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Generac Power Systems 005220-0 manual

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Table of contents for the manual

  • Page 1

    ST ANDBY GENERA T OR O WNER'S MANU AL This manual should remain with the unit. A ne w standar d of reliability Serial Number QT 3.0L 30kW Model: 005220-0 —  CAUTION  — ONL Y QU ALIFIED ELECTRICIANS OR CONTRA CT ORS SHOULD A TTEMPT INST ALLA TION! Cover025 Re v . 0 09/05 Part No. 0F7911[...]

  • Page 2

    Standby Generator Sets T able of Contents SECTION P AGE SAFETY RULES ................................................ 1-1 INTRODUCTION ..................................................... 1-3 Read this Manual Thoroughly ................................... 1-3 Operation and Maintenance ...................................... 1-3 How to Obtain Servic[...]

  • Page 3

    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 reli- ably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental ru[...]

  • Page 4

    • Before performing any maintenance on the gen- erator , disconnect its battery cables to prevent accidental start -up. Disconnect the cable from the battery post indicated by a NEGA TIVE, NEG or (–) first. Reconnect that cable last. • Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and [...]

  • Page 5

    1-3 I NTRODUCTION Thank you for purchasing this model of the standby generator set product line. Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written. However , the manufacturer reserves the right to change, alter or otherwise improve this produ[...]

  • Page 6

    I DENTI F ICA TION R EC ORD D A T A LA BE L Every generator set has a DA T A LABEL that contains important information pertinent to the generator . The data label, which can be found attached to the gen- erator’s lower connection box, lists the unit ’s serial number and its rated voltage, amps, wattage capacity , phase, frequency , rpm, power f[...]

  • Page 7

    E QUIPM ENT DE SCRI PTION This equipment is a revolving field, alternating cur - rent generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers. The unit comes com[...]

  • Page 8

    ENGI N E P RO TE CTIVE DEVICE S The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant tempera- ture, oil pressure or rpm. F or that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shutti[...]

  • Page 9

    F U E L SYST E M FUE L RE QUIRE MEN T S The standby generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (PV) fuel system The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the uni[...]

  • Page 10

    SP ECIF ICA TIONS GEN ERA T OR T ype ............................................................................. Synchronous Rotor Insulation ............................................................ Class F or H Stator Insulation .................................................................. Class H T otal Har monic Distor tion ..........[...]

  • Page 11

    COLD WEA THER KIT F or cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes: • Battery W armer • 4” Junction Box with hardware • 6 qt. pack 5W -30 synthetic oil (engine) R EC ON F IGU R I NG TH E F U EL SY STEM NOTE: All models are configured for natural gas or LP vapor from the factory . T o reconf[...]

  • Page 12

    GEN ER A T OR A C LEAD C ONN ECTIONS See “V oltage Codes”. This generator may be rated at any one of three voltages, either single -phase or three -phase. The electrical wires in the unit ’s AC con- nection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. If there are any q[...]

  • Page 13

    I NST ALL A TION Refer to the separate “Installation Guide QT Product Line” supplied with the unit. P R EP ARA TION B EFOR E S T ART -U P The instructions in this section assume that the standby generator has been properly installed, ser - viced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor .[...]

  • Page 14

    S T ART -U P CH ECKLIS T  Before working on the generator , ensure the fol- lowing: • The AUTO/OFF/MANU AL switch is in the OFF position. • The 120V AC supply to the battery charger is switched OFF . P REP AR A TION FOR S T ART -UP • Ensure that the 120V AC circuit breaker to the bat - tery charger is open. • Remove the fuse from the the[...]

  • Page 15

    GEN ER A T OR C ONTROL AND OP ER A TION Refer to the appropriate control panel operator’s manual for this unit. OP ER A TI NG U N IT WITH MAN U AL TR ANSF ER SWIT CH If the generator was installed in conjunction with a transfer switch capable of manual operation only , the following procedure applies. A manually operated transfer switch is one th[...]

  • Page 16

    MAI NTENANCE P ER FOR M ED B Y AUTHOR IZED SERVICE F A CILITI ES  Before working on the generator , ensure the fol- lowing: • The AUTO/OFF/MANU AL switch is in the OFF position. • The 15A fuse has been removed from the con- trol box. • The 120V AC supply to the battery charger is switched OFF . EVER Y TH R EE MONTHS 1. Check battery state [...]

  • Page 17

    ENGI NE COOL ANT Check coolant level in coolant recovery bottle. See the “Specifications” section. • Add recommended coolant mixture as necessary . • Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly . Coolant should be at bottom of radiator filler neck. If coolant level is low , insp[...]

  • Page 18

    7. Start engine and check for oil leaks. Figure 10.2 - Oil Filter Oil Filter CHANGI NG THE ENGI N E AI R CLEAN ER T o replace the engine air cleaner , (part number 0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover . See the “Service Schedule” section for air clean[...]

  • Page 19

    BA TTER Y MAI NTENANCE The battery should be inspected per the “Service Schedule” section. The following procedure should be followed 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 DISTILLED[...]

  • Page 20

    SERVICE S CH EDU LE 30 KW - 1 5 0 KW ST ANDBY GAS ENGIN E DR IVEN GEN ER A T OR SET S 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. They will n[...]

  • Page 21

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

  • Page 22

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

  • Page 23

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

  • Page 24

    TROU B LESHOO TING GU I DE P ROB LEM CAUSE C OR R ECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse . 2. Loose or corroded or defectiv e 2. Tighten, clean or replace batter y cables. batter y cables as necessary . 3. Defectiv e star ter contactor . 3. Replace contactor .* 4. Defectiv e star ter motor . 4. Replace starter motor .* 5[...]

  • Page 25

    Standby Generator Sets Notes[...]

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    [...]

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    1 0F3137 1 PAN CB CONN BOX 2 0F3188 1 STAND RH CONTR OL 3 0F3189 1 STAND LH CONTRO L 4 0 23484N 1 B U SHING SNAP SB-2.5 -31 5 *** 0F6366B 1 / 2 XFMR DU AL 120 V/16 V (FO R 12 0/ 240V & 277/ 480V UNI T S) 0F63 66A 1 XFMR D UAL 10 4V/ 16V (F OR 120 /208V U NITS) 6 * ** 0431 80 2 / 4 WAS HE R FL AT M 4 7 ** * 022264 2 / 4 W ASHER LO CK #8-M 4 8 **[...]

  • Page 28

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  • Page 29

    1 0 F3438 1 RTR 390 30AD1 C PL 0F344 0 1 RTR 39 0 40AD2 C PL HI-EF 0F61 88 1 AS S Y RTR 39 0 30 KD 1 CP L 0F61 90 1 AS S Y RTR 39 0 40 KD 2 CP L 2 0F3439 1 STR 390 30 AD 1 CP L 0F34 41 1 S TR 39 0 40 AD 2 CP L 0F61 89 1 S TR 39 0 30 G D 1 CPL 0F61 99 1 S TR 39 0 40 G D 2 CPL 0F665 5 1 ASSY STR 390 30KD1 CPL 0F665 6 1 ASSY STR 390 40KD2 CPL 3 0C9708[...]

  • Page 30

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  • Page 31

    COMPONENTS INCLUDED IN 01827E 1 0F1823A 1 ENCL HSB CO NT ROL PANE L 2 0F3078 1 COVER CO NTRO L PANEL 3 0F2606 1 HINGE CONT INUOUS H-PAN EL 4 036261 6 RI VET POP .125 X . 275 SS 5 043 181 4 SCREW PHM M3-0.5 X 10MM 6 052777 7 WASHE R FL AT M 3 7 0F4245E 1 AS SY PCB CPL CT RL R 1800 RPM 8 0 F1262 4 HOLDER FUSE W ICKMANN 178.6150 9 0F1263 1 ADPTR RH SI[...]

  • Page 32

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    1 0F3270A 1 MTG BASE 3.0L 30K W C2 2 0528 60 4 NUT FL ANGE D HEX M 12- 1.7 5 3 0522 51 4 DAMPE NE R VI BRAT ION 40 BLUE 4 052 257 4 SPAC ER .49 X .62 X 1.87 PWDR/ZNC 5 0522 52 4 DAMPE NE R VI BRAT ION 6 0522 59 4 WASHE R F LAT M 12 7 0528 91 4 SCRE W HH C M 12-1. 75 X 80 G 8.8 8 053621 0410 1 ASSY WIRE 14 .0 0 " 9 0429 0 9 1 SCRE W HH C M 8- 1[...]

  • Page 34

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  • Page 35

    1 0F3408 1 TRAY BA TTER Y 2 0F 3 4 11 1 STRAP BA TTE RY RETAI NMENT 3 058208 RE F BAT T 12VD C 24 F 62 5 4 036833 1 SCRE W HH C 3/ 8-1 6 X 1 G8 5 022237 1 WASHE R LO CK 3/8 6 022131 1 WASHE R F LAT 3/8- M10 Z IN C 7 050331A 1 BATT POST COVER RED + 8 0 50331 1 BATT POST COVER BLK - 9 038805 H 1 CAB LE BA TT BL K #1 X 2 3.00 10 0388 04Y 1 CA BLE BATT[...]

  • Page 36

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  • Page 37

    1 0E5 19 3 1 P LATE AIR CLE ANE R AD AP T ER 2 0E0519A 1 AD APTER CAR BU RETOR W/PV C CONN 3 0221 27 1 NUT HEX 1/4- 20 STE EL 4 0629 74 1 STU D TH 1/4- 20 X 4- 1/2 G 2 ZN C 5 0526 19 4 SCREW HH C M 5-0. 8 X 20 G 8. 8 6 0C81 27 1 E LEM ENT A IR CLE ANE R 7 0A55 47 1 CO VER - AI R CLEA NER 8 0375 61 1 NUT W I NG 1/ 4-2 0 NY LK 9 0E658 6 2 GASKET BOSC[...]

  • Page 38

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  • Page 39

    1 0F6842 1 E NGINE 3 .0L FORD (FD) ( MAKE) CPL 2 02 2131 14 WASHER FL AT 3/8- M10 ZIN C (1800 RPM O NLY) 022131 * 9 WASH ER FLAT 3/8-M10 ZINC (3 60 0 R PM ONLY) 3 0E8 96 3 1 PULLE Y CR AN KS H AFT 3.0L F O R D (180 0 RPM ON LY ) 0E6309 1 P ULLE Y CR AN KSH AFT 3.0L FOR D (36 00 RPM ONLY ) 4 0F6912 1 BR ACKET R/H SIDE D.C. ALT 5 0F 68 73 1 BR AC KE [...]

  • Page 40

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  • Page 41

    1 0F3203A 1 WELDMEN T RAD SUPPO RT 3.0L C 2 2 0356 8 5 6 CLAM P HOS E #2 8 1. 32- 2. 25 3 0F2608A 1 RADIAT OR 598 X 568 X 49,CP L LH 4 0F67 61 1 HOSE UP PE R RAD CPL C2 3.0L 5 0F32 28 1 HOS E LOW E R RA D CPL C2 3.0L 6 0F51 43 1 S PA CER FAN 3. 0L C2 7 0F02 30 A 1 FAN COOL I NG 16" DI A 8 BLA DE 8 0457 64 1 SCRE W HH TT M4- 0.7 X 8 BP 9 065852[...]

  • Page 42

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  • Page 45

    1 0 26915 2 NI PPLE C LOSE 3 /4 X 1.375 2 075580 1 FLANGE FUEL INLET 3 0F6390 1 REGULATOR ASSEMBLY D UAL FUEL 4 03925 3 2 S CREW HHC M 8-1. 25 X 20 G8.8 5 02214 5 2 W ASHE R FL AT 5/ 16-M 8 ZIN C 6 0 22129 4 WASH ER LOCK M8 -5 /1 6 7 045771 2 NUT HEX M 8-1.25 G8 CLEAR Z INC 8 04290 7 2 S CREW HHC M 8-1. 25 X 16 G8.8 9 0E9295A 1 ASSY THROTTLE 27MM 1[...]

  • Page 46

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  • Page 47

    1 0F0738 1 MUFFLER 7" X 9"-(2) 2" IN/2. 5" OUT 2 0F28 08B 1 P IPE EXHAUS T MUFFLE R 4 0F2830 1 MUFFLER BRACKE T STIFFENE R 5 0F2962 1 MUFFLER STR AP 6 0 807 62 1 BOLT U 3/ 8-1 6 X 2. 62 7 0E0170 B 1 EXHAUST BLANK ET 80 0MM (C2) 8 0 E0170 1 EXHAUST BLANKET 75 0 MM (C2) 9 0F4343 1 EXHAU ST PIPE 3.0 L C2 C PL RH 10 0F 4 34 4 1 EXHA[...]

  • Page 48

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  • Page 49

    1 0F58 53 (XX ) 1 REA R WRA P C2 2 0C24 5 4 68 S CRE W THF M6- 1 X 16 N WA Z/JS 3 0F58 49 ( XX) 2 DO OR C2 4 087 233 2 RIVET POP .187 5 X .4 50 SS 5 0E 325 7 4 SCREW TH- FR M M6 W/ CAP S HKP RF W 6 0 F585 2 (XX) 2 DISC HARGE DU CT,L H & RH SIDE C 2 7 0F58 50 (XX ) 2 FRON T CO RN ERS C2 8 0 F585 1 (XX) 1 DISC HARGE CENT E R DU CT C2 9 0F33 13 1 [...]

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    Standby Generator Sets W arranty Printed in U.S.A. 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 A uthorized/Cer tified Generac P ow er Systems Dealer , or branch thereof , Generac P ow er Systems, Inc. will, at its [...]