Generac Power Systems 05176-0 Installation And Owner's Manual
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Generac Power Systems 05176-0 Installation And Owner's Manual

Generac Power Systems 05176-0 Installation And Owner's Manual

13 kw ng, 15 kw lp air-cooled automatic standby generators
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POWER SYSTEMS, INC.
Not intended for use as Primary Power in place of utility
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
*This manual should remain with the unit.*
or in life-support applications.
DANGER
Installation and
Owner's Manual
Model:
05176-0 (13 kW NG, 15 kW LP)
GENERAC
POWER SYSTEMS, INC.
Air-cooled Automatic
Standby Generators
R
R
®

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Summary of Contents for Generac Power Systems 05176-0

  • Page 1 Not intended for use as Primary Power in place of utility or in life-support applications. DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!! Installation and Owner’s Manual Air-cooled Automatic Model: 05176-0 (13 kW NG, 15 kW LP) GENERAC POWER SYSTEMS, INC. DANGER ® Standby Generators ...

  • Page 2: Introduction

    This manual contains pertinent owner’s information, including warranty, electrical diagrams, exploded views and lists of repair parts, for model: • 05176-0 – 13 kW NG, 15 kW LP , V-twin GT-990 Engine OPERATION AND MAINTENANCE It is the operator's responsibility to perform all safety...

  • Page 3: Table Of Contents

    Introduction ...Inside Front Cover Read This Manual Thoroughly ... IFC Contents ... IFC Operation and Maintenance ... IFC How to Obtain Service ... IFC Authorized Dealer Locator Number ... IFC Safety Rules ...2 Standards Index ... 3 Section 1 – General Information ...4 Unpacking/Inspection ...

  • Page 4: General Hazards

    IMPORTANT SAFETY INSTRUCTIONS Air-cooled 15 kW Generators  SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to all operators and potential operators of this equipment. ...

  • Page 5: Electrical Hazards

     ELECTRICAL HAZARDS • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in opera- tion.

  • Page 6: Section 1 - General Information

    Section 1 — General Information Air-cooled 15 kW Generators DANGER  Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations. UNPACKING/INSPECTION After unpacking, carefully inspect the contents for damage. • This standby generator set has been factory sup- plied with a weather protective enclosure that is intended for outdoor installation only.

  • Page 7: The Generator

    THE GENERATOR Figure 1.1 – 15 kW, V-twin GT-990 Engine Exhaust Enclosure Figure 1.2 – 15 kW, V-twin GT-990 Engine Rear View Section 1 — General Information Air-cooled 15 kW Generators Control Panel Data Dipstick Decal Composite Base Battery Oil Filter Compartment AUTOMATIC TRANSFER SWITCH...

  • Page 8: Specifications

    Section 1 — General Information Air-cooled 15 kW Generators SPECIFICATIONS 1.5.1 GENERATOR Rated Max. Continuous Power Capacity (Watts*) ... 13,000 NG/15,000 LP Rated Voltage...120/240 Rated Max. Continuous Load Current (Amps) 120 Volts + ... 108.3 NG/125.0 LP 240 Volts ... 54.2 NG/62.5 LP Main Line Circuit Breaker ...

  • Page 9: Section 2 - Installation

    4. Remove the engine air in baffle located on the left- hand side of the battery compartment. Two M6 screws are located on top of the baffle and two M6 screws are located on the inside of the baffle towards the back. 5.

  • Page 10: Roof Open Alarm

    Section 2 — Installation Air-cooled 15 kW Generators Remote monitoring functions are only available with the AUTO/OFF/MANUAL switch in the Auto or Manual position. Since the contacts are SPDT, it is possible to monitor either state of each alarm function. Relay 1: Engine running, normally closed.

  • Page 11: Battery Installation

    Connect power source load conductors to clearly marked transfer mechanism terminal lugs as fol- lows 1. Connect UTILITY (NORMAL) power source cables to switch terminals N1, N2. 2. Connect customer LOAD leads to switch termi- nals T1, T2. Conductors must be properly supported, of approved insulative qualities, protected by approved conduit, and of the correct wire gauge size in accordance with applicable codes.

  • Page 12: The Battery

    Section 3 — Post Installation Start-up and Adjustments Air-cooled 15 kW Generators Figure 2.4 – Battery Cable Connections NOTE: The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation. With the battery installed and utility power source voltage available to the transfer switch, the battery receives a trickle charge while the engine is not running, to prevent...

  • Page 13: Generator Tests Under Load

    3. Check utility power source voltage across termi- nals N1 and the transfer switch neutral lug; then across terminal N2 and neutral. Nominal line-to- neutral voltage should be 120 volts AC. 4. When certain that utility supply voltage is compat- ible with transfer switch and load circuit ratings, turn OFF the utility power supply to the transfer switch.

  • Page 14: Checking Automatic Operation

    Section 3 — Post Installation Start-up and Adjustments Air-cooled 15 kW Generators CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation, proceed as follows: 1. Set the generator’s main circuit breaker to it’s OFF (or open) position. 2. Check that the AUTO/OFF/MANUAL switch is set to OFF .

  • Page 15: Engine Governor Adjustment

    7. Turn utility power to the main distribution panel back on. This can be done by switching the ser- vice main breaker to the on or closed position. Allow the generator to shut down.  Do not make any unnecessary adjustments. Factory settings are correct for most applica- tions.

  • Page 16: Section 4 - Operation

    Section 4 — Operation Air-cooled 15 kW Generators USING THE AUTO/OFF/MANUAL SWITCH (FIGURE 4.1) 4.1.1 “AUTO” POSITION Selecting this switch position activates fully automatic system operation. It also permits starting and exercising of the engine every seven days with the exercise timer (see "Generator Test Under Load").

  • Page 17: Manual Operation

    • Retransfer to utility power source then occurs. F . Engine Cool-down Timer • When the load is transferred back to utility power source, the engine cool-down timer starts tim- ing. • The timer will run for about one minute, and the generator will then shut down.

  • Page 18: Close To Emergency Source Side

    Section 4 — Operation Air-cooled 15 kW Generators 4.4.2 CLOSE TO EMERGENCY SOURCE SIDE Before proceeding, verify the position of the switch by observing the position of the manual operation handle in Figure 4.2. If the handle is DOWN, the contacts are closed in the EMERGENCY (STANDBY) position.

  • Page 19: Setting The Exercise Timer

    7. Move the switch's main contacts back to their UTILITY position. For example, load connected to UTILITY power supply. Refer to "Manual Operation". Handle and operating lever of trans- fer switch should be in UP position. 8. Turn on the UTILITY power supply to transfer switch, using whatever means provided (such as a UTILITY main line circuit breaker).

  • Page 20: Overspeed

    Section 5 — Maintenance Air-cooled 15 kW Generators 4.8.3.1 Approximate Crank Cycle Times • 15 seconds ON • 7 seconds OFF • 7 seconds ON • 7 seconds OFF • Repeat for 45 seconds Approximately 90 seconds total 4.8.4 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit.

  • Page 21: Changing The Oil Filter

    Figure 5.3 – Oil Drain Hose and Filter Drain Hose Oil Filter 3. After the oil has drained, replace the cap onto the end of the oil drain hose. Retain the hose in the clip. 4. Refill with the proper recommended oil (see "Changing the Engine Oil").

  • Page 22: Battery Maintenance

    Section 5 — Maintenance Air-cooled 15 kW Generators BATTERY MAINTENANCE The battery should be inspected per the “Service Schedule”. The following procedure should be fol- lowed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. 2.

  • Page 23: Cooling System

    When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change. Figure 5.6 - Valve Clearance Adjustment Pivot Ball Stud...

  • Page 24: Return To Service

    Section 5 — Maintenance Air-cooled 15 kW Generators 5.12.2 RETURN TO SERVICE To return the unit to service after storage, proceed as follows: 1. Set the generator’s main circuit breaker to its OFF (or OPEN) position. 2. Verify that utility power is turned off and that the AUTO/OFF/MANUAL switch is set to OFF .
  • Page 25 7 KW - 40 KW SMALL STANDBY GENERATOR SETS Following is a recommended maintenance schedule for small standby and residential generator sets from 7 kW to 40 kW in size, and applies to gas engine driven units. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application.
  • Page 26 Section 5 — Maintenance Air-cooled 15 kW Generators 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.
  • Page 27 Maintenance Level 1 Tasks Recom- mended to be done monthly/ 10 hrs. 10. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary. 11. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose...
  • Page 28 Section 5 — Maintenance Air-cooled 15 kW Generators Maintenance Level 1 Tasks Recom- mended to be done monthly/ 10 hrs. 16. Replace the engine air filter(s). 17. Perform a 5 minute no-load operational run of the unit looking for any post service problems.

  • Page 29: Section 6 - Troubleshooting

    TROUBLESHOOTING GUIDE Problem The engine will not crank. The engine cranks but will not start. The engine starts hard and runs rough. The AUTO/OFF/MANUAL switch is set to OFF , but the engine continues to run. There is no AC output from the generator.

  • Page 30: Section 7 - Mounting Dimensions

    Section 7 — Mounting Dimensions Air-cooled 15 kW Generators Drawing No. 0F5927...

  • Page 31: Section 8 - Electrical Data

    DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY C1 - 8 POSITION CONNECTOR C2 - 12 POSITION CONNECTOR C3 - 4 POSITION CONNECTOR C4 - 6 POSITION CONNECTIR CB1 - MAIN OUTPUT BREAKER CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION D - DIODE DSW - PCB MOUNTED DIP SWITCH FS - FUEL SOLENOID...
  • Page 32 Section 8 — Electrical Data Air-cooled 15 kW Generators Wiring Diagram – Drawing No. 0F5643-B Part 2 224A 225A 224B 224B 225B 225B VOLTAGE REGULATOR CONTROL PANEL BOX 224A 225A AUTO MANUAL CLOSEST TO BEARING STATOR...
  • Page 33 COIL COIL Section 8 — Electrical Data Air-cooled 15 kW Generators Wiring Diagram – Drawing No. 0F5643-B Part 3 TRANSFER SWITCH NEUTRAL RELAY BOARD RY1+ RY3+ COM- RY4- RY5- COM+ REMOTE SIGNALS RELAY KEY RY1 - ENGINE RUN RY2 - SWITCH IN EMERGENCY RY3 - SWITCH IN AUTO RY4 - COMMON ALARM RY6 - DOOR OPEN...
  • Page 34 Section 8 — Electrical Data Air-cooled 15 kW Generators Electrical Schematic – Drawing No. 0F5844-B FIELD ELECTRONIC VOLTAGE REGULATOR C2-8 DPE WINDING (STATOR) DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY C1 - 8 POSITION CONNECTOR C2 - 12 POSITION CONNECTOR C3 - 4 POSITION CONNECTOR C4 - 6 POSITION CONNECTIR CB1 - MAIN OUTPUT BREAKER...
  • Page 35 C2-6 C2-5 AUTO C1-5 C1-2 C1-1 Section 8 — Electrical Data Air-cooled 15 kW Generators Electrical Schematic – Drawing No. 0F5844-B C4-3 C4-2 POWER WINDING (STATOR) C3-2 C3-4 C3-5 C3-1 C3-6 C3-3 BLACK CUSTOMER SUPPLIED COIL COIL RELAY BOARD RY1+ RY2+ RELAY KEY RY3+...

  • Page 36: Section 9 - Exploded Views And Parts Lists

    Section 9 — Exploded Views and Parts Lists Air-cooled 15 kW Generators Enclosure – Drawing No. 0F5845...
  • Page 37 ITEM PART NO. QTY. DESCRIPTION 0C6140 ASSEMBLY, ENCLOSURE BASE 0C6735 SUPPORT, ROOF FOLDING 0F0063 ENCLOSURE, FRONT 0C7062 ENCLOSURE, EXHAUST SIDE 0F5629 ENCLOSURE, SIDE & BACK 0E9873 ENCLOSURE, ROOF 0C7065 PANEL, ALTERNATOR DIVIDER 0C8101A PANEL, MUFFLER BOX SIDE 0C8101B COVER, MUFFLER BOX 0C8283 GASKET, DOOR SEAL 0C8284A...
  • Page 38 Section 9 — Exploded Views and Parts Lists Air-cooled 15 kW Generators Control Panel – Drawing No. 0F5846...
  • Page 39 ITEM PART NO. 0E7886G 0A1801 083049 0C2174 075210A 0D3062 0D8615 032300 022676 0E4494 0E7890 023484E 075476 0F4793 0E6480 023897 0C1085 0D8443 054502 0F5747 075235 0D5240 0D9784 0D8502 031879 0F5679 074908 049813 082025 0C3910 022507 099727 046689 063617 075475 043180 0D8439 092036 045770 0E7866...
  • Page 40 Section 9 — Exploded Views and Parts Lists Air-cooled 15 kW Generators GT-990 Engine – Drawing No. 0E8774-Q Part 1...
  • Page 41 ITEM PART NO. QTY. DESCRIPTION 0C5729 ASSEMBLY, CRANKCASE HOUSING WITH SLEEVE 0E9843 SEAL, 38 I.D. CRANKSHAFT 090388 SCREW, TAPTITE M6-1.0 X 12 YC 0C5372 ASSEMBLY, BREATHER 0C3005 GASKET, BREATHER COVER 0E3372B SEPARATOR, OIL BREATHER 0D8067A ASSEMBLY, HEAD #1 G&S 071983 RETAINER, PISTON PIN 20 0C2981C ROCKER, COVER NO OIL FILL...
  • Page 42 Section 9 — Exploded Views and Parts Lists Air-cooled 15 kW Generators GT-990 Engine – Drawing No. 0E8774-Q Part 2...
  • Page 43 ITEM PART NO. QTY. DESCRIPTION 0C5136A KNOB, AIR CLEANER 0C3024 COVER, AIRBOX NG/LP 0C3040 PRE-CLEANER, 0C8127 ELEMENT, AIR CLEANER 0D8564A ASSEMBLY, MIXER/AIRBOX 990 0D8564B ASSEMBLY, MIXER/AIRBOX 760 0D2595 SCREW SHOULDER (8MM) M6-1.0 X 18 0D4417 WASHER,RUBBER 1/4" X 1/8" THICK 0C3025 SWITCH, OIL PRESS 0D3083...
  • Page 44 Section 9 — Exploded Views and Parts Lists Air-cooled 15 kW Generators 15 kW Generator – Drawing No. 0D3417-L...
  • Page 45 ITEM PART NO. 0C6934 0C7930 0D2359 0C7944 0D2356 0C6043 0D2336 0D6634 0D3220 0C8101 056482 0C3168 0D1838 0D1846 0C7038 0D1609 0D2559 0C7038A 0C7758 0388050AD0 0C2417A 082121C 066386 029451 049451 022237 022511 022131 051731 022145 049820 045756 022129 022259 059637 0D4662 0F7065 048031M 0F0462 0C2824...
  • Page 46 Section 9 — Exploded Views and Parts Lists Air-cooled 15 kW Generators Gas Regulator – Drawing No. 0D8720-H...
  • Page 47 ITEM PART NO. 0D5694 0F5022 0C4647 0D4166 0C6070 0F4795 0C5760J 0C6606 097934 0C4645 0C5761 0C5968 0C6066 0C5759 0C5764 0C5764A 070728 0C6069 0C5762 045764 0C6731 0C6067 0C4706 0C6068 0C4643A 026073 026073 0A4032 0D3308 024310 028414A 0D5698A 0D3973 * A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY Section 9 —...
  • Page 48 Section 9 — Exploded Views and Parts Lists Air-cooled 15 kW Generators Transfer Switch – Drawing No. 0F5633$-A...
  • Page 49 ITEM PART NO. 0D9618 0E3375 0F1252 022097 074908 045771 057329 027482 022129 073590A 11***** 073591 090388 0A1495 14***** 063617 0C2454 0A1661 0C4449A 0F5634 0E6056 20**** 0F0668 0C2262 22*** 095282 027770 064101 0F5694 26***** 063378 27***** 028739 0F5893 067210A 0A9457 0A9517 32 * 0E6190 081221...

  • Page 50: Section 10 - Warranty

    Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period.

  • Page 51: Emission Control System Warranty

    Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
  • Page 52 • 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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