.6L 25kW Models: 005324-1 005325-1 Serial Number STANDBY GENERATOR OWNER'S MANUAL A new standard of reliability Not intended for use in critical life support applications. —CAUTION— ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! This manual should remain with the unit. Cover053A Rev. 0 08/06 Part No.
Standby Generator Sets Table of Contents INTRODUCTION .....................................................1-3 Read this Manual Thoroughly ...................................1-3 Operation and Maintenance ......................................1-3 How to Obtain Service ..............................................1-3 IDENTIFICATION RECORD .....................................2-1 Data Label ................................................................2-1 EQUIPMENT DESCRIPTION .............................
Standby Generator Sets Important Safety Instructions WARNING: GENERAL HAZARDS • For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by an Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations.
Standby Generator Sets Important Safety Instructions • 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 personnel, disable the generator’s automatic start circuit (battery cables, etc.) before working on or around the unit. Then, place a “Do Not Operate” tag on the generator control panel and on the transfer switch.
Standby Generator Sets Important Safety Instructions INTRODUCTION This symbol points out potential fire hazard. symbol points out potential electrical shock This hazard. 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.
Standby Generator Sets General Information IDENTIFICATION RECORD 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. DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator.
Standby Generator Sets Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current 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.
Standby Generator Sets Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN 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 temperature, oil pressure or rpm.
Standby Generator Sets Fuel Systems FUEL SYSTEM PROPANE VAPOR WITHDRAWAL FUEL SYSTEM FUEL REQUIREMENTS This type of system utilizes the vapors formed above the liquid fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state. The vapor withdrawal system is generally best suited for smaller engines that require less fuel.
Standby Generator Sets Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ...................................................................... Gear Oil Filter .............................................................Full Flow, Cartridge Crankcase Oil Capacity ....................................................4 U.S. qts. GENERATOR Type ............................................................................. Synchronous Rotor Insulation .................................
Standby Generator Sets Specifications Figure 1 — Interconnections Utility In Transfer Switch CONTROL PANEL NEUTRAL TO ALTERNATOR Gen N1 N2 23 194 GENERATOR CONNECTION BOX NEUTRAL N1 N2 23 194 4- # 14 GA WIRES TO GENERATOR CONNECTION BOX CIRCUIT BREAKER 183 178 Battery Charger Input Load Out 186 178 TO GENERATOR CONNECTION BOX GROUND 120 Volt + Neutral Grd To Generator Control Panel FRAME RAIL Ground Level Concrete Slab KW 25 25 STUB-UP AREA See Install Dwg for Dimensions COLD WEATHE
Standby Generator Sets General Information GENERATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING CONNECTIONS See “Voltage 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 connection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. If there are any questions regarding lead connection, refer to the wiring diagrams at the back of this manual.
Standby Generator Sets Installation PRIOR TO INITIAL START-UP INSTALLATION Refer to the separate “Installation Guide QT Product Line” supplied with the unit. to initially starting the generator, it must Prior be properly prepared for use. Any attempt to PREPARATION BEFORE START-UP The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor.
Standby Generator Sets Installation • Insert the fuse into the control panel. • Move the AUTO/OFF/MANUAL switch to the MANUAL 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 generator set off.
Standby Generator Sets Operation GENERATOR CONTROL AND OPERATION not crank the engine continuously for longer Do than 30 seconds, or the heat may Refer to the appropriate control panel operator’s manual for this unit. • • OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the generator was installed in conjunction with a transfer switch capable of manual operation only, the following procedure applies.
Standby Generator Sets Maintenance MAINTENANCE PERFORMED BY SERVICE FACILITIES COOLING SYSTEM Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow. working on the generator, ensure the fol Before lowing: Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See the installation diagram.
Standby Generator Sets Maintenance EXERCISE SYSTEM Figure 10.1 - Oil Dipstick and Oil Fill Cap Start the generator engine at least once every seven days and let it run at least 20 minutes. For more detailed exercise information, see the respective sections in the Control Panel Technical Manual that is supplied with the unit. OIL FILL CAP INSPECT COOLING SYSTEM • Inspect engine cooling system. See “Maintenance Schedule”. • Check hoses for damage, deterioration, leaks, etc.
Standby Generator Sets Maintenance CHANGING ENGINE OIL Figure 10.3 – Engine Air Cleaner Refer to maintenance performed by service facilities for engine oil and filter change frequencies. Air Cleaner Drain the oil while the engine is still warm from running. 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. Drain oil completely into suitable container. 3.
Standby Generator Sets Maintenance MISCELLANEOUS MAINTENANCE 3. Have the state of charge and condition checked. This should be done with an automotive-type battery hydrometer. CLEANING THE GENERATOR DANGER Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance. Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt.
Standby Generator Sets Service Schedule SERVICE SCHEDULE 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 application.
Standby Generator Sets Service Schedule Maintenance Tasks Level 1 Recommended to be done monthly 10 Hrs. Level 2 Task Comp. (DateInitials) Required to be done 3 months/ Break-in 30 Hrs. 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 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 on gas engine driven units.
Standby Generator Sets Service Schedule Maintenance Tasks Level 1 RecomTask mended Comp. to be done (Datemonthly In itials) 10 Hrs. Level 2 Required to be done 3 months/ Break-in 30 Hrs. Level 3 Task Comp. (DateInitials) Required to be done Semiannually 50 Hrs. Level 4 Task Comp. (DateInitials) Required to be done Annually 100 Hrs. Task Comp. (DateInitials) 13.
Standby Generator Sets Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 5 amp fuse blown. 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor.* 4. Replace starter motor.* 5. Remove, change or replace battery. 6. Replace fuse.* Engine cranks but won't start 1.
Standby Generator Sets Notes
Standby Generator Sets Notes
Standby Generator Sets Notes
Standby Generator Sets Notes
1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 0F7135 0F7022 0F7021 0F7260 0F7136 0F6156 0F4464 0D4698 0F3824 057701 0F6146 081008 0C2267 049226 051713 0C2212 022264 0F6366A 0F6366B 022241 022237 057329 057073 023484J 0E3257 0E7890 0E6002 0A2077 040532 052619 023897 049226 051716 025433 0A1354A 0E3257 022473 022097 067210A 0F7194 057593 0F1733 023762 0G3560 1 1 1 1 1 1 1 REF 1 REF 1 1 2 2 2 11 11 1 1 1 1 1 1 1 15 REF REF REF REF REF REF REF R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 (1) 23 24 25 26 27 28 0G2927 0G2827 098675 098936 0G0820 0G1019 020746 049226 051713 022129 0F8218 0F8220 0G1317 0G1316 0G2926 0G3682 0G2826 0G3683 0A5382 075591 051787 0A5601A 075554B 0A9375 022152 0G0430 042558 0G0965B 053607 051769 023365 0F3353 072578 0G3787 0A8830 077043E 0G2070 ROT0RS BELOW MUST BE VERIFIED BY SERIAL NO. AND B.O.M. 1 RTR-102-20.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 43 44 45 46 47 48 0F1823A 0F3078 0F2606 036261 0E7358 052777 0G1303D 0F1262 0F1263 0F1264 0F1725C 067680 0E6875A 055911 0F5459 0F5462 0A5062J 029673 049350 0F1958 082573 0E4494 0F3215 0F6305 0F6305A 0F5886 051713 049226 0F5752F 0F5884 0F5896 0C2265 0C3990 091526 051716 043182 051714 0F3192 0E7403C 0F9785 0F2627 COMPONENTS INCLUDED IN 0G3365E 1 ENCL HSB CONTROL PANEL 1 COVER CONTROL PANEL 1 HINGE CONTINUOUS H-PA
1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 * 37 38 39 40 41 42 43 0F7211 0G0760 0F7210 0E9837B 0F0230B 046526 0G0910 099502 0G0908 046627 052250 022473 022097 0C8566 049813 0C2454A 042568 0G0932 0G0933 0F7320 0F1433 076749 048031C 029032 050275 050276 029107 0G0568 0G0405 049541 051756 029333A 042907 026850 0A2628 0E2507 055934K 0E3257 0A5768 022131 1 1 1 1 1 5 1 4 1 1 2 10 12 8 4 28 4 1 1 1 1 1 2 1 3 1 1 1 1 1 4 1 4 4 1 1 2 2 4 1 SUPPORT RADIATOR LH SIDE V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0F3408B 0F3411 025507 059980 046526 077483 050331A 050331 038805J 038804N 045771 022131 027482 0F3976 0C2454 022145 1 1 1 1 1 REF 1 1 1 1 REF 1 1 1 4 REF BATTERY TRAY C1 CPL STRAP BATTERY RETAINMENT WASHER SHAKEPROOF EXT 7/16 STL SCREW HHC M10-1.5 X 25 G10.9 WASHER LOCK M10 BATTERY 12VDC 75-AH 26 BATTERY POST COVER RED + BATTERY POST COVER BLK CABLE BATTERY BLACK #1 X 30.00 CABLE BATTERY RED #1 X15.00 NUT HEX M8-1.
1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 0G0759 027482 070936 070936C 039253 022145 022129 045771 071956 051730 021991 026850 049813 055414 047411 022097 022473 1 2 2 2 8 12 12 4 4 4 1 1 1 1 1 1 5 MOUNTING BASE 1.6L WASHER SHAKEPROOF EXT 5/16 STL DAMPENER VIBRATION VIB. ISO. 70-75 DURO SCREW HHC M8-1.25 X 20 G8.8 WASHER FLAT 5/16 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 YEL CHR WASHER FLAT M8 SCREW HHC M8-1.25 X 60 G8.8 EARTH STRAP WASHER SHAKEPROOF EXT 1/4 STL NUT HEX M6 X 1.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 098290 098941A 098958A 098942A 098225 043146 022097 084543A 098783 037398 0E1326 0A7106 0G1381 029333A 022507 0E1694 064526 1 1 REF 1 2 3 5 1 1 2 1 1 1 10 2 1 1 ASM MOTOR STEPPER HOUSING GOVERNOR CONNECTOR CONNECTOR INTERFACE ASSEMBLY COVER CONNECTOR HOUSING SCREW FHM #2 X 5/8 SELF TAP SCREW HHC M6-1.0 X 10 G8.8 WASHER LOCK M6-1/4 SCREW PHM M3-0.5 X 12MM LEVER STEPPER MOTOR NUT LOCK HEX #10-32 NYL INS ASSY.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 0G0207 0G0834 0G0820 0E9747 0G0839 0G0781 0G0722 0G0758 0G0431 0G0663 0G0786 0G0486 0F9617A 0A1354B 0G0823 0G1467 0D2244M 036710 0C5479 059980 046526 022131 0G3922 0G0464 0G0465 052858 061652 0G3920 0A7387 039414 022129 022145 029333A 057821 045771 022507 022097 022473 057823 077996 0A6751 035579 0A8584 0C1852 070928 069860C 0698
1 2 3 4 5 6 7 (1) 8 9 10 11 12 13 14 15 026812 075580 0G1397 039253 022145 022129 045771 0F1570 0A6344 0C5210 025424 0C5210 0A5547 0G3178 0D1509 2 1 1 2 2 4 2 1 1 1 1 1 1 1 1 ELBOW 90D 3/4 NPT FLANGE FUEL INLET FUEL REGULATOR 1.6L REWORK SCREW HHC M8-1.25 X 20 G8.8 WASHER FLAT 5/16 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.
1 2 3 4 5 6 7 8 9 10 11 12 ** 13 14 15 16 17 18 19 20 21 22 23 24 25 0F7003 (XX) 0F7004 (XX) 0F7008 (XX) 0F7005 (XX) 0F7007 (XX) 0F7006 (XX) 0C2634A 0912970091 0912970090 0E5968 0E3257 077992 0F5049 0F5048D 022473 022097 022127 0C2454 078115 0F3890B 0F3890 0F7365 0F7365B 0F7365A 0F8869D 1 1 1 1 2 1 1 1 2 1 6 18 3 3 1 1 1 24 20 2 4 2 1 1 1 ROOF C1 CPL CORNER POST LH SIDE C1 CPL DOOR REAR C1 CPL CORNER POST RH SIDE C1 CPL DOOR LH & RH SIDE C1 CPL DUCT FRONT DISCHARGE C1 CPL ASSEMBLY COVER ACCESS ASSY WIRE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0F7366 0F7647 0F8095 0F7538 0E3257 0F7644 0C6119 036434 036449 022129 022259 038750 0G1043 0F3794 022097 049813 022473 1 1 1 1 4 2 1 3 3 6 6 1 1 1 1 1 6 MUFFLER C1 MUFFLER SADDLE PIPE EXHAUST OUTLET PIPE EXH INLET MUFLR SIDE 1.5L SCREW HWHTF M6-1.0 X 16 MUFFLER STRAP BOLT U 5/16-18 X 2-1/4 BOLT U 5/16-18 X 2.09 SADDLE 2 INCH WASHER LOCK M8-5/16 NUT HEX 5/16-18 STEEL SCREW HHC M6-1.0 X 30 G8.8 EXHAUST PIPE 1.
Standby Generator Sets Warranty GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR HOME STANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELOW For a period of two (2) years from the date of sale, or start-up by Authorized/Certified Generac Power Systems Dealer, or branch thereof, Generac Power Systems, Inc.
