Manual

Standby Generator Sets
Table of Contents
SECTION PAGE
SAFETY RULES ................................................ 1-1
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 ...................................3-1
Equipment Description ................................................3-1
Engine Oil Recommendations ......................................3-1
Coolant Recommendations...........................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
High Coolant Temperature Switch ............................4-1
Low Coolant Level Sensor .........................................4-1
Low Oil Pressure Switch ...........................................4-1
Overcrank Shutdown ................................................4-1
Overspeed Shutdown ................................................4-1
RPM Sensor Loss Shutdown .....................................4-1
DC Fuse ....................................................................4-1
FUEL SYSTEMS .....................................................5-1
Fuel Requirements ....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP Fuel System .........................................................5-1
SPECIFICATIONS ...................................................6-1
Generator .................................................................6-1
Engine.......................................................................6-1
Cooling System .........................................................6-1
Fuel System ..............................................................6-1
Electrical System ......................................................6-1
Cold Weather Kit .......................................................6-2
Reconfiguring the Fuel System ..................................6-2
GENERAL INFORMATION .......................................7-1
Generator AC Lead Connections ..................................7-1
Four-lead, Single-phase Stator ..................................7-1
Alternator Power Winding Connections ........................7-1
3-phase Alternators ..................................................7-1
INSTALLATION .......................................................8-1
Installation ...................................................................8-1
Preparation Before Start-up .........................................8-1
Transfer Switch ........................................................8-1
Fuel System ..............................................................8-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Engine Coolant .........................................................8-1
Belt Tension ..............................................................8-1
Electrical System ......................................................8-1
Initial Inspection for QT Genset Start-up .....................8-1
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 Months ...........................................10-1
Once Annually .........................................................10-1
First 100 Operating Hours ......................................10-1
Every 500 Operating Hours ....................................10-1
Every 800 Operating Hours ....................................10-1
Exhaust Manifold Procedure ......................................10-1
Intake Manifold Procedure .........................................10-1
Cylinder Head Procedure ...........................................10-1
Cooling System ..........................................................10-2
Overload Protection for Engine DC
Electrical System ....................................................10-2
Checking Fluid Levels ................................................10-2
Check Engine Oil ....................................................10-2
Battery Fluid ...........................................................10-2
Engine Coolant .......................................................10-2
Maintenance Owner/Operator Can Perform ................10-3
Check Engine Oil Level ...........................................10-3
Check Battery .........................................................10-3
Exercise System ......................................................10-3
Inspect Cooling System ...........................................10-3
Check Engine Coolant Level....................................10-3
Perform Visual Inspection .......................................10-3
Inspect Exhaust System ..........................................10-3
Check Fan Belt ........................................................10-3
Inspect Engine Governor ........................................10-3
Changing Engine Oil ...............................................10-3
Changing the Engine Air Cleaner ............................10-3
Spark Plugs ............................................................10-4
Coolant Change .......................................................10-4
Miscellaneous Maintenance ........................................10-4
Cleaning the Generator ...........................................10-4
Battery ....................................................................10-4
Battery Maintenance ...............................................10-4
Battery Replacement ...............................................10-5
SERVICE SCHEDULE ...........................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide ...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
WARRANTY
Content004 Rev. 0 09/05