Serial Number 4.6L 80kW Models EPA Certified STATIONARY EMERGENCY 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. Cover184 Rev. A 08/09 Part No.
Stationary Emergency Generator Table of Contents SECTION PAGE SAFETY RULES ............................................................. 1-1 Prior to Initial Start-up ..................................................................8-1 Initial Inspection for QT Genset Start-up ...........................................8-2 INTRODUCTION ...............................................................................1-3 Start-up Inspection ..................................................................
Safety Instructions THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential nSAVE hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. INTRODUCTION This symbol points out potential electrical shock hazard. This symbol points out potential fire hazard. Thank you for purchasing this model of the stationary emergency generator product line.
Safety Instructions SAFETY RULES • The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided. This should be considered prior to installing the generator. The unit should be positioned to direct exhaust gasses safely away from any building where people, animals, etc., will not be harmed.
Safety Instructions 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 equipment only while standing on such insulative mats. • The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground.
General Information IDENTIFICATION RECORD NOTE: 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. DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator.
Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current Stationary Emergency Generator. 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.
Engine Protective Devices ENGINE PROTECTIVE DEVICES OIL PRESSURE SENSING The Stationary Emergency Generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm.
Fuel System FUEL SYSTEM PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid 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 state. The vapor withdrawal system is generally best suited for smaller engines that require less fuel.
Stationary Emergency Generator Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ...............................................................Gear Oil Filter .......................................................Full Flow, Cartridge Crankcase Oil Capacity ............................................ 6 U.S. qts. STATIONARY EMERGENCY GENERATOR Type......................................................................Synchronous Rotor Insulation...................................
Stationary Emergency Generator Specifications WEATHER AND MAINTENANCE KITS DIAGNOSTIC BLINK PATTERNS (RED LED LOCATED ON THE IGNITION CONTROL BOARD) To keep the generator running at its peak, the following kits are offered: During normal ignition operation the RED LED, located on the ignition control board, flashes at a 0.5 second ON and a 0.5 second OFF rate. This is considered one (1) blink. • Cold Weather Kit ~ Recommended for climates with temperatures below 32° F.
General Information ALTERNATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING CONNECTIONS The electrical wires in the unit’s AC connection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. The voltage and phase are described on the generator data label. The number of lead wires can be identified using the Specifications section and the power output rating on the generator data label.
General Information 3-PHASE ALTERNATORS ("DELTA" CONFIGURATION) Figure 7.4 — Stator Power Winding Connections - 3-phase, 120/208V (6 Lead) INTERNAL CONNECTIONS The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory to the main circuit breaker with a “Delta” configuration as shown in Figures 7.7 and 7.8.
Installation INSTALLATION PRIOR TO INITIAL START-UP Refer to the separate “Installation Guide” supplied with the unit. For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by a Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations.
Installation START-UP CHECKLIST • Connect a manometer to the gas line and record the static pressure. It must be as listed in the Specifications. • Insert the fuse into the control panel. • Move the AUTO/OFF/MANUAL switch to the manual position. The engine should now crank and start. • 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.
Operation STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION not crank the engine continuously for longer than 30 seconds, or the heat may nDo damage the starter motor. Refer to the appropriate control panel operator’s manual for this unit. • Let engine stabilize and warm up. • Check all applicable instrument and gauge readings. When certain that all readings are correct, move the transfer switch manual handle to the STANDBY (or EMERGENCY STANDBY) position, i.e.
Stationary Emergency Generator Maintenance MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES exhaust system parts from this product get The extremely hot and remain hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system. Before working on the Stationary Emergency Generator, ensure the following: • The AUTO/OFF/MANUAL switch is in the OFF position.
Stationary Emergency Generator Maintenance ENGINE COOLANT INSPECT EXHAUST SYSTEM Check coolant level in coolant recovery bottle. See the “Specifications” section. Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage. • Add recommended coolant mixture as necessary. • Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly.
Stationary Emergency Generator Maintenance 6. SPARK PLUGS Remove OIL FILL CAP. Add recommended oil (see SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK “FULL” MARK. Crankcase oil capacity is listed in the “Specifications”. Reset the spark plug gap or replace the spark plugs as necessary. 1. refilling the crankcase with oil, always After check oil level on dipstick. NEVER OPERATE 7. 8. 9. 2. ENGINE WITH OIL BELOW THE DIPSTICK “ADD” MARK. Start engine and check for oil leaks.
Stationary Emergency Generator Maintenance BATTERY electrolyte fluid is an extremely caus Battery tic sulfuric acid solution that can cause severe All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery. If such information is not available, observe the following precautions when handling a battery: burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc.
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.
Service Schedule Maintenance Tasks Level 1 Recommended to be done monthly/ 10 hrs. Level 2 Task Comp. (DateInitials) Required to be done 3 months/ Break-in 30 hrs. Level 3 Task Comp. (DateInitials) Required to be done Semiannually/ 50 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. Check the engine coolant thermal protection level. Correct as necessary. 5.
Service Schedule Level 1 Recommended to be done monthly/ 10 hrs. Level 2 Level 3 Task Required Task Required Comp. to be done Comp. to be done (Date- 3 months/ (DateSemiInitials) Break-in Initials) annually/ 30 hrs. 50 hrs. Level 4 Task Comp. (DateInitials) Required to be done Annually/ 100 hrs. Level5 Task Comp. (DateInitials) 10. Check the engine accessory drive belts and fan coupling device if equipped for correct tension, wear, weather cracking, and damage. Replace as necessary. 11.
Service Schedule Maintenance Tasks 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, loose connections or components, and abnormal operating conditions. Correct as necessary. 19. Perform an engine oil analysis (send a sample to a lab for results). Change the engine oil and filters if the analysis results indicate this is required. 20. Change the engine oil. 21. Replace the engine oil filter(s). 22.
Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 5 amp fuse blown. 1. Replace fuse. 2. Tighten, clean or replace batter cables as necessary. 3. Replace contactor.* 4. Replace starter motor.* 5. Remove, change or replace battery. 6. Replace fuse.* Engine cranks but won't start 1. Out of fuel. 2.
Warranty United States Environmental Protection Agency Warranty Statement Warranty Rights, Obligations and Coverage The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new stationary emergency engine.
Warranty United States Environmental Protection Agency Compliance Requirements Purchaser’s/Owner’s Recordkeeping Responsibilities The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac), are pleased to explain your recordkeeping requirements for compliance with Subpart JJJJ – Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0F9952 0F3417 0F2984 0F9949 0F3418 0F2985 0F9950 0F9951 0G6319 0F6183 0F6187 0F6184 0F6212 0G2023 0F8757 068405C 0F3013 072878 0C9708 0F3726B 0F2689 023454 059980 046526 0A2601 072879 022473 022097 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 REF 1 1 1 4 4 1 1 8/12 4/6 ASSY ROTOR 2390 80KB3 CPL ASSY ROTOR 390 2P 100K BRSHLS ASSY ROTOR 390 2P 150K BRSHLS ASSY STATOR 80KW 1PH 2P BRSHLS ASSY STATOR 390 2P 100K BRSHLS ASSY STATOR 390 2P 150K BRSHLS UL STATOR 2390 80 GB3 CPL STATO
EXPLODED VIEW: CPL H CONTROL CB CONNECTION GROUP A DRAWING #: 0H3917 APPLICABLE TO: ITEM PART# QTY. 1 2 3 4 5 6 7 8 9 10 (1) 11 12 13 081008 0F6156 029289 0F3685 0F2885 051713 049226 0C2266 0C2428 022155 0D4698 0F4464 0F4677 067617030A 067617030B 043180 022264 0C3990 057701 024469 025433 067210A 0F3618 0A9457 057073 0D5466 022237 022241 0A7822 0F9637 0C2454 047411 022097 022473 023484N 077043J 0D6029 1 1 1 1 1 2 6 6 2 2 1 1 1 4 4 4 REF. 1 1 1 1 1 2 REF. 4 4 REF.
EXPLODED VIEW: CPL H CONTROL CB CONNECTION GROUP A DRAWING #: 0H3917 APPLICABLE TO: ITEM 3.) A C D E F G H J K L M N P R S T U V (1) W X Y 4.) A C D E F G H J K (2) L (2) M N P R (1) S T U V (2) W (2) X Y 5.) A C E F G H J K L M N P Q R S 6.) A C E H J K L M N P Q PART# QTY.
EXPLODED VIEW: CPL H CONTROL CB CONNECTION GROUP A DRAWING #: 0H3917 APPLICABLE TO: ITEM 7.) A B C D E F G H PART# QTY. DESCRIPTION NEUTRAL BLOCK 390 / 200-400A. 0D5466 2 BUS BAR NEUTRAL BLOCK 390 039287 1 SCREW HHC M8-1.25 X 45 G8.8 FT 022145 1 WASHER FLAT 5/16-M8 ZINC 022129 1 WASHER LOCK M8-5/16 045771 1 NUT HEX M8-1.25 G8 YEL CHR 045335 2 SCREW HHC 1/4-28 X 3/4 G5 022097 2 WASHER LOCK M6-1/4 0A7822 1 LUG SLDLSS 600/250-1/0X1/4-28 (1) HARDWARE FOR MTG.
EXPLODED VIEW: CPL H CONTROL CB CONNECTION DRAWING #: 0H3917 APPLICABLE TO: GROUP A THIS PAGE LEFT INTENTIONALLY BLANK REVISION: H-5277-B DATE: 11/18/09 Page 6 of 6
COMPONENTS INCL UDED IN 0G4139E 1 ENCL H/G CO NTROL PANEL 1 CO VER CONTRO L PANEL 1 HING E CONT INUOUS H PANEL 6 RIVET POP .125 X .275 SS 1 ASSY PROGRAMMED H- 100 1 DECAL FUSES LO CAT ED INSIDE 1 RAIL SNAPTRACK PCB HO LDER BULK ( 12” LG) 1 ASSY PCB 2AMP 12V UL BATT CHG R 1 PLATE HARNESS CLAMP 1 ASSY PCB PW R AVR W /AMP HEADER 1 ASSY PCB BOSCH G OV DRIVER 1 DIO BR IDG E 25A 600V 7 W ASHER LO CK M5 4 SCREW PPHM M5- 0.8 X 30 SS 7 W ASHER FLAT M5 2 SCREW HHPM M5-0.8 X 12 5 NUT HEX M5-0.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 0F3408 0F3411 058208 022131 050331A 050331 038805U 038804U 045771 022129 027482 075763 0C2454 0F3409 1 1 1 1 1 1 1 1 1 1 1 1 8 1 TRAY BATTERY STRAP BATTERY RETAINMENT BATT 12VDC 24F 625 WASHER FLAT 3/8-M10 ZINC BATT POST COVER RED + BATT POST COVER BLK CABLE BATT BLK #1 X 18.00 CABLE BATT RED #1 X 28.00 NUT HEX M8-1.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 0F30990ST03 065852 052252 052257 052259 055597 052251A 052860 0F8864 0F8865 045764 061383 045757 049813 022473 057192 022131 046526 0536210410 0E7230 027482 022097 1 1 5 5 5 4 5 4 1 1 1 1 2 2 3 6 6 6 1 1 2 2 MTG BASE C5 4.6/80KW 5.4/100KW SPRING CLIP HOLDER .37-.62 DAMPENER VIBRATION SPACER .49 X .62 X 1.87 PWDR/ZINC WASHER FLAT M12 SCREW HHC M12-1.75 X 85 G8.8 DAMPENER VIBRATION 50 WHITE NUT LOCKING M12-1.75 SUPPORT ENG 4.6L LH SUPPORT ENG 4.
1 2 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 26 27 28 29 30 0F2807C 0F2807E 0F9207 0F2807B 0F2807D 0F9208 0A6765 0F4710 0F7200 080762 0F2809 0F2981A 0F2962 0C2454 022097 0F2830 0F2773C 0F2773D 0D3159 088775 0F2808 0F5447 022473 0F6214 0F6803 049813 049721 088510 0C9748 1 1 1 1 1 1 2 6 6 8 1 2 2 4 8 2 2 2 1 6 2 1 12 2 4 4 8 6 1 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5) PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5) PIPE EXH MANIFOLD 4.6L RH PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5) PIPE EXH MAN L/H 5.
1 2 3 4 5 6 7 8 9 10 11 0D2513D 0F5419 0F4268 0F4270A 0F6977 037561 047411 022097 049811 0F4269 022473 1 1 1 1 1 1 4 4 4 1 1 AIR CLNR BTM PLT W/CPLR 8.1L ELEMENT AIR FILTER TOP PLATE VENTURI HOLD DOWN AIR CLEANER PLATED PLATE AIR CLEAN TOP 5.4L/6.8L NUT WING 1/4-20 NYLK SCREW HHC M6-1.0 X 16 G8.
1 2 3 4 (2) 5 (2) 6 (1) 7 (3) 8 0F4462 080762 0F4505 0C2454 0F4367 0F4368 0G3263 077992 1 1 1 14 2 1 3 14 RAIN CAP 2-1/2" AL BOLT U 3/8-16 X 2.62 MFLR SEC 23.5"LG 2.5"IN/OUT SCREW THF M6-1X16 N WA Z/JS HEAT SHIELD EXHAUST STACK CAP HEAT SHIELD EXHAUST STACK DECAL WARNING HOT SURFACES BI NUT HEX LOCK M6-1.0 SS NY INS NOTE: SOME “QT SERIES” UNITS WILL REQUIRE (2) GLASS PACK KITS. (1) DECALS APPLIED TO EXHAUST AT THE FACTORY. (2) PART NUMBER SHOWN IS FOR TAN.
EXPLODED VIEW: ENGCOMPRT LH 4.6L G3 GROUP D DRAWING #: 0H3914 APPLICABLE TO: ITEM 1 (1)2 3 4 (1)5 6 (1)7 (1)8 (1)9 (1)10 (1)11 (1)12 13 (1) 14 15 (1)16 (1)17 (1)18 19 (1)20 21 22 23 24 (1)25 (1)26 (3)(2)27 28 29 30 31 32 33 (1)34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 (1)52 53 54 55 (3)56 57 PART# QTY.
EXPLODED VIEW: ENG COM PRT RH 4.6L G3 GROUP D DRAWING #:0H3914A APPLICABLE TO: ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 (1)31 (1)32 33 34 35 36 37 38 39 40 41 42 43 44 PART# QTY.
EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP GROUP D DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY.
EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP GROUP D DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0D6029 055934H 072252 1 1 1 SCREW HHTT M6-1.0 X 16 ZYC CLAMP STL/VNL .62 X .406 Z GROMMET 1.37 X .06 X 1.00 (5) 65 (5) 66 (5) 67 (1) ITEM 48 IS INCLUDED WITH 47. (2) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS. (3) ITEM 61 IS INCLUDED WITH ITEM 1. (4) THESE PARTS ARE 5.4L 80KW SPECIFIC. (5) CATALYST EQUIPPED UNITS ONLY.
EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP GROUP D DRAWING #: 0H3915 APPLICABLE TO: ITEM 1 2 3 4 5 6 (1) 7 (1) 8 PART# QTY. 0G15310GS0R 0G15320GS0R 0G15300GS0R 0G15290GS0R (2) 0H30010GS0R 0G15330GS0R 0C2454 0D3215B 0C2454 2 2 1 1 1 1 20 2 8 DESCRIPTION PANEL C5 FRONT SIDES PANEL C5 REAR SIDES PANEL LOWER FRONT PANEL C5 TOP PANEL C5 TOP PANEL C5 TOP MOUNT SCREW THF M6-1 X 16 N WA Z/JS ACCESS COVER 160 X 170 GALV SCREW THF M6-1 X 16 N WA Z/JS (1) NOT REQUIRED FOR UNITS WITH CATALYST.
EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.
EXPLODED VIEW: FUEL SYSTEM NG 4.
EXPLODED VIEW: FUEL SYSTEM LP VAPOR 4.6L 80KW GROUP E DRAWING #:0H3919 APPLICABLE TO: ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 REVISION: -ADATE: 6/29/09 PART# 0G9239D 057822 0H3894 082121A 0H3921 0H4537 026915 0A8064 064346 031015 030131 039130 065908 0D1509 050280 022304 052645 0G3167 0F3691C 0H39430ST03 059057 022195 045773 0F3885 086133E 0F0960 086133D 0G7104 0E4392 0E4390 0H3766B 097962 022097 042568 049811 0D3700 QTY.
(2) 1 (2) 2 (2) 3 (3) 4 (2) 5 (2) 6 (3) 7 0F58730ST01 0F58680ST01 0F58720ST01 0F58710AL01 0F58690ST01 0F58700ST01 0F58670AL01 1 4 2 2 2 1 1 REAR WRAP C5 DOOR C5 CENTER SUPPORT C5 DISCHARGE DUCT LH & RH SIDE C5 FRONT CORNERS C5 DISCHARGE CENTER DUCT C5 ROOF C5 ALUM 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 42 43 (1) 44 45 46 47 48 49 50 51 0C2454 0F2766 0F3181 0F3185 0F3416 0F3949 0F4487A 022473 022097 022127 0F3072 078115 0F3949B 0F3949A 0F5048D 0E5968 0F
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