Generac Power Systems QT05030AVAN Owner's Manual
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Generac Power Systems QT05030AVAN Owner's Manual

Generac Power Systems QT05030AVAN Owner's Manual

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QT
Serial Number
3.0L
50kW
Models
STANDBY GENERATOR
OWNER'S MANUAL
A new standard of reliability
This manual should remain with the unit.

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Summary of Contents for Generac Power Systems QT05030AVAN

  • Page 1 Serial Number 3.0L 50kW Models STANDBY GENERATOR OWNER'S MANUAL A new standard of reliability This manual should remain with the unit.

  • Page 2: Table Of Contents

    Standby Generator Sets Table of Contents OPERATION ............9-1 SECTION PAGE Generator Control and Operation ........9-1 SAFETY RULES ..........1-1 Operating Unit with Manual Transfer Switch ....9-1 INTRODUCTION .............1-3 Engine Start-up and Transfer ........9-1 Read this Manual Thoroughly ........1-3 Retransfer and Shutdown .........9-1 Operation and Maintenance ........1-3 Operating Unit with Automatic Transfer Switch ...9-1 How to Obtain Service ..........1-3...

  • Page 3: Safety Rules

    Safety Rules INTRODUCTION  This symbol points out potential electrical shock hazard. Thank you for purchasing this model of the Stationary Emergency The operator is responsible for proper and safe use of the equip- Generator set product line. ment. The manufacturer strongly recommends that the operator Every effort was expended to make sure that the information and read this Owner's Manual and thoroughly understand all instruc- instructions in this manual were both accurate and current at the...
  • Page 4 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. Study these SAFETY RULES carefully before installing, operating •...
  • Page 5 Safety Rules FIRE HAZARDS • If personnel must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden platform. Work on the • Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher.

  • Page 6: Identification Record

    ROTOR STATOR WINDING INSULATION AT 25°C AMBIENT (Corrosion Resistant Aluminum Enclosure Material, Steel is Standard) GENERAC POWER SYSTEMS, INC. N — Emission Equipment: N = No Equipment; Y = WAUKESHA, WI Catalytic Converter and Air/Fuel Ratio Controller A — Industrial Dealer Product...

  • Page 7: Equipment Description

    Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current Stationary Use a mixture of half low silicate ethylene glycol base anti-freeze Emergency Generator. It is powered by a gaseous fueled engine and deionized water. Cooling system capacity is listed in the operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for specifications.

  • Page 8: Engine Protective Devices

    Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The Stationary Emergency Generator may be required to operate After a prespecified duration of cranking, this function ends the for long periods of time without an operator on hand to monitor cranking if the engine has failed to start. The overcrank LED will such engine conditions as coolant temperature, oil pressure or turn ON.

  • Page 9: Fuel Systems

    Fuel System FUEL SYSTEM PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid FUEL REQUIREMENTS 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 The Stationary Emergency Generator may be equipped with one of state.

  • Page 10: Specifications

    Standby Generator Sets Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ..............Gear GENERATOR Oil Filter .............Full Flow, Cartridge Crankcase Oil Capacity ............4 U.S. qts. Type ................Synchronous Rotor Insulation ..............Class H COOLING SYSTEM Stator Insulation ..............Class H Total Harmonic Distortion ............<...

  • Page 11: Cold Weather Kit

    Standby Generator Sets Specifications Figure 1 — Interconnections 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)

  • Page 12: General Information

    General Information ALTERNATOR AC LEAD ALTERNATOR POWER WINDING CONNECTIONS CONNECTIONS See “Voltage Codes”. This Stationary Emergency Generator may 3-PHASE ALTERNATORS be rated at any one of three voltages, either single-phase or three- phase. The electrical wires in the unit’s AC connection (lower) The Stationary Emergency Generator is designed to supply panel should be installed according to the number of leads and the 3-phase electrical loads.

  • Page 13: Installation

    Installation INSTALLATION PRIOR TO INITIAL START-UP Refer to the separate “Installation Guide QT Product Line” supplied with the unit. Prior to initially starting the generator, it PREPARATION BEFORE START-UP must be properly prepared for use. Any attempt to crank or start the engine before The instructions in this section assume that the Stationary it has been properly serviced with the rec- Emergency Generator has been properly installed, serviced, tested,...

  • Page 14: Start-Up Inspection

    Installation START-UP CHECKLIST • 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. Before working on the Stationary Emergency • Check for coolant, fuel, oil, and exhaust leaks. Generator, ensure the following: •...

  • Page 15: Operation

    Operation STATIONARY EMERGENCY GENERATOR CONTROL AND Do not crank the engine continuously for lon- OPERATION ger than 30 seconds, or the heat may damage the starter motor. Refer to the appropriate control panel operator’s manual for this • Let engine stabilize and warm up. unit.

  • Page 16: Maintenance

    Maintenance MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES  The exhaust system parts from this product get extremely hot and remains hot after shut- down. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such mate-  Before working on the Stationary Emergency rials may ignite and burn from the heat of the Generator, ensure the following: exhaust system.

  • Page 17: Maintenance Owner/Operator Can Perform

    Maintenance MAINTENANCE OWNER/ INSPECT ENGINE GOVERNOR OPERATOR CAN PERFORM Visually inspect electronic governor. CHECK ENGINE OIL LEVEL Refer to the “Checking Fluid Levels” section. Do not attempt to adjust the governor. Only qualified service facilities should adjust CHECK BATTERY the governor. Excessively high operating speeds are dangerous and increase the •...

  • Page 18: Changing The Engine Air Cleaner

    Maintenance MISCELLANEOUS MAINTENANCE After refilling the crankcase with oil, always CLEANING THE GENERATOR check oil level on dipstick. NEVER OPERATE Keep the generator as clean and as dry as possible. Dirt and ENGINE WITH OIL BELOW THE DIPSTICK moisture that accumulates on internal generator windings have an “ADD”...

  • Page 19: Battery Replacement

    Maintenance BATTERY REPLACEMENT When replacing batteries, use the same number and the type of  Storage batteries give off explosive hydrogen battery that follows: gas. This gas can form an explosive mixture around the battery for several hours after BCI Group No. charging.

  • Page 20: Service Schedule

    Service Schedule SERVICE SCHEDULE 22 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR The following is a recommended maintenance schedule for Gaseous Stationary Emergency Generator sets from 22kW 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. They will need to be decreased (performed more frequently) if the unit is used in a severe application.
  • Page 21 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level 5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...
  • Page 22 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...
  • Page 23 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...

  • Page 24: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defective 2. Tighten, clean or replace battery cables. battery cables as necessary. 3. Defective starter contactor. 3. Replace contactor.* 4.
  • Page 25 Notes...
  • Page 27 0F3137 PAN CB CONN BOX 022127 NUT HEX 1/4-20 STEEL 0F3188 STAND RH CONTROL 0C2454 SCREW THF M6- 1 X 16 N WA Z/JS 0F3189 STAND LH CONTROL 029289 TAPE ELEC 1/2 FOAM (AS REQ’D) 023484N BUSHING SNAP SB-2.5-31 0F1733 DECAL CUSTOMER CONNECT INSIDE 0F6366B XFMR DUAL 120V/16V (F OR 120/240V &...
  • Page 29 UL CIRCUIT BREAKER (QJ-2P) 0F8137 COVER QJ 2P FRM CB NEUTRAL BLOCK 390 / 200-400A 0E7994 CB 0225A 240V 2P S QJ22 0D5466 BUS BAR NEUTRAL BLOCK 390 0F8136 COVER QJ 2P CB DISH 039287 SCREW HHC M8-1.25 X 45 G8.8 FT 036261 RIVET POP .125 X .275 SS 022145...
  • Page 31 0F3380 ASSY RTR 2390 50KD1 CPL 0F3377 ASSY RTR 2390 70KD2 CPL 0F3381 ASSY STR 2390 50AD1 CPL 0F3378 ASSY STR 2390 70AD2 CPL 0F6185 ASSY STR 390 50KW 2P 3PH 480V 0F6186 ASSY STR 390 70KW 2P 3PH 480V 0F6181 ASSY STR 390 50KW 2P 3PH 208V 0F6182...
  • Page 33 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 0F4245F ASSY PCB CPL CTRLR 3600 RPM 0F1262 HOLDER, FUSE WICKMANN 178.6150 0F1263...
  • Page 35 0F2601 ASSY MTG BASE (3.9L C4) 0F2601A ASSY MTG BASE (3.0L C4) 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"...
  • Page 37 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 - 03880400AA CABLE BATT RED #1 X 44.00 038805T...
  • Page 39 0F6842 ENGINE 3.0L FORD (FD) (MAKE) CPL 027482 WASHER SHAKEPROOF EXT 5/16 STL 022131 WASHER FLAT 3/8-M10 ZINC (1800 RPM ONLY) 061012 PLUG STD PIPE 1/8 SOCKET HEAD 022131 * WASHER FLAT 3/8-M10 ZINC (3600 RPM ONLY) 0A6751 SWITCH HI-TEMP 245D X 3/8NPT 0E8963 PULLEY CRANKSHAFT 3.0L FORD (1800 RPM ONLY) 033472...
  • Page 41 0F2688 WELDMENT RADIATOR SUPPORT C4 046526 WASHER LOCK M10 0F2608A RADIATOR 598 X 568 X 49 CPL LH 052243 SCREW HHC M10-1.5 X 60 G8.8 0F5263 V-BELT 31/64" X 57-3/8" 0F2561 HUB FLEX PLATE 046526 WASHER LOCK M10 0C8145 WASHER FLEX (THIN) 059981 SCREW HHC M10-1.5 X 30 G10.9 049721...
  • Page 43 0F4269 GASKET, MIXER BODY 0F4271 BASE PLATE AIR CLEANER 0F4268 TOP PLATE VENTURI 0F4270 HOLD DOWN AIR CLEANER 049811 WASHER FLAT M6 022097 WASHER LOCK M6-1/4 047411 SCREW HHC M6-1.0 X 16 G8.8 0F5418 ELEMENT AIR FILTER 0F6323 PLATE, AIR CLEANER TOP 3.9L 037561 NUT WING 1/4-20 NYLK 074008...
  • Page 45 --------- WELDMENT MOUNTING BASE 075580 FLANGE FUEL INLET 0F6260G REGULATOR ASSM 3.0L 50KW NG 0F6260A REGULATOR ASSM 3.0L 50KW LP 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 CLEAR ZINC 047290 HOSE 3/8 ID SINGLE BRAID 0C2454...
  • Page 47 (2) 1 0F5859 REAR WRAP C4 (2) 2 0F5855 DOOR C4 (2) 3 0F5858 DISCHARGE DUCT LH & RH SIDE C4 (2) 4 0F5856 FRONT CORNERS C4 (2) 5 0F5857 DISCHARGE CENTER DUCT C4 (3) 6 0F5854 ROOF C4 ALUM 0F8869D KEY VISE-ACTION LATCH SLOT CIR 0C2454...
  • Page 49 0F2981 MFLR 7" X 9" (2) 2" IN/2.5" OUT 022473 WASHER FLAT 1/4-M6 ZINC 0F4462 RAIN CAP ALUM FOR 2 1/2" PIPE 0F2830 MUFFLER BRACKET STIFFENER 0F2962 MUFFLER STRAP 080762 BOLT U 3/8-16 X 2.62 0E0170B EXHAUST BLANKET 850MM (C4) 0E0170C EXHAUST BLANKET 725MM (C4) 0F3723...
  • Page 62 Notes...
  • Page 63 Notes...
  • Page 64 COMMERCIAL STATIONARY EMERGENCY PRODUCT 50kW AND ABOVE For a period of two (2) years from the date of sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac or an Authorized/Certified Generac Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.

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