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Generac Power Systems 005259-1 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 2.4L 35kW Models: 005259-1 005260-1 —  CAUTION  — ONL Y QU ALIFIED ELECTRICIANS OR CONTRA CT ORS SHOULD A TTEMPT INST ALLA TION! DEADL Y EXHA UST FUMES. OUTDOOR INST ALLA TION ONL Y!   N ot i [...]

  • 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 DENTIF ICA TION R E C OR D 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 [...]

  • 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 NE 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 shuttin[...]

  • 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 E CIF ICA TIONS GEN ERA T OR T ype ............................................................................. Synchronous Rotor Insulation ................................................................... Class 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 E C ONF IGU RI NG TH E FU EL SY S TEM NOTE: All models are configured for natural gas or LP vapor from the factory . T o reconfi[...]

  • Page 12

    GEN ERA T OR A C LEAD C ON NECTIONS 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 A C 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 NS T ALLA TION Refer to the separate “Installation Guide QT Product Line” supplied with the unit. P REP AR A TION BEFOR E ST ART -UP 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 . Be[...]

  • Page 14

    S T ART -U P CH E CKLIS 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 ST 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 ERA T OR C ONTROL AN D OP ERA TION Refer to the appropriate control panel operator’s manual for this unit. OP ERA TI NG U N IT WITH MAN U AL TR ANSFER 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 that [...]

  • Page 16

    MAI NTENANCE PER FOR M ED B Y AUTHOR IZED SERVICE F ACILITI 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 conditio[...]

  • Page 17

    Figure 10.1 - Oil Dipstick and Oil Fill Cap Oil Dipstick Oil Fill Cap B A TTE R Y FL UID Check battery electrolyte fluid based on the Maintenance Schedule. Fluid should cover separa- tors in all battery cells. If fluid level is low , add dis - tilled water to cover tops of separators. DO NOT USE T AP W A TER IN BA TTERY . ENGI NE COOLANT Check cool[...]

  • Page 18

    CHANGI NG ENGIN E OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies. Drain the oil while the engine is still warm from run- ning . This means warm up the engine, shut it down and drain immediately as follows: 1. Remove OIL DRAIN HOSE from its retaining clip. 2. Loosen and remove OIL DRA[...]

  • Page 19

    M IS CELLAN EOUS MAINTENANCE CLEAN ING TH E GENER A T OR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal gen- erator windings have an adverse effect on insulation resistance. P eriodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dr[...]

  • Page 20

    SERVICE S CH EDULE 30 KW - 1 5 0 KW ST ANDBY GAS ENGIN E DRIVEN 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 nee[...]

  • 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/ Ini[...]

  • 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/ Ini[...]

  • 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/ Ini[...]

  • Page 24

    TROU BLESHOO TI NG GU IDE P ROBLEM CAUSE C OR RECTION 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 cab les as necessar y . 3. Defectiv e star ter contactor . 3. Replace contactor.* 4. Defectiv e star ter motor . 4. Replace star ter motor.* 5. D[...]

  • Page 25

    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    [...]

  • Page 29

    1 0F3137 1 PAN CB CONN BOX 2 0F3188 1 STAND RH CONTR OL 3 0F31 89 1 ST AND L H CO NTRO L 4 0 23484N 1 BUSHING SNAP SB-2.5-31 (3) 5 0F6366 B 1 / 2 XFM R DUAL 120V /16V (F OR 1 20/240V & 2 77/480V UNITS ) 0F6366A 1 XFMR DUAL 104 V/1 6V (FOR 120/208 V UNITS) (3) 6 043180 2 / 4 WA SH ER FLAT M4 (3) 7 022264 2 / 4 WA SH ER LOCK #8-M4 (3) 8 0C3990 2 [...]

  • Page 30

    [...]

  • Page 31

    5) UL CIR CU IT BRE AKER (QJ-2P) A 0F8137 1 COVER QJ 2P FRM CB B 06546 9 1 DECAL, DANGE R HIGH VOLT AGE C 0 E7994 - CB 0225A 24 0V 2P S QJ22 D 0F8136 1 COVER QJ 2P CB DISH E 036 261 4 RIVET POP .125 X .275 SS F 022473 2 WASHER FLAT 1/4 -M6 ZINC G 022097 2 WASHER LOCK M6 -1/4 H 022127 2 NUT HEX 1/4-20 STEEL J 0F8139 1 INSU L CB 2P QJ K 0C2454 7 SCRE[...]

  • Page 32

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  • Page 33

    1 0 G005 6 1 RTR -2390--35 KD1 CP L 0G115 5 1 RTR -2390--35 KD1 CPL (G2 ) 0F967 7 1 RTR -2390--45 KD1 CP L 0G095 9 1 RTR -2390--45 KD1 CPL (G2 ) 2 0 G005 7 1 STR- 2390 --35AD1 CPL 0F96 64 1 STR 39 0 45 K 2P 1P H DI RECT 0G005 8 1 STR -2390 --35K D1 CPL 0G01 84 1 STR 390 45 KW 2P 3P H 4 80V 0G005 9 1 STR -2390 --35 GD 1 CPL 0G01 83 1 STR 390 45 KW 2[...]

  • Page 34

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    COM P O NENT S INCL U DED IN 0F9 69 6E 1 0F1823A 1 ENCL HSB CO NTROL PANE L 2 0F3078 1 COVER CO NTR OL PANE L 3 0F2606 1 HING E C ONTIN UOUS H-PA NEL 4 036261 6 RIVET POP .125 X .275 SS 5 043 181 4 SCREW PHM M3-0 .5 X 10MM 6 052777 7 W ASHER FL AT M 3 7 0F8710B 1 ASSY PCB CPL2 CT RLR 360 0 RP M 8 0 F12 62 4 HOLD ER, F USE WI CKMANN 178. 615 0 9 0F1[...]

  • Page 36

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  • Page 37

    COM P O NENT S INCL U DED IN 0G1 290E 1 0F1823A 1 ENCL HSB CO NTROL PANE L 2 0F3078 1 COVER CO NTR OL PANE L 3 0F2606 1 HING E C ONTIN UOUS H-PA NEL 4 036261 6 RIVET POP .125 X .275 SS 5 043 181 4 SCREW PHM M3-0 .5 X 10MM 6 052777 7 WAS HER FLAT M 3 7 0G1303B 1 AS SY PCB CPL2 A CTRL R 3600 RP M 8 0 F12 62 4 HOLD ER, F USE WI CKMANN 178. 615 0 9 0F1[...]

  • Page 38

    [...]

  • Page 39

    1 0F95 17 1 WEL DM E NT FR AM E 2.4 L C2 2 052860 4 NU T FLANG ED HEX M12 - 1 .75 3 0522 51 5 DAM PENE R VIBR ATION 4 0 BLUE 4 052 257 5 SPA CER . 49 X .62 X 1.87 PWD R/ZNC 5 0522 52 5 DAM PENE R VIBR ATION 6 0522 59 5 W ASHER FL AT M 12 7 0528 91 5 S CREW HH C M12- 1.75 X 8 0 G8. 8 8 053 62104 10 1 ASSY W IRE 14 .00" 9 0429 09 1 S CREW HH C M[...]

  • Page 40

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  • Page 41

    1 0F34 08B 1 BATT ERY TR AY C 1 CPL 2 0F3411 1 STRAP BA T TE RY RETAI NM ENT 3 0255 07 REF WASHE R SH AKEPRO OF EX T 7/1 6 STL 4 0522 12 REF SCREW HHC M 10-1. 25 X 2 5 G8.8 5 0465 26 REF WASHE R LO CK M1 0 6 0221 31 REF WASHE R FL AT 3/ 8-M10 Z INC 7 05033 1A RE F BATTE RY POST COVE R RE D + 8 0503 31 REF BATT ERY POS T COVE R BLACK - 9 03880 5Y 1 [...]

  • Page 42

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    1 0E6586 1 GASKET BOSCH 32 & 40 2 0E0519 A 1 ADAPT ER C ARBURETO R W/ PVC CONN 3 0C81 27 1 E LEMENT AIR CLEANE R 4 0526 19 4 SCREW HHC M 5-0. 8 X 2 0 G8.8 5 022 127 1 NUT HEX 1/4- 20 STEE L 6 0629 74 1 STUD TH 1/ 4-20 X 4-1/ 2 G2 ZNC 7 0G0190 1 P LAT E , AI R CLE A NE R TOP 2. 4L 8 037561 1 NU T WING 1/4-20 NYL K 9 0220 97 1 WAS HER LO CK M6- 1[...]

  • Page 44

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  • Page 45

    1 0 G1008 1 ENGIN E 2.4L G2 (REWORK ) 2 0465 26 7 (REF) WAS HER L OCK M 10 3 0394 14 4 (REF) S CREW HH C M 8-1.25 X 35 G8.8 4 0G01 49 1 (REF ) SCREW S HC M 14-1. 5 X 3 5 G1 0.9 5 0E 9868A 1 (REF ) ALTER NATOR DC W /OUT PULL EY 6 0F3217 1 (REF) SPACER DC A LTERNATOR PULLEY 7 042 574 1 (REF) ADAPTOR 1/ 8N PTF TO 1/8B SPT 8 0A8 584 1 (R E F ) SWITCH, [...]

  • Page 46

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  • Page 47

    1 0F9529 1 WELDMENT RAD I A TOR SUPPORT 2. 4 L 2 0F2608 1 RADIATOR 5 98 X 568 X 49 C PL RH 3 0F 5 2 6 3 1 V- BE L T 31 /64" X 57- 3/8" 4 046526 5 WASHER LOCK M10 5 05998 1 4 SCREW HHC M 10-1.5 X 30 G10.9 6 02222 2 2 S CREW HH C 5/ 16- 24 X 1-1/2 G5 7 0F5050 1 SHIELD RADI ATOR C5 8 04256 8 8 SCRE W HHC M 6-1. 0 X 20 G 8.8 9 0F2573 1 PULLEY[...]

  • Page 48

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    1 0269 1 5 2 NIP P LE CLO SE 3/ 4 X 1. 37 5 2 075580 1 FLANGE FUEL I NLET 3 0F6390B 1 REGULAT OR ASSY 2.4 L 4 0392 5 3 2 SCRE W HH C M8-1. 2 5 X 20 G 8.8 5 0221 45 2 WASHE R FL AT 5/ 16-M 8 ZIN C 60 2 2 1 2 9 2 W A S H E R L O C K M 8 - 5 / 1 6 7 0457 71 2 NUT HEX M8-1. 25 G8 CLEAR Z INC 8 0401 7 3 2 CLAM P HOS E #5 . 5 .62-. 62 9 0E8286 1 STREET E[...]

  • Page 50

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    1 0G0045 (XX) 1 REAR WRAP C2 CPL 2 0C2454 54 SCREW T HF M6-1 X 16 N WA Z/ JS 3 0F58 49 (X X) 2 DOO R C2 4 087233 2 RIVET POP .187 5 X .450 SS 5 0E3257 4 SCREW TH-F RM M6 W /CAP S HKPRF W 6 0F585 2 (XX ) 2 DI SC HARGE DU CT LH & RH SIDE C2 7 0F98 33 (XX ) 2 FRONT COR NERS C2 8 0F585 1 (XX ) 1 DIS C HARGE CE NT E R DU CT C2 9 049813 2 NUT HEX M6 [...]

  • Page 52

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    1 0F9794 2 MUFFL ER 7" X 9" X 1 8-1/2" 2" I N/OUT 2 0G0113 1 EXHAUS T ELB OW 2 1/4 O D 2 1 /2OD 3 0G1007 1 BR ACKET M UFFLE R 4 0F2830 2 MUFFLER BRACKE T STIFFENER 5 0F2962 2 MUFFLER STRAP 6 080762 5 BOL T U 3/8- 16 X 2.62 7 0E 0170A 1 EX HAUST B LANKET 988MM (C2) 8 0C24 5 4 4 SCREW THF M6-1 X 16 N WA Z/ JS 9 0 G0776 1 PIPE EXH [...]

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    1.) C2 UN ITS A 0F98 32 1 SHIE LD CO NN B OX C 2 0F98 32GGS 0R 1 S HIELD CONT ROL S TAND C2 B 0C24 5 4 3 SCREW THF M6- 1 X 16 N WA Z/ JS 2.) C3 UN ITS A 0F 9832 B 1 SHIE LD CO NTRO L ST AND C 3 0F98 32KGS 0R 1 SHI ELD CO NT ROL ST AND C3 B 0C245 4 3 SCREW THF M6- 1 X 16 N W A Z/ JS 3.) C4 UN ITS A 0F 9832 A 1 SHIE LD CO NTRO L ST AND C 4 B 0C245 4 [...]

  • Page 68

    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 ower Systems Dealer , or branch thereof , Generac P ow er Systems, Inc. will, at its o[...]