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Generac 005262-0 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 2.4L 45kW Model: 005262-0 —  CAUTION  — ONL Y QU ALIFIED ELECTRICIANS OR CONTRA CT ORS SHOULD A TTEMPT INST ALLA TION! Cover044 Re v . 0 02/06 Part No. 0G0202[...]

  • 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 Fill Cap Oil Dipstick 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[...]

  • Page 26

    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    [...]

  • Page 29

    1 0F3137 1 PAN CB CO NN BOX 2 0F3188 1 STAND RH CO NTR O L 3 0F3189 1 STAND L H CON TROL 4 0 23 484 N 1 BU SHI NG SNAP SB-2 .5-3 1 5 *** 0F6366B 1 / 2 XFMR DUAL 12 0V/16V (F OR 1 20/240V & 277 /480V U NITS) 0F6366A 1 XFMR DUAL 104V/ 16V (F OR 1 20/208V UNITS) 6 *** 04 3180 2 / 4 WASHER FLAT M 4 7 *** 02 2264 2 / 4 WASHER LOCK #8-M4 8 *** 0C399 [...]

  • Page 30

    [...]

  • Page 31

    5) UL CIRCUIT BREAKE R (QJ-2P) A 0F8137 1 COVER QJ 2P FRM CB B 065469 1 DECAL, DA NGE R HIGH V OLTAGE C 0E799 4 - CB 0225 A 2 40V 2P S QJ 22 D 0F 8136 1 COVER QJ 2P CB DI SH E 036261 4 RI VET POP .125 X .27 5 SS F 022473 2 WASHE R FLAT 1/ 4-M6 ZINC G0 2 2 0 9 7 2 W A S H E R L O C K M 6 - 1 / 4 H 022127 2 NUT HEX 1/4-20 STEEL J 0F8139 1 IN SU L CB [...]

  • Page 32

    [...]

  • Page 33

    1 0G00 56 1 RTR-23 9 0--35K D1 CPL 0F96 77 1 RTR-23 9 0--45K D1 CPL 2 0G 0057 1 STR -2390 --35AD1 CPL 0F96 64 1 S TR 39 0 45 K 2P 1P H DI RE CT 0G00 58 1 S TR- 2 39 0-- 3 5 KD 1 CP L 0G01 84 1 S TR 39 0 45 KW 2P 3PH 4 80V 0G00 59 1 STR- 2390- -3 5GD1 CPL 0G01 83 1 S TR 39 0 45 KW 2P 3PH 2 08V 3 0C9708 RE F INSTR HYPOT TEST ( NOT SHOW N) 4 SE E E NG[...]

  • Page 34

    [...]

  • Page 35

    1.) C2 UN ITS A 0F98 32 1 S HIELD CO NN BO X C 2 0F98 32G GS0 R 1 SHIE LD C ONT ROL S TA ND C 2 B 0C24 5 4 3 S CRE W THF M6- 1 X 16 N WA Z/ JS 2.) C3 UN ITS A 0F9 8 32B 1 S HIE LD CO NT ROL S T AND C 3 0F98 32K GS 0R 1 S HIE LD C ONT ROL S TAND C 3 B 0C245 4 3 SCRE W THF M6- 1 X 16 N WA Z/ JS 3.) C4 UN ITS A 0F9 8 32A 1 S HIE LD CO NT ROL S T AND C[...]

  • Page 36

    [...]

  • Page 37

    COM P O NE NTS I N C LU DE D IN 0F 969 6E 1 0F18 23A 1 ENCL HSB CO NT RO L PANE L 2 0F30 78 1 COVER CO NTR OL PANE L 3 0F2 6 06 1 HIN G E C ONT INUOUS H-P A NEL 4 036261 6 RI VET POP .125 X .275 SS 5 043 181 4 SCR EW PHM M3-0.5 X 10MM 6 052777 7 W ASHE R FLAT M 3 7 0F87 10 B 1 ASSY P CB CPL 2 CTRLR 3600 RP M 8 0F12 62 4 HOLDER , FU SE WICK MANN 17 [...]

  • Page 38

    [...]

  • Page 39

    1 0F 95 17 1 W ELDM ENT FRAM E 2.4L C2 2 0528 60 4 NUT FL ANGE D HE X M1 2-1 .75 3 0522 51 5 DAMPE NER V I BRATIO N 40 B LUE 4 052 257 5 SPA CER .49 X .62 X 1.87 PWDR/ZNC 5 0522 52 5 DAMPE NER V I BRATIO N 6 0522 59 5 WASHE R FL AT M 12 7 0528 91 5 SCREW HHC M 12- 1. 75 X 8 0 G8. 8 8 053621 0410 1 ASS Y W IR E 14 .0 0 " 9 0429 0 9 1 SCREW HH C[...]

  • Page 40

    [...]

  • Page 41

    1 0F34 08B 1 BAT TERY TR AY C1 CPL 2 0F 3 4 11 1 STRAP BA T TE RY RET AI NM ENT 3 0255 07 REF W ASHE R S HAKEP ROO F EXT 7/1 6 ST L 4 0526 47 RE F SCREW SH C M 10-1. 5 X 2 5 G 12.9 5 0465 26 REF W ASHE R LO CK M10 6 0221 31 REF W ASHE R FL AT 3/8- M1 0 ZIN C 7 05033 1A REF BAT T PO ST COVE R RE D + 8 0503 31 REF BAT T PO ST COVER BL ACK - 9 038 805[...]

  • Page 42

    [...]

  • Page 43

    1 0G0158 1 E NGINE 2 .4L HY UNDAI 2 0221 31 3 W ASHE R FL AT 3/8- M1 0 ZI NC 3 0F9585 1 EXHAUST A DAPTE R 2.4L M ACH 4 0465 25 3 NU T HE X M 10- 1. 25 G8 YE L CH R 5 05 2212 1 (REF) SCREW HH C M10- 1.25 X 25 G8. 8 6 0E9868A 1 (REF) ALTERNATOR DC W/OUT PU LLEY 7 0F3 2 16B 1 (REF) PULLEY 117 OD DC ALTERNATO R 8 0G011 5 1 (R EF) BRA CK E T TEN S ION E[...]

  • Page 44

    [...]

  • Page 45

    1 0F9529 1 WELDMENT RADIATOR SUPPORT 2.4L 2 0F2608 1 RADIATOR 598 X 568 X 49 CPL RH 3 0F5263 1 V-BELT 31/6 4" X 57-3/ 8" 40 4 6 5 2 6 5 W A S H E R L O C K M 1 0 5 0599 81 4 SCREW HH C M 10- 1.5 X 30 G 10.9 6 0222 2 2 2 SCREW HH C 5/ 16- 2 4 X 1- 1/ 2 G5 7 0F5050 1 SHIELD RAD IATOR C5 8 04 2568 8 S CREW HH C M6-1. 0 X 2 0 G8.8 9 0F2573 1 [...]

  • Page 46

    [...]

  • Page 47

    1 0E6 586 1 GASKET BOSCH 32 & 40 2 0E0519 A 1 ADA PTER CARBUR ETOR W/PVC CONN 3 0C 8127 1 ELE MENT AIR CLE ANE R 4 0526 19 4 SCREW HH C M 5-0. 8 X 2 0 G 8.8 5 022 127 1 NU T HEX 1/4 -20 STEE L 6 0629 74 1 STUD TH 1/4- 20 X 4- 1/ 2 G2 ZNC 7 0G01 90 1 PLAT E , AI R CLE A NE R TO P 2. 4L 8 037561 1 NU T WIN G 1/4-20 NYL K 9 0220 97 1 W ASHE R LO C[...]

  • Page 48

    [...]

  • Page 49

    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. 4L 4 0392 5 3 2 SCREW HH C M8- 1. 2 5 X 20 G 8.8 5 0221 45 2 WASHE R F LAT 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 G8 CLEA R ZI NC 8 0G0180 1 (REF) GASKET- TH ROTTLE BODY 9 0E8286 1 STREET [...]

  • Page 50

    [...]

  • Page 51

    1 0G0045 (XX) 1 REA R WRA P C2 CPL 2 0C 24 5 4 54 SCREW THF M6-1 X 16 N WA Z/ JS 3 0F5849 (XX ) 2 DOOR C2 4 087233 2 RI V ET POP .1875 X .450 SS 5 0E325 7 4 SCRE W T H-F RM M6 W/CA P SHK PRF W 6 0F585 2 (XX ) 2 DISC HA RGE DU CT L H & RH SIDE C2 7 0F9833 (XX ) 2 FRONT CORNERS C2 8 0F585 1 (XX ) 1 DISC HA RGE CE NTE R DU CT C2 9 049813 2 NU T HE[...]

  • Page 52

    [...]

  • Page 53

    1 0F 97 94 1 MUFFLE R 7" X 9" X 1 8-1/ 2" 2" I N/O UT 2 0G01 13 1 EXHAUS T EL BOW 2 1/4 O D 2 1/ 2OD 3 0F 9937 1 BR ACKE T MU FFLE R 4 0F2830 1 MUFFLER BRACKET STIFFE NER 5 0F2962 1 MUFFLER STRAP 6 0807 62 2 BOLT U 3/8- 16 X 2. 62 7 0E 017 0B 1 EX HAUS T B LANKE T 9 88MM ( C2) 8 0C 245 4 4 SCRE W T HF M6- 1 X 16 N WA Z/ JS 9 0F [...]

  • Page 54

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  • Page 56

    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 [...]