Generac Power Systems 005336-0, 005337-0 Owner's Manual
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Generac Power Systems 005336-0, 005337-0 Owner's Manual

Generac Power Systems 005336-0, 005337-0 Owner's Manual

Standby generator
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1.6L

Serial Number

20kW
Models: 005336-0
005337-0
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.
0G2966
No.
Part
07/06
0
Rev.
Cover079

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Summary of Contents for Generac Power Systems 005336-0, 005337-0

  • Page 1: Serial Number

    1.6L Serial Number 20kW Models: 005336-0 005337-0 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.

  • 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 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...

  • 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 Stator Insulation ...Class F Total Harmonic Distortion ...< 5% Alternator Output Leads 3-phase ... 4-wire Bearings ...Sealed Ball Coupling ...Flexible Disc Load Capacity (Standby Rating) ...20kW* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349, ISO3046 and DIN 6271 Standards.

  • Page 11: Cold Weather Kit

    CONTROL PANEL GENERATOR CONNECTION CIRCUIT BREAKER Battery Charger Input GROUND 120 Volt + Neutral Ground Level STUB-UP AREA Concrete Slab See Install Dwg for Dimensions COLD WEATHER KIT For cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes: •...

  • 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 Checklist

    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 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: Battery Fluid

    Figure 10.1 - Oil Dipstick and Oil Fill Cap OIL FILL CAP DIPSTICK BATTERY FLUID Check battery electrolyte fluid based on the Maintenance Schedule. Fluid should cover separa- tors in all battery cells. If fluid level is low, add dis- tilled water to cover tops of separators.

  • Page 18: Changing Engine Oil

    CHANGING ENGINE OIL Refer to maintenance performed by service facilities for engine oil and filter change frequencies. Drain the oil while the engine is still warm from run- ning. This means warm up the engine, shut it down and drain immediately as follows: 1.

  • Page 19: Miscellaneous Maintenance

    MISCELLANEOUS MAINTENANCE CLEANING THE GENERATOR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal gen- erator windings have an adverse effect on insulation resistance. Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dry, low pressure air to remove any accumulations of dirt.

  • Page 20: 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 applica- tion.
  • Page 21 Maintenance Level 1 Tasks Recom- mended to be done monthly 10 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.
  • Page 22 Maintenance Level 1 Tasks Recom- mended to be done monthly 10 Hrs. 13. 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 components, and abnormal operating conditions.

  • Page 23: 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 24 Standby Generator Sets Notes...
  • Page 25 Standby Generator Sets Notes...
  • Page 26 Standby Generator Sets Notes...
  • Page 27 Standby Generator Sets Notes...
  • Page 29 0F7135 BREAKER TRAY BACK/BOTTOM 0F7022 SUPPORT CONTROL PANEL SIDE RH 0F7021 SUPPORT CONTROL PANEL SIDE LH 0F7260 COVER CIRCUIT BREAKER 2P 0F7136 COVER CIRCUIT BREAKER 3P 0F6156 PLATE WIRE SNGL GALV 0F4464 DECAL CUST CONN 120V UTILITY 0D4698 BLOCK TERM 20A 6 X 3 X 1100V 0F3824 DECAL UTIL SENSE/CUST CONN 057701...
  • Page 31 098675 ASSY RTR 20KW 2PH 098936 ASSY RTR 25KW 2PH 0G0820 HOUSING BLOWER MACHINED 1.6L 0G1019 GUARD BLOWER HOUSING 1.6L 020746 SCREW PPHM M5-0.8 X 8 ZINC 049226 WASHER LOCK M5 051713 WASHER FLAT M5 022129 WASHER LOCK M8-5/16 0F8218 STR 102 20AD1 CPL 0F8220 STR-102-20GD1 CPL...
  • Page 33 COMPONENTS INCLUDED IN 0G1291E 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 0G1303B ASSY PCB CPL2 CTRLR 3600 RPM 0F1262 HOLDER FUSE WICKMANN 178.6150 0F1263...
  • Page 35 0F7211 SUPPORT RADIATOR LH SIDE 0G0760 VENTURI 16" DIA FAN 0F7210 SUPPORT RADIATOR RH SIDE 0E9837B RADIATOR 1.6L CHY 0F0230B FAN COOL 16" DIA 8 BLADE 046526 WASHER LOCK M10 0G0910 LOWER RADIATOR HOSE 1.6L 099502 CLAMP HOSE #24 B1.06-2.00 069860C HOSE OIL DRAIN ASSY 21"...
  • Page 37 0F3408B BATTERY TRAY C1 CPL 0F3411 STRAP BATTERY RETAINMENT 025507 WASHER SHAKEPROOF EXT 7/16 STL 059980 SCREW HHC M10-1.5 X 25 G10.9 022129 WASHER LOCK M8-5/16 077483 BATTERY 12VDC 75-AH 26 050331A BATT POST COVER RED + 050331 BATT POST COVER BLK - 038805J CABLE BATTERY BLK #1 X 30.00 038804N...
  • Page 39 0G0759 MOUNTING BASE 1.6L 027482 WASHER SHAKEPROOF EXT 5/16 STL 070936 DAMPENER VIBRATION 070936C VIB. ISO. 70-75 DURO 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16 ZINC 022129 WASHER LOCK M8-5/16 045771 NUT HEX M8-1.25 G8 YEL CHR 071956 WASHER FLAT M8 051730...
  • Page 41 0G0207 ENGINE GENERAC 1.6L NG 0G0834 ENGINE PLATE 1.6L 0G0820 HOUSING BLOWER MACHINED 1.6L 0E9747 STARTER 12 VOLT 0G0839 ENGINE MOUNTING FOOT STAMPING 0G0781 EXHAUST MANIFOLD 1.6L MACHINED 0G0722 INTAKE MANIFOLD MACHINED 1.6L 0G0758 HEAT SHIELD LOWER 1.6L 0G0431 HEAT SHIELD UPPER 1.6L 0G0663 PULLEY CRANKSHAFT MACHINED 0G0786...
  • Page 43 098290 ASM MOTOR STEPPER 098941A HOUSING GOVERNOR CONNECTOR 098958A CONNECTOR INTERFACE ASSEMBLY 098942A COVER CONNECTOR HOUSING 098225 SCREW FHM #2 X 5/8 SELF TAP 043146 SCREW HHC M6-1.0 X 10 G8.8 022097 WASHER LOCK M6-1/4 084543A SCREW PHM M3-0.5 X 12MM 098783 LEVER STEPPER MOTOR 037398...
  • Page 45 026812 ELBOW 90D 3/4 NPT 075580 FLANGE FUEL INLET 0G1397 FUEL REGULATOR 1.6L REWORK 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16 ZINC 022129 WASHER LOCK M8-5/16 045771 NUT HEX M8-1.25 G8 YEL CHR (1) 8 0F1570 BODY CARBURETOR ASSEMBLY 0A6344 BARBED EL 90 1/8NPT X 3/8...
  • Page 47 0F7003 (XX) ROOF C1 CPL 0F7004 (XX) CORNER POST LH SIDE C1 CPL 0F7008 (XX) DOOR REAR C1 CPL 0F7005 (XX) CORNER POST RH SIDE C1 CPL 0F7007 (XX) DOOR LH & RH SIDE C1 CPL 0F7006 (XX) DUCT FRONT DISCHARGE C1 CPL 0C2634A ASSEMBLY COVER ACCESS 0912970091...
  • Page 49 0F7366 MUFFLER C1 0F7647 MUFFLER SADDLE 0F8095 PIPE EXHAUST OUTLET 0F7538 PIPE EXH INLET MUFLR SIDE 1.5L 0E3257 SCREW HWHTF M6-1.0 X 16 0F7644 MUFFLER STRAP 0C6119 BOLT U 5/16-18 X 2-1/4 036434 BOLT U 5/16-18 X 2.09 036449 SADDLE 2 INCH 022129 WASHER LOCK M8-5/16 022259...
  • Page 64 • 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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