1. Manuals
  2. Brands
  3. CAC / BDP Manuals
  4. Inverter
  5. FOR BYPASS AND FAN POWERED HUMIDIFIERS
  6. Owner's manual

CAC / BDP 4.2L 48kW Models Owner's Manual

Standby generator
Hide thumbs Also See for 4.2L 48kW Models:
Table of Contents

Advertisement

Quick Links

Download this manual

Serial Number

STANDBY GENERATOR
OWNER'S MANUAL
Not intended for use in critical life support applications.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
A new standard of reliability
—CAUTION—
4.2L
48kW
Models
This manual should remain with the unit.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 4.2L 48kW Models and is the answer not in the manual?

Questions and answers

Related Manuals for CAC / BDP 4.2L 48kW Models

Summary of Contents for CAC / BDP 4.2L 48kW Models

  • Page 1: Serial Number

    Serial Number 4.2L 48kW Models STANDBY GENERATOR OWNER'S MANUAL A new standard of reliability   Not intended for use in critical life support applications. —CAUTION— ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! This manual should remain with the unit.

  • Page 2: Table Of Contents

    Standby Generator Sets Table of Contents Belt Tension ..............8-1 SECTION PAGE Electrical System ............8-1 SAFETY RULES ............1-1 Initial Inspection for Genset Start-up ......8-1 INTRODUCTION .............1-3 Start-up Checklist ............8-2 Read this Manual Thoroughly ........1-3 Preparation for Start-up..........8-2 Operation and Maintenance ........1-3 OPERATION ............9-1 How to Obtain Service ..........1-3 Generator Control and Operation ........9-1...
  • Page 3 Standby Generator Sets Important Safety Instructions   SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. ...

  • Page 4: Fire Hazards

    Standby Generator Sets Important Safety Instructions • Before performing any maintenance on the gen- • Generators installed with an automatic transfer erator, disconnect its battery cables to prevent switch will crank and start automatically when accidental start-up. Disconnect the cable from the normal (utility) source voltage is removed or is battery post indicated by a NEGATIVE, NEG or (–) below an acceptable preset level.

  • Page 5: Introduction

    Standby Generator Sets Important Safety Instructions INTRODUCTION  This symbol points out potential explosion Thank you for purchasing this model of the standby hazard. generator set product line.  This symbol points out potential fire hazard. Every effort was expended to make sure that the ...

  • Page 6: Identification Record

    Standby Generator Sets General Information IDENTIFICATION RECORD NOTE: For actual information related to this particular DATA LABEL model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data Every generator set has a DATA LABEL that contains label affixed to the unit.

  • Page 7: Equipment Description

    Standby Generator Sets Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating cur- Use a mixture of half low silicate ethylene glycol rent generator set. It is powered by a gaseous fueled base anti-freeze and deionized water. Cooling system engine operating at 1800 rpm for 4-pole direct drive capacity is listed in the specifications.

  • Page 8: Engine Protective Devices

    Standby Generator Sets Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The standby generator may be required to operate for After a prespecified duration of cranking, this func- long periods of time without an operator on hand to tion ends the cranking if the engine has failed to monitor such engine conditions as coolant tempera- start.

  • Page 9: Fuel Systems

    Standby Generator Sets Fuel Systems FUEL SYSTEM PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above FUEL REQUIREMENTS the liquid fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel The standby generator may be equipped with one of expansion from the liquid to the vapor state.

  • Page 10: Standby Generator Sets

    Standby Generator Sets Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ..............Gear GENERATOR Oil Filter ..........Full Flow Spin-on, Cartridge Crankcase Oil Capacity ..........5.0 U.S. qts. Type ................Synchronous Rotor Insulation ..............Class H COOLING SYSTEM Stator Insulation ..............Class H Type ...........Pressurized Closed Recovery Total Harmonic Distortion ............<5% Water Pump ..............

  • Page 11: Cold Weather Kit

    Standby Generator Sets Specifications Figure 1 — Interconnections Utility In Transfer Switch NEUTRAL Load 4- # 14 GA WIRES TO GENERATOR CONNECTION TO GENERATOR CONNECTION BOX To Generator Control Panel This is a generic representation of the components contained in the transfer switch and connection box. Refer to the wiring and schematic diagrams for generator specific connections.

  • Page 12: 4.2L Ignition Description

    Standby Generator Sets Specifications 3. Disconnect the power wires from the fuel sole- IGNITION POWER-UP INPUT (“56 LINE INPUT) noid located on top of the regulator assembly. When battery voltage is applied to this input the igni- 4. Loosen the spring clamp on the small fuel enrich- tion will power-up.

  • Page 13: General Information

    Standby Generator Sets General Information GENERATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING See “Voltage Codes”. This generator may be rated CONNECTIONS at any one of three voltages, either single-phase or three-phase. The electrical wires in the unit’s AC con- 3-PHASE ALTERNATORS nection (lower) panel should be installed according to the number of leads and the voltage/phase required The generator is designed to supply 3-phase electri-...
  • Page 14 Standby Generator Sets General Information 3-PHASE ALTERNATORS Figure 7.4 — Stator Power Winding Connections - 3-phase, 346/600V (6 Lead) ("DELTA" CONFIGURATION) The generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator S1 E1 power windings. These windings were connected at the factory to the main circuit breaker with a “Delta”...

  • Page 15: Installation

    Standby Generator Sets Installation INSTALLATION PRIOR TO INITIAL START-UP Refer to the separate “Installation Guide” supplied with the unit.  Prior to initially starting the generator, it must PREPARATION BEFORE START-UP be properly prepared for use. Any attempt to The instructions in this section assume that the crank or start the engine before it has been standby generator has been properly installed, ser- properly serviced with the recommended types...

  • Page 16: Start-Up Checklist

    Standby Generator Sets Installation • Battery charger connection to 120 VAC. • Open the valve to the engine fuel line. • Communication wires connected between transfer • Bleed the fuel system of air. (necessary for long fuel lines). switch and generator (HTS only). •...

  • Page 17: Operation

    Standby Generator Sets Operation GENERATOR CONTROL AND OPERATION  Do not crank the engine continuously for longer Refer to the appropriate control panel operator’s than 30 seconds, or the heat may manual for this unit. damage the starter motor. • Let engine stabilize and warm up. OPERATING UNIT WITH MANUAL •...

  • Page 18: Maintenance

    Standby Generator Sets Maintenance MAINTENANCE PERFORMED BY FIRST 30 OPERATING HOURS SERVICE DEALER 1. Change engine "break-in" oil and oil filter. FIRST 100 OPERATING HOURS 1. Change engine oil and oil filter. (After initial  Before working on the generator, ensure the fol- change, service engine oil and filter at 150 oper- lowing: ating hours or six (6) months, whichever comes...

  • Page 19: Battery Fluid

    Standby Generator Sets Maintenance Figure 10.2 - Oil Dipstick and Oil Fill Cap MAINTENANCE OWNER/ OPERATOR CAN PERFORM OIL FILL  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.

  • Page 20: Inspect Exhaust System

    Standby Generator Sets Maintenance INSPECT EXHAUST SYSTEM Figure 10.3 - Oil Filter 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.

  • Page 21: Spark Plugs

    Standby Generator Sets Maintenance SPARK PLUGS Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are Reset the spark plug gap or replace the spark plugs excessively low, the generator may require drying. as necessary. 1.

  • Page 22: Battery Replacement

    Standby Generator Sets Maintenance BATTERY REPLACEMENT DANGER NOTE:  Storage batteries give off explosive hydrogen Unit DOES NOT include battery. gas. This gas can form an explosive mixture around the battery for several hours after charg- When supplying or replacing the battery, the recom- ing.

  • Page 23: Service Schedule

    Standby Generator Sets Service Schedule SERVICE SCHEDULE 30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application.
  • Page 24 Standby Generator Sets Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
  • Page 25 Standby Generator Sets Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
  • Page 26 Standby Generator Sets Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.

  • Page 27: Troubleshooting

    Standby Generator Sets Troubleshooting 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 replace battery cables. battery cables as necessary. 3. Defective starter contactor. 3.
  • Page 28 Standby Generator Sets Notes...
  • Page 29 Standby Generator Sets Notes...
  • Page 31 0G6568 RTR 390 45AD1 CPL 0G6562 RTR 390 35AD1 CPL 0G6564 RTR 390 35KD1 CPL 0G6570 RTR 390 45KD1 CPL 0G6569 STR 390 45AD1 CPL 0G6563 STR 390 35AD1 CPL 0G6566 STR 390 35KD1 CPL 0G6565 STR 390 35GD1 CPL 0G6572 STR 390 45KD1 CPL 0G6571...
  • Page 33 0F3137 PAN CB CONN BOX 0F0199 INSULATOR CB FD FRAME 30MIL 0F3188 STAND RH CONTROL 081320 SCREW SHC 1/4-20 X 4.5 G8.8 NZ 0F3189 STAND LH CONTROL 022473 WASHER FLAT 1/4-M6 ZINC 023484N BUSHING SNAP SB-2.5-31 022097 WASHER LOCK M6-1/4 0F6366B XFMR DUAL 120V/16V (FOR 120/240V &...
  • Page 35 UL CIRCUIT BREAKER (QJ-2P) 0F8137 COVER QJ 2P FRM CB 0E7994 CB 0225A 240V 2P S QJ22 NEUTRAL BLOCK 390 / 200-400A 0F8136 COVER QJ 2P CB DISH 0D5466 BUS BAR NEUTRAL BLOCK 390 036261 RIVET POP .125 X .275 SS 039287 SCREW HHC M8-1.25 X 45 G8.8 FT 022473...
  • Page 37 0G5313 WELDMENT BASEFRAME 4.2L G3 052860 NUT FLANGED HEX M12-1.75 052251 DAMPENER VIBRATION 40 BLUE 052257 SPACER .49 X .62 X 1.87 PWDR/ZNC 052252 DAMPENER VIBRATION 052259 WASHER FLAT M12 052891 SCREW HHC M12-1.75 X 80 G8.8 0536210410 ASSY WIRE 14.00" 042909 SCREW HHC M8-1.25 X 30 G8.8 047411...
  • Page 39 0F3408 TRAY BATTERY 0F3411 STRAP BATTERY RETAINMENT 051768 SCREW HHC M12-1.75 X 25 G8.8 022145 WASHER FLAT 5/16-M8 ZINC 022195 WASHER LOCK 1/2 022304 WASHER FLAT 1/2 ZINC 050331A BATTERY POST COVER RED + 050331 BATTERY POST COVER BLACK - 038804U CABLE BATT RED #1 X 28.00 038805J...
  • Page 41 0E6586 GASKET BOSCH 32 & 40 0E0519A ADAPTER CARBURETOR W/PVC CONN 0C8127 ELEMENT AIR CLEANER 049815 SCREW HHC M5-0.8 X 16 G8.8 022127 NUT HEX 1/4-20 STEEL (1) 6 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC 0G0190 PLATE, AIR CLEANER TOP 2.4L 037561 NUT WING 1/4-20 NYLK (1) APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON...
  • Page 43 0G68030ST03 WELDMENT RADIATOR SUPPORT C2 022131 WASHER FLAT 3/8-M10 ZINC 0F2608A RADIATOR 598 X 568 X 49,CPL LH 0E2507 PROBE COOLANT LEVEL 3/8 NPTF 0E3256 V-BELT A58 (60IN O.C.) DDC S60 035685 CLAMP HOSE #28 1.32-2.25 046526 WASHER LOCK M10 0F2561 HUB FLEX PLATE (1) 5...
  • Page 45 0G4969 ENGINE 4.2L G3 (FWD) 045772 NUT HEX M10-1.5 G8 YEL CHR 047411 SCREW HHC M6-1.0 X 16 C8.8 0E0992A PLUG EXPANSION 14 OD 022097 WASHER LOCK M6-1/4 055934V CLAMP VINYL 1.5 X .281 Z 022473 WASHER FLAT 1/4-M6 ZINC (1) 46 REF.
  • Page 49 026915 NIPPLE CLOSE 3/4 X 1.375 075580 FLANGE FUEL INLET 0F6390E REGULATOR ASSY 4.2L 45KW 0F6390F REGULATOR ASSY 4.2L 35KW 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16-M8 ZINC 022129 WASHER LOCK M8-5/16 045771 NUT HEX M8-1.25 G8 CLEAR ZINC 0E8286 STREET EL 45D 1/2 NPT BRASS 026812...
  • Page 51 0F9794 MUFFLER 7" X 9" X 18-1/2" 2" IN/OUT 0G0113 EXHAUST ELBOW 2"ID X 2-1/2"OD 0G1007 BRACKET MUFFLER 0F2830 MUFFLER BRACKET STIFFENER 0F2962 MUFFLER STRAP 080762 BOLT U 3/8-16 X 2.62 0G5821 PIPE EXHAUST LEFT 2"OD 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0G5822 PIPE EXHAUST RIGHT 2"OD 0G0007...
  • Page 53 0G0045 (XX) REAR WRAP C2 CPL 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0F5849 (XX) DOOR C2 087233 RIVET POP .1875 X .450 SS 0E3257 SCREW TH-FRM M6 W/CAP SHKPRF W 0F5852 (XX) DISCHARGE DUCT LH & RH SIDE C2 0F9833 (XX) FRONT CORNERS C2 0F5851 (XX)
  • Page 69 COMPONENTS INCLUDED IN 0G8458E 0F1823B ENCL HSB CONTROL PANEL 0F3078BST06 COVER CONTROL PANEL R-200B 0F2606 HINGE CONTINUOUS H-PANEL 036261 RIVET POP .125 X .275 SS 0E7358 SCREW PPPH HI-LO #4-24 X 3/8 052777 WASHER FLAT M3 0G8455A ASSY PCB R-200B CNTRL 1800 0F1262 REF.
  • Page 71 C2 UNITS 0F9832 SHIELD CONN BOX C2 0F9832GGS0R SHIELD CONTROL STAND C2 0C2454 SCREW THF M6-1 X 16 N WA Z/JS C3 UNITS 0F9832B SHIELD CONTROL STAND C3 0F9832KGS0R SHIELD CONTROL STAND C3 0C2454 SCREW THF M6-1 X 16 N WA Z/JS C4 UNITS 0F9832A SHIELD CONTROL STAND C4...
  • Page 72 Catalog No: OMASPFY048A ---01 Copyright 2008 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 07/08 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Table of Contents