Generac Power Systems 005221-0 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 3.9L 40kW Model: 005221-0 —  CAUTION  — ONL Y QU ALIFIED ELECTRICIANS OR CONTRA CT ORS SHOULD A TTEMPT INST ALLA TION! Cover026 Re v . 0 09/05 Part No. 0F7924[...]

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 state [...]

ENGI NE COOL ANT 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 , insp[...]

7. Start engine and check for oil leaks. Figure 10.2 - Oil Filter Oil Filter CHANGI NG THE ENGI N E 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 clean[...]

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 EDU LE 30 KW - 1 50 KW S T ANDBY GA S ENGI N E DR IVEN 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[...]

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/ Init[...]

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/ Init[...]

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/ Init[...]

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. batter y cables as necessary . 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 CONTRO L 4 0 23484N 1 BU SHING SNAP SB-2 .5 -31 5 *** 0F6366B 1 / 2 XFMR DU AL 120 V/16 V (FO R 12 0/ 240V & 277/ 480V UNIT S) 0F63 66A 1 XFMR D UAL 104 V/ 16V (F OR 120 /208V UN ITS) 6 * ** 0431 80 2 / 4 WAS HE R FL AT M 4 7 ** * 022264 2 / 4 W ASHER LO CK #8-M 4 8 ***[...]

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1 0F343 8 1 RTR 390 30AD1 C PL 0F344 0 1 RTR 390 40AD2 C PL HI-EF 0F61 88 1 AS S Y RTR 39 0 30 KD 1 CP L 0F61 90 1 AS S Y RTR 39 0 40 KD 2 CP L 2 0F3 4 39 1 S TR 39 0 30 AD 1 CP L 0F34 41 1 S TR 39 0 40 AD 2 CP L 0F61 89 1 S TR 39 0 30 G D 1 CPL 0F61 99 1 S TR 39 0 40 G D 2 CPL 0F665 5 1 ASSY STR 390 30KD1 C PL 0F665 6 1 ASSY STR 390 40KD2 C PL 3 0[...]

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COMPONENTS INCLUDED IN 01827E 1 0F1823A 1 E NCL HSB CO NTRO L PANE L 2 0F3078 1 COVER CO NTRO L PANEL 3 0F2606 1 HINGE CONT INUOUS H-PAN EL 4 036261 6 RI VET POP .125 X . 275 SS 5 043181 4 SCREW PHM M3-0.5 X 10MM 6 052777 7 W ASHE R FL AT M 3 7 0F4245E 1 AS SY PCB CPL CT RL R 1800 RPM 8 0F1262 4 HOLDER FUS E W ICKMANN 178.61 50 9 0F1263 1 ADPTR RH [...]

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1 0F327 0 1 MTG BASE 3. 9L 40KW C2 2 0528 6 0 4 NUT FL ANGE D HE X M1 2-1 .75 3 05225 1 4 DAMPE NE R VI BRATIO N 40 B LUE 4 052257 4 SPACER .49 X .62 X 1.87 PWDR /ZNC 5 05225 2 4 DAMPE NE R VI BRATIO N 6 05225 9 4 WASHE R FL AT M 12 7 0528 91 4 SCREW HHC M 12- 1. 75 X 8 0 G8. 8 8 053621 0410 1 ASSY WIRE 14 .0 0 " 9 0429 0 9 1 SCREW HH C M 8-1.[...]

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1 0F3408 1 TRA Y BAT TER Y 2 0F 3 4 11 1 STRAP BA TTE RY RETAI NMENT 3 0582 08 REF BATT 12VDC 24 F 62 5 4 0368 3 3 1 S CRE W HH C 3/8- 1 6 X 1 G8 5 02223 7 1 WASHE R LO CK 3 /8 6 0221 31 1 WASHE R FL AT 3/8-M 10 Z INC 7 050331A 1 BATT POST COVER RED + 8 050331 1 BATT POST COVER BLK - 9 038805 H 1 CAB LE BA TT BL K #1 X 2 3.00 10 0388 04Y 1 CABLE BA[...]

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1 0E504 8A 1 FLEXPLATE HSB 3 .9L CHRYS LER ( 1800RPM ) 0F3903A 1 FLEX PLATE 2 POLE 3.9L CHRY (3600RPM) 2 0F29 82 1 ENG AD AP TER M AC H 3.9L HS B NSPS 3 0E6703 1 COVER FLYWHEEL ACC ESS 4 0F3795 REF ENGINE INSER TED VALVE 3.9L (3600 RPM) 0E8336 REF MAKE 3.9L CH RYSLER E NGINE (18 00 RPM) 5 0E7841 2 GASKET TH ERMOSTAT ADAPTOR 6 0E7254 1 MACH THE RM A[...]

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1 0F32 03 1 WEL DMENT R AD S UPPOR T 3. 9L C2 2 03 568 5 4 CLAM P HOS E #2 8 1.32- 2. 25 3 0F260 8 1 RADIAT OR 598 X 568 X 49 C PL RH 4 0F4 413 1 HOSE UPP ER R AD CPL C2 3.9L 5 0F4 4 14 1 HOS E LOWE R RAD CP L C2 3. 9L 6 0E7854 1 CLUTC H COOLING FAN 7 0F282 0 1 FAN 22 " DIA 10 BL ADE 8 05 175 6 4 SCRE W HH C M 10- 1.5 X 20 G 8.8 9 0 465 26 4 W[...]

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1 0F65 04 1 P IPE R/ H S IDE MUFF LER 2 0F 3127 1 PIPE L/H S I D E 3.9L C PL 3 0F2808B 1 PIPE EXHAUST M UFFLER OUT 4 0F07 38 1 M UFFLER 7" X 9"-( 2) 2" IN/ 2. 5" O UT 5 0F29 62 1 M UFFLER STR AP 6 0F28 30 1 M UFFLE R B RACKE T STI F FENE R 7 047411 2 SCREW H HC M6 -1 .0 X 16 G8.8 8 02 209 7 2 WASHE R LO CK M 6- 1/4 9 02 247 3 2 [...]

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1 0F6322 1 BOTTOM PLATE, AIR CLEANE R 3.9L 2 0F5418 1 ELEMENT AIR FILTE R 3 0E6406 1 HOLDER VE NTURI 4 0E 7 70 2 1 HOL D DO WN AI R CLE A NE R 5 0F6323 1 PLATE, AIR CLEANER TOP 3.9L 6 03756 1 1 NUT WING 1/4-20 NYLK 7 04981 5 4 SCREW HHC M 5-0.8 X 16 G8.8 8 04922 6 4 WASHER LOCK M5 9 05171 3 4 WASHER FL AT M5 10 0E6586 1 GASKET BOS CH 3 2 & 40[...]

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1 03 32 1 2 4 SCRE W HH C 5/ 16- 18 X 1-1/ 4 G 5 2 075580 1 FLANGE FUEL INLET 3 0F6 3 90 1 RE GU L AT O R ASS E M BLY DU AL FUE L 4 03 92 53 2 SCRE W HH C M 8- 1.2 5 X 20 G 8.8 5 02 21 45 2 WAS HER F LAT 5/ 16-M 8 Z INC 6 02 212 9 6 WASHE R L OCK M8- 5/ 16 7 04 577 1 2 NUT HEX M 8- 1.2 5 G8 CLE AR Z IN C 9 0E8 28 6 1 STRE E T EL 4 5 DE G 1/2" [...]

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1 0F58 53 (XX ) 1 REA R WRA P C2 2 0C24 5 4 68 SCREW THF M6- 1 X 16 N WA Z/ JS 3 0F58 49 ( XX) 2 DO OR C2 4 087233 2 RIV ET PO P .187 5 X .4 50 SS 5 0E 325 7 4 SCREW TH-F RM M6 W/ CAP S HKP RF W 6 0 F585 2 (XX) 2 DISC HARGE DU CT,L H & RH SIDE C 2 7 0F58 50 (XX ) 2 FRON T CO RN ERS C2 8 0 F585 1 (XX) 1 DISC HARGE CENT E R DU CT C2 9 0F3 3 13 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 ow er Systems Dealer , or branch thereof , Generac P ow er Systems, Inc. will, at its [...]