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Generac Power Systems 005336-0, 005337-0 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 1.6L 20kW Models: 005336-0 005337-0 —  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 [...]

  • 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 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. Inspec[...]

  • Page 17

    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[...]

  • Page 18

    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[...]

  • 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 t[...]

  • 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. Initiat[...]

  • 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. 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[...]

  • 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 0F7135 1 BREAKE R TR AY BACK /BOTTOM 2 0F7022 1 SUPP ORT CO NTROL P ANEL SIDE RH 3 0F7021 1 SUPP ORT CO NTROL P ANEL SIDE LH 4 0F7260 1 COVE R CIRC U IT BRE A KER 2P 0F71 36 1 COVER CI RC UIT BRE A KE R 3P 5 0F 6156 1 PLA T E WIRE SNGL GAL V 6 0F4464 1 DECA L CUS T CO NN 120V UTILITY 7 0D469 8 REF BL O CK TE RM 20A 6 X 3 X 110 0V 8 0F3824 1 DECAL[...]

  • Page 30

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  • Page 31

    1 0986 7 5 1 ASS Y RTR 20KW 2P H 09893 6 1 ASS Y RTR 25 KW 2P H 2 0G0820 1 HOUS I NG BL OWER M ACHI NED 1.6L 3 0G10 19 1 GUARD BLOWER HOUSING 1.6L 4 020746 4 SCREW PPHM M5 -0 .8 X 8 ZINC 5 0492 26 4 WASHE R LOCK M5 6 0517 13 4 WASHE R FLAT M 5 7 0221 29 4 WASHE R LOCK M8-5/ 16 8 0F8218 1 STR 102 20 AD 1 CP L 0F822 0 1 STR -102-20 GD1 CPL 0G131 7 1 [...]

  • Page 32

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  • Page 33

    C O M P O N EN T S IN C L U D ED IN 0 G 1 2 9 1 E 1 0F 18 23A 1 ENCL HSB CO NTROL PANE L 2 0F3 07 8 1 COVE R CONTR OL PANE L 3 0F2 60 6 1 HI NGE C ONTI NUOUS H- PANE L 4 036261 6 RIVET P O P .125 X .275 SS 5 043181 4 SCR E W PH M M 3 -0.5 X 10M M 6 0 527 77 7 WASHER F LAT M3 7 0G130 3B 1 A SS Y PC B C PL2 C TR L R 36 00 R P M 8 0F1262 4 H O LD ER F[...]

  • Page 34

    [...]

  • Page 35

    1 0F7211 1 SUPPORT RADIATO R LH SI DE 2 0G07 6 0 1 V E N T U RI 16" DI A F A N 3 0F7210 1 SUPPO RT RADI ATOR RH SIDE 4 0E98 37 B 1 RAD I ATO R 1.6 L CH Y 5 0F0230 B 1 FAN CO OL 16" DI A 8 BLA DE 6 04652 6 5 WASHE R LOCK M1 0 7 0G0 9 10 1 LOWER RA DIATO R HOSE 1.6 L 8 0 99502 4 CL AMP H OSE #24 B1.0 6-2. 00 9 06986 0C 1 HOSE OIL DRAIN ASSY[...]

  • Page 36

    [...]

  • Page 37

    1 0F3 408B 1 BAT TERY T RAY C 1 CPL 2 0F3411 1 S TRAP BA TTERY RET AINME NT 3 0255 07 1 WAS HER S HAKEP ROOF EXT 7/16 S TL 4 0599 8 0 1 SCRE W HH C M10- 1. 5 X 25 G10. 9 5 0221 29 1 W ASHER L OCK M8-5/ 16 6 0774 8 3 REF BATT ERY 12V DC 75-A H 26 7 0503 31A 1 BAT T POS T COVE R RE D + 8 0503 31 1 BAT T POST COVER BLK - 9 03 8805J 1 CA BLE BAT TERY B[...]

  • Page 38

    [...]

  • Page 39

    1 0G0759 1 MOUN TING BASE 1. 6L 2 027 482 2 WA SH ER SHAK EPRO O F EXT 5/ 16 STL 3 0709 36 2 DAMPENE R VI BRATIO N 4 070936C 2 VIB . ISO . 70- 75 DURO 5 0392 5 3 8 SCREW HH C M 8- 1. 2 5 X 20 G8. 8 6 0221 45 12 WASHE R FLAT 5/16 ZINC 7 0221 29 12 WASHE R LOCK M8- 5/16 8 0457 71 4 NUT HEX M8-1. 25 G8 YE L C HR 90 7 1 9 5 6 4 W A S H E R F L A T M 8 [...]

  • Page 40

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  • Page 41

    1 0G0207 REF E NGI NE GENE RA C 1. 6L NG 2 0G0834 1 ENG I N E PLATE 1.6L 3 0G0820 REF HO USING BLOWE R MAC HINED 1.6L 4 0E9 74 7 1 S TART E R 12 VOLT 5 0G0839 2 ENGI NE MO UNTI NG FOOT STAM PING 6 0G0781 1 EX HAUST M ANIFO LD 1. 6L M ACHINE D 7 0G0722 1 INT AKE M ANIFOL D MACH INED 1.6L 8 0G0758 1 HEAT S HIEL D LOW ER 1.6L 9 0G0431 1 HEAT S HIE L D[...]

  • Page 42

    [...]

  • Page 43

    1 098290 1 ASM MOTOR ST EPPER 2 098941A 1 HOUSING GOVER NOR CONNECTOR 3 09895 8A REF CO NNECT OR INT ERFACE ASSE MBLY 4 09894 2A 1 COVE R CO NNE CTO R HO USI NG 5 098225 2 SCREW FH M #2 X 5/8 SELF TAP 6 0431 46 3 SCREW HHC M 6-1.0 X 10 G 8.8 7 0220 97 5 WASHE R LOCK M6-1/ 4 8 084543A 1 SCR EW PHM M3 -0.5 X 12MM 9 098783 1 LEVER STEPPER MOTOR 10 037[...]

  • Page 44

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  • Page 45

    1 026812 2 ELBOW 90 D 3/4 NPT 2 075580 1 FLANG E FUEL INLET 3 0G1397 1 FUEL REGULATOR 1.6L REWO RK 4 039253 2 SCREW HHC M8-1 .25 X 20 G8.8 5 022145 2 WASHER FL AT 5/16 ZINC 6 022129 4 WASHER LO CK M8- 5/16 7 045771 2 NUT HEX M8-1.25 G8 YEL CHR (1) 8 0F1570 1 BOD Y CARBURET OR A SSEMBLY 9 0A6344 1 BARBED EL 90 1/8NPT X 3/8 10 0C5 210 1 HOSE 3/8 ID L[...]

  • Page 46

    [...]

  • Page 47

    1 0F 700 3 (XX) 1 ROOF C1 CP L 2 0F 7004 ( XX) 1 COR NER PO ST L H SIDE C1 CP L 3 0F 7008 ( XX) 1 DOO R REA R C1 CPL 4 0F 7005 ( XX) 1 COR NER PO ST RH SIDE C1 CP L 5 0F 7007 ( XX) 2 DOO R LH & RH SI DE C1 CPL 6 0F 7006 ( XX) 1 DUCT FRO NT DISC HARGE C1 CP L 7 0C26 34A 1 AS SEMBLY COV ER AC CESS 8 091297 0091 1 ASSY WIRE 14 AW G 13. 8 " GR[...]

  • Page 48

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  • Page 49

    1 0F7366 1 MUFFLER C1 2 0F7647 1 MUFFLER SADDLE 3 0F8095 1 PIPE EXHAUST OUTL ET 4 0F7538 1 PIPE EXH INLET M UFLR SIDE 1.5L 5 0E3 257 4 SCRE W HW HTF M6-1 .0 X 1 6 6 0F7644 2 MUFFLER STRAP 7 0C611 9 1 BOLT U 5/16- 18 X 2-1/ 4 8 03 64 34 3 BOLT U 5/16-1 8 X 2. 09 9 036449 3 SADDLE 2 INCH 10 0221 29 8 WASHE R LOCK M8- 5/16 11 0222 59 6 NUT HEX 5/16- 1[...]

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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[...]