • • • ••••.. • • ••••• • • • • • • • •••.• •• •• • PAGE 2 OF 2 e • • • • • • 15 16 5 4 \,.w 10 16 HARNESS WIRE 13 14 GROUP C TO STARTER CONTACTOR e • • • • • •.' ... '.. • : EXPLODED VIEW: BATTERY C1 CPL 1.6L DRAWING #: 0G0432 APPLICABLE TO: ITEM PART # QTY. DESCRIPTION 1 0F3408B 1 BATTERY TRAY C1 CPL 2 OF3411 1 STRAP BATTERY RETAINMENT 3 025507 1 WASHER SHAKEPROOF EXT 7/16 STL 4 059980 1 SCREW HHC M10 -1.5 X 25 G10.9 5 022129 1 WASHER LOCK M8 -5116 6 077483 REF BATTERY 12VDC 75-AH 26 7 050331A 1 BATT POST COVER RED + 8 050331 1 BATT POST COVER BLK - 9 038805J 1 CABLE BATTERY BLK #1 X 30.00 10 03 04N 1 CABLE BATT RED #1 X15.00 11 045771 REF NUT HEX M8-1.25 G8 YEL CHR 12 022129 REF WASHER LOCK M8.5116 13 027482 1 WASHER SHAKEPROOF EXT 5/16 STL 14 075763 1 BOOT BATTERY CABLE 15 002454 4 SCREW THE M6-1 X 16 N WA ZIJS 16 022145 2 WASHER FLAT 5116 -M8 ZINC GROUP C • • • • •• • •••••• • •••• • •••S •1•••• • • •• •• • • • • • •••• • • • • •••• • • • •• • ••• • • • • •• • • • • • •• • • • •••••• • • • • • • •• •• • DATE: 3/21/06 PAGE 2 OF 2 • • • • • •••••• • • • • • • • 8 - 6 ..� 11 6 TO ENGINE `14'1/' BLOCK 1 C 5 9 4 12 12 L t 16 GROUP C 8--- + -5 i,'' 4_0 / / / 10 ' / I- ' DATE: 3/22/06 PAGE 1 OF 2 • • • •9 • • • • • •% • • • • ••• •• • • • •• _ •• ••• ••• �• •:• V' ;� :1� • • • •• • • •) 7 •' EXPLODED "VYEE�i1': MOUNTING BASE • :i: 1 V #OGQ754 • ••• • • • • • • • •••• • • EXPLODED VIEW: MOUNTING BASE DRAWING #: OG0754 APPLICABLE TO: ITEM PART # QTY. DESCRIPTION 1 000759 1 MOUNTING BASE 1.6L 2 027482 2 WASHER SHAKEPROOF EXT 5116 STL 3 070936 2 DAMPENER VIBRATION 4 070936C 2 VIB. ISO. 70-75 DURO 5 039253 8 SCREW HHC M8 -1.25 X 20 G8.8 6 022145 12 WASHER FLAT 5116 ZINC 7 022129 12 WASHER LOCK M8 -5116 8 045771 4 NUT HEX M8.1.25 G8 YEL CHR 9 071956 4 WASHER FLAT M8 10 051730 4 SCREW HHC M8 -1.25 X 60 G8.8 11 021991 1 EARTH STRAP 12 OF7194 2 BRACKET PANEL SUPPORT 13 026850 1 WASHER SHAKEPROOF EXT 1/4 STL 14 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR 15 055414 1 LUG SLDLSS #2-#8 X 17/64 CU 16 0E3257 4 SCREW HWHTF M6-1.0 X 16 17 022097 1 WASHER LOCK M6-114 18 022473 5 WASHER FLAT 114 -M6 ZINC DATE: 3/22/06 GROUP C • • • • • •• • • • • • • •• •• • • • • • •••• • • • • • • • •• • • • • • •• • • • •••••• • ••••.• • • • • • • • • • • • • ••••• • .• •• • •••• •• • ••• • PAGE 2 OF 2 • • • • • 38 51N 1 19 J 36 �37 T38 5 4 41 25 39 GROUP D )17 40 34 32 122 ' 4 16 23 /`i 22 \` -i 1 socio `120 T 22 ~fit*28 22 29 18 24 15 22 26 52 DATE: 3/22/06 212 20 <' > 14 47 45 13 46 44 i 227�� v PAGE 1 OF 2 12 22 20 231 X30 •• ,•• • • • •• • • • • • C. • • •., • • .. • •• e•• ••. "•' • • •• 2 3j / 35 • • • • • •• • ... ..• ••• ••• • • • • • • • • • • •.. • EXP`LA]3ED.VIEW: ENGINE COMMON PARTS '; • ; DitiaRTQ it: O%487 ••• ••�•.g • • • ••'•• • • • ••• • • EXPLODED VIEW: ENGINE COMMON PARTS ,DRAWING #: 0G0487 APPLICABLE TO: ITEM PART # QTY. DESCRIPTION 1 000207 REF ENGINE GENERAC 1.61 NG 2 060834 1 ENGINE PLATE 1.61. 3 060820 REF HOUSING BLOWER MACHINED 1.6L 4 0E9747 1 STARTER 12 VOLT 5 OG0839 2 ENGINE MOUNTING FOOT STAMPING 6 000781 1 EXHAUST MANIFOLD 1.6L MACHINED 7 OG0722 1 INTAKE MANIFOLD MACHINED 1.6L 8 0G0758 1 HEAT SHIELD LOWER 1.6L 9 060431 1 HEAT SHIELD UPPER 1.6L 10 060663 1 PULLEY CRANKSHAFT MACHINED 11 OG0786 1 WASHER PULLEY 12 0G0486 1 BRACKET TENSIONER 13 OF9617A 1 SPACER ALTERNATOR 14 0A1354B 1 DC ALTERNATR HAN -KOK 15 OG0823 1 V -BELT 3/8 X 30.6 16 0G1467 1 HEAT SHIELD FRONT 1.6L 17 002244M 1 ASSY MAGPICKUP(318 -24 MALE) 18 036710 2 PIN SPRING 1/4 X 3/4 19 005479 1 SCREW HHC M12 -1.5 X 40 G10.9 20 059980 7 SCREW HHC M10 -1.5 X 25 G10.9 21 046526 16 WASHER LOCK M10 22 022131 17 WASHER FLAT 318 -M10 ZINC 23 045772 9 NUT HEX M10 -1.5 G8 YEL CHR 24 0G0464 1 GASKET INTAKE MANIFOLD 1.6L 25 000465 1 GASKET EXHAUST MANIFOLD 1.6L 26 052858 14 NUT TOP LOCK FL M8 -1.25 27 061652 1 SCREW HHC M10 -1.5 X 85 68.8 28 057644 4 SCREW HHC M10 -1.5 X 100 G8.8 29 049541 4 SCREW HHC M10-1.5 X 35 G8.8 30 039414 1 SCREW HHC M8 -1.25 X 35 G8.8 31 022129 4 WASHER LOCK M8 -5116 32 022145 4 WASHER FLAT 5/16 -M8 ZINC 33 029333A 1 TIE WRAP UL 7.4" X .19" BLK 34 057821 3 SCREW HHC M8 -1.25 X 40 G8.8 35 045771 3 NUT HEX M8 -1.25 G8 CLEAR ZINC 36 022507 2 SCREW HHC 114-20 X 112 G5 37 022097 2 WASHER LOCK M6-1/4 38 022473 5 WASHER FLAT 1/4-M6 ZINC 39 057823 1 CLAMP HOSE #10.56 -1.06 40 077996 1 CAP ANTIFREEZE RUBBER 41 0A6751 1 SWITCH HI -TEMP 245 D X 3/8 NPT 42 035579 1 BSHG RDCR HEX 1/4 TO 1/8 43 0A8584 1 SWITCH OIL PRESSURE 10PSI 2POL 44 0C1852 1 ADAPTER DRAIN OIL 45 070928 1 CLAMP HOSE - OIL DRAIN 46 069860C 1 HOSE 01L DRAIN ASSY 21" 47 069811 1 CAP HEX 1/4 NPT BRASS 48 001241 1 THERMOSTAT HOUSNG MACHIND 1.6L 49 000144 1 CAP BY -PASS COOLANT 50 040173 1 CLAMP HOSE #5.5.62 -.62 51 0E3257 3 SCREW HWHTF M6-1.0 X 16 52 0A8830 28 WASHER FLAT .341D X .75 OD 53 000905 1 HARN 1.6L R -200 CPL (NOT SHOWN) GROUP D • • • • • • • • •••••• •• • •• • • • • • • •••••• • • • •• • •••••• • • • •••• • „• • • • •••• • •••••• • • • • • • • • • • • • •••• •• •• •• •. • • • • • • • • •••• • • • • • • ••• •••• • • •• • ••• • e • • •• DATE: 3/22/06 PAGE 2 OF 2 GROUP D , 7 16 TO "A° 10 I I \` �, -' I S , ( ENGINE , 1 DIP STICK 4. _1. 1 12 1 / /: c � Is< *c.i7 8 14 WIRE HARNESS «c t «c �c � c c c e c «` a c 11 DATE: 3/24/06 10 CARBURETOR ARM (REF.) 7-4 6 INTAKE MANIFOLD (REF.) PAGE 1 OF 2 13 1.6L •• ••• MANIPJLD • • • • • • ••• •0• • • • •• •• •.• • • • • • • • •• • • . • • • • •.• .•. ..• .•. • • • • • • • • • • • • • • • • • • .. • • • • • • EXPLO'DEDMEW: GOVERNOR ASSEMBLY •. • ; DikAjAyINQ #: OG4231 • • • • • • ••• • • • • •• •• • • • ••••• ••• • • • ••• • • EXPLODED VIEW: GOVERNOR ASSEMBLY DRAWING #: 0G1231 APPLICABLE TO: ITEM PART # QTY. DESCRIPTION 1 098290 1 ASM MOTOR STEPPER 2 098941A 1 HOUSING GOVERNOR CONNECTOR 3 098958A REF CONNECTOR INTERFACE ASSEMBLY 4 098942A 1 COVER CONNECTOR HOUSING 5 098225 2 SCREW FHM 42 X 5/8 SELF TAP 6 043146 3 SCREW HHC M6-1.0 X 10 08.8 7 022097 5 WASHER LOCK M6-1/4 8 084543A 1 SCREW PHM M3-0.5 X 12MM 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX 410-32 NYL INS 11 0E1326 1 ASSY. CARBURETOR LINKAGE ROD 12 0A7106 1 BRACKET STEPPER MOTOR 13 0G1381 1 OIL DIP -STICK BRACKET 1.6L 14 029333A 10 11E WRAP 7.4 "X.19" BLK UL 15 022507 2 SCREW HHC 114-20 X 1/2 G5 16 0E1694 1 SPRING ANTI LASH 17 064526 1 SCREW TAP HWH 46-25 X 318 ZINC GROUP D • • • • • •• • •••••• • •••••• •••• • : • •••••• • • •• •• • • •• • • • • • •• • • • •.•••• • ••••.• • • • • • • • • • • • • • • ••••• •• •• • • • • • • • •••• • • • • • • • • •••• • • •• • ••• • • •••••• • • • DATE: 3/24/06 PAGE 2 OF 2 EXISTING HOSE FROM CRANKCASE GROUP E CONNECT TO ENGINE HARNESS CARBURETOR ASSY. (I /N 19) 20 DATE: 3/22/06 41 0 28 $ «B» 23 PORT 6 7 -,,` "OUT 1" 15 ♦s a 27 ** PAGE 1 OF 2 3 SEE NOTE 1,2, &3FOR REGULATOR INFORMATION IMPORTANT SOLENOID MUST BE INSTALLED WITH FLOW ARROW POINTING IN DIRECTION SHOWN IN ILLUSTRATION ABOVE. • • • • ••• • • • • • • • • • • • •• • • • • • • • • • • ••••••• ••• •• • • • • • ••• • • • • • • • • • "9r • • •:POFIT 'OUT 2" L.P. VAPOR • • • CONVERSION • • • • • . • • • • • • • • • • • • • • • • • • • • • ••• MtitA JDED VIEW: FUEL SYSTEM NG/LPV 1.6L C1 CPL DRt. WN€ : • . • ••• • r.°7:769 •••• .• • • • • ••• EXPLODED VIEW: FUEL SYSTEM NG/LPV 1.6L C1 CPL ,DRAWING #: OG0769 APPLICABLE TO: ITEM PART # QTY. DESCRIPTION 1 026812 2 075580 3 0G1397 4 039253 2 5 022145 2 6 022129 4 7 045771 2 (1) 8 OF1570 1 9 0A6344 1 10 005210 1 11 025424 1 12 005210 1 13 0A5547 1 14 060321 1 15 001509 1 2 ELBOW 960 314 NPT 1 FLANGE FUEL INLET 1 FUEL REGULATOR 1.6L REWORK SCREW HHC M8-1.25 X 20 G8.8 WASHER FLAT 5116 ZINC WASHER LOCK M8 -5116 NUT HEX M8 -1.25 G8 YEL CHR BODY CARBURETOR ASSEMBLY BARBED EL 90 1/8NPT X 3/8 HOSE 3/8 ID LOW PRES 01UWATER (8 "LG) NIPPLE PIPE 3/4 NPT X 6 HOSE 318ID LOW PRES OIUWATER (13 "LG) COVER AIR CLEANER HOSE COOL 518°8) 250#WP (3"LG) DECAL INLET PRESSURE GROUP E ITEM PART # QTY. DESCRIPTION (1) 16 0E0591 1 17 059402 1 18 037561 1 19 0E1028D 1 20 059401 1 (1) 21 091526 4 (1) 22 049226 4 23 026915 2 24 062522 1 25 022127 1 (1) 26 0E1339 1 27 " 050279 1 050280 1 28 030795 2 29 OF6155 1 (1) 30 0E1104 1 (1) 31 0E0668 1 (1)32 0E0590A 1 (1) 33 005133 1 (1)34 0E0665 1 (1) 35 0E1108 1 (1) 36 033138 1 (1) 37 022152 1 (1) 38 0E0645 1 (1) 39 034339 1 40 059194 1 41 057823 2 42 048031G 2 (1) 43 039450 1 44 029470 1 45 059057 1 46 0G1461 1 47 OF3994 1 48 061462 1 (1) 49 0E0568 1 (1) 50 0E0527 1 (1) 51' 025105 1 (1) 52 0E0991 1 53 048031P 2 54 048031J 4 55 0480311 5 56 035579 1 ADAPTER CARE. TO AIR CLNR FILTER ELEMENT • • NUT WING 1/4.20 NYLW • • ASSY CARBURETOR 1.6P • • CARBURETOR GASKFJ• • • • SCREW PPHM M5-0.8 X 12 VIC WASHER LOCK M5 •••••• NIPPLE CLOSE 3/4 X 1.315.• *' STUD TH 1/4-20 X 3 GDZNC FUu• NUT HEX 1/4 -20 STEEL • • • • PIN SPRING 3116 X 51$% DECAL FUEL INLET NG • • DECAL FUEL INLET MI • • SCREW HHC 5116-18Y3Q5••• • HARNESS FUEL JUMPER SINGIf REG GASKET AIR CLEANER ADAPTLR •••• O-RING 2 -0281.38 X 6.50 X.Ofj • • VENTURI 20MM • • • •••• O-RING 29.82 X 2.62 • • • SCREW THROTTLE PIN STOP THROTTLE ARM REWORK SCREW HHM #10-32 X 5/8 WASHER LOCK #10 LEVER THROTTLE STOP BARBED EL 903/8 NPT X 518 HOSE 518 ID LPG & NG (16° LG) CLAMP HOSE #10.56.1.06 CLAMP HOSE BAND .41 BARBED EL 903/16 X118 HOSE 3/161D FUEL LINE (22 "LG) HOSE 3/41D SAE -30R2 ( 31.6) HOSE BARB TEE 314° NYLON PCV VALVE 2.51 FORD HOSE BARB REDUCER 5/8 " -3/81D SHAFT, THROTTLE 1.5L THROTTLE VALVE PLATE 27MM SCREW RHMS 6.32 X 114 ZINC SEAL, SHAFT COVER CLAMP HOSE BAND .88° CLAMP HOSE BAND .63 CLAMP HOSE BAND 1.0" BSHG RDCR HEX 1/4 TO1 /8 • • 000000 • •• • • • • • •• • • •••••• • • • • • • •• •• ••• • • • •• (1) INCLUDED IN ITEM 19 (CARBURETOR ASSY ) NOTES: 1. REGULATOR (UN 3) AS SHOWN IN ILLUSTRATION IS SET UP FOR NATURAL GAS APPLICATION. 2. TO CONFIGURE REGULATOR FOR LP VAPOR, SWITCH HOSE BARB, HOSE CLAMP (UN 41) AND HOSE (UN 40) FROM "OUT -1° TO "OUT -2". REPLACE PIPE PLUG FROM "OUT -2" TO "OUT -1 °. USE PIPE SEALANT ON HOSE BARB AND PIPE PLUG. MAKE SURE TO KEEP PORTS FREE FROM DEBRIS DURING RECONFIGURATION PROCESS. 3'. APPLY LOCTITE TO I/N 51 BEFORE THREADING INTO UN 49. r. FOR LP VAPOR APPLICATION SUBSTTNE LPG FUEL INLET DECAL PIN 050280 FOR NG FUEL INLET DECAL PIN 050279 (ITEM 27). 5. WHEN SWITCHING FUEL TYPES, THE PROPER DIP SWITCH SETTINGS MUST BE MADE TO THE CONTROL PANEL SEE OWNERS MANUAL, FUEL SECTION FOR MORE DETAILS. DATE: 3/22/06 PAGE 2 OF 2 •••1•• • •• • • 1111•• • • ••••• • . • •••••• • • • • • •••••• • • REVISION: G- 7989 -C DATE: 4/25/06 r- 15-'4 16-4 17 18 GROUP F . OINSULATION AND RETAINERS LOCATED ON THE NEAR SIDE. . ^`INSULATION AND RETAINERS '. ^' LOCATED ON THE FAR SIDE. 19 RETAINER 001 TYPICAL MOUNTING OF ACOUSTIC INSULATION. 12 ** 18 '<, 8 j[ iGi ,:i15.,'-<:' -�•� - -- .:'ssss .-. 1 ''•:1 a. 10 11 4 10 PAGE 1 OF 2 13 `1.1 14 25 • • • • • •• • • • • • • • • • • ..,.. • •10•• • • • • •• • • • • • • ••• ••• .•• •.• • • • • • • • • • • • • • • • • • • • • • • • • • •• • •.• •• • • •• • EXPLODED VIEW: ••• ENCLOSURE C1 CPL • Deli #:OF1356 • •• • •• • • • • • • • • • ••• • • •• ••• •• • •• • EXPLODED VIEW: ENCLOSURE C1 CPL ,DRAWING #: OF7356 APPLICABLE TO: ITEM PART # QTY. DESCRIPTION 1 OF7003 (XX) 1 ROOF C1 CPL 2 OF7004 (XX) 1 CORNER POST LH SIDE C1 CPL 3 OF7008 (XX) 1 DOOR REAR C1 CPL 4 OF7005 (XX) 1 CORNER POST RH SIDE C1 CPL 5 OF7007 (XX) 2 DOOR LH & RH SIDE C1 CPL 6 OF7006 (XX) 1 DUCT FRONT DISCHARGE C1 CPL 7 0C2634A 1 ASSEMBLY COVER ACCESS 8 0912970091 1 ASSY WIRE 14AWG 13.8" GRNIYEL 9 0912970080 2 ASSY WIRE 14AWG 33.5" GRNIYEL 10 0E5968 1 GASKET EXTRUDED TRIM (356" LG) 11 0E3257 6 SCREW HWHTF M6-1.0 X 16 12 " 077992 18 NUT HEX LOCK M6-1.0 SS NY INS 13 OF5049 3 TAB PULL 14 OF5048D 3 VISE - ACTION LATCH SLOTTED CIR 15 022473 1 WASHER FLAT 114-M6 ZINC 16 022097 1 WASHER LOCK M6-1/4 17 022127 1 NUT HEX 1/4-20 STEEL 18 0C2454 24 SCREW THE M6-1 X 16 N WA ZIJS 19 078115 20 WASHER SELF LOCKING DOME 20 0F3890B 2 RETAINER INSULATION (820) 21 OF3890 4 RETAINER INSULATION (450) 22 0F7365 2 INSULATION SIDE DOOR C1 23 OF7365B 1 INSULATION REAR DOOR C1 CPL 24 0F7365A 1 INSULATION ROOF C1 CPL 25 0F8869D 1 KEY VISE - ACTION LATCH SLOT CIR OPTIONAL COMPARTMENT MATERIALS: ALL P /N'S WITH AN (XX) SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION. USE THE FOLLOWING LEGEND TO IDENTIFY THE CORRECT PART NUMBER: PART NO. MATERIAL COLOR OXXXXXSN STEEL TAN OXXXXXAN ALUMINUM TAN OXXXXXSG STEEL GRAY OXXXXXAG ALUMINUM GRAY " ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 18 & 11 THREAD FORMING FASTENER AND ITEM 12 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER. GROUP F • • • • • •• • 000000 • •••••• •••• • " • •••• •••o•• • • •• •• • • • • • • • • • • •• • • • •• • • • • • •• • • • •••••• • • • • • • •• •• • • • ••• • • • REVISION: G- 7989 -C DATE: 4/25/06 PAGE 2 OF 2 •••••• • • • • • • • • • ••••• • • • •••••• • • •••••• • • GROUP F i 17 17 DATE: 3/21/06 I _ I PAGE 1 OF 2 ••• " • • • • • • •• • • • • • • • • • •• • • • • • •• ••• •• • • • • Cr • •• •• • • • •• • • • • • • • • ••• ••• ••• ••• • • • • • • • • • • • • •• • • • • ••• E tflDED VIEW EXHAUST SYSTEM 1.6L C1 ••• : DRf3.Vylit€r#: °G31435 • • • • • ••• • • • • ••••• • •` • • • • ••• • • • ••• •• •• EXPLODED VIEW: EXHAUST SYSTEM 1.6L C1 ,DRAWING #: OG0435 APPLICABLE TO: ITEM PART # QTY. DESCRIPTION 1 OF7366 1 MUFFLER C1 2 OF7647 1 MUFFLER SADDLE 3 OF8095 1 PIPE EXHAUST OUTLET GROUP F 4 OF7538 1 PIPE EXH INLET MUFLR SIDE 1.5L • • 5 0E3257 4 SCREW HWHTF M6-1.0 X 16 • • • 6 OF7644 2 MUFFLER STRAP • • • 7 006119 1 BOLT U 5116 -18 X 2 -114 • • • •' • • • • 8 036434 3 BOLT U 5116 -18 X 2.09 9 036449 3 SADDLE 2INCH •••••• • • 10 022129 8 WASHER LOCK M8.5116 ...loos • • 11 022259 6 NUT HEX 5116 -18 STEEL 12 038750 1 SCREW HHC M6-1.0 X 30 G8.8 • 13 0G1043 1 EXHAUST PIPE 1.6L • • 14 OF3794 1 EXHAUST BLANKET 600MM LONG too • • • • • 15 022097 1 WASHER LOCK M6-114 16 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR • • • • 17 022473 6 WASHER FLAT 114 -M6 ZINC • • • • • • • • • • • •••• •• • DATE: 3/21/06 ••• • • • PAGE 2 OF 2 OPTION 1 — SINGLE PHASE, R— SERIES CONTROL PANEL, 240V LEGEND AS MLCB NB 44 )IOI MLCB oIoio E3 11 44 GENERATOR OUTPUT CUSTOMER CONNECTION El — E3 = 240VAC El — NB = 120VAC E3 — NB = 120VAC L REVISION: G- 7501 -B DATE: 02/22/06 22 33 DIRECT DRIVES GROUP G • • • • • • •• • • = AL•V�E!•I� ATOR RCTiBR �. = A■•ERaIATOR STOTOR = MALNL.GIRCUI BR €AKER = NEVIwEt. BL • I(.•• 1..•. • • • • • •• h • • • • •• •• • • • • • • • 1 -4 ®2® 4 ---I® 3 2-4®14� 6 -4®5® 11 --4 ®6® 44--H® 7® I I AS • • 0000 • • •••• ••• • • • •• TB1 • ••0000 • • PAGE I OF 4 J WIRING - DIAGRAM R- SERIES CPL ALTERNATOR DRAWING #: OF6839 OPTION 2 — THREE PHASE, R— SERIES CONTROL PANEL, 6 —WIRE 120/208V GROUP G • • • ••• LEGEND •• • AR = ALTERN4TQR. ROTCP •. • • AS = ALTERNAVU. STATOR MLCB = MAIN CIVWU T BREAKER NB = NEUTRArL BLOCK • • • 61016 MLCB 01010 1 E2 E3 SI S2 S3 DIRECT DRIVE • •• •• • •. • • • • •• r • • • r {®2® 4 ,I ®3® I ®4® 6 I ®s® TB1 r S1 ----�® 6 ® S3 —4r 9 7 SI r I I • AS GENERATOR OUTPUT CUSTOMER CONNECTION E1 TO E2 E2 TO E3K208VAC E1T ❑E3 J El, E2, OR E3 TO NB = E 120VAC wNOTE: THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE '6' = 120 /208VAC PAGE 2 of 4 L. REVISION: G- 7501 -B DATE: 02/22/06 • • • • • •• •• • •••. • • ••.. ••• • • • •• ••...• .• • • • • • •.•.. r r +.• J WIRING - DIAGRAM R SERIES CPL ALTERNATOR DRAWING #: OF6839 •• • • .: r OPTION 3 – THREE PHASE, R– SERIES CONTROL PANEL, 6 –WIRE 277/480V 01010 MLCB 01010 1 E2 E3 s GROUP G -; • • • • • • • LEGEND '• • •• • AR = ALTERAA ROTE1R ••• • AS = ALTERNM-014 STATOR. MLCB = NEUTRAL.. .PL•OCKRAKF� NB R ss S3 •• •• •• • • • • • ®5® -SI 6 —sl � I I DIRECT DRIVE AS GENERATOR OUTPUT CUSTOMER CONNECTION E1 TO E2 E2 TO E3K480VAC- EI TO E3 El, E2, OR E3 TO NB = 277VAC *N❑TE1 THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE 'K° = 227/480VAC L REVISION: G- 7501 -B DATE: 02/22/06 • • • • •• •• •• • 0000 • • 0000 ••• • • • •• TB1 • • • 1. e . �•••• 3 11 • •• • PAGE 3 OF 4 J WIRING - DIAGRAM R- SERIES CPL ALTERNATOR DRAWING #: OF6839 • OPTION 4 - THREE PHASE, R- SERIES CONTROL PANEL, 12 -WIRE 120/208 1 (BLACK 4 (REDS OIO MLCB 01010 1 E2 E3 NB SI S3 S7 S1 SO S� S9 S3 GROUP G 1 • • • • • • LEGEND •• • •• • AR = ALTERNAaCe ROT JR'••' AS = ALTERW•TO'hi STATOR MLCB = MAIN CIRCUIT . •� BR AKER NB ' S4 S5 DIRECT DRIVE S6 S10 S11 S12 • • •• •• • • • • • • • I..1• 1 I ®2® 4 1 ®3® 2 rl ®4® TB1 6 1 ®5® S1 -}®6® r S3 ® 7® ,I I AS GENERATOR OUTPUT CUSTOMER CONNECTION E1 TO E2 ll E2 TO E3E208VAC} E1TOE3 -' El, E2, OR E3 TO NB = 120VAC *NOTE, THE 8th DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE 'G° = 120/208VAC PAGE 4 OF 4 L REVISION: G- 7501 -B DATE: 02/22/06 •••••• • • • L • • •••• • • •••• ••• • •• 1 • • • • • • J WIRING - DIAGRAM R SERIES CPL ALTERNATOR DRAWING #: 0F6839 • r CONTROL PANEL LEGEND AVR - AUTOMATIC VOLTAGE REGULATOR BCH - BATTERY CHARGER BRI - DIODE (FIELD BOOST) CB2 - CIRCUIT BREAKER (EXCITATION) EC - EMISSIONS CONNECTOR Fl - FUSE, BAT. POWER (15A ATO TYPE) J2 - CONNECTOR 2 (ON PCB) J3 - CONNECTOR 3 CON PCB) R4 - FIELD BOOST RESISTOR, 25 OHM RL1 - RELAY 1 (START RELAY) RL2 - (RELAY 2 (ENGINE RUN) SW1 - AUTO /OFF /MANUAL SWITCH SW2 - SET EXERCISER SWITCH TB_ - TERMINAL BLOCK TR1 - TRANSFORMER 1 GROUP G 1 CUSTOMER CONNECTION . ALTERNATOR LEGEND BA - BRUSH ASSEMBLY (GENERATOR) ICT - INTERCONNECT TERMINAL BLOCK MCB - MAINLINE CIRCUIT BREAKER NB - NEUTRAL BLOCK UCT - UTILITY CONNECT TERMINAL BLOCK • NOTE, ALL WIRES ARE 18 AWG UL LISTED UNLESS OTHERWISE NOTED AS SHOWN+ SIZ (AWG) 15 � X15 PIEL 15 15- ,+, �II■ SW211)lb -PCB J3- u11I I - 1 INOtat -3 —WI arse -4 —W2 MI1H9 -5 —W3 tat>H4 -6 —W4 AFS OUT START RELAY FUEL(RUN) RELAY 2 WIRE STARTCI) MOMENT. OPEN 2 WIRE START(2) MAN /AUTO INPUT 16VAC SENSE(1) ALARM RELAY XFER RELAY MAN. INPUT 16VAC SENSEC2) EMISSIONS ENABLE GND -B SW1 • • • • •• • •, ••••y• • • 000 of 120 VAC • .` • • UTILITY • SUPPLY: • • • • • 1 • • • CUSTOMER CONNECTIONS • • 000000 • •• • • • • • •• • • •• •••••• • • • • • • •• •• • •••. • • •••. ••• • • • • PCB J2- - 1 -808 - 2 —56A -3 -14A -4 -183 -5Am15E 6 —178 I7�15A 18 a247---' 9— -10-23 -11 -239 -12 -225 13 -0 -14Am 0 :.o '614A WO 14 15A� W 15 A —' ©1 ©I ©1 • • • • • P • ••••• •f••• •4•••• •4•••• • • ••1••••• • • •••••• • • 5— ,-11 /S1 -44/S3 Wn 14 14 15A 1 56 SA 5 z W 1C CPO- L-- - --0 -- 44/S3 11 /S1-' GO 56' 44/S3' UTILITY FROM T /SW UTILITY FROM T /SW TRANSFER RELAY COIL TRANSFER RELAY COIL REMOTE START REMOTE START MEC CBI OUO CT N1- N2- 23" 4 83'res2C 78" NB L SINGLE -PHASE STATOR SHOWN. FUR 3 -PHASE SEE DWG. OF6839. BA STATOR CENTER TERMINAL NOT USED 601 LFP REVISION: * DATE: 03/03/06 CUSTOMER _ CONNECTIONS 14 J WIRING - DIAGRAM 1.6L 2-POLE DRAWING #: 000925 r GROUP G PCB J DEG +12V - 1- OX INP RET 2 805 DEG GND -3- COOLANT TEMP - 4 - 85 GOV OV -5- GOV +5V+6- DISTRIBUTOR 12V - 7 - COOLANT LEVEL - 8 -573 I CRANK SENSOR IN . 9 -7') CRANK SENSE RET. 10-0 LFP IN 11 -601 GOV FDBK 12- OX INP 13-804 COIL CO 1412115R COIL (A-) - 151175125A DISTRIBUTOR RET. +16- DISTR. INPUT -, 17- DEG PWM+18- DEG ENABLE -19- LOW OIL PRESS. -20-- 86 CRANK SHIELD -21 -SHLD COIL (C-) -22- COIL CB- )- 23112325B 8 1-15 1 OPTIONAL EMISSION CONTROL Cob 02 A -805 - B-804_ SHLD ENGINE WIRING LEGEND AFS - AIR/FUEL SOLENOID ALT - D.C. CHARGE ALTERNATOR BAT - 12VDC BATTERY CP - COIL PACK DCVR - DC VOLTAGE REGULATOR FS - FUEL SOLENOID FS2 AUX. FUEL SOLENOID GND - GROUND HCT - HIGH COOLANT TEMP VITCH JI - CONNECTOR .1 CON PC P • • • • LFP - LOV FUEL ERESWW SWITCH LOS - LOW 1291. PRESSURE•ZWITGH MP1 - MAGKIIG JICKUP • • • 02 - OXYGEN •S SOR • •• SC - STARIiEfi t NTACTOR • SM - STA TER MOTOR STM - ST R NICITOR • • WLS - CO I T•L' -VEL WPM* • • - WIRE SPLICE • • •• •• I-0- irm 14 DC -VR 1 2 3 4 5 48 6 491!3 14 • • • MP•1 • • •• • `--ES-25A Pm 25B °7115R 2 �lo FRONT 601 -0 4 -573 A GND ALT • • • • •• •• •••• • • •••• ••• • • • •• 1 • • • • T • �•••• • • •• I • • • • ID •••• • • L REVISION: * DATE: 03/03/06 J WIRING -DIAGRAM 1.6L 2 -POLE DRAWING #: 000925 r GROUP G —PCB J3— NOT USED - NOT USED - 2 BLACK -W1- 3 - W1 RED -W2 - 4 - W2 WHITE -W3 - 5 - W3 GREEN -W4 - 6 - W4 F1 dlp -IS 13 AFS OUT - PCB 808 START RELAY - 2 -56A FUEL(RUN) RELAY- 3 -14A 2 WIRE START(1) - 4 -183 MOMENT. OPEN 5 -15E 2 WIRE START(2) 6 -178 MAN /AUTO INPUT 4- 7 15A 16VAC SENSE(1) T 8 -224 ALARM RELAY 9 - XFER RELAY -10- 23 MAN. INPUT -11 239 16VAC SENSE(2) -12- -225 EMISSIONS ENABLE -13 -0- - GND -B -14 -0 225 ----� ... TR1 n N 1 CONNECT FOR OPTIONAL EMISSIONS ONLY NOTE 1� WIRING SHOWN FOR CB1, NB, BA AND STATOR IS TYPICAL FOR SINGLE PHASE. FOR 3- PHASE, SEE DWG. OF6839. L REVISION: • DATE: 03/13/06 15 SW2 SW1 15E -US- 15 N1 N2 CONTROL PANEL LEGEND AVR - AUTOMATIC VOLTAGE REGULATOR BCH - BATTERY CHARGER BR1 - BRIDGE RECTIFIER CB2 - CIRCUIT BREAKER (EXCITATION) Fl - FUSE, BAT POWER (15A ATO TYPE) J2 - CONNECTOR 2 (ON PCB) • • J3 - CONNECTOR 3 (RN PCB) • R4 - FIELD BOOST RESiISTOR RL1 - RELAY 1 (S ?ART•RELAY)• • • RL2 — RELAY 2 44pAI C RUN) • • • SW1 - AUTO /OFF/MA SWITC?1 :SW2 • - SET EXER�04S9fS8WITCH TR1 - TRANSFORh t• ,(6VA 240/1VAC) • • • • • • ••S•• ISIS • �••••• • • • • • • 6•••• •••• • • • • • • • • 1 • • • •••• • • l••••• • • • • • • •••• S •• • ••••• 4 • ISIS•• • • • px4 elm �I EYY ©I ©I ©I ©I M1 UCT 1 L1 NOTE 1 UCT 2 N CB1 UCT -3 GND 0 -0-6- -I1 44 1 (31-6-1-6---44 11 4 '-Ni ICT 1/UTILITY FROM T /SW ANC ICT 2 /UTILITY FROM T /SW X23 PICT 3 /TRANSFER COIL RELAY `--194 ICT 4 /TRANSFER COIL RELAY NB `-183 IICT -5 /REMOTE START "-170 ICT -6 /REMOTE START CUSTOMER CONNECTION & ALTERNATOR LEGEND BA - BRUSH ASSEMBLY (GENERATOR) CBI - MAINLINE CIRCUIT BREAKER 240V OUTPUT TO TRANSFER SWITCH ICT - INTERCONNECT TERMINAL BLOCK NB - NEUTRAL BLOCK UCT - UTILITY CONNECT TERMINAL BLOCK •S• • • • • • J SCHEMATIC - DIAGRAM 1.6L 2 -POLE DRAWING #: OG1042 • r • GROUP G PCB J1 DEG +12V - 1- DX INP RET 2 805 DEG GND - 3 - COOLANT TEMP - 4 - 85 GOV OV -5- GOV +5VI.6- DISTRIBUTOR 12V -7- COOLANT LEVEL - 8 -573 — CRANK SENSOR IN - 9 —79 CRANK SENSE RET. 10-0 LFP INP 11-601 - GOV FDBK 12- OX INP 13 -804 COIL (+) 14-15R COIL (A ) - 15-25A DISTRIBUTOR RET. 1-16- DISTR. INPUT -, 17- DEG PWM;-18- DEG ENABLE -19- LOW OIL PRESS. -20- 86 CRANK SHIELD -21 -SHLD COIL CC-) -22 COIL CB -) -23 -253 —STM 2 3 -W1 4 -W2 5 -W3 6 -W4 OPTIONAL EMISSION CONTROL C FNRINF WIRING LEGEND AFS - AIR/FUEL SOLENOID ALT D. C. CHARGE ALTERNATOR BAT - 12VDC BATTERY CP - COIL PACK DCVR - DC VOLTAGE REGULATOR FS - FUEL SOLENOID FS2 - AUX. FUEL SOLENOID HCT - HIGH COOLANT T SWITCH JI - CONNECTOR 1 C PC LFP OW FUEL PRES E•ePICH LOS - IQJJ QIL•PRESSURE SWITCH MP1 - MAGNET It PICKUP• • 02 — OKYYito SENSOR • • • SC RV sTAER CONTACTOR•• SM - ti eat MOTOR • STM - SjFpj' R MOTOR WLS - COOLA L LEVEL: %wJ t• •••••• • • • • •• •• • • • 79 • • • •• •• • • •••• • • • • •••• 1.1„1.:1 i • MP1 FRONT ALT REVISION: * DATE: 03/13/06 J SCHEMATIC —DIAGRAM I.6L 2 -POLE DRAWING #: 0G1042 •••••• • • • OOOOOO • • •••••• • • • • ••••• •••••• •• • •••••• • • •••••• • •' REVISION: DATE: 5/2/06 WEIGH DATA 1. 6L 20KW - 289KG C 774 l b] 1, 6L 25KW - 296KG C 794 l b] WOODEN SHIPPING SKIDS INCREASE OVERALL WEIGHT - T. B. D. NDTE_St 1) MINIMUM RECOMMENDED CONCRETE PAD SIZE D 1346 < 53. 0 °) WIDE X 2413 (95.0') L❑NG,REFERENCE INSTALLATION GUIDE P/N OF5298 FOR CONCRETE PAD REINFORCEMENT AND PAD DEPTH GUIDELINES. 2) GENERATOR MUST BE LOCATED A MINIMUM DISTANCE OF 5 FEET FROM A WALL OR FENCE. ALLOW A 5 FOOT MINIMUM PERIMETER OF OPEN SPACE AROUND THE ENTIRE GENERATOR, REFERENCE INSTALLATION GUIDE P/N OF5298 FOR OUTDOOR ROOF MOUNTED APPLICATIONS. 3) CIRCUIT BREAKER INFORMATION: SEE SPECIFICATION SHEET WITHIN OWNERS MANUAL 4) INSIDE STUB -UP AREA FOR AC LOAD LEAD CONDUIT CONNECTION, NEUTRAL CONNECTION, BATTERY CHARGER 120 VOLT AC C , 5 AMP MAX.) CONNECTION, AND ACCESS TO TRANSFER SWITCH CONTROL WIRES. REMOVE FRONT COVER FOR ACCESS. 4A) FIELD CUT HOLE IS ONLY REQUIRED FOR MOUNTING OF GENERATOR ON AN EXISTING PAD, 5) REFERENCE OWNERS MANUAL FOR LIFTING WARNINGS. 6) REMOVE LIFT -OFF ENCLOSURE TO ACCESS EXHAUST MUFFLER. EXHAUST AND AIR DISCHARGE LOUVERS - FRONT AND SIDES 3 MMEN MMMMN EMENN 305 MMMN 305 ••• ••• • • • .. 13.5 (.53') DIA. MOUNTING MIN, M IV] :• • • • •• HOLE (4) PLACES, 12,7 (1/2') MIN. • •• DIA. MASONRY ANCHOR BOLTS RECOMMENDED GROUP G • • • ••• ••• • • • • • • • • . • • • CONCRETE MOUNTING PAD •• • • • • T. • • .' • • SEE NOTE 1 ••• • ••• :• '• • WIRING DIAGRAM FRONT VIEW PAGE 1 OF 2 • • • •INSTALLATION DRAWING 1.6L 20 & 25KW • • AWING #: 0G1044 • • • •••• • • • • • • • • • • • • • • • • •• •• • • • •• • '•• ••• • • • ••• • REMOVE COVER FOR ACCESS TO RADIATOR FILL CAP 870 [34.25'] CENTER OF GRAVITY 708 [27.87'] TYP 100 C3.94'] TYP EXHAUST MUFFLERS ENCLOSED WITHIN, SEE NOTE 6 30.5 [1.2'] TYP ri y 146.5 C5.77'] — 90 [3.54'] j ^ STUB -UP AREA SEE NOTE 4 388.5 [15.3'] 3 BATTERY 12 VOLT 24F 625 COLD CRANKING AMPS 1603 (63.11'] TYP TOP VIEW 1803 (70.98'] f 928 [36.54'] DOOR TYP 173.25 C6.82'] GROUP SERVICE ITEM ACCESSIBILITY CHART SERVICE ITEM ACCESS OIL FILL CAP THRU LEFT DOOR OIL DIP STICK THRU RIGHT DOOR OIL FILTER THRU RIGHT DOOR OIL DRAIN HOSE THRU RIGHT DOOR RADIATOR DRAIN HOSE THRU RIGHT DOOR AIR CLEANER ELEMENT THRU RIGHT DOOR SPARK PLUGS THRU RIGHT DOOR MUFFLERS SEE NOTE 6 FAN BELT THRU RIGHT DOOR BATTERY THRU RIGHT DOOR REFERENCE OWNERS MANUAL FOR PERIODIC REPLACEMENT PART LISTINGS 13.5 (.53') DIA. MOUNTING HOLE (4) PLACES LOCATED ON BOTTOM OF GENERATOR MOUNTING FRAME VISE ACTION LATCH, ONE PER DOOR, ONE LIFT -OFF DOOR PER SIDE OF GENERATOR CONTROL PANEL R200 TYPE BATTERY CHARGER IS ENCLOSED WITHIN mm 305 [12'] r-o- MIN. NNW 305 [12'] MIN. AIR INLET LOUVERS 733.5 [28.88'] DOOR FRONT COVER TYP SEE NOTE 4 906 [35.67'] 636 [25,04'] (RIGHTHAND SIDE) 1.5L FUEL LINE CONNECTION 3/4' NPT FEMALE COUPLING REVISION: DATE: 5/2/06 EFT SIDE VIEW CIRCUIT BegAjC SEE: NOTE 736 [28.98'] low • I�I • • 1 LIFTING PROVISION REAR VIEW (4) PLACES, SEE iNOT.E 5 Atf'�1D CENTER OF GRAVIT`� $IMENiIONS:• ••• ••• FIELD CUT HOLE FCC• OL�TSIDt CONDUIT • • CONNECTION ONLY, SEE NOTE 4A•• • `V� LAAAGRAM INSTALLATION DRAWING 1.6L 20 & 25KW • PAGE 2 OF 2 • • • : : : .:191/AWN G #: 0G1044 • • • • • .•. • • • •.• • • • • • • • • ••• • 08 • • • •. 00 GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR HOME STANDBY /LIGHT COMMERCIAL PRODUCT 45kW AND BELOW • For a period of two (2) years from the date of sale, or start-up by Authorized/Certified Generac Power Systems Dealer, orbranctythereof, R@teP Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by G& •F�wer Systems or an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accalZiend>bwith the warranty schedule set forth below. Any equipment that the purchaser /owner claims to be defective must be examined by giiEltarest Rtithofited/ Certified Generac Power Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Gene}dtdf3 OSA in °Standby° applications, as Generac Power Systems, Inc. has defined Standby, provided said generator has been properly installed er 1iinepected orrsite k appropriate personnel. Scheduled maintenance, as outlined by the generator owner's manual, is highly recommended. ThI %sdlpi l be perrivntd 4y an Authorized/Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been performed throughout the warranty period. • • • • • • •• •• •• •• WARRANTY SCHEDULE YEARS ONE and TWO — Limited comprehensive coverage on mileage, labor, and parts listed. • - ALL COMPONENTS 'Start -u• and/or On -line Re•istration, or Re.istration Card, alone with Proof of Purchase, must be .erformed and/or se in. •••••• • • • • • • •••• • • • Guidelines: • 000 • • • • • • Any and all warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems De3itir, or branch thereof. • A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply. • All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate Manual. • Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable. • Unit enclosure is only covered against rust or corrosion the first year of the warranty provision. • Use of Non - Generac replacement part(s) will void the warranty in its entirety. • Engine coolant heaters (block- heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision (If applicable). THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING: 1. Any unit built/manufactured prior to January 1, 2005. 2. Costs of normal maintenance (i.e. tune -ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up). 3. Any failure caused by contaminated fuels, oils, coolants /antifreeze or lack of proper fuels, oils or coolants/antifreeze. 4. Units sold, rated or used for "Prime Power°, "Trailer Mounted" or "Rental Unit° applications as Generac Power Systems have defined Prime Power, Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition and warranty. 5. Units used for prime power in place of existing utility power where utility is present or in place of utility power where utility power service does not normally exist. 6. Failures caused by any external cause or act of God such as, but not limited to, collision, fire, theft, freezing, vandalism, riot or wars, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tomado, hurricane, terrorist acts or nuclear holocaust. 7. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing. S. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing. 9. 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). 10. Failure due to misapplication, misrepresentation, or bi -fuel conversion. 11. Telephone, facsimile, cell phone, satellite, intemet, or any other communication expenses. 12. Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.). 13. Overtime, holiday, or emergency labor. 14. Planes, ferries, railroad, busses, helicopters, snowmobiles, snow -cats, off -road vehicle or any other mode of transportation deemed abnormal. 15. Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct cause of the problem. 16. Startin batteries fuses, II ht bulbs en.ine fluids and overni.ht frei ht cost for re lacement art s THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser /owner. GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/ owner. Purchaser /owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser /owner specific legal rights. Purchaser /owner also may have other rights that vary from state to state. Generac Power Systems, Inc. • P.O. Box B • Waukesha, WI 53187 Ph: (262) 544-4811 • Fax: (262] 544 -4851 Bulletin 017I36OSVE r Printed trt U.S.A. 7.05 Printed in USA 000000 • • • • • 000000 • • • • ••••• • • • •••••• • • •••••• • •