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Generac Power Systems 005324-0 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 1.6L 25kW Models: 005324-0 005325-0 —  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 F Stator Insulation ................................................................... Class F 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 FILL CAP OIL DIPSTIC K 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 coo[...]

  • 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 The following is a recommended maintenance schedule for small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe applica- ti[...]

  • Page 21

    Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp. Required Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly Initials) Break-in Initials) annually Initials) Annually Initials) 10 Hrs. 30 Hrs. 50 Hrs. 100 Hrs. 1. Disable t[...]

  • Page 22

    Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp. Required Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly In itials) Break-in Initials) annually Initials) Annually Initials) 10 Hrs. 30 Hrs. 50 Hrs. 100 Hrs. 13. Initiat[...]

  • Page 23

    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. battery cables 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 24

    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    [...]

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    1 0F71 35 1 BREAKE R TRA Y BA CK/BOTT OM 2 0F70 22 1 SUPP ORT CO NTROL P ANEL SIDE R H 3 0F70 21 1 SUPP ORT CO NTROL P ANEL SIDE L H 4 0F72 60 1 COVER CI RC UIT BRE AKE R 2P 0F71 36 1 COVE R CI RC UIT BREA KE R 3P 5 0F 6156 1 PL ATE WIR E SNGL GAL V 6 0F44 64 1 DECA L CU ST CO NN 120V UTILITY 7 0D46 9 8 REF BL O CK TE RM 20A 6 X 3 X 1100V 8 0F38 24[...]

  • Page 30

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  • Page 31

    1 0989 36 1 ASS Y RTR 25KW 2P H 2 0G08 20 1 HOUSI NG BL OWER M ACHI NED 1. 6L 3 0G10 19 1 GUARD BL OWER HOUSI NG 1. 6L 4 020 746 4 SCREW P PHM M5 -0.8 X 8 ZINC 5 0492 26 4 WASHE R LO CK M5 6 0517 13 4 WASHE R FL AT M5 7 0221 29 4 WASHE R LO CK M8- 5/ 16 8 0G13 17 1 ASS Y STAT OR 2 5KW 1P H D 0G13 16 1 ASS Y STAT OR 25KW 3P H D 9 0A5382 1 BEA RING C[...]

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    C O M P O N EN T S IN C L U D ED IN 0 G 1 2 9 1 E 1 0F 18 23A 1 ENCL HS B CONT ROL P ANEL 2 0F 30 78 1 COVE R CONTR OL PANE L 3 0F 26 06 1 HI NGE C ONTI NUOUS H- PANE L 4 036261 6 RIVET P O P .125 X .275 SS 5 043181 4 SCR E W PH M M 3 -0.5 X 10M M 6 05 277 7 7 WAS HER F LAT M 3 7 0G130 3B 1 ASS Y PC B C PL2 C TR L R 36 00 R PM 8 0F 126 2 4 H O LD E[...]

  • Page 34

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    1 0F 7211 1 S UPPORT RADIATO R LH SI DE 2 0G0760 1 V E NTU RI 16" DI A FAN 3 0F 7210 1 S UPPORT RADIATO R RH S IDE 4 0E9837B 1 RADI ATOR 1. 6L CHY 5 0F0 2 30 B 1 FAN CO OL 16" DI A 8 BLADE 6 04652 6 5 WAS HER LO CK M1 0 7 0G09 10 1 LOW E R RA DI AT O R HOSE 1.6 L 8 0 99502 4 CLAMP H OSE # 24 B 1.06 -2.00 9 0 69860 C 1 HOSE OIL DR AIN A SS[...]

  • Page 36

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  • Page 37

    1 0F3 408B 1 BAT TERY T RAY C1 CPL 2 0F3 411 1 S TRAP BA TTERY RET AINME NT 3 02550 7 1 WAS HER S HAKEP ROOF EXT 7/16 S TL 4 05998 0 1 SCRE W HH C M 10- 1.5 X 25 G 10. 9 5 02212 9 1 W ASHER L OCK M8-5/ 16 6 07748 3 RE F BAT TE RY 12V DC 75-A H 26 7 05033 1A 1 BATT POST COVER RED + 8 05033 1 1 BAT T POST COVER BLK - 9 03 8805J 1 CABLE BATTE RY BLK #[...]

  • Page 38

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  • Page 39

    1 0G0759 1 MOUN TING BA SE 1.6L 2 02 7482 2 WASHER S HAKEP ROOF EXT 5/16 S TL 3 07 0936 2 DAMPENE R VI BRATION 4 07093 6C 2 VIB. ISO. 7 0-75 DU RO 5 03 92 5 3 8 SCREW HHC M 8- 1. 2 5 X 20 G8.8 6 02 2145 12 WASHER FLAT 5/16 ZINC 7 022129 12 WA SHER LOCK M8 -5/16 8 045771 4 NUT HE X M8-1.25 G8 YEL CHR 9 07 1956 4 WASHER F LAT M 8 10 05173 0 4 SCREW H[...]

  • Page 40

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  • Page 41

    1 0G0207 REF ENGINE GENERA C 1. 6L NG 2 0G083 4 1 ENGIN E PLATE 1.6L 3 0G0820 REF HOUSING BLOW ER MACHINED 1.6L 4 0E9747 1 STARTER 12 VOLT 5 0G0 839 2 ENGINE MOU NTING FOOT STAMP ING 6 0G0781 1 EXHAUST MA NIFOLD 1.6L MACHI NED 7 0G0 722 1 INTA KE M ANIFOL D MA CHINE D 1.6L 8 0G0 758 1 HEAT S HIELD L OWER 1.6L 9 0G0 4 31 1 HEAT S HIE L D UPPE R 1. 6[...]

  • Page 42

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  • Page 43

    1 098290 1 ASM MOT OR STEPPE R 2 09894 1A 1 HOUSING GOVE RNOR CONNECTOR 3 09895 8A REF CO NNECT OR INT ERFACE ASSE M BLY 4 09894 2A 1 COVE R CO NNECT O R HO USI NG 5 098225 2 SCREW FHM #2 X 5 /8 SELF TAP 6 04 3146 3 SCRE W HHC M6-1. 0 X 1 0 G8. 8 7 02 2097 5 WASHE R LO CK M6- 1/4 8 084543A 1 SCRE W PHM M3-0.5 X 12MM 9 098783 1 LEVER STEPPER MO TOR [...]

  • Page 44

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    1 026812 2 ELBOW 90 D 3 /4 NPT 2 075580 1 FLA NGE FUEL INLET 3 0G1397 1 FUEL REGULAT OR 1. 6L REWO RK 4 03925 3 2 SCREW HHC M 8-1.25 X 20 G8.8 5 022145 2 WASHER FLA T 5/1 6 ZINC 6 022129 4 WASHER LOCK M8-5 /16 7 045771 2 NUT HEX M8-1.25 G8 YEL CHR (1) 8 0F1570 1 B ODY CARBURETOR ASSEMBLY 9 0A6344 1 BARBED EL 90 1/8NPT X 3/8 10 0C5 210 1 HOSE 3/8 ID[...]

  • Page 46

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  • Page 47

    1 0F 700 3 (XX) 1 ROOF C1 CP L 2 0F 7004 ( XX) 1 CORNE R POS T LH S IDE C1 CPL 3 0F 7008 ( XX) 1 DOO R REAR C1 CP L 4 0F 7005 ( XX) 1 CORNE R POS T RH S IDE C1 CPL 5 0F 7007 ( XX) 2 DOO R LH & RH SI DE C 1 CPL 6 0F 7006 ( XX) 1 DUCT FRO NT DISC HARGE C1 CP L 7 0C26 34A 1 ASS EMBLY COVER ACCES S 8 091297 0091 1 ASSY WIRE 14AWG 13.8 " GRN/YE[...]

  • Page 48

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    1 0F7366 1 MUFFLER C 1 2 0F7647 1 MUFFLER S ADDLE 3 0F 8095 1 PIPE EXH AUST OUTLET 4 0F7538 1 PIPE EXH INLET MUFLR SI DE 1.5L 5 0E3257 4 SCREW HWHTF M6-1 .0 X 16 6 0F7644 2 MUFFLER S TRAP 7 0C 61 1 9 1 BOLT U 5/16-1 8 X 2-1 /4 8 03 64 3 4 3 BOL T U 5/16- 18 X 2. 09 9 036449 3 SADDLE 2 IN CH 10 02212 9 8 WAS HER LO CK M 8-5/ 16 11 0222 5 9 6 NUT HEX[...]

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