Installation guide

PAGE 16
F) The exhaust piping system is subject to engine
vibration, so it must be solidly installed to reduce
potential for pipe cracks or breakage.
G) It is very important to discharge exhaust gasses
away from the engine and out of the generator
building. If these gasses remain in the engine
cylinders, poor engine performance and eventual
engine damage may result. This condition usually
results from excessive back-pressure, which can
result from:
1) Exhaust pipe diameter is too small or exhaust
system is too long.
2) Excessive amount of bends in exhaust pipe run.
3) Obstructions (old birds nest, bees, insects, etc.)
in the exhaust system.
All three items are examples that will cause back
pressure that MUST NOT EXCEED 20”/WATER
COLUMN.
Models SP-200 thru SP-620 has either residential or
Critical grade muffler factory mounted to the engine
pipe manifold. * Models SP-800 thru SP-1500 are
equipped with loose catalytic converters
(conforming to EPA exhaust emissions standards),
shipped loose in a separate shipping box, along with
open generator set. These catalytic converters are
heavy and will require separate support structure for
the exhaust system. Do not try to install these
catalytic converters with only pipe connections on
both ends. Special, gasket flange connections must
be used to connect exhaust piping to catalytic
converter. Consult factory if installation questions
arise.
COOLING THE GENERATOR
This manual explains the use of engine mounted
radiators, as the only cooling method used for
GILLETTE generators. Environmental issues require
cleaner burning engine. Engine manufacturers have
raised engine operating temperatures in order to
reduce exhaust emissions and improve fuel
economy. Today’s engines run on the borderline of
overheating, with in-cylinder temperatures close to
2000º.
GENERATOR
MODEL
PIPE
SIZE
COWL
MODEL
MUFFLER DESCRIPTION
NET
WEIGHT
LBS.
SP-200
SP-250
SP-300
2’
CR-2 RESIDENTIAL GRADE 15
CC-2 CRITICAL GRADE 19
SP-410
SP-520
SP-620
2 ½”
CR-2 ½”
RESIDENTIAL GRADE 20
CC-2 ½”
CRITICAL GRADE 32
SP-800 *
SP-1000 *
3”
CR-3 RESIDENTIAL GRADE 32
CC-3 CRITICAL GRADE 52
SP-1250 *
SP-1400 *
3 ½”
CR-3 ½”
RESIDENTIAL GRADE 38
CC-3 ½”
CRITICAL GRADE 63
MUFFLER MOUNTING TO GENERATOR
GILLETTE uses a 50/50 mix of glycol/di-ionized
water. When we know generator destination is in
colder climates such as Northern USA, Canada, or
Alaska, a 60/40 mix is used. When replacing coolant
in radiator DO NOT USE a 50% glycol and 50% tap
water. Tap water contains minerals, dissolved
oxygen, and chorine, which will cause scaling and
corrosion in the engine. Always use a mixture of
glycol and de-ionized water or distilled water, never
use tap water. Radiators of today’s design are
extremely fragile and light weight, containing
smaller cooling tubes and ,more cooling fins, so it
has become easier to clog radiators with corrosive
coolants. GILLETTE, the radiator manufacturer, and
engine block manufacture will decline warranty on
clogged radiator and engine block problems when it
is known that tap water is used rather than distilled
water.
When coolant system is drained and fresh coolant is
added, it’s best to use a hydrometer for testing the
value of antifreeze mixture. A correct 50/50 mix
allows freeze protection to –34º F and boil-over
protection to 265º F.
COOLING THE GENERATOR AND
ENGINE THAT IS MOUNTED IN A
GENERATOR ROOM
Whenever an open (no housing) generator set is
installed inside a room, in a building the radiator
should be ducted outside the room. See Figure 5,
page 14.
The most common method of generator set cooling,
is that of a generator mounted radiator. The major
components are:
A) Engine driven blower fan.
B) Circulating coolant pump
C) Cooling radiator.
D) Thermostat.
The blower fan pulls cooling air across the radiator
coils. The coolant pump circulates coolant through
the engine until it reaches operating temperature.
The engine thermostat open and allows coolant to
GENERATOR
MODEL
GALLONS LITERS
SP-200
SP-250
SP-300
3 11.4
SP-410
SP-520
SP-620
5.7 21.6
SP-800
SP-1000
7 26.5
SP-1250 7 26.5
SP-1400 7 26.5
RADIATOR COOLANT CAPACITY
(INCLUDING ENGINE BLOCK)