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Generac Power Systems 005262-1 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 QT 2.4L 45kW Model: 005262-1 —  CAUTION  — ONL Y QU ALIFIED ELECTRICIANS OR CONTRA CT ORS SHOULD A TTEMPT INST ALLA TION! Cover060 Re v . 0 04/06 Part No. 0G0202A[...]

  • 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 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 condit[...]

  • 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 COOL ANT Check coo[...]

  • Page 18

    CHANGI NG ENGIN E OI L 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 DR[...]

  • Page 19

    M ISCELLAN EOUS MAINTENANCE CLEAN ING TH E GEN ER 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 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 star ter motor .* 5.[...]

  • Page 25

    Standby Generator Sets Notes[...]

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    1 0F3137 1 PAN CB CONN BOX 2 0F3188 1 STAND RH CONTR OL 3 0F31 89 1 S TAN D L H CON TRO L 4 0 23484N 1 BUSHING SNAP SB-2.5-31 (3) 5 0F6366 B 1 / 2 XFMR D UA L 12 0V/ 16V (F OR 120 /240V & 277 /480V U NITS) 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[...]

  • Page 28

    [...]

  • Page 29

    5) UL CIR CU IT BRE AKER (Q J-2P) A 0F8137 1 COVER QJ 2P FRM CB B 06546 9 1 DECAL, DANGE R HIGH VOLT AG E 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 SC[...]

  • Page 30

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  • Page 31

    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 39 0 45 KW 2P 3P H 4 80V 0G005 9 1 STR -2390 --35 GD 1 CPL 0G01 83 1 STR 39 0 45 KW[...]

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    COM P O NE NTS I N C LU DE D IN 0F 969 6E 1 0F1823A 1 ENCL HSB CO NT ROL PANE L 2 0F3078 1 COVER CO NTR OL PANE L 3 0F2606 1 HING E C ONT INUO US 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 ASHE R FLAT M 3 7 0F8710B 1 ASSY PCB CPL 2 CTRLR 3600 RP M 8 0 F12 62 4 HOLD ER, F USE WI CKMANN 178. 615 0 9[...]

  • Page 34

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    COM P O NE NTS I N C LU DE D IN 0G 129 0E 1 0F1823A 1 ENCL HSB CO NT ROL PANE L 2 0F3078 1 COVER CO NTR OL PANE L 3 0F2606 1 HING E C ONT INUO US 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 FL AT M 3 7 0 G13 03B 1 AS SY P CB CP L2 A CT RLR 3600 RP M 8 0 F12 62 4 HOLD ER, F USE WI CKMANN 178. [...]

  • Page 36

    [...]

  • Page 37

    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 DAMPE NE R VIBR ATIO N 4 0 BLUE 4 052 257 5 SPA CER . 49 X .62 X 1.87 PWD R/ZNC 5 0522 52 5 DAMPE NE R VIBR ATIO N 6 0522 59 5 WASHE R FL AT M 12 7 0528 91 5 SCREW HH C M 12-1. 75 X 8 0 G8. 8 8 053 6210410 1 ASSY W IRE 14 .00" 9 0429 09 1 SCREW HH C M[...]

  • Page 38

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  • Page 39

    1 0F34 08B 1 BAT TERY TR AY C1 CPL 2 0F3411 1 S TRAP BA TT ERY RET AI NM E NT 3 0255 07 REF WAS HE R SH AKEP ROOF EX T 7/16 S TL 4 0522 12 REF S CREW HHC M 10- 1.25 X 2 5 G8. 8 5 0465 26 REF WAS HER LO CK M1 0 6 0221 31 REF WAS HE R FL AT 3/ 8-M 10 Z IN C 7 05033 1A REF BAT TERY PO ST COVE R RED + 8 0503 31 REF BAT TERY POS T CO VE R BL ACK - 9 038[...]

  • Page 40

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    1 0E6586 1 GASKET B OSCH 32 & 40 2 0E0519 A 1 ADAPTER CARBUR ETOR W/PVC CONN 3 0C81 27 1 E LEME NT A IR CL EA NER 4 0526 19 4 SCREW HH C M 5-0. 8 X 20 G 8. 8 5 022 127 1 NU T HEX 1/4 -20 ST EEL 6 0629 74 1 STUD TH 1/4- 20 X 4- 1/ 2 G2 ZNC 7 0G0190 1 PLATE, AI R CLE A NE R TOP 2. 4L 8 037561 1 NU T WING 1/4-20 NYL K 9 0220 97 1 W ASHE R LO CK M6[...]

  • Page 42

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  • Page 43

    1 0 G1008 1 ENGI N E 2.4L G2 (REWORK ) 2 0465 26 7 (REF ) WASHE R L OCK M1 0 3 0394 14 4 (REF ) SCREW HH C M 8-1. 25 X 35 G 8.8 4 0G01 49 1 (REF ) SCREW S HC M 14- 1.5 X 3 5 G 10.9 5 0E 986 8A 1 (REF ) ALTE RNA TOR DC W/ OUT P UL LEY 6 0F3217 1 (REF) SPACER DC A LTERNATOR PUL LEY 7 042 574 1 (REF) ADA PT O R 1/ 8N PTF TO 1/8B SPT 8 0A8 584 1 ( R E [...]

  • Page 44

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  • Page 45

    1 0F9529 1 WELDMEN T RADIATOR SUPPORT 2.4L 2 0F2608 1 RADI ATOR 598 X 568 X 49 C PL RH 3 0F 5 2 6 3 1 V-BEL T 31 /6 4" X 57- 3/8" 4 046526 5 WASHER LOCK M1 0 5 05998 1 4 S CREW HHC M 10- 1.5 X 30 G 10.9 6 02222 2 2 SCRE W HH C 5/ 16- 24 X 1-1/2 G5 7 0F5050 1 SHIEL D RADIA TOR C5 8 04256 8 8 SCRE W HH C M 6-1. 0 X 20 G 8. 8 9 0F2573 1 PULL[...]

  • Page 46

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  • Page 47

    1 0269 1 5 2 NIPP LE CLO SE 3/ 4 X 1. 37 5 2 075580 1 FLANGE FUEL I NLET 3 0F6390B 1 REGU LATOR AS SY 2.4 L 4 0392 5 3 2 SCREW HH C M 8- 1.2 5 X 20 G8. 8 5 0221 45 2 WAS HER FLAT 5/ 16-M 8 Z IN 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 M 8-1.2 5 G 8 CLEA R Z INC 8 0401 7 3 2 CLAMP HOS E #5 .5 .62-. 6 2 9 0E8286 1 STREET[...]

  • Page 48

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  • Page 49

    1 0G0045 (XX) 1 REAR WRA P C2 C PL 2 0C2454 54 SCREW T HF M6-1 X 16 N WA Z/ JS 3 0F 584 9 (X X) 2 DOO R C2 4 087233 2 RIVET PO P .187 5 X .450 SS 5 0E3257 4 SCREW TH-F RM M6 W /CAP S HKP RF W 6 0F585 2 (XX ) 2 DISC HA RGE DU CT L H & RH SIDE C2 7 0F 983 3 (XX ) 2 FRO NT CORNE RS C2 8 0F585 1 (XX ) 1 DISC HA RGE CE NTE R DU CT C2 9 049813 2 NUT [...]

  • Page 50

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  • Page 51

    1 0F9794 2 M UFFLE R 7" X 9" X 1 8-1/ 2" 2" I N/O UT 2 0G 01 13 1 E XHAUS T E LB OW 2 1/ 4 O D 2 1/2O D 3 0G 10 07 1 BR ACKE T MU FFLE R 4 0F2830 2 M UFFLER BRACKE T STIFFENE R 5 0F2962 2 M UFFLER STRAP 6 080762 5 BOLT U 3/8-16 X 2.62 7 0E 017 0A 1 E XHAUS T B LANKE T 9 88MM ( C2) 8 0C24 5 4 4 SCREW T HF M6-1 X 16 N WA Z/ JS 9 0[...]

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    1.) C2 UNI T S A 0F98 32 1 S HIELD CO NN BO X C 2 0F98 32G GS0 R 1 S HIE LD CO NT ROL ST AND C 2 B 0C24 5 4 3 S CR EW THF M6- 1 X 16 N WA Z/ JS 2.) C3 UNI T S A 0F98 32B 1 S HIELD CO NT ROL S TA ND C3 0F98 32K GS 0R 1 S HIELD CO NT ROL S T AND C 3 B 0C245 4 3 SCR EW THF M6- 1 X 16 N WA Z/ JS 3.) C4 UNI T S A 0F98 32A 1 S HIELD CO NT ROL S TA ND C4 [...]

  • Page 64

    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 [...]