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Generac Power Systems Quietsource 005220-0 Owner's Manual

Standby generator
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QT

Serial Number

3.0L
30kW
Model: 005220-0
STANDBY GENERATOR
OWNER'S MANUAL
A new standard of reliability
—CAUTION—
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
This manual should remain with the unit.
0F7911
No.
Part
09/05
0
Rev.
Cover025

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Summary of Contents for Generac Power Systems Quietsource 005220-0

  • Page 1: Serial Number

    Serial Number 3.0L 30kW Model: 005220-0 STANDBY GENERATOR OWNER'S MANUAL A new standard of reliability —CAUTION— ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! This manual should remain with the unit. 0F7911 Part 09/05 Rev. Cover025...

  • Page 2: Table Of Contents

    SECTION 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 Requirements ...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...

  • Page 3: Safety Rules

     SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment.  WARNING: The engine exhaust from this product contains chemicals known to the state...

  • Page 4: Fire Hazards

    • Before performing any maintenance on the gen- erator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last. • Never use the generator or any of its parts as a step.

  • Page 5: Introduction

    INTRODUCTION 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.

  • Page 6: Identification Record

    ENGINE RPM ALTERNATOR SUBTRANSIENT REACTANCE ALTERNATOR TRANSIENT REACTANCE CLASS ROTOR GENERAC POWER SYSTEMS, INC. Standby Generator Sets General Information 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.

  • Page 7: Equipment Description

    EQUIPMENT DESCRIPTION This equipment is a revolving field, alternating cur- rent 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.

  • Page 8: Engine Protective Devices

    ENGINE PROTECTIVE DEVICES 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 tempera- ture, oil pressure or rpm. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low, the coolant temperature is too high, the coolant...

  • Page 9: Fuel Systems

    FUEL SYSTEM FUEL REQUIREMENTS The standby generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (PV) fuel system The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the unit.

  • Page 10: Specifications

    SPECIFICATIONS GENERATOR Type ... Synchronous Rotor Insulation ...Class F or H Stator Insulation ... Class H Total Harmonic Distortion ...< 3.5% Telephone Interference Factor (TIF) ...< 50 Alternator Output Leads 3-phase ... 4-wire Bearings ...Sealed Ball Coupling ...Flexible Disc Load Capacity (Standby Rating) ...30kW* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349, ISO3046 and DIN 6271 Standards.

  • Page 11: Cold Weather Kit

    COLD WEATHER KIT For cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes: • Battery Warmer • 4” Junction Box with hardware • 6 qt. pack 5W-30 synthetic oil (engine) RECONFIGURING THE FUEL SYSTEM NOTE: All models are configured for natural gas or LP vapor from the factory.

  • Page 12: General Information

    GENERATOR AC LEAD 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 con- nection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application.

  • Page 13: Installation

    INSTALLATION Refer to the separate “Installation Guide QT Product Line” supplied with the unit. PREPARATION BEFORE START-UP The instructions in this section assume that the standby generator has been properly installed, ser- viced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor. Be sure to read the “Safety Rules”, as well as all other safety information in this manual, before attempting to operate this (and related) equipment.

  • Page 14: Start-Up Inspection

    START-UP CHECKLIST  Before working on the generator, ensure the fol- lowing: • The AUTO/OFF/MANUAL switch is in the OFF position. • The 120VAC supply to the battery charger is switched OFF . PREPARATION FOR START-UP • Ensure that the 120VAC circuit breaker to the bat- tery charger is open.

  • Page 15: Operation

    GENERATOR CONTROL AND OPERATION 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. A manually operated transfer switch is one that will not provide automatic start-up and does not include an intelligence circuit.

  • Page 16: Maintenance

    MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES  Before working on the generator, ensure the fol- lowing: • The AUTO/OFF/MANUAL switch is in the OFF position. • The 15A fuse has been removed from the con- trol box. • The 120VAC supply to the battery charger is switched OFF .

  • Page 17: Engine Coolant

    ENGINE COOLANT Check coolant level in coolant recovery bottle. See the “Specifications” section. • Add recommended coolant mixture as necessary. • Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck.

  • Page 18: Changing The Engine Air Cleaner

    7. Start engine and check for oil leaks. Figure 10.2 - Oil Filter Oil Filter CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner, (part number 0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover.

  • Page 19: Battery Maintenance

    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 clean as necessary. 2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY.

  • Page 20: Service Schedule

    SERVICE SCHEDULE 30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application.
  • Page 21 Maintenance Level 1 Tasks Recom- mended Comp. to be done Comp. to be done to be done (Date- monthly/ Initials) 10 hrs. 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary.
  • Page 22 Maintenance Level 1 Tasks Recom- mended Comp. to be done Comp. to be done to be done (Date- monthly/ Initials) 10 hrs. 10. Check the engine accessory drive belts and fan coupling device if equipped for correct tension, wear, weather cracking, and damage.
  • Page 23 Maintenance Level 1 Tasks Recom- mended Comp. to be done Comp. to be done to be done (Date- monthly/ Initials) 10 hrs. 18. Start and exercise the unit at full rated load (use a load bank if the site load is not enough) for at least 2 hours looking for leaks,...

  • Page 24: Troubleshooting

    TROUBLESHOOTING GUIDE PROBLEM CAUSE Engine won’t crank. Engine cranks but won't start Engine starts hard, runs rough. Engine starts then shuts down. AUTO/OFF/MANUAL Switch at OFF, engine continues to run No AC output from generator. *Contact the nearest Authorized Dealer for assistance. Standby Generator Sets Troubleshooting 1.
  • Page 25 Standby Generator Sets Notes...
  • Page 27 0F3137 PAN CB CONN BOX 0F3188 STAND RH CONTROL 0F3189 STAND LH CONTROL 023484N BUSHING SNAP SB-2.5-31 5 *** 0F6366B 1 / 2 XFMR DUAL 120V/16V (FOR 120/240V & 277/480V UNITS) 0F6366A XFMR DUAL 104V/16V (FOR 120/208V UNITS) 6 *** 043180 2 / 4 WASHER FLAT M4...
  • Page 29 0F3438 RTR 390 30AD1 CPL 0F3440 RTR 390 40AD2 CPL HI-EF 0F6188 ASSY RTR 390 30KD1 CPL 0F6190 ASSY RTR 390 40KD2 CPL 0F3439 STR 390 30AD1 CPL 0F3441 STR 390 40AD2 CPL 0F6189 STR 390 30GD1 CPL 0F6199 STR 390 40GD2 CPL 0F6655 ASSY STR 390 30KD1 CPL 0F6656...
  • Page 31 COMPONENTS INCLUDED IN 01827E 0F1823A ENCL HSB CONTROL PANEL 0F3078 COVER CONTROL PANEL 0F2606 HINGE CONTINUOUS H-PANEL 036261 RIVET POP .125 X .275 SS 043181 SCREW PHM M3-0.5 X 10MM 052777 WASHER FLAT M3 0F4245E ASSY PCB CPL CTRLR 1800 RPM 0F1262 HOLDER FUSE WICKMANN 178.6150 0F1263...
  • Page 33 0F3270A MTG BASE 3.0L 30KW C2 052860 NUT FLANGED HEX M12-1.75 052251 DAMPENER VIBRATION 40 BLUE 052257 SPACER .49 X .62 X 1.87 PWDR/ZNC 052252 DAMPENER VIBRATION 052259 WASHER FLAT M12 052891 SCREW HHC M12-1.75 X 80 G8.8 0536210410 ASSY WIRE 14.00" 042909 SCREW HHC M8-1.25 X 30 G8.8 047411...
  • Page 35 0F3408 TRAY BATTERY 0F3411 STRAP BATTERY RETAINMENT 058208 BATT 12VDC 24F 625 036833 SCREW HHC 3/8-16 X 1 G8 022237 WASHER LOCK 3/8 022131 WASHER FLAT 3/8-M10 ZINC 050331A BATT POST COVER RED + 050331 BATT POST COVER BLK - 038805H CABLE BATT BLK #1 X 23.00 038804Y...
  • Page 37 0E5193 PLATE AIR CLEANER ADAPTER 0E0519A ADAPTER CARBURETOR W/PVC CONN 022127 NUT HEX 1/4-20 STEEL 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC 052619 SCREW HHC M5-0.8 X 20 G8.8 0C8127 ELEMENT AIR CLEANER 0A5547 COVER - AIR CLEANER 037561 NUT WING 1/4-20 NYLK 0E6586 GASKET BOSCH 32 &...
  • Page 39 0F6842 ENGINE 3.0L FORD (FD) (MAKE) CPL 022131 WASHER FLAT 3/8-M10 ZINC (1800 RPM ONLY) 022131 * WASHER FLAT 3/8-M10 ZINC (3600 RPM ONLY) 0E8963 PULLEY CRANKSHAFT 3.0L FORD (1800 RPM ONLY) 0E6309 PULLEY CRANKSHAFT 3.0L FORD (3600 RPM ONLY) 0F6912 BRACKET R/H SIDE D.C.
  • Page 41 0F3203A WELDMENT RAD SUPPORT 3.0L C2 035685 CLAMP HOSE #28 1.32-2.25 0F2608A RADIATOR 598 X 568 X 49,CPL LH 0F6761 HOSE UPPER RAD CPL C2 3.0L 0F3228 HOSE LOWER RAD CPL C2 3.0L 0F5143 SPACER FAN 3.0L C2 0F0230A FAN COOLING 16" DIA 8 BLADE 045764 SCREW HHTT M4-0.7 X 8 BP 065852...
  • Page 45 026915 NIPPLE CLOSE 3/4 X 1.375 075580 FLANGE FUEL INLET 0F6390 REGULATOR ASSEMBLY DUAL FUEL 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16-M8 ZINC 022129 WASHER LOCK M8-5/16 045771 NUT HEX M8-1.25 G8 CLEAR ZINC 042907 SCREW HHC M8-1.25 X 16 G8.8 0E9295A ASSY THROTTLE 27MM 026812...
  • Page 47 0F0738 MUFFLER 7" X 9"-(2) 2" IN/2.5" OUT 0F2808B PIPE EXHAUST MUFFLER 0F2830 MUFFLER BRACKET STIFFENER 0F2962 MUFFLER STRAP 080762 BOLT U 3/8-16 X 2.62 0E0170B EXHAUST BLANKET 800MM (C2) 0E0170 EXHAUST BLANKET 750MM (C2) 0F4343 EXHAUST PIPE 3.0L C2 CPL RH 0F4344 EXHAUST PIPE 3.0L C2 CPL LH 044149...
  • Page 49 0F5853 (XX) REAR WRAP C2 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0F5849 (XX) DOOR C2 087233 RIVET POP .1875 X .450 SS 0E3257 SCREW TH-FRM M6 W/CAP SHKPRF W 0F5852 (XX) DISCHARGE DUCT,LH & RH SIDE C2 0F5850 (XX) FRONT CORNERS C2 0F5851 (XX)
  • Page 60 • A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.

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