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Generac Power Systems 005210-0 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 1.5L 20kW Model: 005210-0 —  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[...]

  • 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 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 [...]

  • 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 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[...]

  • 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 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 .....[...]

  • 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 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[...]

  • Page 12

    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[...]

  • Page 13

    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[...]

  • Page 14

    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[...]

  • Page 15

    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 [...]

  • Page 16

    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 conditio[...]

  • 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 COOLANT Check coo[...]

  • Page 18

    CHANGI NG ENGIN E OIL 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 DRA[...]

  • Page 19

    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[...]

  • Page 20

    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[...]

  • 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 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 cables as necessary . 3. Defectiv e star ter contactor . 3. Replace contactor .* 4. Defectiv e star ter motor . 4. Replace star ter motor .* 5. D[...]

  • Page 24

    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    1 0F7135 1 BREA KER TR AY BA CK/BOTTOM 2 0F7022 1 SUPP ORT CO NTROL P ANEL S IDE RH 3 0F7021 1 SUPP ORT CO NTROL P ANEL S IDE 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 CUS T CONN 120V UTILITY 7 0D469 8 REF BLO CK TERM 20 A 6 X 3 X 1100V 8 0F3824 1 DECA L UT IL S[...]

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    1 098675 1 ASSY ROTO R 20 K W 2 0A5336A 1 HOUSING BL OWER 3 0A16 59 1 SCREE N AIR O UTLET 4 020746 4 SCRE W PPHM M5 -0 .8 X 8 ZINC 5 049226 4 WAS HER LO CK M5 6 051713 4 WAS HER FL AT M 5 7 022129 4 WAS HER LO CK M8- 5/16 8 0F8 218 1 AS SY S TATOR 20KW 1PH A 0F82 20 1 ASS Y STAT OR 2 0KW 3P H GJK 9 0A5382 1 BEARI NG CA RR IER REAR 10 0 75 591 1 ASS[...]

  • Page 30

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  • Page 31

    1 0F1 823 A 1 ENCL HSB CONTROL PANEL 2 0F3 078 1 COVE R CO NTRO L P ANEL 3 0 F2606 1 HI NGE C ONTI NUOUS H-PN L 4 036261 6 RIVET PO P .125 X .275 SS 5 043181 4 SCREW PH M M 3 -0.5 X 10MM 6 05277 7 7 WASHE R FL AT M3 7 0F4 245F 1 ASS Y PCB CPL CT RLR 3600 RPM 8 0F 126 2 4 HO LDE R FU SE W I C K M A NN 178 .61 50 9 0F1 263 1 ADPT R RH SIDE WI CKMA N [...]

  • Page 32

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  • Page 33

    1 0F34 08B 1 BAT TERY T RAY C 1 CPL 2 0F3 4 11 1 STRAP BA TT E RY RET A INM E NT 3 0 255 07 RE F WASHE R SHAKEP ROOF EXT 7/16 STL 4 0 52647 REF S CREW S HC M 10-1.5 X 25 G12.9 5 0 465 26 REF WASHE R LOCK M10 6 0 221 31 RE F WASHE R FLAT 3/8-M1 0 ZIN C 7 05033 1A REF BAT T POST COVER RE D + 8 0 503 31 REF BATT PO ST COV ER BL K - 9 038 805J 1 CAB LE[...]

  • Page 34

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    1 0F715 5 1 MOUN TING BA SE 1.5L C1 CPL 2 0274 82 2 WASHE R SH AKEPROO F EX T 5/1 6 STL 3 0709 36 2 DAMPE NER VI BRATIO N 4 07093 6C 2 V IB. I S O . 7 0-75 DU RO 5 0392 5 3 8 S CREW HH C M 8-1. 25 X 20 G8.8 6 0221 45 12 WASHER FLAT 5/16 ZINC 7 022129 12 WASHER LOCK M8-5/1 6 8 045771 4 NUT HE X M8-1.25 G8 YEL CHR 9 0719 56 4 WASHE R FLAT M8 10 0517 [...]

  • Page 36

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    1 0F7 211 1 SUP PORT R ADIATO R LH S IDE 2 0F7 2 09 1 VENTU RI 15" DI A FA N 3 0F7 210 1 SUP PORT R ADIATO R RH SIDE 4 0E9 837A 1 RADIA TOR 2 .5L CPL 5 0E 1936 1 FAN COOL ING 15" 6 02212 9 1 WA SHER LO CK M 8-5/16 7 0F7 166 1 RA DIATOR HOSE LW R 1.5L C1 CP L 8 099502 4 CLA MP HO SE #24 B1.06 -2.00 9 069860C 1 HOSE O IL DRAIN ASSY 21 "[...]

  • Page 38

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  • Page 39

    1 0 98290 1 ASM MOTOR ST EPPER 2 098 941 A 1 HOU SING GO VERN OR CONN ECT OR 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 MOTOR 10 03[...]

  • Page 40

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  • Page 41

    1 0A4531 REF E NGINE-1.5L 2 022473 2 WASH ER F LA T 1/4 ZINC 3 * 055934 C 1 CLA MP VIN YL .5 X .406 Z 4 0A45 310 258 RE F. GASKET -EX HAUS T MA NIFOL D 5 0 A4355 1 MANIFOLD-EXHAUST 6 0E2632 1 HEAT SHI ELD 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 G5 9 052212 4 SCR EW HHC M10-1.25 X 25 G8 .8 10 0 4652 6 4 WASHE [...]

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    1 026812 2 ELBOW 90 D 3 /4 N PT 2 075580 1 FLANGE FUE L IN L E T 3 0F6 3 64 A 1 FUEL RGLT R 1.5L REW O RK 4 0392 53 4 S CREW HH C M8-1. 25 X 20 G8.8 5 0221 45 2 WAS HER FL AT 5/16 ZI NC 6 0221 29 6 WAS HER LO CK M8-5/ 16 7 045771 2 NUT HEX M8-1.25 G8 YE L CHR 8 * 0F157 0 1 BOD Y CARBUR ET OR ASS E MBL Y 9 032552 1 BARBED EL 90 5/16 X 1/8 NPT 10 029[...]

  • Page 46

    [...]

  • Page 47

    1 0F 700 3 (XX) 1 ROOF C 1 CP L 2 0F 7004 ( XX) 1 CO RNER POST L H SI DE C1 CPL 3 0F 7008 ( XX) 1 DO OR RE AR C 1 CPL 4 0F 7005 ( XX) 1 CO RNER POST RH SI DE C 1 CPL 5 0F 7007 ( XX) 2 DO OR L H & R H SIDE C1 CP L 6 0F 7006 ( XX) 1 DU CT F RONT DI SCHA RGE C 1 CPL 7 0 C2634 A 1 ASS EMBLY COVER ACCES S 8 091297 0091 1 ASSY WIRE 14AW G 13.8 "[...]

  • Page 48

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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 0F7538 1 PIPE EXH INLET MUFLR SI DE 1.5L 5 0E3257 4 SCREW HWHTF M 6-1.0 X 16 6 0F7644 2 MUFFLER S TRAP 7 0C 61 1 9 1 BOLT U 5/16- 18 X 2-1 /4 8 0364 3 4 3 BO LT U 5/16-1 8 X 2. 09 9 036449 3 SADDLE 2 INCH 10 0221 29 8 WASHE R LO CK M8- 5/16 11 0222 59 6 NUT HE X 5/[...]

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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[...]