Table of Contents
SECTION PAGE
INTRODUCTION ............................................................................... 1-1
Read this Manual Thoroughly .......................................................1-1
Operation and Maintenance ..........................................................1-1
How to Obtain Service .................................................................1-1
SAFETY RULES ...............................................................................1-2
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
Engine Protective Devices ................................................................4-1
Coolant Temperature Sensing .......................................................4-1
Low Coolant Level .......................................................................4-1
Oil Pressure Sensing ....................................................................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 Liquid Fuel System ..................................................................5-1
SPECIFICATIONS .............................................................................6-1
Stationary Emergency Generator ..................................................6-1
Engine .........................................................................................6-1
Cooling System............................................................................6-1
Fuel System .................................................................................6-2
Electrical System .........................................................................6-2
5.4L & 6.8L Ignition Description .......................................................6-2
Ignition Power-up Input ("56 Line Input") ......................................6-2
Ignition Enable ("14 Line Input") ...................................................6-2
Ignition Shutdown on Loss of Crank or Cam Signals ....................6-2
Diagnostic Blink Patterns (Red LED Located
on the Ignition Control Board) ...................................................6-2
GENERAL INFORMATION.................................................................7-1
Alternator AC Lead Connections .......................................................7-1
Four-lead, Single-phase Stator ......................................................7-1
Alternator Power Winding Connections .............................................7-1
3-phase Alternators ......................................................................7-1
3-phase Alternators ("Delta" Configuration)...................................7-2
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 Genset Start-up ................................................8-1
Start-up Checklist ............................................................................8-2
Preparation for Start-up ................................................................8-2
OPERATION ..................................................................................... 9-1
Stationary Emergency Generator Control and Operation ....................9-1
Operating Unit with Manual Transfer Switch ......................................9-1
Engine Start-up and Transfer ........................................................9-1
Retransfer and Shutdown .............................................................9-1
Operating Unit with Automatic Transfer Switch .................................9-1
MAINTENANCE .............................................................................. 10-1
Maintenance Performed by Authorized Service Dealers ..................10-1
Every Three Months ...................................................................10-1
Once Every Six Months ..............................................................10-1
Once Annually ............................................................................10-1
First 30 Operating Hours ............................................................10-1
First 100 Operating Hours ..........................................................10-1
Every 500 Operating Hours ........................................................10-1
Cooling System..............................................................................10-1
Checking Fluid Levels .....................................................................10-1
Check Engine Oil ........................................................................10-1
Battery Fluid ...............................................................................10-1
Engine Coolant ...........................................................................10-2
Maintenance Owner/Operator Can Perform .....................................10-2
Check Engine Oil Level ...............................................................10-2
Check Battery ............................................................................10-2
Exercise System ........................................................................10-2
Inspect Cooling System .............................................................10-2
Check Engine Coolant Level .......................................................10-2
Perform Visual Inspection ..........................................................10-2
Inspect Exhaust System .............................................................10-2
Check Fan Belt ...........................................................................10-2
Inspect Engine Governor ............................................................10-2
Changing Engine Oil ...................................................................10-2
Changing the Engine Air Cleaner.................................................10-3
Spark Plugs ...............................................................................10-3
Coolant Change .........................................................................10-3
Miscellaneous Maintenance ...........................................................10-3
Cleaning the Stationary Emergency Generator ............................10-3
Battery .......................................................................................10-4
Battery Maintenance ..................................................................10-4
Battery Replacement ..................................................................10-4
SERVICE SCHEDULE .....................................................................11-1
TROUBLESHOOTING .....................................................................12-1
Troubleshooting Guide ....................................................................12-1
EMISSIONS WARRANTY ...............................................................13-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
Content042 Rev. A 07/09
