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Generac QT 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 1.5L 20kW Models Cover013 Re v . A 08/05 Part No. 0F7437[...]

  • 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 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 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 -U P • Ensure that the 120V AC circuit breaker to the bat - tery charger is open. • Remove the fuse from the th[...]

  • 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 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 COOL ANT Check co[...]

  • 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 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- t[...]

  • 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 [...]

  • 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. Initia[...]

  • Page 23

    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 . battery 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 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 BRE AKER TR AY BA CK/ BOTTO M 2 0F70 22 1 S UPPORT CO NTRO L P ANEL S IDE RH 3 0F70 21 1 S UPPORT CO NTRO L P ANEL S IDE LH 4 0F72 60 1 COVER CI RC UIT B RE A KER 2P 0F71 36 1 COVER CI RC UIT B RE A KER 3P 5 0F6156 1 PLATE WIRE SNGL GALV 6 0F44 64 1 DECAL CUS T CO NN 120V UT ILIT Y 7 0D46 9 8 REF BLOCK TE RM 20A 6 X 3 X 110 0V 8 0F38 24[...]

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  • Page 31

    1 098675 1 ASSY ROTOR 20K W 2 0A5336A 1 HOUSING BLOWER 3 0A16 59 1 S CREEN AIR O UTLE T 4 020746 4 SCREW PPHM M5-0 .8 X 8 ZINC 5 04 9226 4 WASHER LOCK M5 6 05 1713 4 WASHER FL AT M 5 7 02 2129 4 WASHER LOCK M8- 5/ 16 8 0F82 18 1 AS SY STAT OR 20KW 1P H A 0F82 20 1 AS SY STAT OR 20KW 3P H G JK 9 0A5 382 1 B EA RING CARR IER REAR 10 075591 1 ASS Y H [...]

  • Page 32

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  • Page 33

    1 0F1 8 23 A 1 E NCL HSB CONT ROL PANE L 2 0F30 78 1 COVER CO NTR OL PANE L 3 0F2 606 1 HI NGE CONT I NUOUS H- PN L 4 036261 6 RIVET POP .125 X .275 SS 5 043181 4 SC R EW PH M M 3 -0.5 X 10MM 6 05 27 77 7 WASHE R FL AT M 3 7 0F42 45F 1 AS SY P CB CP L CT RL R 3600 RPM 8 0 F 126 2 4 HO LD ER FU SE W I C K MA NN 17 8 .61 50 9 0F12 63 1 ADPT R RH S I [...]

  • Page 34

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  • Page 35

    1 0F34 08B 1 BAT TERY T RAY C 1 CP L 2 0F34 11 1 STRAP BA TTE RY RETA I NM E NT 3 02 5507 REF W ASHE R SHAK EP ROOF EXT 7/1 6 STL 4 05 264 7 RE F SCRE W S HC M10- 1.5 X 2 5 G 12.9 5 04 6526 REF W ASHE R LOCK M1 0 6 02 213 1 REF W ASHE R FL AT 3/ 8-M1 0 ZIN C 7 050331A REF BATT POS T COVER RE D + 8 05 0331 REF BAT T POS T CO VER BLK - 9 038805 J 1 C[...]

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  • Page 37

    1 0F 7155 1 MOUNTIN G BASE 1. 5L C1 CPL 2 02 7482 2 WASHER SH AKEP ROOF EX T 5/ 16 S TL 3 07 0936 2 DAMPENE R VI BR ATION 4 070936C 2 VIB. I SO. 70-75 DURO 5 03 92 5 3 8 S CREW HH C M 8-1. 2 5 X 20 G8.8 6 02 214 5 12 WAS HER FL AT 5/ 16 ZINC 7 022129 12 WA SH ER LOCK M8-5/1 6 8 045771 4 NUT HEX M8-1 .25 G8 YEL CHR 9 07 1956 4 WASHER FLAT M 8 10 051[...]

  • Page 38

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    1 0F72 11 1 SUPP ORT R ADI ATOR LH S IDE 2 0F72 09 1 VENTU RI 15" DI A F AN 3 0F72 10 1 SUPPO RT R ADIAT OR RH SIDE 4 0E 9837A 1 RADIA TOR 2.5L CPL 5 0E1 936 1 FAN COO LING 15" 6 0221 29 1 WA SHE R LO CK M8- 5/ 16 7 0F71 66 1 RA DIATO R HOS E LW R 1 .5L C 1 CPL 8 099502 4 CLAMP H OSE # 24 B 1.06-2. 00 9 069860C 1 HO SE OIL DR AIN A SSY 21[...]

  • Page 40

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  • Page 41

    1 0 98290 1 ASM MOTOR ST EPPER 2 098 94 1A 1 H OUS ING GO VE RN OR CO NN ECTO R 3 098958A 1 CONNECTOR INTE RFACE ASSEMBL Y 4 098942A 1 COVER CONNECTOR HO USING 5 0 98225 2 SCREW FHM #2 X 5/8 SELF TAP 6 0 43146 3 SCREW HHC M6-1.0 X 10 G8.8 7 0 22097 5 WASHER L OCK M6-1/4 8 0 64526 2 SCREW TAP HWH #6-25 X 3/8 ZINC 9 0 98783 1 LEVER S TEPPER M OTOR 10[...]

  • Page 42

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  • Page 43

    1 0A4531 REF E NGINE- 1.5L 2 022473 2 WASH ER FLAT 1/4 ZINC 3 * 055934 C 1 CLA MP VIN Y L .5 X .406 Z 4 0A45 3 1025 8 REF. GAS KET- EX HA US T MA NIF OLD 5 0 A4355 1 MANIFOLD-EXHAUST 6 0E2632 1 HEAT SHIELD EXH 1.5L 7 022097 4 WASH ER LOCK M6 -1/4 8 02250 7 2 SCRE W HH C 1/ 4- 2 0 X 1/ 2 G 5 9 052212 4 SCR E W HHC M1 0 -1.25 X 25 G8.8 10 0 465 26 4 [...]

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    1 026812 2 ELBOW 90D 3/4 NPT 2 075580 1 FLANGE FUEL IN LET 3 0F63 64A 1 FUEL RG LT R 1. 5L RE W O RK 4 03 92 5 3 4 S CRE W HH C M 8- 1. 2 5 X 20 G8.8 5 02 214 5 2 WASHE R FL AT 5/ 16 ZINC 6 02 2129 6 WASHER LOCK M8- 5/ 16 7 045771 2 NUT HEX M8-1 .25 G8 YE L CHR 8 * 0F 1570 1 BODY CARBUR ETOR A SSEMBLY 9 032552 1 BARBED EL 90 5/16 X 1/8 NPT 10 0290 [...]

  • Page 46

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  • Page 47

    1 0F 700 3 (X X) 1 ROOF C 1 CP L 2 0F 700 4 (X X) 1 CORNER POS T L H SI DE C1 CP L 3 0F 700 8 (X X) 1 DOOR RE AR C1 CPL 4 0F 700 5 (X X) 1 CORNER POS T RH SI DE C1 CP L 5 0F 700 7 (X X) 2 DOOR L H & RH S IDE C1 CPL 6 0F 700 6 (X X) 1 DUCT F RONT DIS CHA RGE C 1 CPL 7 0C26 34A 1 ASS EMBLY CO VER AC CESS 8 091297 0091 1 ASSY WIRE 14 AW G 13.8 &qu[...]

  • Page 48

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  • Page 49

    1 0F7366 1 MUFFLER C1 2 0F7647 1 MUFFLER SADDLE 3 0F 8095 1 PIPE EXHAU ST OUTL ET 4 0F7538 1 PIPE EXH INLET M UFLR SIDE 1.5L 5 0E3 25 7 4 SCREW HWHT F M 6-1.0 X 1 6 6 0F7644 2 MUFFLER STRAP 7 0C61 1 9 1 BOLT U 5/16- 1 8 X 2-1 / 4 8 03 64 3 4 3 BO LT U 5/16- 1 8 X 2. 09 9 036449 3 SADDLE 2 INCH 10 0221 29 8 W ASHE R LO CK M8- 5/ 16 11 0222 59 6 NUT [...]

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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 [...]