Generac Power Systems QT06030GNSNR Owner'S Manual Download

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STANDBY GENERATOR

OWNER'S MANUAL

This manual should remain with the unit.

A new standard of reliability

Serial Number

3.0L

60kW

Models

Cover122 Re

v. A 01/08

Par

t No

. 0G7933

Summary of Contents for QT06030GNSNR

Page 1: ...STANDBY GENERATOR OWNER S MANUAL This manual should remain with the unit A new standard of reliability Serial Number QT 3 0L 60kW Models Cover122 Rev A 01 08 Part No 0G7933 ...

Page 2: ...ection for QT Genset Start up 8 1 Start up Checklist 8 2 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 Dealer 10 1 Every Three Months 10 1 Once Every Six...

Page 3: ...ential fire hazard 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 un...

Page 4: ...ith 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 mon oxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequ...

Page 5: ...result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Stationary Emergency Generators installed with an automatic transfer switch will crank and start automatically when normal utility source volt age is removed or is below an acceptable preset level To prevent such automatic start up and pos sible injury to personnel...

Page 6: ...roduction date etc NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Stationary Emergency Generator Model and Serial Number This number is the key to numerous engineering and manufactur ing details pertaining to your unit Always supply this number when requesting service...

Page 7: ...r start the engine before it has been properly serviced with the recom mended oil may result in an engine failure NOTE For temperatures below 32 F it is strongly recommended 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 gl...

Page 8: ...h 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 turn ON Turn OFF the AUTO OFF MANUAL switch then turn switch back to AUTO to reset the generator control board NOTE If the fault is not corrected the overcrank feature will continue to activate Approxima...

Page 9: ...may not supply such a regulator It is the responsibility of the gas supplier to make 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...

Page 10: ...s Speed Selectable Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Cartridge Crankcase Oil Capacity 6 5 U S qts COOLING SYSTEM Type Closed Water Pump Belt Driven Fan Speed 2180 rpm Fan Diameter 22 inches Fan Mode Puller Air Flow inlet air including alternator and combustion air 4380 ft3 min Coolant Capacity 2 5 U S gal Heat Rejection to Coolant 270 000 Btu h Maximum Operating ...

Page 11: ...c Oil engine COOLANT HEATER KIT The optional Coolant Heater Kit part number 0G2675 is available to be used in cunjuntion with the Optional Cold Weather Kit This kit includes 1000 watt 120 volt Engine Block Heater Heater Mounting Bracket All fittings hoses and hardware to mount and plumb heater Figure 1 Interconnections 6 2 Standby Generator Sets Specifications GenSpec036 Rev 0 03 07 ...

Page 12: ...etween each circuit 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 3 PHASE ALTERNATORS Y CONFIGURATION The Stationary Emergency Generator is designed to supply 3 phase electrical loads Electric power is produced in the alternator power windings These windings were connected at the factory t...

Page 13: ...s produced in the alternator power windings These windings were connected at the factory to the main circuit breaker with a Delta configuration as shown in Figures 7 5 The rated voltage between circuit breaker terminals E1 E2 E1 E3 and E2 E3 is 208V The rated voltage between E1 or E3 and the neutral point 00 is 120V Figure 7 5 Stator Power Winding Connections 3 phase 120 240V 12 Lead E2 E1 E 7 2 S...

Page 14: ...r 30 hours of operation Check the 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...

Page 15: ...nto the control panel Move the AUTO OFF MANUAL switch to the MAN UAL position 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 gen...

Page 16: ...ine circuit break er Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the generator s main line circuit breaker 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...

Page 17: ...rvice air cleaner 2 Check starter 3 Check engine DC alternator COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper 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 ...

Page 18: ...even days and let it run at least 20 minutes For more detailed exercise information see the respective sec tions in the Control Panel Technical Manual that is supplied with the unit INSPECT COOLING SYSTEM Inspect engine cooling system at least once each month Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness CHECK ENGINE COOLANT LEVEL Se...

Page 19: ...heck for oil leaks 8 Shut off engine Wait 10 minutes for oil to settle down into the oil pan Recheck oil level on dip stick Figure 10 2 Oil Filter Oil Filter CHANGING THE ENGINE AIR FILTER To replace the engine air filter remove the air cleaner cover and replace the air filter making sure it is posi tioned properly before reattaching the cover Figure 10 3 See the Service Schedule section for air c...

Page 20: ...ery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury BATTERY MAINTENANCE 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 cl...

Page 21: ...d views parts lists and electrical data pertaining to this generator set The parts lists consist of a an item number b a part number c the quantity required and d a description of the part The item number corresponds to an identical number on the exploded view drawing Standby Generator Sets Maintenance 10 5 Maint015 Rev 0 03 07 ...

Page 22: ... for normal opera tion 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 ...

Page 23: ...heck 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 Adjust a...

Page 24: ...clearance lash 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 least 1 hour looking for leaks loose connections or com...

Page 25: ...or 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 as n...

Page 26: ... 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 Cool...

Page 27: ...Stationary Emergency Generator Notes ...

Page 28: ...Stationary Emergency Generator Notes ...

Page 29: ...Stationary Emergency Generator Notes ...

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Page 31: ...CB SHORT STND C 0D5552 1 CB 0050A 3P 480V S ED4 LL 0D5553 CB 0060A 3P 480V S ED4 LL 0D5554 CB 0070A 3P 480V S ED4 LL 0D5556 CB 0090A 3P 480V S ED4 LL 0D9693 CB 0125A 3P 480V S ED4 LL D 0F0492 1 INSULATOR CB S ED 3P E 048927 4 SCREW RHM 10 32 X 4 1 2 F 023897 4 WASHER FLAT 10 ZINC G 022152 4 WASHER LOCK 10 H 022158 4 NUT HEX 10 32 STEEL J 0C2454 9 SCREW THF M6 1 X 16 N WA Z JS K 029289 1 TAPE ELEC ...

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Page 33: ...DAPTOR 1 W W CB 2 TERMINAL COVER CB X 0G3259 1 DECAL TERMINAL SHOCK HZD BI 7 UL CIRCUIT BREAKER 400AF A 0F4187 1 COVER CB C2 C4 400AF C 0F4166 REF CIRCUIT BREAKERS 400A FRAME D 0F1733 1 DECAL CUSTOMER CONNECT INSIDE E 042419 4 SCREW RHM 10 32 X 4 F 023897 4 WASHER FLAT 10 ZINC G 022152 4 WASHER LOCK 10 H 022158 4 NUT HEX 10 32 STEEL J 0C2454 9 SCREW THF M6 1 X 16 N WA Z JS K 029289 1 TAPE ELEC 1 2...

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Page 35: ...4 1 KEY WOODRUFF E 12 077043F 1 CONDUIT FLEX 1 1 4 30 LG 13 04576100AQ 3 STUD M14 2 0 X 615 G5 ZINC 70KW 14 052646 4 WASHER FLAT M14 15 043123 6 WASHER LOCK M14 16 051779 4 NUT HEX M14 2 0 G8 YEL CHR 17 0A2601 1 SCREW HHC M16 2 0 X 45 G8 8 18 072879 1 SPACER 69 X 2 75 X 37 ST ZNC 19 0F3398 4 SCREW SHC M10 1 5 X 16 G10 9 20 046526 4 WASHER LOCK M10 21 0C3993 4 SCREW HHTT M4 0 7 X 25 BP 22 022264 4 ...

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Page 37: ...R 3 18X12 7X382 27 0F6305A 1 SEAL COVER 3 18X12 7X283 28 0F5886 3 SCREW HHPM M5 0 8 X 12 29 051713 12 WASHER FLAT M5 30 049226 12 WASHER LOCK M5 31 0F5752F 1 RES WW 15R 5 25W QK CONN 32 0F5884 2 SCREW PHTT M3 5 0 6 X 10 33 0F5896 2 SCREW PHTT M3 5 0 6 X 16 34 0C2265 4 SCREW PHTT M4 0 7 X 12 ZYC 35 0C3990 2 SCREW PHTT M4 0 7 X 10 ZYC 36 091526 4 SCREW PPHM M5 0 8 X 12 ZNC 37 051716 9 NUT HEX M5 0 8...

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Page 39: ...NT 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 025507 1 WASHER SHAKEPROOF EXT 7 16 STL 17 0F9174 1 SUPPORT ENGINE LH 18 045771 1 NUT HEX M8 1 25 G8 CLEAR ZINC 19 049814 5 SCREW HHC M10 1 5 X 25 G8 8 20 022302 5 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 ...

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Page 41: ... BATTERY POST COVER BLACK 9 038804Y 1 CABLE BATTERY RED 1 X 35 00 10 038805T 1 CABLE BATTERY BLACK 1 X 40 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 0F3976 1 BOOT CONTACTOR CABLES 15 0C2454 6 SCREW THF M6 1 X 16 N WA Z JS 16 0F3409 1 SUPPORT BATTERY TRAY 17 042568 2 SCREW HHC M6 1 0 X 20 G8 8 18 022097 2 WASHER LOCK M6 1 ...

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Page 43: ...OP PLATE VENTURI 4 0F4270 1 HOLD DOWN AIR CLEANER 5 049811 4 WASHER FLAT M6 6 022097 4 WASHER LOCK M6 1 4 7 047411 4 SCREW HHC M6 1 0 X 16 G8 8 8 0F5418 1 ELEMENT AIR FILTER 9 0F6323 1 PLATE AIR CLEANER TOP 10 037561 1 NUT WING 1 4 20 NYLK 11 038057 1 GROMMET 7 8 X 1 16 X 3 4 ...

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Page 45: ...4 26 076749 1 TANK COOLANT RECOVERY 1 27 048031C 2 REF CLAMP HOSE BAND 1 4 28 031971 1 BEARING 6205 2NSE C3 E SRI2 S 29 0F4032 1 PULLEY 5 5 DIA MACHINED 30 042911 1 SCREW HHC M10 1 5 X 30 G8 8 31 0F2872 1 SCREW HHC 1 2 13 X 2 G8 32 022304 2 WASHER FLAT 1 2 ZINC 33 022195 1 WASHER LOCK 1 2 34 022196 1 NUT HEX 1 2 13 STEEL 35 0F8651 9 SCREW HHFC M8 1 25 X 20 W M6 36 070015 1 NUT HEX LOCK 5 16 18 NY ...

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Page 47: ... 59 0D3488E 1 BELT SERPENTINE 71 04 60 0G3643 1 REF WATER PUMP 3 0L 61 0G3791A 1 HOSE WATER PUMP 3 0L 62 099502 2 CLAMP HOSE 24 B1 06 2 00 63 0G7856A 1 REWORK BREATHER TUBE 3 0L G3 LS 64 052265 3 SCREW HHC M8 1 25 X 65 G8 8 65 0D8028 2 PULLEY GROOVED ENGINE IDLER 66 0G3842 1 SPACER IDLER PULLEY 3 0L 67 042568 1 SCREW HHC M6 1 0 X 20 G8 8 68 0G3644 1 REF SENSOR CRANKSHAFT SPEED 3 0L 69 0G38040ST03 ...

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Page 49: ... 59 0D3488E 1 BELT SERPENTINE 71 04 60 0G3643 1 REF WATER PUMP 3 0L 61 0G3791A 1 HOSE WATER PUMP 3 0L 62 099502 2 CLAMP HOSE 24 B1 06 2 00 63 0G7856A 1 REWORK BREATHER TUBE 3 0L G3 LS 64 052265 3 SCREW HHC M8 1 25 X 65 G8 8 65 0D8028 2 PULLEY GROOVED ENGINE IDLER 66 0G3842 1 SPACER IDLER PULLEY 3 0L 67 042568 1 SCREW HHC M6 1 0 X 20 G8 8 68 0G3644 1 REF SENSOR CRANKSHAFT SPEED 3 0L 69 0G38040ST03 ...

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Page 51: ... DECAL INLET PRESSURE 17 050280 1 DECAL FUEL INLET LPG 18 0F9398A 1 INTAKE ADAPTER BOSCH 19 0E6586 1 GASKET BOSCH 32 40 20 0E4394 1 ACTUATOR BOSCH 40 GOVERNOR 21 0F3857 1 REDUCER RUBBER 3 0 2 00 22 0F3885 1 MIXER 40 60MM ACTUATOR ASSY 23 0G3167 2 O RING 2 3 4 X 3 32 X 2 15 16 24 0F3691 1 VENTURI THROTTLE 32MM 25 097962 2 SCREW SHC M6 1 0 X 25 G12 9 ZP 26 022097 6 WASHER LOCK M6 1 4 27 051751 4 SCR...

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Page 53: ...1 INTAKE ADAPTER BOSCH 19 0E6586 1 GASKET BOSCH 32 40 20 0E4394 1 ACTUATOR BOSCH 40 GOVERNOR 21 0F3857 1 REDUCER RUBBER 3 0 2 00 22 0F3885 1 MIXER 40 60MM ACTUATOR ASSY 23 0G3167 2 O RING 2 3 4 X 3 32 X 2 15 16 24 0F3691 1 VENTURI THROTTLE 32MM 25 097962 2 SCREW SHC M6 1 0 X 25 G12 9 ZP 26 022097 6 WASHER LOCK M6 1 4 27 051751 4 SCREW HHC M6 1 0 X 50 G8 8 28 042561 1 CLAMP HOSE 36 1 88 2 75 29 057...

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Page 55: ...ION SPLITTER 33 0F3760E 3 INSULATION LOWER SPLITTER 34 0F5048D 4 VISE ACTION LATCH SLOTTED CIR 35 0E5968 1 GASKET EXTRUDED TRIM 374 64 LG 36 0F3760J 1 INSULATION DISCHARGE FRONT 37 0F3890A 9 RETAINER INSULATION 740 38 0F3890 6 RETAINER INSULATION 450 39 0F3760H 1 INSULATION DISCHARGE TOP 40 0F3760F 1 INSULATION ROOF TOP 41 0F5049 4 TAB PULL 42 0F3760L 1 INSULATION LOWER SPLITTER 43 0F3760C 2 INSUL...

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Page 57: ...1 15 0F4505 REF GLASS PACK 23 5 LG 2 5 IN OUT 16 022097 4 WASHER LOCK M6 1 4 1 17 0C2454 REF SCREW THF M6 1 X 16 N WA Z JS 1 18 0F4367 REF HEAT SHIELD EXHAUST STACK 1 19 0F4368 REF CAP HEAT SHIELD EXHAUST STACK 20 036797 4 BOLT U 5 16 18 X 2 25 21 024114 8 NUT HEX 5 16 24 STEEL 22 022129 8 WASHER LOCK M8 5 16 23 088775 4 WASHER FLAT 3 8 SS 24 0F2808A 1 EXHAUST OUTLET PIPE CPL 1 25 080762 REF BOLT ...

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Page 71: ... B 0C2454 3 SCREW THF M6 1 X 16 N WA Z JS 3 C4 UNITS A 0F9832A 1 SHIELD CONTROL STAND C4 B 0C2454 3 SCREW THF M6 1 X 16 N WA Z JS 4 C5 UNITS A 0F9832C 1 SHIELD CONTROL STAND C5 0F9832D 1 SHIELD CONTROL STAND C5 0F9832EGS0R 1 SHIELD CONTROL STAND C5 0F9832HGS0R 1 SHIELD CONTROL STAND C5 0F9832JGS0R 1 SHIELD CONTROL STAND C5 B 0F9832FGS0R 1 SHIELD CONTROL STAND C5 C 0C2464 3 SCREW THF M6 1 X 16 N WA...

Page 72: ... start up 3 Any failure caused by contaminated 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 ...

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