Generac Power Systems 005324-1, 005325-1 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 1.6L 25kW Models: 005324-1 005325-1 —  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 [...]

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 Stator Insulation ................................................................... Class F 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[...]

• Battery charger connection to 120 V AC. • Communication wires connected between transfer switch and generator (HTS only). • Unit secured to pad. 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 swit[...]

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 SERVICE F ACI LITIES  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 condition. 2. Inspect and test f[...]

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 COOLANT Check cool[...]

CHANGI NG ENGIN E OIL Refer to maintenance performed by 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 DRAIN HOSE CAP[...]

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[...]

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[...]

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[...]

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[...]

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[...]

Standby Generator Sets Notes[...]

Standby Generator Sets Notes[...]

Standby Generator Sets Notes[...]

Standby Generator Sets Notes[...]

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1 0F71 35 1 BREAKE R TRAY BACK/BO TTOM 2 0F7022 1 SUPPORT CONTROL P ANEL SIDE RH 3 0F7021 1 SUPPORT CONTROL P ANEL SIDE LH 4 0F72 60 1 COVER CIRCUIT BREA KER 2P 0F71 36 1 COVER CIRC UIT BREAKER 3P 5 0F61 56 1 PLATE WIRE S NGL GALV 6 0F4 4 64 1 DE CA L CUS T CO NN 120V UTIL ITY 7 0D469 8 RE F BLOCK TERM 20 A 6 X 3 X 1100V 8 0F38 24 1 DECA L UTIL SEN[...]

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ROT 0RS BE LOW M UST BE VE R IFIE D BY SE RIAL NO. AND B.O .M . 1 0G29 27 1 RTR- 102-20. 0AD1 CPL (2 006) (FOR U NITS B UILT AFTER FEBRU ARY 20 07) 0G28 27 1 ASS Y RTR 25KW 2P (20 06) (FO R UNIT S B UILT AF TER FE BRUARY 200 7) 09867 5 1 AS SY RTR 20 KW 2PH (FOR U NITS B UILT BE FORE FE BRUARY 2007) 09893 6 1 AS SY RTR 25 KW 2PH (FOR U NITS B UILT [...]

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C O M PO N EN T S IN CL UD ED IN 0 G3 3 6 5 E 1 0F 18 2 3A 1 E N CL HS B C ON T R OL P A N EL 2 0F 3 0 7 8 1 C OV ER C O N TR O L PA N E L 3 0F 2 6 0 6 1 H IN G E C O N T IN U OU S H - P A N E L 4 03 6 26 1 6 R IV E T P O P .1 2 5 X .2 7 5 S S 5 0 E 7 3 5 8 4 S C RE W P PP H H I- L O #4 -24 X 3 /8 6 05 2 77 7 3 W A S H ER F LA T M 3 7 0G 13 0 3 D 1[...]

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1 0F7211 1 SUPPORT R AD IATOR LH SIDE 2 0G07 60 1 VENTU RI 16" DIA F AN 3 0F7210 1 SUPPORT R ADIATOR RH SIDE 4 0E98 37B 1 RADI ATOR 1.6 L CHY 5 0F0230 B 1 FAN COOL 16" DI A 8 BLA DE 6 04652 6 5 WASHE R LO CK M10 7 0G0910 1 LOWE R RA DIATO R HOSE 1. 6 L 8 09 95 02 4 CLA M P HO S E #24 B1 .0 6- 2 .0 0 11 0G 0908 1 UP PER RA DIATOR HOSE 1 .6[...]

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1 0F34 08B 1 BATT ERY TRAY C1 CPL 2 0F34 11 1 STRAP BA TTERY RET AINME NT 3 02 5507 1 WASHE R SH AKEPRO OF EX T 7/1 6 STL 4 05 9980 1 SCREW HHC M 10-1. 5 X 25 G10. 9 5 0465 26 1 WASH ER LO CK M1 0 6 07748 3 REF BATTE RY 12V DC 75- AH 26 7 0503 31A 1 BAT TERY POS T COVE R RED + 8 0503 31 1 BAT TERY POS T COVE R BLK - 9 03 88 0 5J 1 CABLE BAT T ERY B[...]

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1 0G075 9 1 MOUN TI N G BAS E 1. 6L 2 0 27 482 2 WASHER SHAK EPROOF EXT 5/ 16 STL 3 07093 6 2 DAMPE NER VI BRATIO N 4 070936 C 2 VIB. ISO. 70 -75 D URO 5 0392 5 3 8 SCRE W HH C M8-1. 2 5 X 20 G 8.8 6 0221 45 12 WAS HER FL AT 5/16 ZI NC 7 0221 29 12 WAS HER LO CK M 8-5/16 8 0457 71 4 NUT HE X M8- 1.25 G 8 YEL C HR 90 7 1 9 5 6 4 W A S H E R F L A T [...]

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1 098 290 1 ASM MOTOR STEPPER 2 09894 1A 1 HOUSING GOVERNOR CON NECTOR 3 09 8958A REF CON NECTO R INTE RFACE ASSEM BLY 4 09 89 4 2A 1 COVE R CO NNE CTO R HOUS I NG 5 098225 2 S CREW FHM #2 X 5/ 8 SELF TAP 6 0431 46 3 SCREW HHC M 6-1. 0 X 1 0 G8. 8 7 0220 97 5 WASHE R LO CK M6- 1/4 8 084543A 1 SCREW PHM M3-0.5 X 12MM 9 098783 1 LEVER STEPPER MOTOR 1[...]

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1 0G0207 REF ENGINE GE NERAC 1. 6L NG 2 0G0834 1 E NGINE PLATE 1.6L 3 0G0820 REF HOUSING BLOWER MACHI NED 1.6L 4 0E9747 1 STARTE R 12 VOLT 5 0G0839 2 E NGINE MOUNTING FOOT STAMPING 6 0G0781 1 E XHAUST MANIFOL D 1.6L MACHINED 7 0G0722 1 IN TAKE MANIFOLD MACHINED 1.6L 8 0G0758 1 H EAT SHIELD LOW ER 1.6L 9 0G0431 1 H EAT SHIELD UPPE R 1.6L 10 0G0663 1[...]

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1 02681 2 2 EL BO W 9 0D 3/4 NP T 2 07558 0 1 FLANGE F UEL INLE T 3 0G1397 1 FUE L RE G U LATO R 1. 6L RE W O R K 4 0392 53 2 S CREW HH C M 8-1.2 5 X 20 G 8.8 5 0221 45 2 WA SHER FL AT 5/ 16 ZI NC 6 0221 29 4 WA SHER LO CK M 8-5/ 16 7 0457 71 2 NUT HEX M 8-1. 25 G 8 YEL C HR (1) 8 0F157 0 1 BODY CARBURETOR ASSEMBLY 9 0A63 44 1 BAR BED E L 90 1 /8 N[...]

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1 0F 700 3 (XX) 1 ROO F C 1 CPL 2 0F 7004 ( XX) 1 COR NER P OST L H SIDE C1 CPL 3 0F 7008 ( XX) 1 DOO R REA R C1 CPL 4 0F 7005 ( XX) 1 COR NER P OST RH SIDE C1 CP L 5 0F 7007 ( XX) 2 DOO R LH & RH S IDE C1 CPL 6 0F 7006 ( XX) 1 DUC T FRO NT DIS CHARGE C 1 CPL 7 0C26 34A 1 ASS EMBLY COVER ACCE SS 8 091297 0091 1 ASSY WIR E 14 AW G 13.8 " GR[...]

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1 0F73 66 1 MUF FLER C1 2 0F76 47 1 MUFFL ER SA DDLE 3 0F8095 1 PIPE EXHAUST OUTLET 4 0F75 38 1 PIPE EXH I NLET M UFLR S IDE 1.5L 5 0E 3257 4 SCREW HWHTF M 6-1.0 X 16 6 0F76 44 2 MUF FLER STR AP 7 0C 6119 1 BOLT U 5/ 16-18 X 2-1 /4 8 03 6434 3 BOLT U 5/16- 18 X 2.09 9 03644 9 3 SADD LE 2 I NCH 10 022129 6 WASHE R LO CK M8- 5/16 11 022259 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[...]