Generac Power Systems QuietSource 005262-0 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

2.4L

45kW

Model: 005262-0

—



CAUTION



—

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!

Cover044 Re

v. 0 02/06

Par

t No

. 0G0202

Summary of Contents for QuietSource 005262-0

Page 1: ...UAL This manual should remain with the unit A new standard of reliability Serial Number QT 2 4L 45kW Model 005262 0 CAUTION ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION Cover044 Rev 0 02 06 Part No 0G0202 ...

Page 2: ... Start up Checklist 8 2 Preparation for Start up 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 Facilities 10 1 Every Three Months 10 1 Once Every Six...

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: ...lectronic 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 2150 rpm Fan Diameter 22 inches Fan Mode Puller Air Flow inlet air including alternator and combustion air 2725 ft3 min Coolant...

Page 11: ... 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 NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made DANGER Serious injury or damage may occur if not con figured properly Pleas...

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: ...ion 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 A...

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: ...nd 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 See the installation diagram The exhaust system parts from this product get extremely hot and remains hot after shutdown High grass weeds brush leaves etc mu...

Page 17: ...ses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM I...

Page 18: ... for oil leaks CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 10 3 See the Service Schedule for air cleaner mainte nance Figure 10 3 Engine Air Cleaner Air Cleaner Doors Removed for Clarity SPARK PLUGS Reset the spark plug gap or replace the spark plu...

Page 19: ...explosion which can shatter the battery causing blindness or other serious injury BATTERY MAINTENANCE The battery should be inspected per Section 4 7 Scheduled Maintenance 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 f...

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 ...

Page 26: ...Standby Generator Sets Notes ...

Page 27: ...Standby Generator Sets Notes ...

Page 28: ......

Page 29: ...92 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 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 2 UL CIRCUIT BREAKER FD A 0F3138 1 COVER CB CONN BOX B 065469 1 DECAL DANGER HIGH VOLTAGE C 0D5572 1 CB 0150A 3P 600V S FD6 LL 0D5...

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Page 31: ...MCM 6 AL CU S 049897 9 SCREW SHC M8 1 25 X 20 G8 T 022145 6 WASHER FLAT 5 16 M8 ZINC U 045771 3 NUT HEX M8 1 25 G8 CLEAR ZINC V 0F8843 3 BUS BAR 200A LUG ADAPTOR W W CB 2 TERMINAL COVER CB 7 UL CIRCUIT BREAKER 400AF A 0F4187 1 COVER CB C2 C4 400AF B 065469 1 DECAL DANGER HIGH VOLTAGE C 0F4166 REF CIRCUIT BREAKERS 400A FRAME D 0F1733 1 DECAL CUSTOMER CONNECT INSIDE E 042419 4 SCREW RHM 10 32 X 4 F ...

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Page 33: ...ER 390 DRCT 8 0F7874 1 ASSY BRUSH HOLDER 390 HSB 9 0F6124 1 GUARD REAR BEARING CARRIER CPL 10 038150 4 WASHER FLAT 8 ZINC 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 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 HHC M16 2 0 X 45 G8 8 18 0A2602 1 WASHER FLAT 688 ID X 3 25...

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Page 35: ... 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 2 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...

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Page 37: ...6 0F6305 3 SEAL COVER 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 37 051...

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Page 39: ...T 1 4 13 022097 1 WASHER LOCK M6 1 4 14 022473 2 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 0F9597A 1 SUPPORT LH ENGINE 2 4L 18 045764 1 SCREW HHTT M4 0 7 X 8 BP 19 052212 4 SCREW HHC M10 1 25 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 0F9597 1 SUPPORT RH ENGINE 2 4L...

Page 40: ......

Page 41: ...NC 7 050331A REF BATT POST COVER RED 8 050331 REF BATT POST COVER BLACK 9 038805Y 1 CABLE BATT BLACK 1 X 18 00 10 038804Z 1 CABLE BATT RED 1 X 18 00 11 045771 REF NUT HEX M8 1 25 G8 YEL CHR 12 022129 REF WASHER LOCK M8 5 16 13 027482 REF WASHER SHAKEPROOF EXT 5 16 STL 14 0F3976 1 BOOT CONTACTOR CABLES 15 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 16 022145 REF WASHER FLAT 5 16 M8 ZINC 17 077483 REF BA...

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Page 43: ... EL 90 3 8 NPT X 3 8 33 057765 1 ADAPTER M14 1 50 X 3 8 NPT 34 061650 2 SCREW HHC M10 1 25 X 65 G8 8 35 022129 3 WASHER LOCK M8 5 16 36 022145 3 REF WASHER FLAT 5 16 M8 ZINC 37 057772 1 WASHER NYLON 565 38 052212 2 SCREW HHC M10 1 25 X 25 G8 8 39 0G0114 6 SCREW HHC M12 1 25 X 15 G10 9 40 046526 3 WASHER LOCK M10 41 0F3217 1 REF SPACER DC ALTERNATOR PULLEY 42 051736 1 REF SCREW HHC M10 1 5 X 80 G8 ...

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Page 45: ...HINED 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 045772 1 NUT HEX M10 1 5 G8 YEL CHR 37 0F9867 1 SHAFT FAN DRIVE 38 0F2461 1 RETAINER BEARING 39 022145 1 WASHER FLAT 5 16 M8 ZINC 40 022129 10 WASHER LOCK M8 5 16 41 039414 1 SCREW...

Page 46: ......

Page 47: ...ETOR W PVC CONN 3 0C8127 1 ELEMENT AIR CLEANER 4 052619 4 SCREW HHC M5 0 8 X 20 G8 8 5 022127 1 NUT HEX 1 4 20 STEEL 6 062974 1 STUD TH 1 4 20 X 4 1 2 G2 ZNC 7 0G0190 1 PLATE AIR CLEANER TOP 2 4L 8 037561 1 NUT WING 1 4 20 NYLK 9 022097 1 WASHER LOCK M6 1 4 ...

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Page 49: ... 1 69 35KW 22 0E6382B 1 VENTURI HOLDER W 32MM ACTUATOR 23 0F7790E 1 VENTURI THROTTLE 26MM 24 0E7121 1 O RING 47 625 ID X 2 38 WIDTH 25 040976 4 REF SCREW SHC M8 1 25 X 20 G12 9 26 022097 4 WASHER LOCK M6 1 4 27 051751 4 SCREW HHC M6 1 0 X 50 G8 8 28 035685 2 CLAMP HOSE 28 1 32 2 25 29 0F6155 1 HARNESS CPL FUEL JUMPER 30 047290 1 HOSE 3 8 ID SINGLE BRAID 10 0 LG 31 030340 1 HOSE 1 4 ID SAE 30R7 22 ...

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Page 51: ... 1 GASKET EXTRUDED TRIM 440 64 LG 27 0F3760K 2 INSULATION SPLITTER 28 0F3760E 2 INSULATION SPLITTER 29 0F4051C 1 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...

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Page 53: ...6 1 X 16 N WA Z JS 9 0F9736 1 PIPE EXHAUST 2 4L HYUNDAI 10 0G0007 1 DIFFUSER EXHAUST WELDMENT 11 044149 1 GASKET EXHAUST RING 12 085917 2 WASHER LOCK 3 8 SS 13 0D2611 2 SCREW HHC 3 8 16 X 1 3 4 SS 14 0E8816 1 EXHAUST FLANGE 2 PIPE 15 047411 2 SCREW HHC M6 1 0 X 16 G8 8 16 022097 2 WASHER LOCK M6 1 4 17 022473 2 WASHER FLAT 1 4 M6 ZINC 18 036797 1 BOLT U 5 16 18 X 2 25 19 024114 2 NUT HEX 5 16 24 S...

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Page 56: ...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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