Generac Power Systems 05176-0 manual

PO WER SY STEMS, INC. ® Installation and Owner’ s Man ual Air -cooled A utomatic Standb y Generators Model: 05176-0 (13 kW NG, 15 kW LP) D ANGER DEADL Y EXHAUST FUMES. OUTDOOR INST ALLA TION ONL Y!! Not intended f or use as Primary P ower in place of utility or in life-support applications.  GENERA C POWER SYSTEMS, INC. R R *This manual shoul[...]

I NTRODUCTION Thank you for purchasing this model by Generac P ower Systems Inc.. This model is a compact, high performance, air - cooled, engine - driven generator designed to automatically supply electrical power to operate critical loads during a utility power failure. This unit is factory installed in an all-weather , metal enclosure that is in[...]

T able of Cont ents Air-cooled 1 5 kW Generators 1 Introduction ........................ Inside F ront Cover Read This Manual Thoroughly ........................ IFC Contents .......................................................... IFC Operation and Maintenance ............................ IFC How to Obtain Service ...............................[...]

2 Study these SAFETY RULES carefully before install- ing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental ru[...]

3  ELE CTR ICAL HA Z AR DS  • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in opera- tion. A void contact with bare wires, terminals, connections, e[...]

D ANGER  Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations. 1.1 U N P ACKING/I NSP ECTION After unpacking, carefully inspect the contents for damage. • This standby generator set has been factory sup - plied with a weather protective enclosu[...]

Section 1 — General Information Air-cooled 1 5 kW Generators 5 1.4 TH E GEN ER A T OR Exh aust En c lo su r e O il Filte r Batter y Com p artmen t F uel Inl et C ontro l P a n el D a t a D ecal O i l Di p stic k F uel Re g ulato r Com p osite Bas e Figure 1.1 – 15 kW , V -twin GT -990 Engine A U T O MATI C TRAN S FE R S WIT CH Figure 1.2 – 15[...]

6 Section 1 — General Information Air-cooled 1 5 kW Generators 1.5 SP E CI F ICA TIONS 1.5.1 GEN ERA T OR Rated Max. Continuous P ower Capacity (W atts*) .......................... 13,000 NG/15,000 LP Rated V oltage........................................................ 120/240 Rated Max. Continuous Load Current (Amps) 120 V olts + .............[...]

7 4. Remove the engine air in baffle located on the left - hand side of the battery compartment. T wo M6 screws are located on top of the baffle and two M6 screws are located on the inside of the baffle towards the back. 5. Remove the small hose clamp and hose from the fuel regulator . It may be necessary to pry the hose off of the brass fitting us[...]

Remote monitoring functions are only available with the A UTO/OFF/MANU AL switch in the Auto or Manual position. Since the contacts are SPDT , it is possible to monitor either state of each alarm function. Relay 1: Engine running, normally closed. Engine not running, normally open Relay 2: T ransfer Switch in Emergency , normally closed Transfer Sw[...]

9 Connect power source load conductors to clearly marked transfer mechanism terminal lugs as fol- lows 1. Connect UTILITY (NORMAL) power source cables to switch terminals N1, N2. 2. Connect customer LOAD leads to switch termi- nals T1, T2. Conductors must be properly supported, of approved insulative qualities, protected by approved conduit, and of[...]

10 Figure 2.4 – Battery Cable Connections NOTE: The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation. W ith the battery installed and utility power source voltage available to the transfer switch, the battery receives a trickle charge while the engine is not running , to prevent s[...]

11 3. Check utility power source voltage across termi- nals N1 and the transfer switch neutral lug; then across terminal N2 and neutral. Nominal line -to - neutral voltage should be 120 volts AC. 4. When certain that utility supply voltage is compat- ible with transfer switch and load circuit ratings, turn OFF the utility power supply to the transf[...]

12 3.5 CH E CKI NG AUT OMA TIC OP ER A TION T o check the system for proper automatic operation, proceed as follows: 1. Set the generator’s main circuit breaker to it ’s OFF (or open) position. 2. Check that the AUTO/OFF/MANU AL switch is set to OFF . 3. Manually set the transfer switch to the UTILITY position, i.e., load terminals connected to[...]

13 Section 3 — Post Installation Start-up and Adjustments Air-cooled 1 5 kW Generators 7. T urn utility power to the main distribution panel back on. This can be done by switching the ser - vice main breaker to the on or closed position. Allow the generator to shut down.  Do not make any unnecessary adjustments. Factory settings are corr ect f[...]

14 Section 4 — Operation Air-cooled 1 5 kW Generators 4.1 USI NG TH E AUT O/OF F/MAN UAL SWIT CH (F IGU R E 4.1) 4.1.1 “ AUT O” POSITION Selecting this switch position activates fully automatic system operation. It also permits starting and exercising of the engine every seven days with the exercise timer (see "Generator T est Under Load[...]

15 • Retransfer to utility power source then occurs. F . Engine Cool- down Timer • When the load is transferred back to utility power source, the engine cool- down timer starts tim- ing . • The timer will run for about one minute, and the generator will then shut down. 4.4 MAN U AL OP ER A TION D ANGER  Do NOT manually transfer under load.[...]

16 4.4.2 CL OSE T O EM ERGENCY SOURCE SI DE Before proceeding, verify the position of the switch by observing the position of the manual operation handle in Figure 4.2. If the handle is DOWN , the contacts are closed in the EMERGENCY (ST ANDBY) position. No further action is required. If the handle is UP , proceed with Step 1. Step 1: With the hand[...]

17 7. Move the switch's main contacts back to their UTILITY position. F or example, load connected to UTILITY power supply . Refer to "Manual Operation". Handle and operating lever of trans- fer switch should be in UP position. 8. T urn on the UTILITY power supply to transfer switch, using whatever means provided (such as a UTILITY m[...]

18 4.8.3.1 Approximat e Crank Cycle Times • 15 seconds ON • 7 seconds OFF • 7 seconds ON • 7 seconds OFF • Repeat for 45 seconds Approximately 90 seconds total 4.8.4 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit. This protection also prevents the gen- erator[...]

19 Figure 5.3 – Oil Drain Hose and Filter Oil Filter Oil Drain Ho s e L o o s e n 3. After the oil has drained, replace the cap onto the end of the oil drain hose. Retain the hose in the clip. 4. Refill with the proper recommended oil (see "Changing the Engine Oil"). See the "Specifications" section for oil capacities. 5.4 CHA[...]

20 5.7 B A T TER Y MAI NTENANCE The battery should be inspected per the “Service Schedule”. The following procedure should be fol- lowed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary . 2. Check the battery fluid level of unsealed batteries and, if necessary , fill with DISTIL[...]

21 When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change. Figure 5.6 - V alve Clearance Adjustment Jam Nut Pivot Ball Stud Rock er Arm V alve Stem • [...]

22 5.1 2.2 R ETUR N T O SERVICE T o return the unit to service after storage, proceed as follows: 1. Set the generator’s main circuit breaker to its OFF (or OPEN) position. 2. V erify that utility power is turned off and that the A UTO/OFF/MANU AL switch is set to OFF . 3. Check the tag on the engine for oil viscosity and classification. V erify [...]

23 Section 5 — Maintenance Air-cooled 1 5 kW Generators 7 KW - 40 KW SMALL ST ANDBY GENER A T OR SET S F ollowing is a recommended maintenance schedule for small standby and residential generator sets from 7 kW to 40 kW in size, and applies to gas engine driven units. The established intervals in the schedule are the maximum recommended when the [...]

24 Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask T ask Required T ask T ask Required T ask mended Comp. Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- Required (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) to be done Initials) annually/ Initials) Annually/ Initials) annually/ [...]

25 Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask T ask Required T ask T ask Required T ask mended Comp. Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- Required (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) to be done Initials) annually/ Initials) Annually/ Initials) annually/ [...]

26 Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask T ask Required T ask T ask Required T ask mended Comp. Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- Required (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) to be done Initials) annually/ Initials) Annually/ Initials) annually/ [...]

27 Section 6 — T roubleshooting Air-cooled 1 5 kW Generators 6.1 TROU B LE SHOO TI NG GU I DE Problem Cause Correction The engine will not crank. 1. F use blown 1. Replace 15A fuse on generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary . 3. Defective starter motor 3. * 4. Dead Battery [...]

28 Section 7 — Mounting Dimensions Air-cooled 1 5 kW Generators Drawing No. 0F592 7[...]

29 Section 8 — Electrical Data Air-cooled 1 5 kW Generators Wiring Diagram – Drawing No. 0F5 643-B Part 1 TR - RELAY , TRANSFE R CUS T O MER SU PPLIE D BLA CK BATTERY 12V 0 HT O S P 2 S P 1 L OP 0 86 85 IM2 85 IM1 D D BA - BR US H A SS EMBL Y DIA G RAM KE Y CB2 - CIRCUIT BREAKER , ALTERNATOR EXCITATIO N C B1 - MAIN OU TP U T BREAKE R B C R - BA[...]

G R D G R D 22 5 22 5 224 224 1 5 224 225 0 2 39 1 5A 66A 2 3 1 94 4 14 0 22 5B 224B 1 3A 0 1 1 C L OS E S T T O BEARIN G 0 66 77 4 4 0 F2 1 5 1 3 RE GU LAT OR V O LTA GE 1 94 2 3 N1 N1 4 66A N2 351 N2 N1 162 6 0 0 0 66A 6 1 62 0 MAN U A L S W 2 A U T O S W 1 1 b 1 1 a 0 351 C B 1 0 0 0 0 55 0 0 11 44 55 C2 3 2 1 66 1 3A 22 5B 224B TX 224 22 5 224A[...]

31 Section 8 — Electrical Data Air-cooled 1 5 kW Generators Wiring Diagram – Drawing No. 0F5 643-B Part 3 G R D CO M + RY5- RY1+ RY 3+ RY4- COM - RELAY B O AR D S I G NAL S REM O T E N1 N2 F4 1 94 T S N1A N1A N2A N1A N1 A N2A 1 94 2 3 N1A TR N2A N1 A E2 1 94 N1A 2 05 E2 2 3 12 6 1 2 05 N1A N2A N2 N1 194 2 3 N1 N2 1 94 1 5B A2 1 5A A2 22 9 147 1[...]

32 Section 8 — Electrical Data Air-cooled 1 5 kW Generators Electrical Schematic – Drawing No. 0F5844-B C HAR G E R BATTERY 1 62 22 V O LTA GE RE GU LAT OR ELE C TR O NI C 6 4 0 11 ( STATOR ) DPE WINDIN G C 2- 8 2 C 2- 7 C B 2 4 0 6 BA FIELD 1 3A 1 1 0 77 C 2- 1 3 1 2 C 1- 3 4 14 11 1 6 17 12 1 3 1 5 14 C 2- 3 PRINTED C IR CU I T 0 C 1- 6 C 2- [...]

33 Section 8 — Electrical Data Air-cooled 1 5 kW Generators Electrical Schematic – Drawing No. 0F5844-B SM C 1- 1 C 1- 5 SCR 0 0 0 1 6 0 1 8 D D IM2 IM1 S P 2 S P 1 1 6 0 SC 0 S W 1 1 5A 1 5 1 94 F S 0 14 WINDIN G ( STATOR ) P O WE R 22 44 11 C B 1 33 C 2- 5 C 2- 6 CUS T O ME R SU PPLIE D BATTERY 12 V BLA CK RED SC N1 TR N O XA 1 A COM CO I L B[...]

34 47 54 7 2 2 2 0 49 4 9 4 3 43 36 4 37 2 5 35 32 34 35 2 6 53 74 4 6 51 8 7 8 80 39 81 1 8 52 44 63 1 5 51 2 1 71 69 42 1 0 41 7 3 49 9 51 4 9 11 0 72 7 9 5 2 7 35 4 9 44 5 56 1 57 1 9 52 47 4 0 69 50 22 65 1 2 68 1 4 7 5 4 9 71 55 17 30 68 67 3 35 25 2 8 1 2 9 Section 9 — Exploded Views and P arts Lists Air-cooled 1 5 kW Generators Enclosure ?[...]

35 ITEM P ART NO . QTY . DESCRIPTION 1 0C6140 1 A SS EMBL Y , ENCLO S URE BA S E 2 0C67 3 5 2 S UPPORT , ROOF FOLDING 3 0F006 3 1 ENCLO S URE, FRONT 4 0C7062 1 ENCLO S URE, EXHA U S T S IDE 5 0F562 9 1 ENCLO S URE, S IDE & BACK 6 0E 98 7 3 1 ENCLO S URE, ROOF 7 0C7065 1 P ANEL, AL TERNA TOR DIVIDER 8 0C 8 101A 1 P ANEL, MUFFLER BO X S IDE 9 0C [...]

36 3 1 19 3 7 38 22 8, 9 27 45 46 44 28 47 10 25 3 2 5 14 13 17 23 34 15 21 35 20 4 15 29 5 13 38 6 7 23 25 12 27 40 41 36 39 45 44 43 1 30 15 11 47 45 24 45 47 50 49 48 5 1 53 Section 9 — Exploded Views and P arts Lists Air-cooled 1 5 kW Generators Control Panel – Drawing No. 0F5 846[...]

37 ITEM P ART NO . QTY . DESCRIPTION 1 0E7 88 6G 1 CIRCUIT BREAKER 70A X 2P 240V (15KW) 2 0A1 8 01 1 A SS EMBL Y , BA TTER Y CHARGER ENGINE 3 0 83 04 9 1 A SS EMBL Y , POTTED REGULA TOR 4 0C2174 1 RELA Y , 12V 25A S P S T 5 075210A 2 BLOCK 1 PO S ITION 6 0D 3 062 4 HEX S T AND-OFF #6- 3 2 x 3 / 8 " 7 0D 8 615 1 A SS EMBL Y , HOME S T ANDBY CON[...]

38 Section 9 — Exploded Views and P arts Lists Air-cooled 1 5 kW Generators GT -990 Eng ine – Drawing No. 0E8 7 7 4-Q Part 1[...]

39 ITEM P ART NO. QTY . DESCRIPTION 1 0C572 9 1 A SS EMBL Y , CRANKCA S E HOU S ING WITH S LEEVE 2 0E 98 4 3 1 S EAL, 38 I.D . CRANK S HAFT 3 0 9 0 388 3 S CREW , T APTITE M6-1.0 X 12 YC 4 0C5 3 72 1 A SS EMBL Y , BREA THER 5 0C 3 005 1 GA S KET , BREA THER CO VER 6 0E 33 72B 1 S EP ARA TOR, OIL BREA THER 7 0D 8 067A 1 A SS EMBL Y , HEAD #1 G& [...]

40 Section 9 — Exploded Views and P arts Lists Air-cooled 1 5 kW Generators GT -990 Eng ine – Drawing No. 0E8 7 7 4-Q Part 2[...]

41 ITEM P ART NO. QTY . DESCRIPTION 74 0C51 3 6A 2 KNOB, AIR CLEANER 75 0C 3 024 1 CO VER, AIRBO X NG/LP 76 0C 3 040 1 PRE-CLEANER, 77 0C 8 127 1 ELEMENT , AIR CLEANER 7 8 0D 8 564A 1 A SS EMBL Y , MIXER/AIRBOX 99 0 0D 8 564B 1 A SS EMBL Y , MIXER/AIRBO X 760 7 9 0D25 9 5 4 S CREW S HOULDER ( 8 MM) M6-1.0 X 1 8 8 0 0D4417 4 W A S HER,R UBBER 1/4&qu[...]

42 2 9 3 6 3 4 11 2 3 5 24 4 3 21 7 1 3 33 12 38 17 3 2 3 1 2 8 3 1 20 1 9 10 17 15 3 2 16 22 39 4 9 8 6 3 7 14 3 2 40 1 3 2 24 25 10 3 0 1 9 26 2 8 27 2 8 3 2 3 1 41 10 1 8 3 6 2 8 3 5 41 2 9 42 3 6 3 6 3 5 Section 9 — Exploded Views and P arts Lists Air-cooled 1 5 kW Generators 1 5 kW Generator – Drawing No. 0D34 1 7 -L[...]

43 Section 9 — Exploded Views and P arts Lists Air-cooled 1 5 kW Generators 1 5 kW Generator – Drawing No. 0D34 1 7 -L ITEM P ART NO . QTY . DESCRIPTION 1 0C6 93 4 1 AD APT OR, ENGINE 2 0C7 93 0 1 S T A T OR 12KW 0D2 3 5 9 S TAT O R 1 3 KW / 15KW 3 0C7 9 44 1 RO T OR 12KW 0D2 3 56 RO T OR 1 3 KW / 15KW 4 0C604 3 1 CARRIER, REAR BEARING 5 0D2 33[...]

44 7KW 17 12 2 8 11 20 10 25 21 24 1 9 2 3 22 22 15 26 14 1 3 16 2 9 1 8 8 2 8 12 3 2 10 11 27 3 1 4 5 3 2 10 17 1 26 15 14 16 1 3 3 7 1 9 9 3 0 21 25 20 24 2 9 1 8 2 3 11 12 2 8 Section 9 — Exploded Views and P arts Lists Air-cooled 1 5 kW Generators Gas Regulator – Drawing No. 0D8 7 20-H[...]

45 ITEM P ART NO . QTY . DESCRIPTION 1 0D56 9 4 1 CA S TING, TWIN REGULA T OR HOU S ING 2 0F5022 1 S OLENOID COIL, 12VDC 3 0C4647 1 GA S KET , S OLENOID 4 0D4166 1 PLUNGER, LP REGULA TOR A SS EMBL Y 5 0C6070 1 S PRING- S OLENOID , PLUNGER 8 0F47 9 5 4 S CREW PPHM S EM S M4-0.7 X 10 9 0C5760J 1 JET , GN 410 ENGINE LP (7KW) 10 0C6606 2* BARBED S TRAI[...]

46 Section 9 — Exploded Views and P arts Lists Air-cooled 1 5 kW Generators T ransfer Switch – Drawing No. 0F563 3$-A[...]

47 ITEM P ART NO . QTY . DESCRIPTION 1 0D 9 61 8 1 TR S W- H S B 200A 2P 250V 2 0E 33 75 6 LUG S LDL SS 250-#6 AL/CU 3 0F1252 6 S CREW BH S C 1/4-20 X 3 / 8 4 0220 9 7 6 W A S HER LOCK M6-1/4 5 074 9 0 8 5 S CREW HHTT M5-0. 8 X 16 BP 6 045771 1 NUT HEX M 8 -1.25 G 8 YEL CHR 7 057 3 2 9 1 LUG S LDL SS 3 50-#6 X 1 3 / 3 2 AL/CU 8 0274 8 2 1 W A S HER[...]

48 CALI FOR N IA EM IS SION CONTROL W ARR ANT Y ST A TEM ENT Y OUR W AR R ANTY R IGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to explain the Emission Control System W arranty on your new engine. * In California, new utility , and lawn and garden equipment engines must be de[...]

49 EM IS SION CONTROL S Y STEM W AR RANT Y Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS W arranty P eriod shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purcha[...]

Part No. 0F5631 Revision C (12/07/06) Printed in U.S.A. Section 1 0 – W arranty Air-cooled 1 5 kW Generators GENERA C PO WER SYSTEMS ST ANDARD LIMITED W ARRANTY FOR HOME ST ANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELO W For a period of two (2) y ears from the date of sale, or start-up by Authorized/Certified Generac P ower Systems Dealer , or bra[...]