Elite 005212-0 manual

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 2.5L 25kW Model: 005212-0 —  CAUTION  — ONL Y QU ALIFIED ELECTRICIANS OR CONTRA CT ORS SHOULD A TTEMPT INST ALLA TION! Cover018 Re v . 0 09/05 Part No. 0F7922[...]

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[...]

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[...]

• 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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 ........[...]

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[...]

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[...]

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 .[...]

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[...]

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[...]

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[...]

Figure 10.2 — Cylinder Head Installation C OOLI NG SY STEM Air intake and outlet openings in the generator com- partment must be open and unobstructed for contin- ued proper operation. This includes such obstruc- tions as high grass, weeds, brush, leaves and snow . W ithout sufficient cooling and ventilating air flow , the engine/generator quickl[...]

MAI NTENANCE OWNER/ OP ER A T OR CAN PER FOR M CH ECK ENGIN E OI L LEVEL Refer to “Checking Fluid Levels”. CH ECK B A TTER Y • See “Checking Fluid Levels”. • Check battery cables for condition, tightness, cor- rosion or damage. Clean, tighten or replace as necessary . EXERCISE SY STEM Start the generator engine at least once every seven[...]

SP ARK P L UGS Reset the spark plug gap or replace the spark plugs as necessary (Figure 10.4). 1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean. 2. Remove the spark plugs and check the conditio[...]

 Battery electrolyte fluid is an extr emely corro- sive sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear pr otective goggles, protective clothing and gloves when handling a battery . If fluid is spilled, flush the affected ar ea immediately with clear water . [...]

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[...]

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 [...]

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[...]

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 necessar y . 3. Defectiv e star ter contactor . 3. Replace contactor .* 4. Defectiv e star ter motor . 4. Replace starter motor .* 5[...]

Standby Generator Sets Notes[...]

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1 0F7135 1 BREA KER TRAY BA CK/BOT TOM 2 0F7022 1 SUPP ORT CONT ROL P ANEL SIDE RH 3 0F7021 1 SUPP ORT CONT ROL P ANEL SIDE LH 4 0F7260 1 COVE R CIRC UIT BREA KER 2P 0F7136 1 COV ER CIRC UIT BRE AKE R 3P 5 0F6156 1 PLATE WIRE SNGL GALV 6 0F4464 1 DECA L CUST CONN 120V UT ILITY 7 0D469 8 REF BLO CK TE RM 20A 6 X 3 X 1100V 8 0F3824 1 DECA L UT IL SEN[...]

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1 0F7 4 89 1 ROTO R 30 KW DI RE CT 390 4P 180 0 0F74 90 1 ROTO R 25 KW 3PH DI REC T 390 18 00 2 0F7 4 58 A 1 STR 390 30 AD 1 HS B TE C UM 0F745 9 1 ASSY STR 390 25 GD1 CP L 3 0C9708 REF INSTR HYPO T TEST ( NOT SHOW N) 4 S EE E NGINE EV RE F ENGIN E A DAPT ER 5 SEE ENG INE EV R EF FL EXPLA TE 6 0F736 4B 1 ASSY FLYWHEEL CPL W/25 MM FAN B 7 0E570 6 1 [...]

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1 0F 707 4 1 S UPP OR T RA DIA TOR LH SIDE 2 0F7 076 1 VENT U RI 16" DI A. FA N 3 0F7 075 1 SUPP ORT RADI ATO R RH SIDE 4 0E983 7A 1 RAD I ATO R 2 .5L CP L 5 0F0 2 30 A 1 FAN COO L 16" DI A 8 BLA DE 6 0F7 130 1 SPACE R F AN 2.5L C1 7 0E9833 1 HOSE 2 .5L FO RD L OWE R RADIA TOR 8 09950 2 4 CLAMP HO SE #2 4 B1 .0 6- 2 .0 0 9 06986 0 C 1 HOS[...]

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1 0498 13 1 NUT HEX M 6 X 1. 0 G8 Y EL C HR 2 0220 97 1 WASHE R LOCK M6- 1/ 4 3 0268 50 2 WASHE R SHAK EP ROOF EXT 1/4 STL 4 05541 4 1 LUG SLDLS S #2- # 8 X 17/ 64 CU 5 0224 73 1 WASHER FL AT 1/ 4-M6 ZI NC 6 0474 11 1 SCREW H HC M 6-1. 0 X 1 6 G8. 8 7 052860 4 NUT FLA N G ED HEX M 12 -1.75 8 0522 5 1 4 DAMPENE R V I BRATI ON 40 BLUE 9 0522 57 4 SPA[...]

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1 0F3 408 B 1 BAT TERY TRAY C 1 CP L 2 0F3 4 11 1 STRAP BA TT E RY RET A INM E NT 3 02550 7 REF WAS HE R SHAK EP ROOF EXT 7/16 S TL 4 05264 7 REF S CREW S HC M1 0-1. 5 X 25 G 1 2.9 5 04652 6 REF WAS HE R LOCK M1 0 6 02213 1 REF W ASHE R FLAT 3/8- M1 0 ZIN C 7 050331A RE F BAT T POS T CO VER RE D + 8 05033 1 REF BAT T POS T COV ER BLK - 9 038 805J 1[...]

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1 0E9909 REF EN GINE 2.5 L FORD 2 0E9739 1 PULL EY 2.5L FORD WATER PU MP 3 0498 14 7 SCREW HHC M10- 1. 5 X 25 G8.8 5 0D34 8 8 B 1 SER PE N T I N E BE L T – 40 . 8 5” LE NG T H 6 0 A8584 1 SWITCH OIL P RESSURE 10PSI 2POL 7 0E0561 1 ASSY WA T ER LEVEL SEN SOR C/E PL 8 0A6751 1 SW-TMP 245 DEG 3/8 NPT 9 035579 1 BUS HING R EDUC ER 1 /4 TO 1/8 10 02[...]

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1 0E8456 1 BR AC KET F UEL REGU LAT OR 2 075580 1 FLANGE FUEL INL ET 3 0F6 3 64 1 FUEL RE G. 2. 5L FO R D RE WO RK 4 03925 3 4 SCREW HH C M 8-1. 2 5 X 20 G8.8 5 02214 5 2 WASHE R F LAT 5/ 16 ZI NC 6 02212 9 6 WASHE R LO CK M8- 5/ 16 7 045771 2 NUT HE X M8-1.25 G8 YEL CHR 8 * 0F 1570 1 BOD Y CARBURET OR ASSE MBLY 9 0A6344 1 BARBED E L 90 1/8 N PT X [...]

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1 0F 700 3 (X X) 1 ROOF C 1 CP L 2 0F 700 4 (X X) 1 CO RNE R P OST L H S IDE C1 CPL 3 0F 700 8 (X X) 1 DO OR REA R C 1 CP L 4 0F 700 5 (X X) 1 CO RNE R P OST RH S IDE C 1 CPL 5 0F 700 7 (X X) 2 DO OR LH & R H SI DE C1 CP L 6 0F 700 6 (X X) 1 DU CT F RO NT DISC HARGE C 1 CPL 7 0C26 34A 1 ASS EMBLY CO VER AC CESS 8 091297 0091 1 ASSY WIRE 14 AW G[...]

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1 0F7366 1 MUFFLER C 1 2 0F7647 1 MUFFLER S ADDLE 3 0F809 5 1 PIPE E XHAUST OUTLET 4 0F7172 1 PIPE EXH INLET M FLR SIDE 2.5L 5 0E3257 4 SCREW HWHT F M 6-1.0 X 1 6 6 0F7382 1 PIPE EX H INLET MANIFLD SI DE 2.5 7 0C 61 1 9 1 BOLT U 5/16- 1 8 X 2-1 /4 8 03643 4 2 BOLT U 5/16- 1 8 X 2. 09 9 036449 2 SADDLE 2 INCH 10 0221 29 6 WAS HE R LO CK M 8- 5/16 11[...]

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