Generac Power Systems 005219-0 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 3.0L 30kW Model: 005219-0 —  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 nt ende[...]

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 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 [...]

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 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[...]

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 E CIF ICA TIONS GEN ERA T OR T ype ............................................................................. Synchronous Rotor Insulation ............................................................ Class F or 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 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[...]

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[...]

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[...]

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[...]

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 [...]

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 state of[...]

ENGI NE COOLANT Check coolant level in coolant recovery bottle. See the “Specifications” section. • Add recommended coolant mixture as necessary . • Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly . Coolant should be at bottom of radiator filler neck. If coolant level is low , inspe[...]

7. Start engine and check for oil leaks. Figure 10.2 - Oil Filter Oil Filter CHANGI NG THE ENGI NE AI R CLEAN ER T o replace the engine air cleaner , (part number 0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover . See the “Service Schedule” section for air cleane[...]

BA TTER Y MAI NTENANCE The battery should be inspected per the “Service Schedule” section. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary . 2. Check the battery fluid level of unsealed batteries and, if necessary , fill with DISTILLED[...]

SERVICE S CH EDULE 30 KW - 1 5 0 KW ST ANDBY GAS ENGIN E DRIVEN 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 nee[...]

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/ Ini[...]

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/ Ini[...]

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/ Ini[...]

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. batter y cab les 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 0F3137 1 PAN CB CONN BOX 2 0F3188 1 STAND RH CONTR OL 3 0F3189 1 STAND LH CONTROL 4 0 23484N 1 B U SHING SNAP SB-2.5 -31 5 *** 0F6366B 1 / 2 XFMR DU AL 120 V/16 V (FO R 12 0/ 240V & 277/ 480V UNI T S) 0F63 66A 1 XFMR DUA L 10 4V/16V (FOR 120/2 08V U NITS) 6 * ** 04318 0 2 / 4 W ASHER FLAT M4 7 ** * 022264 2 / 4 W ASHER LOCK #8-M4 8 *** 0C3990[...]

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1 0 F3438 1 RTR 390 30 AD1 CPL 0F344 0 1 RTR 39 0 40AD2 C PL HI-EF 0F61 88 1 ASSY RTR 39 0 30 KD 1 CP L 0F61 90 1 ASSY RTR 39 0 40 KD 2 CP L 2 0F3439 1 STR 390 30 AD 1 CP L 0F34 41 1 STR 390 40 AD 2 CP L 0F61 89 1 STR 390 30 G D 1 CPL 0F61 99 1 STR 390 40 G D 2 CPL 0F665 5 1 ASSY STR 390 30KD 1 C PL 0F665 6 1 ASSY STR 390 40KD 2 C PL 3 0C9708 1 INS[...]

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COMPONENTS INCLUDED IN 01827E 1 0F1823A 1 ENCL HSB CO NT ROL PANE L 2 0F3078 1 COVER CO NTRO L PANEL 3 0F2606 1 HINGE CONT INUOUS H-PANEL 4 036261 6 RI VET POP .125 X . 275 SS 5 043 181 4 SCREW PHM M3-0.5 X 10MM 6 052777 7 WASHE R FLAT M 3 7 0F4245E 1 AS SY PCB CPL CT RL R 1800 RPM 8 0 F1262 4 HOLDER FUSE W ICKMANN 178.6150 9 0F1263 1 ADPTR RH SIDE[...]

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1 0F3270A 1 MTG BASE 3.0L 30K W C2 2 0528 60 4 NUT FLANG ED HE X M12- 1.75 3 0522 51 4 DAM PENE R VI BRATIO N 40 B LUE 4 052 257 4 SPAC ER .49 X .62 X 1.87 P WDR/ZNC 5 0522 52 4 DAM PENE R VI BRATIO N 6 0522 59 4 W ASHER FLAT M 12 7 0528 91 4 SCREW HHC M 12-1. 75 X 80 G 8.8 8 053621 0410 1 ASSY WIRE 14 .0 0 " 9 0429 0 9 1 SCRE W HH C M 8- 1. 2[...]

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1 0F3408 1 TRAY BA TTER Y 2 0F 3 4 11 1 STRAP BAT TE RY RETAI NM E NT 3 058208 RE F BAT T 12VD C 24 F 62 5 4 036833 1 S CRE W HH C 3/8-1 6 X 1 G 8 5 022237 1 WASHE R LO CK 3/8 6 022131 1 WAS HER FL AT 3/ 8-M10 Z INC 7 050331A 1 BATT POST COVER RED + 8 0 50331 1 BATT POST COVER BLK - 9 038805 H 1 CABL E BA TT BL K #1 X 2 3.00 10 0388 04Y 1 CABLE BAT[...]

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1 0E5 19 3 1 P LATE AIR CLEANE R AD AP T ER 2 0E0519A 1 AD APTER CAR BU RETOR W/PVC CONN 3 0221 27 1 NUT HEX 1/4- 20 STEE L 4 0629 74 1 STUD TH 1/4- 20 X 4- 1/2 G 2 ZNC 5 0526 19 4 S CREW HH C M 5-0.8 X 20 G 8.8 6 0C81 27 1 ELE MENT A IR CLE ANER 7 0A55 47 1 COV ER - AI R CLEA NER 8 0375 61 1 NUT WING 1/ 4-20 NY LK 9 0E658 6 2 GASK ET BOSCH 32 &[...]

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1 0F6842 1 E NGINE 3.0L FORD (FD) ( MAKE) CP L 2 02 2131 14 WASHER FL AT 3/8-M1 0 ZINC (1800 RPM ONLY) 022131 * 9 WASH ER FLAT 3/8-M10 ZINC (3 60 0 R PM ONLY) 3 0E8 96 3 1 P U L LE Y CRA N K S H AFT 3. 0L F O R D (180 0 RP M ON LY) 0E6309 1 P ULLE Y CR AN KSH AFT 3.0L FORD (360 0 RPM ONLY) 4 0F6912 1 BR ACKET R/H S IDE D.C. ALT 5 0F 6873 1 BRAC KET[...]

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1 0F3203A 1 WELDMEN T RAD SUPPO RT 3.0L C 2 2 0356 8 5 6 CLAM P HOS E #2 8 1. 32- 2. 25 3 0F2608A 1 RADIATO R 598 X 568 X 49,CP L LH 4 0F67 61 1 HOSE UPPE R RAD CPL C2 3.0L 5 0F32 28 1 HOS E LOWE R RA D CPL C2 3. 0L 6 0F51 43 1 S PA CER FAN 3.0L C2 7 0F02 30 A 1 FAN COO LI NG 16" DI A 8 BLA DE 8 0457 64 1 S CREW HHTT M 4-0. 7 X 8 BP 9 065852 1[...]

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1 0 26915 2 NIP PLE CL OSE 3 /4 X 1 .375 2 075580 1 FLANGE F UEL INLET 3 0F6390 1 REGULATOR ASSEMBLY D UAL FUEL 4 03925 3 2 SCREW HHC M 8-1.25 X 20 G 8.8 5 02214 5 2 WASHE R FLAT 5/16-M 8 ZINC 6 0 22129 4 WASH ER L OC K M8-5/1 6 7 045771 2 NUT HEX M 8-1.25 G8 CLEAR ZINC 8 04290 7 2 SCREW HHC M 8-1.25 X 16 G 8.8 9 0E9295A 1 ASSY THROTTLE 2 7 MM 10 0[...]

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1 0F0738 1 MUFFLER 7" X 9"-(2) 2" I N/2.5" OUT 2 0F28 08B 1 PIPE EXHAUST MUFFLE R 4 0F2830 1 MUFFLER BRACKE T STIFFENER 5 0F2962 1 MUFFLER STR AP 6 0 8076 2 1 BOLT U 3/8-1 6 X 2 .62 7 0E0170 B 1 EXHAUST BLANK ET 80 0MM (C2) 8 0 E0170 1 EXHAUST BLANKET 75 0 MM (C2) 9 0F4343 1 EXHAU ST PIPE 3.0L C2 C PL RH 10 0F 4 344 1 EXHAUS T P[...]

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1 0F58 53 (XX ) 1 REAR WRA P C2 2 0C24 5 4 68 S CRE W THF M6- 1 X 16 N WA Z/JS 3 0F 58 49 (XX ) 2 DOOR C 2 4 087 233 2 RIVET POP .1875 X .4 50 SS 5 0E 3257 4 SCRE W TH- FRM M6 W/ CAP S HKPRF W 6 0 F5852 (X X) 2 DISC HARGE DUCT, LH & RH SIDE C2 7 0F58 50 (XX ) 2 FRON T CO RNE RS C2 8 0 F5851 (X X) 1 DISC HARGE CENTE R DUCT C2 9 0F33 13 1 (REF.) [...]

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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[...]