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Generac Power Systems 005221-0, Owner'S Manual

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Generac Power Systems 005221-0 Owner'S Manual Download Page 41

1

0F6504

1

PIPE R/H SIDE MUFFLER

2

0F3127

1

PIPE L/H SIDE 3.9L CPL

3

0F2808B

1

PIPE EXHAUST MUFFLER OUT

4

0F0738

1

MUFFLER 7" X 9"-(2) 2" IN/2.5" OUT

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0F2962

1

MUFFLER STRAP

6

0F2830

1

MUFFLER BRACKET STIFFENER

7

047411

2

SCREW HHC M6-1.0 X 16 G8.8

8

022097

2

WASHER LOCK M6-1/4

9

022473

2

WASHER FLAT 1/4-M6 ZINC

10

080762

1

BOLT U 3/8-16 X 2.62

11

0D9832

4

SCREW HHC M12-1.75 X 75 SS

12

087171

8

WASHER FLAT 1/2 SS

13

083215

4

WASHER LOCK 1/2 SS

14

051548

4

NUT HEX M12-1.75 G8 SS

15

0F3794

1

EXHAUST BLANKET 549MM LONG (R/H)

16

0F3794A

1

EXHAUST BLANKET 448MM LONG (L/H)

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0E8816

1

EXHAUST FLANGE 2" PIPE

19

036797

4

BOLT U 5/16-18 X 2.25

20

024114

8

NUT HEX 5/16-24 STEEL

21

022129

8

WASHER LOCK M8-5/16

22

0F5078

1

PIPE L/H SIDE MUFFLER

23

0F3133

1

PIPE R/H SIDE 3.9L CPL

Summary of Contents for 005221-0

Page 1: ...UAL This manual should remain with the unit A new standard of reliability Serial Number QT 3 9L 40kW Model 005221 0 CAUTION ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION Cover026 Rev 0 09 05 Part No 0F7924 ...

Page 2: ...or to Initial Start up 8 1 Initial Inspection for QT Genset Start up 8 1 Start up Inspection 8 2 OPERATION 9 1 Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch 9 1 Engine Start up and Transfer 9 1 Retransfer and Shutdown 9 1 Operating Unit with Automatic Transfer Switch 9 1 MAINTENANCE 10 1 Maintenance Performed by Authorized Service Facilities 10 1 Cooling System 10 ...

Page 3: ...rator is installed operated and serviced in accordance with the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon monox ide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can c...

Page 4: ...s will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to person nel disable the ge...

Page 5: ...zard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepar...

Page 6: ...his manual or to the data label affixed to the unit Generator Model and Serial Number This number is the key to numerous engineering and manufacturing details pertaining to your unit Always supply this number when requesting service order ing parts or seeking information 2 1 Standby Generator Sets General Information Identy 002 Rev A 12 05 WAUKESHA WI RATED KW RATED VOLTAGE POWER FACTOR ENGINE RPM...

Page 7: ...ay result in an engine failure NOTE For temperatures below 32 F it is strongly recom mended to use the optional Cold Weather Start Kit part number listed in the Specification Section The oil grade for temperatures below 32 F is 5W 30 synthetic oil COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is listed in the...

Page 8: ...ng cranking and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO OVERCRANK SHUTDOWN After a prespecified duration of cranking this func tion ends the cranking if the engine has failed to start The overcrank LED will t...

Page 9: ...e sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff sole noid should not exceed approximately 14 inches water column 0 5 psi Optimum pressure at the fuel shutoff solenoid is 11 inches water column 0 4 psi PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid fuel in the supply tank...

Page 10: ...Gas Flow at rated power 60 Hz 118 cfm Governor Type Electronic Frequency Regulation Isochronous Steady State Regulation 0 25 Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Spin on Cartridge Crankcase Oil Capacity 4 U S qts COOLING SYSTEM Type Pressurized Closed Recovery Water Pump Belt Driven Fan Speed 2060 rpm Fan Diameter 22 inches Fan Mode Pusher Air Flow inlet air includi...

Page 11: ...Install pipe plug into Port 1 7 Connect carburetor gas hose to brass fitting 8 Tighten all clamps and plugs 9 Make sure fuel supply is of the proper pressure and type for configuration 10 Reverse the procedure to convert back to natural gas 11 The Dip switch inside the control panel must be in the LP or NG position when switching to differ ent fuels Figure 6 2 Reconfigure the Fuel System NG FUEL S...

Page 12: ...breaker ter minal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS The generator is designed to supply 3 phase electri cal loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit...

Page 13: ...oil level in the generator gearbox if so equipped prior to initial use and at the intervals indicated by the Service Schedule The recom mended oil is SAE 90 gear lubricant Also if the engine is equipped with a mechanical gov ernor make sure the governor is properly lubricated with clean engine oil PRIOR TO INITIAL START UP Prior to initially starting the generator it must be properly prepared for ...

Page 14: ...on The engine should now crank and start Check voltage at the generator terminals For 3 phase units check phase rotation at the transfer switch terminals The generator phase rotation must match the utility phase rotation Check for coolant fuel oil and exhaust leaks Close the generators main line circuit breaker Turn the generator set off Connect the UTILITY supply to the transfer switch Set the AU...

Page 15: ...ransfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the standby generator s main line circuit break er to its OFF or OPEN position Start the generator Do not crank the engine continuously for longer than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge read ings When...

Page 16: ...operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down The exhaust system parts from this product get extremely hot and remain hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn fr...

Page 17: ...e any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 inch Adjust belt tension as required INSPECT ENGINE GOVERNOR Visually inspect electronic governor DANGER Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds ...

Page 18: ...generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer That dealer will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of ...

Page 19: ...s when handling a battery If the fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster battery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to A...

Page 20: ...on when required 2 A wear in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit This inspection contains some maintenance tasks which require special tools equipment and or knowledge to ...

Page 21: ... 3 Check the engine coolant level Adjust as necessary 4 Check the engine coolant thermal protection level Correct as necessary 5 Check the natural gas delivery system for leaks and correct pressure on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level and specific gravity if accessible Adju...

Page 22: ...and damage Replace as necessary 11 Check the engine valve clearance Adjust as necessary 12 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 13 Test the engine and transfer switch safety devices Correct and or adjust as necessary 14 Initiate an automatic start and transfer of the unit to site load and exercise it for at le...

Page 23: ...gh for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 19 Perform an engine oil analysis send a sample to a lab for results Change the engine oil and filters if the analysis results indicate this is required 20 Change the engine oil 21 Replace the engine oil filter s 22 Replace engine spark plugs Clean and re gap or replace ...

Page 24: ...nded in SPECIFICATIONS Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defective Low ...

Page 25: ...Standby Generator Sets Notes ...

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Page 27: ...P 600V S FD6 LL 0D5575 CB 0225A 3P 600V S FD6 LL 0D5576 CB 0250A 3P 600V S FD6 LL D 0F0199 1 INSULATOR CB FD FRAME 30MIL E 081320 4 SCREW SHC 1 4 20 X 4 5 G8 8 NZ F 022473 4 WASHER FLAT 1 4 M6 ZINC G 022097 4 WASHER LOCK M6 1 4 H 022127 4 NUT HEX 1 4 20 STEEL J 0C2454 7 SCREW THF M6 1 X 16 N WA Z JS K 029289 1 TAPE ELEC 1 2 FOAM AS REQ D L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE 3 UL CIRCUIT BREAKE...

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Page 29: ...GUARD REAR BEARING CARRIER CPL 3 0L 30KW 0F6123 1 GUARD REAR BEARING CARRIER CPL 3 9L 40KW 10 0E6076 1 REVCOR FAN 12 63 X 2 W PRESSDISK 11 023454 1 KEY WOODRUFF E 12 077043F 1 CONDUIT FLEX 1 1 4 30 LG 13 04576100BU 4 STUD M14 2 0 570 G5 ZINC 30KW 04576100AQ 4 STUD M14 2 0 X 615 G5 ZINC 14 052646 4 WASHER FLAT M14 15 043123 4 WASHER LOCK M14 16 051779 4 NUT HEX M14 2 0 G8 YEL CHR 17 0A2601 1 SCREW ...

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Page 31: ... ON 24 0F3215 1 DECAL CONTROL HSB 25 0F5886 3 SCREW HHPM M5 0 8 X 12 26 051713 12 WASHER FLAT M5 27 049226 12 WASHER LOCK M5 28 0F5752F 1 RES WW 15R 5 25W QK CONN 29 0F5884 2 SCREW PHTT M3 5 0 6 X 10 30 0F5896 2 SCREW PHTT M3 5 0 6 X 16 31 0C2265 4 SCREW PHTT M4 0 7 X 12 ZYC 32 0C3990 2 SCREW PHTT M4 0 7 X 10 ZYC 33 091526 4 SCREW PPHM M5 0 8 X 12 ZNC 34 051716 9 NUT HEX M5 0 8 G8 CLEAR ZINC 35 07...

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Page 33: ...ROOF INT 1 4 13 022097 1 WASHER LOCK M6 1 4 14 022473 1 WASHER FLAT M6 1 4 ZINC 15 049813 1 NUT HEX M6 1 0 G8 YEL CHR 16 022261 1 WASHER SHAKEPROOF INT 3 8 17 0F2230 2 SUPPORT ENGINE 3 9L LH RH SD 18 0F5898 2 PLATE ALT VARMINT 19 036833 4 SCREW HHC 3 8 16 X 1 G8 20 022302 1 WASHER LOCK 7 16 21 022131 4 WASHER FLAT 3 8 M10 ZINC 22 065852 1 SPRING CLIP HOLDER 37 62 23 045764 1 SCREW HHTT M4 0 7 X 8 ...

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Page 35: ...022131 1 WASHER FLAT 3 8 M10 ZINC 7 050331A 1 BATT POST COVER RED 8 050331 1 BATT POST COVER BLK 9 038805H 1 CABLE BATT BLK 1 X 23 00 10 038804Y 1 CABLE BATT RED 1 X 35 00 11 045771 1 NUT HEX M8 1 25 G8 YEL CHR 12 022129 1 WASHER LOCK M8 5 16 13 027482 2 WASHER SHAKEPROOF EXT 5 16 STL 14 075763 1 BOOT BATTERY CABLE 15 0C2454 6 SCREW THF M6 1 X 16 N WA Z JS ...

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Page 37: ...ELD R H SIDE 39 050873A REF PLUG PIPE 1 4 CSK W VIBRA SL 40 031919 REF PLUG STD PIPE 3 8 COUNTERSUNK 41 022145 15 WASHER FLAT 5 16 M8 ZINC 42 030231 6 SCREW HHC 5 16 18 X 1 1 2 G5 3600 RPM 030795 6 SCREW HHC 5 16 18 X 1 G5 1800 RPM 43 048031J REF HOSE CLAMP BAND 5 8 44 069860E 1 HOSE DRAIN ASSY 28 45 0E7954 1 CABLE IGN COIL 3 9L CHRYSLER 46 057824 1 CLAMP HOSE 16 87 1 50 3600 RPM 47 023645 5 SCREW...

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Page 39: ...OOLANT RECOVERY 23 048031C 1 CLAMP HOSE BAND 1 4 24 0F4051D 3 INSULATION INNER DUCT 25 0F4073C 1 INSUL DUCT SIDE OR INNER DUCT 26 0F3890 3 RETAINER INSULATION 450 27 0F3890C 2 RETAINER INSULATION 220 28 0F3072 10 INSULATION RETAINMENT HANGER 29 078115 10 WASHER SELF LOCKING DOME 30 089961 1 FOAM STRIP 3 4 WIDE X 3 16 THK 46 LG 31 052250 2 TAPE FOAM 1 X 1 22 5 LG 32 0F4767 1 TUBE FAN CLUTCH PREHTR ...

Page 40: ......

Page 41: ...2 WASHER FLAT 1 4 M6 ZINC 10 080762 1 BOLT U 3 8 16 X 2 62 11 0D9832 4 SCREW HHC M12 1 75 X 75 SS 12 087171 8 WASHER FLAT 1 2 SS 13 083215 4 WASHER LOCK 1 2 SS 14 051548 4 NUT HEX M12 1 75 G8 SS 15 0F3794 1 EXHAUST BLANKET 549MM LONG R H 16 0F3794A 1 EXHAUST BLANKET 448MM LONG L H 17 0E8816 1 EXHAUST FLANGE 2 PIPE 19 036797 4 BOLT U 5 16 18 X 2 25 20 024114 8 NUT HEX 5 16 24 STEEL 21 022129 8 WASH...

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Page 43: ... AIR FILTER 3 0E6406 1 HOLDER VENTURI 4 0E7702 1 HOLD DOWN AIR CLEANER 5 0F6323 1 PLATE AIR CLEANER TOP 3 9L 6 037561 1 NUT WING 1 4 20 NYLK 7 049815 4 SCREW HHC M5 0 8 X 16 G8 8 8 049226 4 WASHER LOCK M5 9 051713 4 WASHER FLAT M5 10 0E6586 1 GASKET BOSCH 32 40 ...

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Page 47: ...6382B 1 REF VENTURI HOLDER W 40MM ACTUATOR 23 0E7121 1 REF O RING 47 625 ID X 2 38 WIDTH 24 0E6376B 1 REF VENTURI 28 ID THROTTLE W CHOKE 25 042561 2 CLAMP HOSE 36 1 88 2 75 26 0E9295 1 ASSY THROTTLE 28MM 27 061012 1 PLUG STD PIPE 1 8 SOCKET HEAD 28 022097 4 WASHER LOCK M6 1 4 29 044118 1 BARBED STR 1 2 NPT X 5 8 30 046580 4 SCREW SHC M6 1 0 X 45 G12 9 31 026915 2 NIPPLE CLOSE 3 4 X 1 375 33 0F6155...

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Page 49: ...TER 28 0F3760E 2 INSULATION SPLITTER 29 0F4051C 2 INSULATION DUCT 30 0F3890B 8 RETAINER INSULATION 820 31 0F4051B 2 INSULATION DUCT SIDES 32 0F3890 4 RETAINER INSULATION 450 33 0F3890A 3 RETAINER INSULATION 740 34 0F3760L 1 INSULATION LOWER SPLITTER 35 042568 2 SCREW HHC M6 1 0 X 20 G8 8 36 0912970094 2 ASSY WIRE 14 AWG 34 8 GRN YEL 37 022447 2 WASHER SHAKEPROOF INT 1 4 38 049813 2 NUT HEX M6 X 1 ...

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Page 60: ...taminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze 4 Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted or Rental Unit definition and warranty 5 Units used for prime p...

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