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  3. JG103236

Miller JG103236, TRAILPOWER 25DA3 Owner's manual

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September
1986
FORM:
OM-471A
OWN
ERS
MANUAL
MILLER
ELECTRIC
MFG.
Co.
718
S.
BOUNDS
ST,
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
75
CENTS
Effective
With
Serial
No.
JG103236
MODEL
TRAILPOWERfi25DA3
IMPORTANT
Read
and
understand
the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equip
ment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
un
trained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
b
LIMITED
WARRANTY
EFFECTIVE:
JANUARY
2,
1986
-
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-
Subject
to
the
terms
and
condi-
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
tions
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
4
warrants
to
its
Distributor/Dealer
that
all
new
and
unused
therefore
shall
be,
at
Millers
option
(1)
repair
or
(2)
replacement
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
~)
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
accessories
or
other
items
manufactured
by
others.
Such
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
engines,
trade
accessories
and
other
items
are
sold
subject
to
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
the
warranties
of
their
respective
manufacturers,
if
any
.
All
option
of
repair
or
replacement
will
be
F.O.B.,
Factory,
at
Œ1
engines
are
warranted
by
their
manufacturer
for
one
year
from
Appleton,
Wisconsin,
or
F.O.B.,
at
a
MILLER
authorized
service
date
of
original
purchase,
except
Tecumseh
and
Onan
engines
-
facility,
therefore,
no
compensation
for
Uansportation
costs
of
which
have
a
two
year
warranty,
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent

defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
warranty
Except
as
specified
below,
Millers
warranty
does
not
apply
claim
procedures
to
be
foIIo~ved.
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
wire
including
nozzles
and
nozzle
insulators
where
failure
does
ANY
IMPUED
WARRANTY,
GUARANTY
OR
REPRESENTA
not
result
from
defect
in
workmanship
or
material.
liON
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
CUSTOM
OF
TRADE
OR
COURSE
OF
DEAUNG,
INCLUDING
within
the
following
periods
from
the
date
of
delivery
of
Equip-
ANY
IMPUED
WARRANTY
OF
MERCHANTABILITY
OR
OF
ment
to
the
original
user;
.
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
~:
~
....!~.......
3y~are
CLUDED
AND
DISCLAIMED
BY
MILLER.
3.
Mw
~ins,feeder/gur~nd~atorches...
90
days
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
!.)
4.
All
other
Millermatic
Feeders
1
year
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
~
5.
Replacement
or
repair
parts
exclusive
of
labor..
60
days.
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
6.
Batteries
6
months
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
ThE
USE
AND
MAINTENANCE
OF
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
of
the
date
of
such
failure
CONSUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
~
~
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
INTRODUCTION
1
-
1.
General
Information
And
Safety
1
1
-
2.
Receiving-Handling
2
1
-
3.
Description
2
1
-
4.
Generator
Set
Applications
2
SECTION
2
-
INSTALLATION
2-1.
Location
5
2
-
2.
Extension
Elbow
Installation
6
2
-
3.
Spark
Arrestor/Muffler
Installation
(Optional)
6
2
-
4.
Connecting
The
Battery
6
2-5.
Fuel
7
2
-
6.
Engine
Pre-Start
Checks
7
2
-
7.
Ether
Starting
Aid
(Optional)
7
2
-
8.
Equipment
Grounding
Terminal
7
2
-9.
Frequency
Changeover
8
2-10.
Generator
Reconnections
8
2-11.
Auxiliary
Power
Connections
9
SECTION
3
-
OPERATOR
CONTROLS
3
-
1.
Safety
Shutdown
System
10
3-2.
StartPushButton
11
3
-
3.
Voltage
Adjustment
Control
11
3
-
4.
Ammeters
11
3
-
5.
Voltmeter
11
3
-
6.
Frequency
Meter
11
3
-
7.
Stop
Control
11
3
-
8.
Battery
Charge
Indicator
Lamp
11
3
-9.
Hour
Meter
11
3-10.
Ether
Starting
Aid
(Optional)
12
SECTION
4
-
SEQUENCE
OF
OPERATION
4
-
1.
Starting
The
Engine
12
4
-
2.
Engine
Shutdown
12
SECTION
5
-
MAINTENANCE
5-1.
General
13
5
-
2.
Periodic
Cleaning
And
Inspection
13
5
-
3.
Fuel/Water
Separator
And
Sludge
Drain
Plug
13
5-4.
Air
Cleaner
Service
13
5
-
5.
Servicing
The
Spark
Arrestor
(Optional)
14
5-6.
BrushesAndSlipRings
15
5-7.
EtherStartingAid(Optional)
15
5
-
8.
Engine
Speed
Adjustment
15
5
-
9.
Electrical
System
16
5-10.
Maintenance-Free
Battery
Charging
16
SECTION
6
-
TROUBLESHOOTING
6-1.
General
17
6
-
2.
Troubleshooting
Chart
17
6
-
3.
Booster
Battery
Jump
Starting
17
SECTION
1
-
INTRODUCTION
Output
Elee
trical
Information
Wire
Maximum
Engine
Weight
Connections
Voltage
Amp
Voltage
Amp
Hertz
Phase
Connections
KW
KVA
and
PF
RPM
Net
Ship
Three-Phase
Connection
120/208
69
254/440
33
60
3
4
20
25at0.8
1850
.
.
,~
1898
lbs.
(861
kg)
1941
lbs.
(880
kg)
127/220
66
277/480
30
139/240
60
120/240
240/416
35
110/190
61
240/416
28
50
3
4
.
16
2OatO.8
1550
115/200
53
254/440
26
120/208
56
110/220
53
127/220
53
115/230
j~
220/380
30
120/240
48
230/440
29
Single-Phase
Connection
120
2081
60
1
2
20
25at0.8
1850
120/240
115/230
104
87
115
174~j
60
50
50
1
1
1
3
2
3
20
16
16
25
at
0.8
20
at
0.8
2OatO.8
J.~!850
].
1550
1550
Figure
1
-
1.
Specifications
eUse
indicated
holes
when
mounting
on
EDT-2400-2
trailer
To
obtain
proper
tongue
weight.
inchee
Miiiimetere
A
59-118
1502
B
47-1/4
1200
43-1/4
1099
D
32-3/4
832
E
24-15/16
633
10-1/2
267
6-1/2
165
2-7/8
73
15/18
24
29-7/8
759
C-048
720-C
Base
Mounting
Hole
Dimensions
Figure
1
-
2.
Dimensional
Drawing
And
Base
Mounting
Hole
Layout
1
-
1.
GENERAL
INFORMATION
AND
SAFETY
B.
Safety
A.
General
ment.
WARNING
21/32
in.
(17
mm)
60-1/2
in.
(1537
mm)
31
-1
/4
~
~~79~
mm)
Information
presented
in
this
manual
and
on
various
labels,
tags,
and
plates
provided
on
this
unit
pertains
to
equipment
design,
installation,
operation,
maintenance
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equip-
The
nameplate
of
this
unit
uses
international
symbols
for
labeling
front
panel
controls.
The
symbols
also
ap
pear
at
the
appropriate
section
in
the
text.
The
installation,
operation,
maintenance,
and
troubleshooting
of
this
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
sons
in
accordance
with
this
manual
and
all
applicable
codes.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
____________
and
sf.tI1Is1~I
which
identify
different
levels
of
hazard.
OM-471
Page
1
W~i.1
thl
I
~
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
I~tUI
I
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed could
result
in
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
A
third
signal
word,
______________,
highlights
instruc
tions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
of
this
equipment.
Always
use
approved
wiring
and
switching
devices.
All
electrical
installations
to
be
performed
by
a
qualified
electrician.
Do
not
connect
to
any
electrical
distribution
system
normally
supplied
by
utility
power
unless
a
proper
transfer
switch
and
grounding
procedure
are
employed.
LOW
VOLTAGE
AND
FREQUENCY
can
damage
electrical
equipment.
Turn
off
or
disconnect
all
electrical
equipment
connected
to
the
unit
before
starting
or
stopping
the
engine.
1
-
2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
will
be
furnished
by
the
manufacturer
on
re
quest
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
Number
of
the
equipment
be
supplied.
1
-
3.
DESCRIPTION
-
This
generator
is
designed
to
supply
25
kva,
60
Hz
or
20
kva,
50
Hz
ac
power
primari
ly
for
use
where
no
utility
power
is
available.
If
this
unit
is
used
on
a
standby
or
emergency
basis,
always
con
sult
the
local
electrical
utility,
local
and
state
codes,
and
the
latest
issue
of
the
National
Electrical
Code
for
proper
installation
procedures.
All
units
are
shipped
set
up
to
provide
the
type
of
power
output
specified
by
the
customer.
If
no
specific
output
request
is
made,
units
are
shipped
set
up
to
supply
120/240
volts,
60
Hz
three-phase
output
(Series
Delta
generator
connection).
However,
the
generator
is
reconnectable
to
supply
120-240
volts
single-phase
or
three-phase
ac
power
depending
on
the
connectins
made.
Equipment
that
must
be
operated
on
an
electrical
supply
that
has
a
precise
frequency
tolerance
or a
pure
sinisoidal
wave
form
should
not
be
connected
to
the
output
of
this
generator.
This
generator,
driven
by
a
three-cylinder,
air-cooled,
Deutz
diesel
engine,
is
reconnectable
in
parallel
or
series
wye,
or
parallel,
series,
double
delta
connection
with
available
voltages
listed
in
Figure
2-4.
WARNING
_________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Keep
all
covers
and
panels
in
place
while
operating.
Stop
and
disable
engine
before
inspecting
or
ser
vicing.
Stop
the
engine
before
making
electrical
connec
tions
to
this
unit.
Ground
generator
as
required
by
all
applicable
na
tional
and
local
electrical
codes.
Provide
ground
fault
and
over
current
protection
as
required
by
all
national
and
local
electrical
codes.
1
-4.
GENERATOR
SET
APPLICATIONS
(Table
1-1)
A.
Three-Phase
Load
Characteristics
Loads
often
consist
of
both
three-phase
and
single-
phase
equipment.
Generators
used
to
provide
power
to
systems
having
combinations
of
single-phase
and
three-
phase
loads
are
susceptible
to
load
unbalance.
An
un
balanced
load
is
one
of
the
major
causes
of
equipment
failure.
Three-phase
loads
are
self
balancing;
however,
single-phase
loads
must
be
carefully
planned
and
distributed
between
the
phases
to
obtain
balanced
voltages
and
prevent
the
overloading
of
one
or
two
phases.
Delta
connections
for
this
unit
are
basically
designed
for
240
volts
three
phase
in
combination
with
120
volts
single-phase.
Delta
connections
are
commonly
used
where
the
bulk
of
the
load
is
three-phase
motors
(balanced
load)
and
only
a
small
120
volts
output
is
re
quired.
Wye
connections
can
be used
with
any
com
bination
of
single-phase
and
three-phase
loads
as
long
as
the
rated
current
in
amperage
between
the
load
leads
is
not
exceeded
(see
Figure
2-4).
The
load
leads
are
marked
Li,
12,
L3,
and
LO.
Check
the
generator
con
nection
diagrams
and
output
specifications
before
mak
ing
connections.
Overloading
is
apparent
when
the
ampere
rating
of
one
or
more
of
the
windings
is
exceeded.
An
effort
should
be
made
to
equalize
the
amperes
taken
from
each
phase,
but
the
separate
phases
need
not
necessarily
be
equal.
The
ammeters
on
the
front
panel
of
the
generator
are
provided
to
ensure
that
the
amperes
in
any
phase
do
not
exceed
the
amperage
rating
of
the
generator.
B.
Load
Analysis
And
Generator
Set
Sizing
Load
analysis
and
generator
set
sizing
are
essential
for
satisfactory
generator
set
and
equipment
operation.
The
power
available
from
the
generator
set
is
limited
by
the
engine
horsepower.
Any
single
load
may
represent
usage
of
a
large
portion
of
the
total
power
available.
Carefully
determine
the
total
load
that
will
be
applied
by
adding
up
all
the
individual
loads.
Some
tools
are
rated
in
watts,
others
in
amperes.
Check
equipment
nameplate
to
determine
wattage.
If
watts
are
not
shown,
but
amperage
and
voltage
are
given,
follow
this
formula:
Amp
x
Volts
=
Watts
1000
=
kilowatts.
OM-471
Page
2
Example:
4.5
(amps)
x
115
(volts)
=
517
watts
–
1000
=
0.52
kilowatts.
Most
equipment
will
specify
on
its
nameplate
what
its
specific
requirements
will
be.
For
ex
ample,
a
drill
requires
4.5
amperes
at
115
volts.
Watts
equals
volts
times
amperes.
Therefore,
this
drill
requires
approximately
520
watts
or
0.52
kilowatts
to
operate.
Add
three
200
watt
flood
lamps,
and
requirments
in
crease
by
600
watts
for
a
total
of
1120
watts
or
1.12
kilowatts.
Continue
in
this
fashion
until
all
loads
have
been
added.
Be
sure
to
consider
the
extra
load
values
of
motorized
equipment
(see
Motorized
Applications
sec
tion).
Consider
also
that
a
load
is
not
always
constant.
Lights
and
resistance
heaters
are
relatively
constant,
but
portable
power
tools
are
not.
One
rarely
grinds
or
drills
with
a
constant,
even
pressure.
Thus,
the
load
re
quirements
change
greater
than
anticipiated.
Miller
generator
sets
are
designed
to
operate
at
max
imum
load,
but
doing
so
allows
very
little
reserve
engine
horsepower
to
follow
changes
in
load
requirments.
This
makes
itself
known
by
noticeable
voltage
and
frequency
changes.(light
bulbs
flicker,
etc.)
as
the
engine
governor
attempts
to
regulate
the
output.
Improved
voltage
and
frequency
regulation
can
be
realized
by
not
loading
the
generator
to
100%
of
its
capacity.
For
best
perfor
mance
and
load
handling,
use
only
approximately
90%
of
the
available
output.
The
10%
margin
allows
for
more
satisfactory
engine
governor
responsto
chang
ing
load
situations.
The
rule
becomes
simple:
Always
know
the
total
load
requirements
and
the
generators
capability.
Limit
load
requirements
to
the
capabilities
of
the
generator
set.
C.
Motorized
Applications
Electric
motors
require
more
power
when
starting
than
when
running.
Therefore,
it
is
the
starting
watts
figure
which
is
critical
when
estimating
the
load
on
the
generator
set
and
not
the
nameplate
or
running
watts
figure.
Starting
wattage
is
usually
equal
to
approximate
ly
four
times
the
running
wattage.
If
two
or
more
motors
are
to
be
started
at
the
same
time,
the
values
of
the
motors
must
be
totaled.
For
example:
four
1/2
HP
fan
motors
would
be
valued
at
4
x
1100
=
4400
watts
or
4.4
kilowatts
for
the
running
load
and
4
x
2400
=
9600
watts
or
9.6
kilowatts
for
the
additional
generating
capacity
required
for
starting.
Therefore,
it
would
require
a
total
of
440
watts
+
9600
watts
=
14000
watts
or
14
kilowatts
to
start
all
four
fan
motors
simultaneously
(See
Table
1-1
Starting
And
Running
Watts).
A
point
to
remember:
When
loading
small
generator
systems,
always
apply
the
largest
load
first
and add
loads
in
secession
with
the
smallest
applied
last.
If
a
motor
does
not
start
within
five
seconds,
disconnect
power
to
it
or
the
motor
could
be
damaged.
This
five
seconds-maximum-time
rule
should
be
applied
to
all
motor
starting
situations
to
prevent
damage
to
the
start
windings.
D.
Summary
To
determine
the
load,
make
a
list
of
the
total
wattage
for
the
equipment
to
be
powered
by
the
generator
set.
Always
try
to
keep
the
load
requirements
within
90%
of
the
available
output
of
the
generator
set.
For
standby
emergency
service
include
only
the
essential
equipment
(refrigerator,
sump
pump,
etc.)
which
must
be
kept
in
operation.
Table
1-1
shows
approximate
starting
and
running
watts
required
for
various
equipment.
E.
Extension
Cables
Extension
cables
are
normally
used
when
electric
power
is
supplied
to
tools
or
loads
at
some
distance
from
the
generator
set.
Select
cables
of
adequate
amperage
capacity
and
proper
wire
size
for
the
distance
involved
and
to
keep
voltage
drop
to
a
minimum.
Table
1-2
pro
vides
a
guide
for
selecting
the
proper
size
cable
for
single-phase
or
three-phase
loads
based
on no
more
than
a
2%
voltage
drop
in
the
cables.
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Stop
engine
and
disconnect
negative
(-)
batter,
cable
before
making
electrical
connections.
Use
cab/es
with
properly
fitting
plugs.
Ensure
that
all
equipment
is
properly
grounded.
Do
not
use
frayed
or
damaged
cab/es.
OM-471
Page
4
Single-Phase
120
Volts
Copper
Conductor
Wire
Current
Amperage
Max
imum
AllowabI
e
Cable
Length
In
Feet
250
MCM
#2/0
#0
#2
#4
#6
#8
#10
200
140
150 185
100
100
275
145
115
75
370
195
155
100
50
555
295
235
145
93
60
25
115
590
470
295
185
115
75
45
For
other
voltages
mult~pIy
the
above
lengths
by
new
voltage
and
divide
by
120.
Three-Phase
208
Volts
Copper
Conductor
Wire
Current
Amperes
Max
imum
Allowabl
e
Cable
Length
n
Feet
2/0
0
2
4
6
8
10
12
70
420
260
210
130
60
490 310 245
155
50
590 370
295
185
117
.
40
740
465
370
230
145
95
30
985
620
495
310
195 125
80
20
1480
930
740
460 290
185
115
75
For
other
voltages
multiply
the
above
lengths
by
new
voltage
and
divide
by
208.
Table
1
-
2.
Maximum
Allowable
Cable
Lengths
1.
Distances
are
based
upon
2%
voltage
drop
bet
ween
the
generator
and
load
connections
to
the
cable.
2.
Distances
are
for
the
length
of
cable
between
the
generator
and
the
load.
3.
If
a
distance
is
not
given,
the
current
rating
of
the
60C
cable
is
exceeded.
4.
Charts
are
based
upon
ambient
temperature
of
30C
and
cable
temperatures
rating
of
60C.
5.
For
current
ratings
of
other
cable
constructions
or
ambient
temperatures,
refer
to
table
310-16
of
National
Eelctric
Code
-
1984.
6.
Do
not
exceed
current
rating
of
the
cable.
SECTION
2
-
INSTALLATION
WARNING
ENGINE
EXHAUST
GASES
can
kill.
Operate
in
open
well
ventilated
areas
or
if
operated
indoors
vent
engine
exhaust
outside
the
building.
Keep
engine
exhaust
vent
outlet
away
from
building
air
intakes.
ENGINE
EXHAUST
SPARKS
can
cause
fire.
Exhaust
spark
arrestor
must
be
installed
in
accor
dance
with
local,
state,
and
federal
regulations.
Keep
a
properly
maintained
fire
extinguisher
near
by
and
be
familiar
with
its
proper
use.
The
engine
exhaust
system
on
this
generator
set
has
not
been
equipped
with
a
spark
arrestor
unless
it
was
ordered
as
an
optional
accessory.
A
spark
arrestor,
maintained
in
effective
working
order,
is
mandatory
if
this
generator
set
is
to
be
operated
in
a
National
Forest
or
on
California
Grasslands,
brush,
or
forest
covered
land
(see
Section
4442
of
California
Public
Resources
Code).
For
other
areas,
check
your
state
and
local
laws.
2
-
1.
LOCATION
(Figure
2-1)
OM-471
PageS
WARNING
__________
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
trailer,
or
any
other
heavy
ac
cessories.
Use
equipment
of
adequate
capacity
to
lift
the
unit.
If
using
lift
forks
to
handle
this
unit,
be
sure
the
lift
forks
are
long
enough
to
extend
out
of
the
op
posite
side
of
the
base.
OPERATION
ON
UNLEVEL
SURFACE
can
cause
improper
lubrication
and
result
in
severe
engine
damage.
Operate
unit
in
an
approximately
level
position.
See
Figure
2-1
for
maximum
allowable
tilt
for
pro
per
operation.
Check
crankcase
oil
level
with
unit
on
a
level
sur
face.
Exceeding
these
limits
can
cause
severe
engine
damage.
-
RESTRICTED
AIR
FLOW
causes
overheating
and
possible
damage
to
internal
parts.
Maintain
at
least
18 inches
(457
mm)
of
unrestricted
space
on
all
sides
of
unit
and
keep
underside
free
of
obstructions.
Do
not
place
any
filtering
device
over
the
intake
air
passages
of
this
generator
set.
Warranty
is
void
if
any
type
of
filtering
device
is
used.
UNCONTROLLED
TILTING
OF
TRAILER
can
result
in
personal
injury
or
equipment
damage.
Distribute
weight
so
that
trailer
tongue
weight
is
approximately
10%
of
the
gross
trailer
weight.
Follow
trailer
manufacturers
instructions
when
mounting
generator
set
onto
trailer.
Install
a
properly
fitting
canvas
cover
(optional)
over
the
genrator
set
when
not
in
operation
to
protect
the
unit
from
the
environment.
Be
sure
unit
is
cool
before
install
ing
any
cover.
Figure
2
-
1.
Allowable
Tilt
Angles
This
generator
is
provided
with
a
lifting
eye
for
moving
the
unit
and
mounting
holes
in
the
base
for
securing
the
unit
in
a
permanent
location,
or
to
a
trailer,
running
gear,
or
transport
vehicle.
Figure
1-2
gives
overall
dimensions
and
base
mounting
hole
layout.
The
mounting
location
should
allow
sufficient
room
to
open
the
doors
for
maintenance
and
repair
functions.
The
service
life
and
operating
efficiency
of
this
unit
are
reduced
when
the
unit
is
subjected
to
high
levels
of
dust,
dirt,
moisture,
corrosive
vapors,
and
extreme
heat.
2
-2.
EXTENSION
ELBOW
INSTALLATION
WARNING:
HOT
ENGINE
PARTS
can
cause
severe
burns.
Shut
down
engine
and
allow
exhaust
system
to
cool before
installing
extension elbow.
Installation
to
be
performed
only
by
qualified
persons.
1.
Raise
left
side
door
and
secure
open.
2.
Install
extension
elbow
onto
internal
muffler
ex
tension
elbow.
3.
Position
external
extension
elbow
toward
side
of
unit
away
from
air
filter,
and
secure
with
clamp.
4.
Close
and
secure
left
side
door.
2
-
3.
SPARK
ARRESTOR/MUFFLER
INSTALLA
TION
(Optional)
WARNING
sever
burns.
HOT
ENGINE
PARTS
can
cause
Shut
down
engine
and
allow
exhaust
system
to
cool
before
installing
spark
arrestor.
Installation
to
be
performed
only
by
qualified
persons.
1.
Raise
the
left
side
door
and
secure
open.
2.
Remove
and
discard
muffler
clamp
and
external
muffler
extension
elbow.
3.
Install
spark
arrestor/muffler
onto
internal
muf
fler
extension
elbow
so
that
exhaust
is
discharge
toward
side
of
unit
away
from
air
cleaner.
4.
Secure
spark
arrester/muffler
in
place
with
sup
plied
muffler
clamp.
5.
Close
and
secure
side
door.
2
-4.
CONNECTING
THE
BATTERY
WARNING
__________
BATTERY
ACID
can
burn
eyes
and
skin
and
destroy
clothing
and
other
material.
Wear
a
face
shield
and
proper
protective
clothing
TA-046
152
when
working
with
batteries.
ABNORMAL
VOLTAGE
can
cause
damage
to
engine
electrical
components.
Do
not
operate
engine
without
the
battery
con
nected.
Do
not
disconnect
the
battery
while
the
engine
is
running.
OM-471
Page
6
This
unit
is
equipped
with
a
maintenance-free
battery.
To
place
the
unit
in
service,
connect
the
negative
(-)
battery
cable
to
the
negative
battery
terminal.
No
other
preparation
should
be
required.
If
the
battery
does
not
supply
enough
power
to
crank
the
engine,
the
battery
will
require
charging.
See
Sec
tion
5-10
for
battery
charging
procedures.
2.
Check
the
blower
belt
for
proper
tension
(see
the
Engine
Manufacturers
Manual).
3.
Check
the
blower
impeller
for
obstructions
and
free
movement.
4.
Ensure
that
all
sheet
metal
cowlings,
shrouds,
and
panels
are
properly
in
place
and
secure.
WARNING:
ENGINE
FUEL
can
cause
fire
or
ex
plosion.
Do
not
spill
fuel;
if
spilled,
wipe
up.
Do
not
fill
fuel
tank
if
engine
is
hot
or
running.
Do
not
refuel
near
sparks
or
open
flame.
Do
not
smoke
while
refueling.
Do
not
fill
fuel
tank
to
top;
allow3/4
inch
(19
mm)
from
fuel
to
tank
top
for
expansion.
USE OF
GASOLINE
will
damage
engine.
Do
not
use
gasoline
to
fuel
a
diesel
engine.
Lack
of
lubrication
in
the
fuel
will
damage
the
injector
pump
and
injectors.
This
generator
is
shipped
with
a
small
amount
of
fuel
in
the
fuel
tank,
and
fuel
shut-off
valve,
located
under
the
fuel
tank,
in
the
open
position.
See
the
Engine
Manufacturers
Manual
for
fuel
recommendations.
The
capacity
of
the
fuel
tank
is
23
gallons
(87
liters).
IMPORTANT
____________
Fill
fuel
tank
up
to
3/4
in
(19
mm)
from
top
with
fresh
fuel
before
starting
engine
the
first
time.
Rust
and
corrosion
preventative
was
added
to
in
side
of
fuel
tank
and
engine
at
the
factory
and
could
cause
rough
engine
running
if
not
properly
diluted
with
a
full
tank
of
fresh
fuel.
Keep
the
fuel
tank
filled
to
ensure
that
the
injector
system
receives
an
adequate
supply
of
fuel.
If
the
fuel
tank
is
allowed
to
empty,
air will
enter
the
system
caus
ing
starting
problems.
The
Engine
Manufacturers
Manual
outlines
procedures
for
air
venting
the
fuel
system.
2
-
7.
ETHER
STARTING
AID
(Optional)
-
This
unit
is
shipped
without
the
ether
cylinder.
Before
this
device
is
operational,
an
ether
cylinder
must
be
obtained
and
installed.
WARNING
_________
IMPROPER
HANDLING
OR
EX
POSURE
TO
ETHER
can
seriously
harm
your
health.
Follow
the
manufacturers
safety
instructions
on
the
cylinder
when
handling
ether
components.
IMPORTANT
______________
Prior
to
installing
the
ether
cylinder,
ensure
that
the
nozzle
on
the
ether
cylinder
and
the
fit
ting
into
which
the
ether
cylinder
is
inserted
are
both
clean.
If
dirt
is
present
in
either
of
these
areas,
the
system
may
be
rendered
inoperative.
To
install
ether
cylinder,
proceed
as
follows:
1.
Open
right
side
panel
and
secure
open.
Identify
ether
start
components
on
center
frame
upright.
2.
Remove
protective
cap
from
ether
valve.
3.
Loosen
cylinder
clamp.
4.
Place
new
cylinder
onto
valve
fitting,
and
rotate
clockwise
until
secure.
5.
Secure
cylinder
with
clamp.
6.
Using
a
liquid
soap
solution,
check
all
ether
start
system
connections
for
leaks.
If
a
leak
exists,
escaping
gas
will
produce
bubbles
in
the
soap
solution.
2
-
6.
ENGINE
PRE-START
CHECKS
A.
Oil
Level
IMPORTANT:
______
After
installing
or
replacing
ether
cylinder,
do
not
use
or
test
ether
start
system
for
at
least
10
to
15
minutes
to
allow
particles
in
fuel
to
settle
to
prevent
atomizer
plugging.
The
engine
is
shipped
with
its
crankcase
filled
with
break-in
oil.
If
the
oil
level
is
not
up
to
the
full
mark
on
the
dipstick,
add
oil
according
to
the
recommendations
in
the
Engine
Manufacturers
Manual
before
starting
the
engine.
B.
Cooling
System
Perform
the
following
checks
on
the
air
cooling
system
before
operating
the
engine:
1.
Check
the
engine
air
intake
and
exhaust
open
ings
to
ensure
no
blockage
exists.
2
-8.
EQUIPMENT
GROUNDING
TERMINAL
-
This
unit
is
equipped
with
a
grounding
terminal,
located
on
the
left
base
rail,
for
frame
and
case
grounding.
Depending
on
the
connections
used,
one
of
the
win
dings
may
have
to
be
grounded.
For
detailed
grounding
instructions
consult
your
local
and
state
codes
and
the
latest
issue
of
the
National
Electrical
Code.
If
additional
information
regarding
your
particular
operating
cir
cumstances
and/or
grounding
requirements
is
needed,
consult
a
qualified
electrician
or
your
dealer.
After
determining
the
extent
to
which
any
grounding
re
quirements
apply
to
your
particular
situation,
follow
them
explicitly.
2
-
5.
FUEL
OM-471
Page
7
2
-
9.
FREQUENCY
CHANGEOVER
(Figure
2-2)
CAUTION
_________
EXCESSIVELY
HIGH
EXCITATION
CURRENT
can
damage
generator.
Be
sure
engine
speed
for
50
Hz
operation
is
1550
rpm.
This
unit
is
equipped
with
a
frequency
changeover
ter
minal
strip
31,
located
inside
the
connection
box
on
the
stator
frame
behind
the
right
side
door.
If
it
becomes
necessary
to
change
the
output
frequency
of
the
generator
proceed
as
follows:
ITiTIjl~IhiIef
ELECTRIC
SHOCK
can
kill.
Do
not
touch
five
electrical
parts.
Shut
down
engine
and
disconnect
negative
(-)
batter,
cable
from
battery
before
attempting
fre
quency
changeover.
1.
Open
and
secure
right
side
door.
2.
Remove
cover
from
connection
box.
3.
Reposition
jumper
links
on
3T
to
match
desired
frequency
(see
Figure
2-3).
4.
Replace
connection
box
cover.
5.
Reconnect
negative
battery
cable.
6.
Close
and
secure
right
side
door.
7.
Readjust
engine
speed
as
2-1
1,
Section
5-8.
3T
A~5;0
50HZ~
B~
51
60Hz
~
511
D~3oo
50Hz
(
E~2
60Hz
F200
5OHZ
r
H~84
SOHZ
I
~O8,
instructed
in
Steps
Ref.
C-096
400
This
generator
set
is
shipped
from
the
factory
con
nected
for
three-phase
series
delta
operation
at
60
Hertz.
Jumper
links
and
stator
leads
LO,
L2
and
ground
are
reconnectable
for
operation
in
three-phase
series
or
parallel
wye,
or
single-phase
double
or
parallel
delta
at
50
or
60
Hertz.
The
reconnectable
ground
lead
inside
the
connection
box
may
or
may
not
have
to
be
ground
ed,
depending
on
the
selected
configuration
and
usage
of
the
generator
set.
The
voltages
available
for
each
generator
connection
and
output
frequency
(see
Figures
2-3
and
6-1)
can
be
set
by
the
VOLTAGE
AD
JUSTMENT
control.
To
reconnect
the
generator,
pro
ceed
as
follows:
_________
ELECTRIC
SHOCK
can
kiI~.
Do
not
touch
five
electrical
parts.
Shut
down
engine
and
disconnect
negative
1-)
battery
cable
from
battery
before
attempting
generator
reconnection.
Ground
in
accordance
with
NEC,
state,
and
local
codes;
connect
grounding
lead
to
appropriate
generator
leads
depending
on
output
load
lead
connection.
Be
sure
that
a
proper
ground
is
con
nected
to
the
equipment
grounding
terminal
on
the
generator
frame.
Series
Delta
Connection
Shown
Figure
2
-
3.
Connection
Box
TA-107
930
WARNING
Figure
2
-
2.
Frequency
Changeover
Connections
1.
Open
and
secure
right
side
door.
2.
Open
connection
box
on
stator
barrel.
3.
Reconnect
jumper
links
and
leads
LO,
L2,
92,
and
ground
(if
applicable)
to
obtain
desired
generator
output.
Refer
to
Figures
2-3
and
2-4.
4.
Close
connection
box.
5.
Reconnect
negative
battery
cable.
6.
Close
side
door
and
secure.
IMPORTANT
_____________
After
changing
output
frequency,
it
may
be
necessary
to
readjust
the
VOL
TAGE
ADJUST
MENT
control
(see
Section
3-3)
to
obt8in
the
desfred
output
voltage.
2-10.
GENERATOR
RECONNECTIONS
CAUTION
IMPROPER
CONNECTIONS
can
damage
generator
If
generator
set
is
equipped
with
optional
recep
tacles,
disconnect
receptacles
before
performing
generator
reconnections.
OM-471
Page
8
61
58
56
53
110/
ISO
115/200
120/208
127/220
Figure
2
-
4.
Generator
Connection
Diagrams
And
Output
Specifications
IJMP0RTANT
_____________
If
120/240
volts
single-phase
Double
Delta
connection
is
used,
insulate
the
L3
lead,
If
120
volts
single-phase
Parallel
Delta
connection
is
used,
in
sulate
the
supplied
exit
leads
and
install
cab/es
to
cariy
the
rated
current
to
the
overcrrent
device.
2
-
11.
AUXILIARY
POWER
CONNECTIONS
I~i~II~rcE
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Keep
all
covers
and
pane/s
in
place
while
operating.
Stop
the
engine
before
making
any
connections
to
this
unit.
Connect
circuit
ground
as
appropriate
for
the
choosen
connections
(see
connection
label).
Be
sure
generator
phase
rotation
matches
re
quirements
of
three-phase
equipment;
generator
phase.
rotation
is
c/ockwsie
L
1,
L2,
and
L3.
Check
generator
output
voltage
and
frequency
before
connecting
leads.
Provide
gound
fault
and
overcurrent
protection
as
required
by
any
national
and
local
electrical
codes.
Always
use
approved
wiring
and
switching
devices.
All
electrical
installations
to
be
performed
by
a
qualified
electrician.
Do
not
connect
to
any
electrical
distribution
system
normally
supplied
by
utility
power
unless
a
proper
transfer
switch
and
grounding
procedure
are
employed.
Do
not
attempt
to
provide
emergency
power
to
a
building
by
feeding
power
through
any
receptacle.
LOW
VOLTAGE
AND
FREQUENCY
can
damage
electrical
equipment.
Turn
off
or
disconnect
all
electrical
equipment
connected
to
the
unit
before
starting
or
stopping
the
engine.
GENERATOR
CONNECTION
SCHEMATIC
DIAGRAM
59
66
60
/
FRONT
SIDE
VIEW
OF
/
GENERATOR
CONNECTION
WIRING
DIAGRAM
(CHANGE-OVER
BOARD
ar)
120
/20e
127/220
131/240
3
3
3
80
SO
So
8
-I
S
-I
4
4
3
3
3
3
50
50
SO
50
35
240/418
33
254,440
30
277/480
3
3
3
SO
80
SO
8
4
~
4
~
LI
L2
TI
t__%I~~
~
~
~~.)TI2
LO
T4
L3
i!~1~
D
4
~
10
&
0
~
3~
~II
D
~
1~
*12
30
220/380
29
230/400
28
240/4
II
26
254/440
3
3
3
3
50
50
50
50
120/240
3
SO
4
~
0
4
S
~
~
LI
112
~
i
L3T3~~
~T4
r-0
TII.4~
~TT
T~
1~2
L2
l!~1~
D
4
2~
0
10
8*
D
3*
D
D
*6
~
.
53
110/220
50
115/230
120/240
3
3
3
50
50
50
104
120/240
1
~o
:
-J
0
S
~
0
~
16~LI
~
~TI
TM~2~T4
~
LO
TV(4~T7
~
i~
L2
4to
0
0
j
~
4
2
(8
L.8
~
*3
I
~
I
¶9
6~
D
12
110/220
115/230
120/240
I
1
1
50
50
50
208
120
I
60
4
~
S
0
S
~
~
~,
76
LI
T3..~\1
12
117
~
(~.t.j~
~,jJ1io
~
A~4~~---~
8
5
II
¶A
~
!~
I
182
110
174
115
187
120
1
1
I
50
50
50
OM-471
PageS
3.
Reconnect
negative
battery
cable.
1.
Locate
generator
output
leads
behind
left
side
door.
2.
Connect
load
leads
directly
to
generator
output
leads,
or
install
desired
customer-supplied
junc
tion
box
or
panel
for
connecting
generator
out
put
leads
and
the
load
circuit.
4.
Be
sure
generator
phase
rotation
matches
re
quirements
of
three-phase
equipment;
generator
phase
rotation
is
clockwise
Li,
L2,
and
L3.
5.
Check
generator
output
voltage
and
frequency
before
connecting
load(s).
SECTION
3
-
OPERATOR
CONTROLS
Figure
3
-
1.
Front
Panel
Controls
3
-
1.
SAFETY
SHUTDOWN
SYSTEM
(Figure
3-1)
This
switch
is
protected
by
an
in-line
fuse
Fl
located
directly
behind
the
front
panel.
Should
this
fuse
open,
the
engine
would
not
start.
A.
Oil
Pressure
Switch/Gauge
OIL
PRESSURE
SHUTDOWN
The
SHUTDOWN
switch
must
be
depressed
and
held
closed
until
the
engine
starts.
If
oil
pressure
or
oil
temperature
reach
unsafe
levels,
or
if
the
overvoltage
device
is
actuated,
the
Safety
Shutdown
System
stops
the
engine.
Do
not
attempt
to
operate
the
engine
until
the
trouble
is
remedied.
IMPORTANT
______________
The
shut-off
time
for
the
engine
is
1
to
1-1/2
minutes.
The
engine
will
falter
before
coming
to
a
complete
stop.
The
OIL
PRESSURE
switch/gauge
indicates
lubrication
system
pressure.
If
oil
pressure
drops
to
an
unsafe
level
the
switch/gauge
shuts
down
the
engine.
B.
Engine
Temperature
Switch/Gauge
ENGINE
TEMPERATURE
Voltmeter
\
Hertz
Meter
Hour
Meter
I
/
Stop
Control
Oil
Pressure
Switch/Gauge
.
Engine
Temperature
Switch/Gauge
Amps
Warning
Light
I
/
oveLoitage
~
\
\
Voltage
Start
Shutdown
Ammeters
Condition
Adjustment
Push
Switch
Light
Control
Button
OM-471
Page
10
3
-
4.
AMMETERS
(Figure
3-1)
The
ENGINE
TEMPERATURE
switch/gauge
indicates
crankcase
oil
temperature.
If
oil
temperature
rises
to
an
unsafe
level,
the
switch/gauge
shuts
down
the
engine.
C.
Overvoltage.Condition
Light
OVERVOLTAGE
CONDITION
Vfi
The
OVERVOLTAGE
CONDITION
light
turns
on
to
in
dicate
an
immediate
interruption
of
generator
output
caused
by
an
overvoltage
condition.
The
tight
remains
on
until
the
SAFETY
SHUTDOWN
switch
is
depressed.
IMPORTANT
___________
If
the
OVERVOLTAGE
CONDITION
light
turns
on,
the
generator
set
will
shut
down
automatically)
Do
not
attempt
to
operate
the
generator
set
again
until
the
trouble
has
been
remedied
(see
Troubleshooting
chart).
LIL2L3
This
unit
is
equipped
with
three
ammeters,
labeled
Li,
L2,
and
L3.
Ammeters
Li
and
12
indicate
single-phase
loading,
and
ammeters
Li,
12,
and
L3
indicate
three-
phase
loading.
The
ammeters
monitor
the
individual
line
current
of
each
phase.
Under
balanced
three-phase
loading,
all
ammeters
will
read
the
same
value.
If
one
ammeter
indicates
a
current
reading
different
from
the
others,
one
phase
is
loaded
differently
causing
an
in-
balance.
3
-
6.
VOLTMETER
(Figure
3-1)
V
The
voltmeter
indicates
the
regulated
ac
voltage
output
of
the
generator
and
the
load
voltage.
3
-
2.
START
PUSH
BUTTON
(Figure
3-1)
START
A
START
push
button
is
provided
on
the
front
panel
for
starting
the
engine.
Pressing
the
START
push
button,
while
depressing
SHUTDOWN
switch,
will
engage
the
starter
motor
and
start
the
engine.
Once
the
engine
has
started,
release
the
START
button
and
the
SHUT
DOWN
switch.
3
-6.
FREQUENCY
METER
(Figure
3-1)
Hz
The
Frequency
Meter
indicates
the
output
frequency
from
45
to
65
Hertz.
3
-
7.
STOP
CONTROL
(Figure
3-1)
PULL
OUT
TO
STOP
ENGINE
CAUTION
_________
REENGAGING
STARTER
MOTOR
while
flywheel
is
rotating
can
damage
starting
components.
S
Do
not
reengage
starter
motor
until
starter
pinion
and
flywheel
have
stopped
rotating.
3
-
3.
VOLTAGE
ADJUSTMENT
CONTROL
(Figure
3-1)
VOLTAGE
ADJUSTMENT
V
The
VOLTAGE
ADJUSTMENT
control
fine
adjusts
out
put
voltage.
Place
a
standard
screwdriver
through
the
hole
in
the
front
panel
and
rotate
the
control
shaft
clockwise
to
increase
output
voltage/load
voltage
or
counterclockwise
to
decrease
output
voltage/load
voltage.
Accurate
voltage
adjustments
can
be
made
by
reading
the
ac
voltmeter.
I.
The
PULL
OUT
TO
STOP
ENGINE
control,
when
pulled
fully
out,
cuts
off
.the
flow
of
fuel
at
the
fuel
injection
pump,
thereby
stopping
the
engine.
This
control
is
spring-loaded
and
must
be
held
fully
out
until
the
engine
is
completely
stopped.
3
-8.
BATTERY
CHARGE
INDICATOR
LAMP
(Figure
3-1)
i-~i
The
AMPS
warning
lamp
will
be
illuminated
when
the
engine
battery
charge
current
is
not
flowing.
3
-
9.
HOUR
METER
(Figure
3-1)
t
This
unit
is
equipped
with
an
hour
meter.
The
meter
registers
the
total
hours
of
engine
operation.
This
infor
mation
is
useful
for
routine
maintenance
on
the
engine.
OM-471
Page
11
3
-
10.
ETHER
STARTING
AID
(Optional)
-
The
cold
weather
starting
components
which
are
incor
porated
into
this
generator
provide
a
means
of
supply
ing
a
premeasured
portion
of
ether
into
the
manifold.
The
amount
of
ether
supplied
should
be
sufficient
to
permit
easy
engine
starting
under
cold
weather
condi
tions.
Actuating
the
ETHER
STARTING
AID
switch,
located
to
the
left
of
the
START
push
button,
for
1
second
while
cranking
the
engine
will
provide
the
proper
amount
of
ether
to
the
manifold.
This
control
will
func
tion
only
while
cranking
the
engine.
IMPORTANT
______________
The
measured
quantity
of
ether
is
sprayed
into
the
engine
when
this
switch
is
re/eased.
Depressing
the
switch
does
not
spray
the
ether
into
the
engine
but
rather
fills
the
valve
chamber.
SECTION
4
-
SEQUENCE
OF
OERATION
WARNING
_________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Keep
all
covers
and
panels
in
place
while
operating.
Stop
and
disable
engine
before
inspecting
or
ser
vicing.
Stop
the
engine
before
making
electrical
connec
tions
to
this
unit.
Ground
generator
as
required
by
any
applicable
national
and
local
electrical
codes.
Provide
ground
fault
and
over
current
protection
as
required
by
any
national
and
local
electrical
codes.
Always
use
approved
wiring
and
switching
devices.
All
electrical
installations
to
be
performed
by
a
qualified
electrician.
Do
not
connect
to
any
electrical
distribution
system
normally
supplied
by
utility
power
unless
a
proper
transfer
switch
and
grounding
procedure
are
employed.
LOW
VOLTAGE
AND
FREQUENCY
can
damage
electrical
equipment.
Turn
off
or
disconnect
all
electrical
equipment
connected
to
the
unit
before
starting
or
stopping
the
engine.
ENGINE
EXHAUST
GASES
can
kill.
Use
in
open,
well
ventilated
areas
or
vent
exhaust
out
of
doors.
HOT
EQUIPMENT
can
cause
burns.
Allow
equipment
to
cool
before
inspecting
or
ser
vicing.
MOVING
PARTS
can
cause
serious
injury.
Keep
clear
of
moving
parts,
i.e.,
fans,
belts,
rotors,
etc.
EXHAUST
SPARKS
can
cause
fire.
Use
and
maintain
exhaust
spark
arrestor
in
accor
dance
with
local,
state
and
federal
regulations.
Keep
a
properly
maintained
fire
extinguisher
near
by
and
be
familiar
with
its
use.
-
ENGINE
FUEL
can
cause
fire
or
explosion.
Do
not
spill
fuel;
if
spilled,
wipe
up.
Do
not
refuel
if
engine
is
hot
or
running.
Do
not
refuel
near
sparks
or
open
flame.
Do
not
smoke
while
refueling.
Do
not
fill
fuel
tank
to
top;
allow
room
for
expan
sion.
Warranty
is
void
if
the
generator
is
operated
with
any
portion
of
the
outer
enclosure
open
or
removed.
IMPORTANT:
_____
______
See
Section
1-4
at
beginning
of
this
manual
for
load
information.
4
-
1.
STARTING
THE
ENGINE
1.
Press
the
START
push
button
(see
Section
3-2)
and
the
SHUTDOWN
switch
(see
Section
3-1)
and
actuate
the
ETHER
STARTING
AID
switch,
if
applicable,
for
1
second and
release
(see
Sec
tion
3-10).
_________
REENGAGING
STARTER
MOTOR
while
flywheel
is
rotating
can
damage
starting
components.
Do
not
reengage
starter
motor
until
starter
pinion
and
flywheel
have
stopped
rotating.
2.
As
soon
as
the
engine
starts,
release
the
START
push
button
and
the
SHUTDOWN
switch
and
allow
the
engine
to
warm
up
for
approximately
three
minutes
with
no
power
load
applied.
4
-2.
ENGINE
SHUTDOWN
1.
Remove
the
power
load
from
the
unit.
2.
Allow
the
engine
to
run
for
a
few
minutes
to
per
mit
the
internal
engine
temperature
to
equalize.
Increase
the
time
if
the
engine
has
been
operating
for
an
extended
period
or
at
full
load.
3.
Pull
the
STOP
control
fully
out
and
hold
it
in
this
position
until
the
engine
stops
completely.
CAUTION
IMPORTANT:
______
Be
sure
the
unit
has
been
installed
and
prepared
as
instructed
in
Section
2
before
attemp
ting
to
start
the
engine.
Phase
rotation
and
voltage
must
be
checked
after
initial
start-up
and
before
load
is
connected.
OM-471
Page
12
SECTION
5
-
MAINTENANCE
WARNING
__________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
five
electrical
parts.
I
Shut
down
the
engine
and
disconnect
negative
(-)
battery
cable
from
battery
before
inspecting,
maintaining,
or
servicing.
MOVING
PARTS
can
cause
serious
injury.
Keep
c/ear
of
moving
parts,
i.e.,
fans,
belts,
rotors,
etc.
HOT
ENGINE
PARTS
can
cause
severe
burns.
Wear
protective
gloves
and
clothing
when
work
ing
on
a
hot
engine.
Maintenance
to
be
performed
only
by
qualified
persons.
IMPORTANT
_______________
Periodically
inspect
the
labels
on
this
unit
for
legibility.
All
precautionary
labels
must
main
tained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
the
Parts
List
for
part
number
of
precau
tionary
labels.
5
-
1.
GENERAL
-
The
service
life
of
this
generator
can
be
prolonged
and
operating
efficiency
maintained
under
normal
conditions
by
following
the
routine
ser
vice
and
workshop
maintenance
procedures
outlined
in
this
section
and
in
the
Engine
Manufacturers
Manual
(F3L912
Engine).
Where
operating
conditions
are
severe,
more
frequent
attention
must
be
given
to
all
routine
service
categories;
however
a
special
effort
must
be
made
to
maintain
clean
internal
and
external
engine
surfaces.
5
-2.
PERIODIC
CLEANING
AND
INSPECTION
Check
for
fluid
leaks
indicating
loose
oil
or
fuel
connec
tions.
Tighten
loose
connections
and
clean
oil
or
fuel
spills
or
leaks
off
of
engine
surfaces.
5
-
3.
FUEL/WATER
SEPARATOR
AND
SLUDGE
DRAIN
PLUG
WARNING
plosion.
ENGINE
FUEL
can
cause
fire
or
ax-
Stop
engine
and
allow
unit
to
cool
down
before
servicing.
Do
not
drain
fuel
tank
while
engine
is
running.
Do
not
smoke
while
handling
fuel.
Do
not
allow
fuel
to
drain
onto
the
engine
or
other
components.
Do
not
spill
fuel;
if
spilled,
wipe
up.
The
fuel/water
separator,
located
below
the
fuel
tank
on
the
right
side
of
the
generator,
is
provided
to
drain
off
water
from
the
fuel
tank.
Before
starting
the
engine
for
the
first
time
each
day,
open
the
petcock
on
the
bot
tom
of
the
separator
and
drain
the
water
into
a
metal
container.
Close
the
petcock
at
the
first
signs
of
fuel.
The
fuel/water
separator
should
be
changed
every
125
hours
of
operation
or
4
months,
whichever
occurs
first.
A
sludge
drain
plug
is
provided
on
the
bottom
of
the
fuel
tank
to
drain
off
sediment
from
the
fuel
tank.
IA1I~~Il~Icg
ELECTRIC
SHOCK
can
kill.
Do
not
touch
five
electrical
parts.
Shut
down
the
engine
and
disconnect
negative
(-)
battery
cable
from
battery
before
inspecting,
maintaining,
or
servicing.
MOVING
PARTS
can
cause
serious
injury.
Keep
clear
of
moving
parts,
i.e.,
fans,
belts,
rotors,
etc.
HOT
ENGINE
PARTS
can
cause
severe
burns.
Wear
protective
gloves
and
clothing
when
work
ing
on
a
hot
engine.
Maintenance
to
be
performed
only
by
qualified
persons.
A
schedule
for
cleaning
and
inspection
should
be
set
V
up,
based
on
the
type
and
conditions
of
service,
to
in-
dude
the
following:
-
V
Keep
the
inside
of
the
unit
clean
by
blowing
out
the
unit
with
clean,
dry
compressed
air.
Examine
all
intake
and
discharge
air
openings,
and
en
sure
that
they
are
not
blocked
in
any
manner
and
are
free
of
foreign
matter.
Examine
blower
impeller
to
be
sure
that
the
blades
do
not
have
an
obstruction
of
any
kind
lodged
between
them.
The
blower
must
be
able
to
turn
freely.
The
air
cleaner
is
one
of
the
most
important
parts
of
the
engine
from
the
standpoint
of
engine
life.
An
engine
consumes
several
thousand
cubic
feet
of
air
per
hour
when
operating.
If
dirty
air
gets
into
the
engine,
it
can
wear
out
a
set
of
piston
rings
within
a
few
operating
hours.
Every
50
hours
or
less,
depending
on
conditions,
empty
the
dust
cup
and
inspect
the
element.
IMPORTANT
A
dirty
air
cleaner
element
is
usually
accompanied
by
a
loss
of
power
and
black
smoke
in
the
engine
exhaust.
When
it
becomes
necessary
to
service
the
air
cleaner
in
the
field,
follow the
steps
in
Figure
5-1.
It
is
recom
mended
that
a
spare
element
always
be
kept
on
hand
for
replacement.
New
elements
are
available
from
your
distributor.
5
-
4.
AIR
CLEANER
SERVICE
(Figure
5-1)
CAUTION
___________
DIRTY
AIR
can
damage
engine.
Do
not
operate
engine
with
dirty
air
cleaner
ele
ment
in
place.
Do
not
operate
engine
without
air
cleaner
element
in
place.
OM-471
Page
13
Follow
~
~
Easy
Stens
r
1.
Stop
engine.
5.
Wipe
out
element
chamber
7.
Reinstall
element.
with
clean,
damp
cloth.
2.
Wipe
off
cover
before
opening
8.
Replace
cover.
air
cleaner.
6.
Inspect
new
element
and
all
gaskets
for
shipping
damage
3.
Remove
cover,
before
use.
4.
Remove
element.
Important
1.
Dont
attempt
to
service
air
3.
Dont
leave
open
air
cleaner
5.
For
Donaclone
air
cleaners
-
cleaner
with
engine
running.
exposed
to
blowing
dust
while
dont
blow
out
Donaclone
tube
you
clean
element.
Replace
section
without
element,
cover
2.
Dont
blow
out
the
inside
of
the
cover,
and
inner
cover
(if
any)
correctly
air
cleaner
with
compressed
air.
installed
or
you
will
blow
dust
4.
If
air
cleaner
is
horizontally
into
the
engine.
mounted,
be
sure
that
dust
cup
is
positioned
so
arrows
point
up.
How
To
Clean
Elements
F
or
~
Re-Use
.
Clean
element
by
one
of
the
a
better
job
and
must
be
used
(When
cleaning
Cyclopac
following
methods:
when
exhaust
soot
has
lodged
in
elements,
do
not
remove
plastic
fine
pores
of
the
filter
media.
fin
assembly
-
back-flowing
with
Compressed
Air
or
Washing.
Use
Donaldson
0-1400
detergent
compressed
air
or
washing
will
which
contains
a
special
additive
remove
dust
from
beneath
the
Compressed
air
is
recommended
for
removing
soot
and
carbon.
f
in
assembly.)
when
element
will
be
re-used
immediately
because
a
washed
Replace
element
after
6
cleanings
element
must
be
dried
before
or
annually,
whichever
re-use.
However,
washing
does
occurs
first.
Compressed
Air
Washing
Inspection
Direct
air
through
element
in
1.
Soak
element
15
minutes
or
Place
bright
light
inside
element
the
direction
opposite
to
normal
more
in
Donaldson
D-1400
and
and
rotate
elembnt
slowly.
If
air
flow
through
the
element,
water
solution.
See
carton
for
full
any
rupture,
holes
or
damaged
Move
nozzle
up
and
down
while
instructions,
gaskets
are
discovered
-
replace.
rotating
element.
Keep
noz1zle
at
least
one
inch
from
pleated
2.
Rinse
until
water
is
clear
paper.
Maximum
air
pressure
(Maximum
water
pressure
-
100
PSI.
40
P.S.l.)
3.
Air-dry
or
use
warm
flowing
air,
max.
160F.
Do
not
use
compressed
air
or
light
bulbs.
Figure
5
-
1.
AirCleanerService
TA-Ofl
606
5
-
5.
SERVICING
THE
SPARK
ARRESTOR
(Op
tional)
WARNING
cause
fire.
ENGINE
EXHAUST
SPARKS
can
Exhaust
spark
arrestor
must
be
installed
in
accor
dance
with
local,
state,
and
federal
regulations.
Shut
down
engine
before
cleaning
spark
arrestor.
Clean
spark
arrestor
in
a
noncombustible
en
v/ron
ment.
HOT
ENGINE
PARTS
can
cause
severe
burns.
The
exhaust
system
must
be
cold
when
servicing
the
spark
arrestor.
The
engine
exhaust
system
on
this
generator
set
is
not
equipped
with
a
spark
arrestor.
A
spark
arrestor,
main
tained
in
effective
working
order,
is
mandatory
if
this
generator
set
is
to
be
operated
in
a
National
Forest
or
on
California
Grasslands,
brush,
or
forest
covered
land
(see
Section
4442
of
California
Public
Resources
Code).
For
other
areas,
check
your
state
and
local
laws.
If
a
spark
arrestor
(optional)
is
desired,
contact
your
dealer/distributor.
Internal
combustion
engines
operating
in
a
highly
com
bustible
environment
are
a
common
fire
hazard.
Glow
ing
carbon
particles
blown
out
with
the
exhaust
can
re
tain
sufficient
heat
to
ignite
materials.
While
no
prac
OM-471
Page
14
tical
spark
arresting
device
will
stop
all
sparks,
this
device
will
minimize
fire
hazards
by
removing
and
trapp
ing
most
solid
particles
provided
that
it
is
properly
main
tained.
The
carbon
trap
should
be
serviced
weekly
or
every
50
operating
hours,
whichever
occurs
first.
The
entire
spark
arrestor
should
be
inspected
every
1000
operating
hours
or
three
times
per
season.
Proceed
as
follow
to
service
the
spark
arrestor:
1.
Stop
the
engine
and
allow
the
exhaust
system
to
cool.
2.
Remove
the
cleanout
plug
from
the
bottom
of
the
spark
arrestor.
If
a
crust
has
formed
over
the
hole,
break
it
loose
with
a
screwdriver
or
similar
tool.
3.
Start
the
engine
and
run
it
at
idle
rpm
to
blow
collected
particles
out
the
cleanout
hole.
If
par
ticles
are
slow
to
discharge,
momentarily
cover
the
end
of
the
exhaust
stack.
4.
Stop
the
engine,
and
allow
the
exhaust
system
to
cool.
5.
Replace
and
secure
the
cleanout
plug.
5
-
6.
BRUSHES
AND
SLIP
RINGS
(Figure
5-2)
WARNING
_________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
the
engine
and
disconnect
negative
(-)
battery
cable
from
battery
before
inspecting,
maintaining,
or
servicing.
MOVING
PARTS
can
cause
serious
injury.
Keep
clear
of
moving
parts,
i.e.,
fans,
belts,
rotors,
etc.
HOT
ENGINE
PARTS
can
cause
severe
burns.
Wear
protective
gloves
and
clothing
when
work
ing
on
a
hot
engine.
Maintenance
to
be
performed
only
by
qualified
persons.
Brush
life
is
very
good
under
normal
operating
condi
tions.
The
brushes
and
slip
rings
should
be
inspected
every
six
months
or
whenever
excitation
voltage
is
lost.
Check
for
cleanliness
of
the
slip
rings
and
freedom
of
motion
of
the
brushes.
If
the
generator
has
been
operating
under
extremely
dusty
or
dirty
conditions,
in
crease
the
frequency
of
inspection.
If
the
generator
has
not
been
used
for
an
extended
period
of
time,
oxidation
may
form
on
the
slip
rings
causing
excitation
voltage
to
be
lost.
This
can
usually
be
remedied
by
simply
spraying
the
slip
rings
with
an
an
tioxidant
type
contact
cleaner
and
running
the
engine.
Under
normal
use
the
slip
rings
will
discolor
to
a
dark
brown.
if
a
build
up
of
brush
material
is
noted,
it
may
be
necessary
to
clean
the
slip
rings.
Use
a
3/0
or
finer
sandpaper
followed
by
a
crocus
cloth.
Never
use
emery
cloth
as
part
of
the
emery
will
embed
itself
into
the
rings
and
in
turn
destroy
the
carbon
brushes.
Replace
the
brushes
if
they
become
chipped
or
broken
or
if
less
than
1/2
inch
(12.7
mm)
of
brush
material
is
left.
5
-
7.
ETHER
STARTING
AID
(Optional)
-
The
ether
used
in
the
cold
weather
starting
aid
system
is
contained
in
a
replaceable
cylinder
located
behind
the
right
side
access
door
on
the
center
portion
of
the
frame.
No
indicator
is
provided
to
show
the
amount
of
ether
left
in
the
cylinder;
therefore
it
is
recommended
that
a
spare
cylinder
be
kept
on
hand.
Generally,
the
ether
cylinder
is
empty
when
the
engine
fails
to
start
in
cold
weather
while
utilizing
the
cold
weather
starting
system.
To
check
if
the
cylinder
is
empty,
remove
the
cylinder
and
shake
it.
If
a
slushing
sound
is
not
heard,
the
ether
cylinder
is
empty.
The
ether
cylinder
can
also
be
weighed
to
check
for
contents,
33
ounces
is
the
weight
of
the
cylinder
when
empty.
To
replace
the
ether
cylinder,
loosen
the
clamp
which
secures
the
cylinder
to
the
mounting
bracket,
and
rotate
the
ether
cylinder
in
a
counterclockwise
direction.
IMPORTANT
______________
Prior
to
installing
the
new
ether
cylinder,
ensure
that
the
nozzle
on
the
ether
cylinder
and
the
fitting
into
which
the
ether
cylinder
is
inserted
are
both
clean.
If
dirt
is
present
in
either
of
these
areas
the
system
may
be
rendered
inoperative.
Also
check
for
damage
to
the
valve
gasket
which
is
located
on
the
in
side
of
the
fitting
into
which
the
ether
cylinder
is
in
serted.
Replace
the
valve
gasket
if
worn
or
damaged.
I
h~
I
~s :
I..ikI
~
After
installing
or
rep/acing
ether
cylinder,
do
not
use
or
test
ether
start
system
for
at/east
10
to
15
minutes
to
allow
particles
in
fuel
to
settle
to
prevent
atomizer
plugging.
See
the
manufacturers
instruction
sheet
for
maintenance
and
troubleshooting
procedures.
5
-
8.
ENGINE
SPEED
ADJUSTMENT
(Figure
5-3)
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
MOVING
PARTS
can
cause
serious
injury.
Keep
c/ear
of
moving
parts,
i.e.,
fans,
belts,
rotors,
etc.
HOT
ENGINE
PARTS
can
cause
severe
burns.
Wear
protective
gloves
and
clothing
when
work
ing
on
a
hot
engine.
Maintenance
to
be
performed
only
by
qualified
persons.
1/2
in.
(12.7
mm)
Minimum
Figure
5
-
2.
Brush
Replacement
TA-083
205
OM-471
Page
15
This
engine
was
shipped
fully
adjusted
and
ready
for
operation.
If
an
engine
speed
adjustment
becomes
necessary,
proceed
as
follows:
Fuel
Injector
Pump
Protective
Plactic
Cap
(lock
nut
underneath)
A-045
768
Figure
5
-
3.
Engine
Speed
Adjustment
1.
Shut
down
the
engine.
2.
Remove
lead
seal
and
protective
plastic
cap
from
high
speed
stop
screw.
3.
Loosen
high
speed
stop
screw
lock
nut,
and
back
high
speed
stop
screw
out
(toward
front
of
engine)
several
turns.
4.
Tighten
high
speed
stop
screw
lock
nut.
5.
Loosen
linkage
lock
nuts.
6.
Start
engine.
7.
Adjust
engine
speeds
(no
load)
as
follows:
A.
For
60
Hz
Operation
Adjust
linkage
until
61.5
Hz
is
indicated
on
HERTZ
meter
on
front
panel.
If
setting
engine
speed
with
a
tachometer,
adjust
linkage
for
1850
rpm.
B.
For
50
Hz
Operation
Adjust
linkage
until
51
.5
Hz
is
indicated
on
HERTZ
meter
on
front
panel.
If
setting
engine
speed
with
a
tachometer,
adjust
linkage
for
1550
rpm.
8.
Tighten
linkage
lock
nuts.
9.
Be
sure
linkage
lock
nuts
are
completely
tighten
ed,
and
then
recheck
rpm.
10.
Stop
the
engine.
11.
Completely
tighten
high
speed
stop
screw
lock
nut,
and
reinstall
protective
plastic
cap
onto
high
speed
stop
screw.
Reseal
cap/stop
screw.
5
-
9.
ELECTRICAL
SYSTEM
~
ELECTRIC
SHOCK
can
kill.
Do
not
touch
five
electrical
parts.
Shut
down
the
engine
and
disconnect
negative
(-1
battery
cable
before
inspecting,
maintaining,
or
servicing.
MOVING
PARTS
can
cause
serious
injury.
Keep
clear
of
moving
parts,
i.e.,
fans,
belts,
rotors,
etc.
HOT
ENGINE
PARTS
can
cause
severe
burns.
Wear
protective
gloves
and
clothing
when
work
ing
on
a
hot
engine.
Maintenance
to
be
performed
only
by
qualified
persons.
II
~
I
~.1
1
V..~
~
I
~
Inspect
cables,
wiring,
and
battery
when
performing
routine
oil
changes
at
intervals
specified
on
the
unit
maintenance
label.
A.
Cables
And
Wiring
Check
interconnecting
wiring
and
connections
for
tightness
and
flaws.
Ensure
that
the
weld
output
cable
connections
are
clean
and
tight.
Check
the
insulation
for
breaks
or
other
signs
of
damage.
Repair
or
replace
cables
or
wiring
as
necessary.
B.
Battery
IYiYIia~Il~
BATTERY
ACID
can
burn
eyes
and
skin
and
destroy
clothing
and
other
material.
Wear
correct
eye
and
body
protection.
Inspect
the
battery
for
loose
connections,
defective
cables,
corrosion,
cracked
case
or
cover,
loose
hold-
downs,
and
loose
or
deformed
terminal
posts.
Clean
and
tighten
connections,
replace
cables,
or
replace
battery
if
necessary.
5-10.
MAINTENANCE-FREE
BATTERY
CHARG
ING
WARNING
_______
CHARGING
A
FROZEN
BATTERY
can
cause
the
battery
to
explode
and
result
in
serious
personal
injury
or
damage
to
equipment.
Allow
battery
to
warm
up
to
60F
(16C)
before
charging
if
battery
is
frozen.
I~iJ:hlI~eE
BATTERY
ACID
can
burn
eyes
and
skin
and
destroy
clothing
and
other
materials;
BATTERY
GASES
can
explode
and
shatter
the
bat
tery.
Wear
a
face
shield,
proper
protective
clothing,
and
remove
all
metal
jewelry.
Do
not
spill
or
splash
battery
fluid.
Do
not
apply
pressure
to
walls
of
filled
bat
tery
use
battery
carrier
or
place
hands
on
op
posite
corners
when
lifting
battery.
Keep
sparks, flames,
cigarettes,
and
other
ignition
sources
away
from
batteries.
Use
enough
ventilation
to
keep
battery
gases
from
building
up
during
and
for
several
hours
after
bat
tery
charging.
High
Speed
Stop
Screw
OM-471
Page
16
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