Page 2 - Table of Contents
SECTION PAGEINTRODUCTION ........................................................... 1-1 Read this Manual Thoroughly ....................................................... 1-1 Operation and Maintenance .......................................................... 1-1 How to Obtain Service ...............
Page 3 - INTRODUCTION; READ THIS MANUAL THOROUGHLY; Indicates a hazardous situation or action which, if not; OPERATION AND MAINTENANCE; Safety Instructions
INTRODUCTION Thank you for purchasing this model of the stationary emergency generator product line.Every effor t 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 r...
Page 4 - SAFETY RULES; GENERAL HAZARDS
SAFETY RULES Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, effi-ciently and reliably only if it is properly installed, operated and maintained. Many accidents ...
Page 6 - IDENTIFICATION RECORD; DATA LABEL; General Information; Data Label
IDENTIFICATION RECORD DATA LABEL Every generator set has a DATA LABEL that contains impor tant information per tinent to the generator. The data label, which can be found attached to the generator’s lower connection box, lists the unit’s serial number and its rated voltage, amps, wattage capacity, p...
Page 7 - COOLANT RECOMMENDATIONS; Equipment Description
EQUIPMENT DESCRIPTION This equipment is a revolving field, alternating current Stationary Emergency Generator. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the ...
Page 8 - ENGINE PROTECTIVE DEVICES; Approximate Crank Cycle Times; Engine Protective Devices
ENGINE PROTECTIVE DEVICES The Stationary Emergency Generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm. For that reason, the engine has several devices designed to protect it against p...
Page 9 - FUEL SYSTEM; FUEL REQUIREMENTS; Fuel System
FUEL SYSTEM FUEL REQUIREMENTS The Stationary Emergency Generator may be equipped with one of the following fuel systems:• Natural gas fuel system• Propane vapor (LPV) fuel systemRecommended fuels should have a Btu content of at least 1,000 Btu's per cubic foot for natural gas; or at least 2,520 Btu'...
Page 10 - SPECIFICATIONS; GENERATOR; Specifications
SPECIFICATIONS GENERATOR Type......................................................................Synchronous Rotor Insulation ............................................................. Class H Stator Insulation ............................................................ Class H Telephone Inter...
Page 11 - WEATHER AND MAINTENANCE KITS
WEATHER AND MAINTENANCE KITS To keep the generator running at its peak, the following kits are offered: Cold Weather Kit • ~ Recommended for climates with temperatures below 32° F. Extreme Cold Weather Kit • ~ Recommended Block Heater Kit for protection in tempera- tures below 32° F. Scheduled Maint...
Page 12 - Figure 7.2 — Stator Power Winding; Figure 7.3 — Stator Power Winding
ALTERNATOR AC LEAD CONNECTIONS The electrical wires in the unit’s AC connection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. The voltage and phase are described on the generator data label. The number of lead wires can be iden...
Page 13 - Figure 7.4 — Stator Power Winding; Figure 7.5 — Stator Power Winding; Figure 7.7 — Stator Power Winding; Figure 7.8 — Stator Power Winding
Figure 7.4 — Stator Power Winding Connections - 3-phase, 120/208V (6 Lead) E3 E2 00 (NEUTRAL) INTERNAL CONNECTIONS E1 L-L L-N S1 S1 S4 S4 S6 S6 S3 S3 S5 S5 S2 S2 Figure 7.5 — Stator Power Winding Connections - 3-phase, 120/208V (12 Lead) E3 E2 E1 L-L L-N S7 S1 S10 S4 S12 S6 S9 S3 S5 S11 S2 S8 Figure...
Page 14 - DISPLAY INTERFACE MENUS; Control Panel
CONTROL PANEL INTERFACE USING THE AUTO/OFF/MANUAL SWITCH With the switch set to AUTO, the engine may crank and start at any time without warning. Such automatic starting occurs when utility power source voltage drops below a preset level or during the normal exercise cycle. To prevent possible inj...
Page 15 - ACTIVATION CHART
8-2 CntrlNexus001 Rev . D 04/11 Control Panel ACTIVATION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired lan-guage. Press ENTER to select. If the wrong language is chosen, it can be changed later using the “edit” menu. Display Reads: Press ENTER to begin the ...
Page 16 - INSTALLATION ASSISTANT; SETTING THE EXERCISE TIMER; LOW SPEED EXERCISE; USER ADJUSTABLE SETTINGS; AUTOMATIC TRANSFER OPERATION
INSTALLATION ASSISTANT Interconnect System Self Test Feature (follow the on-screen prompts).Upon power up, this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits. This is done to prevent damage if the installer mistakenly connects A...
Page 18 - Figure 1 – Generator Control Panel
CHECK ENGINE MESSAGE The control system has detected an emissions related fault. This fault cannot be cleared using the control panel interface. The unit will continue to operate in automatic mode. Contact your local servicing dealer. UNDER-FREQUENCY SHUTDOWN ALARM After star ting, if the generator ...
Page 19 - COMMON ALARM RELAY
OVERVOLTAGE ALARM If the generator voltage rises above 110% for >3 seconds, an alarm will be issued.If the generator voltage rises above 130% for >0.2 seconds, an alarm will be issued. INTERNAL FAILURE SHUTDOWN ALARM Any internal failure that can be detected such as corrupted firmware will cau...
Page 20 - MAINTENANCE ALERT CHART
MAINTENANCE ALERT CHART CONDITION 1.6 CHERY 2.4/1800 MITSU 2.4/3600 MITSU 4.2 FORD Change oil & filter aler t 3mo/30hrs break-in 1yr/100hrs 3mo/30hrs break-in 1yr/100hrs 3mo/30hrs break-in 1yr/100hrs 3mo/30hrs break-in 1yr/100hrs Inspect/clean air inlet & exhaust aler t 3mo/30hrs break-in 6m...
Page 21 - MENU
8-8 CntrlNexus001 Rev . D 04/11 Control Panel A CTIV A TION R UN LOG ALARM LOG HIST OR Y ST A TUS COMMAND S TAT E VERSIONS DISPLA Y GENERA T OR FREQ UENCY ENGINE HOURS ENGINE RPM B A TTER Y V O LTA G E DEB UG INPUTS OUTPUTS DISPLA YS EDIT LANGU A GE TIME/D A TE EXERCISE TIME/SPEED ESC Press the “ESC...
Page 22 - Operation
STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator’s manual for this unit. OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the Stationary Emergency Generator was installed in conjunction with a transfer switch capable of manual operation only, the fol-...
Page 23 - GENERAL MAINTENANCE; CHECK ENGINE OIL; Figure 10.1 - Oil Dipstick and Oil Fill Cap; Oil; CHANGING ENGINE OIL; Maintenance
GENERAL MAINTENANCE Before working on the Stationary Emergency Generator, ensure the following: The AUTO/OFF/MANUAL switch is in the OFF position. • The control panel fuse has been removed from the control • box. The 120VAC supply to the battery charger is switched OFF. • The negative battery cabl...
Page 24 - Figure 10.2 – Fan Belt
ENGINE COOLANT Check coolant level in coolant recovery bottle. See the Specifications and Service Schedule sections. 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 ...
Page 25 - Figure 10.3 – Engine Air Filter; Air Filter; SPARK PLUGS; BATTERY FLUID
Figure 10.3 – Engine Air Filter Air Filter SPARK PLUGS Reset the spark plug gap or replace the spark plugs as neces- sary.1. Clean the area around the base of the spark plugs to keep dir t and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not bl...
Page 26 - SERVICE SCHEDULE; Frequency; Service Schedule
SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Yearly - Y Inspect Change Clean Fuel Fuel Lines & Connections M X Lubrication Oil Level M X* Oil Y X** Oil Filter Y X** Cooling Engine Coolant Lines & Connections M X Engine Coolant Level M X Engine Coolant Y X En...
Page 27 - Troubleshooting; TROUBLESHOOTING GUIDE; PROBLEM CAUSE
Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 amp fuse blown. 1. Replace fuse.* 2. Loose or corroded or defective 2. Tighten, clean or replace battery cables. battery cables as necessary.* 3. Defective star ter contactor. 3. Replace contactor...
Page 33 - EXPLODED VIEW: CONBOX C2 CPL; GROUP A; ITEM
EXPLODED VIEW: CONBOX C2 CPL DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: H-9621-F Page 4 of 8 DATE: 9/26/11 ITEM PART# QTY. DESCRIPTION 1 0H6266 1 BACK PANEL CONBOX SUPPORT C2 2 0H6265 1 TOP PANEL CONBOX SUPPORT C2 3 0H6160 1 COVER WIRE ENTRY CONBOX 4 057073 2 JUNCTION BLOCK 3/8-16 5 056739 1...
Page 37 - THIS PAGE LEFT INTENTIONALLY BLANK
EXPLODED VIEW: CONBOX C2 CPL DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: H-9621-F Page 8 of 8 DATE: 9/26/11 THIS PAGE LEFT INTENTIONALLY BLANK
Page 43 - AIR CLEANER 2.4L G2 TURBO; GROUP D
EXPLODED VIEW: AIR CLEANER 2.4L G2 TURBO DRAWING #: 0H1954 GROUP D APPLICABLE TO: REVISION: H-3963 –B PAGE 2 OF 2 DATE: 2/27/09 ITEM PART# QTY. DESCRIPTION 1 0F4269 2 GASKET MIXER BODY 2 0H0030 1 ADAPTOR-MIXER 3 0G39340ST03 1 BRACKET AIR INTAKE 4 035480 1 BOLT U 5/16-18 X 2.06 5 0H0028 1 ADAPTOR-AIR...
Page 51 - EXPLODED VIEW: MUFFLER EXH 2.4L G2 TURBO; GROUP F
EXPLODED VIEW: MUFFLER EXH 2.4L G2 TURBO DRAWING #: 0H3357 GROUP F APPLICABLE TO: REVISION: H-5192-B PAGE 1 OF DATE: 10/12/09 ITEM PART# QTY. DESCRIPTION 1 0G86870ST03 1 BRACKET MUFFLER 2 0G8686 1 BRACKET STIFFENER 3 0G6150 1 MUFFLER 60kW 4 0G0113 1 EXHAUST ELBOW 5 0F2808D 1 EXHAUST PIPE 6 0G0007 1 ...
Page 54 - ENGINE COMMON PARTS 2.4L G2 TURBO 60K
EXPLODED VIEW: ENGINE COMMON PARTS 2.4L G2 TURBO 60K DRAWING #:0H7323 GROUP D APPLICABLE TO: REVISION: H-7244-D Page 3 of 4 DATE: 8/10/10 ITEM PART# QTY. DESCRIPTION 1 0H1619 1 ENGINE 2.4L G2 CERTIFIED 2 035472 1 CLAMP HOSE #6 .43-.78 3 0G1738 1 CAP ANTIFREEZE RUBBER 9.5DIA 4 0G0950 1(REF) GASKET IN...
