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Serial Number
QT
3.9L
40kW
Model: 005221-0
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.
Cover026 Rev. 0 09/05 Part No. 0F7924
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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 .........
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Standby Generator Sets Important Safety Instructions 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. GENERAL HAZARDS WARNING: � For safety reasons, the manufacturer recommends The engine exhaust from this product that this equipment be installed, serviced and contains ch
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Standby Generator Sets Important Safety Instructions � Before performing any maintenance on the gen- � Generators installed with an automatic transfer erator, disconnect its battery cables to prevent switch will crank and start automatically when accidental start-up. Disconnect the cable from the normal (utility) source voltage is removed or is battery post indicated by a NEGATIVE, NEG or (–) below an acceptable preset level. To prevent such first. Reconnect that cable last. automatic start-
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Standby Generator Sets Important Safety Instructions INTRODUCTION This symbol points out potential fire hazard. Thank you for purchasing this model of the standby generator set product line. This symbol points out potential electrical shock hazard. Every effort was expended to make sure that the information and instructions in this manual were The operator is responsible for proper and safe use both accurate and current at the time the manual was of the equipment. The manufacturer st
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Standby Generator Sets General Information NOTE: IDENTIFICATION RECORD For actual information related to this particular DATA LABEL model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data Every generator set has a DATA LABEL that contains label affixed to the unit. important information pertinent to the generator. The data label, which can be found attached to the gen- Generator Model and Serial Number erator’s lower connection box, lists the un
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Standby Generator Sets Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating cur- Use a mixture of half low silicate ethylene glycol rent generator set. It is powered by a gaseous fueled base anti-freeze and deionized water. Cooling system engine operating at 1800 rpm for 4-pole direct drive capacity is listed in the specifications. Use only deion- units, 3600 rpm for 2-pole direct drive units and ized water and only low silicate a
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Standby Generator Sets Engine Protective Devices OVERCRANK SHUTDOWN ENGINE PROTECTIVE DEVICES The standby generator may be required to operate for After a prespecified duration of cranking, this func- long periods of time without an operator on hand to tion ends the cranking if the engine has failed to monitor such engine conditions as coolant tempera- start. The overcrank LED will turn ON. Turn OFF the ture, oil pressure or rpm. For that reason, the engine AUTO/OFF/MANUAL switch, then tur
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Standby Generator Sets Fuel Systems PROPANE VAPOR WITHDRAWAL FUEL SYSTEM FUEL SYSTEM This type of system utilizes the vapors formed above FUEL REQUIREMENTS the liquid fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel The standby generator may be equipped with one of expansion from the liquid to the vapor state. The the following fuel systems: vapor withdrawal system is generally best suited for � Natural gas fuel system smaller engines that r
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Standby Generator Sets Specifications Engine Lubrication System SPECIFICATIONS Type of Oil Pump ...................................................................... Gear Oil Filter ............................................... Full Flow Spin-on, Cartridge GENERATOR Crankcase Oil Capacity ....................................................4 U.S. qts. Type ............................................................................. Synchronous Rotor Insulation ..............................
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Standby Generator Sets Specifications Figure 1 — Interconnections 10. Reverse the procedure to convert back to natural COLD WEATHER KIT gas. For cold climates, optional cold weather kit (part 11. The Dip switch inside the control panel must be number 0F6148) is recommended. The kit includes: in the LP or NG position when switching to differ- � Battery Warmer ent fuels. � 4” Junction Box with hardware Figure 6.2 — Reconfigure the Fuel System � 6 qt. pack 5W-30 synthetic oil (engine) Port 1 Po
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Standby Generator Sets General Information GENERATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING See “Voltage Codes”. This generator may be rated CONNECTIONS at any one of three voltages, either single-phase or three-phase. The electrical wires in the unit’s AC con- 3-PHASE ALTERNATORS nection (lower) panel should be installed according to the number of leads and the voltage/phase required The generator is designed to supply 3-phase electri- for the application. If there are any questions
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Standby Generator Sets Installation PRIOR TO INITIAL START-UP INSTALLATION Refer to the separate “Installation Guide QT Product Line” supplied with the unit. Prior to initially starting the generator, it must PREPARATION BEFORE START-UP be properly prepared for use. Any attempt to The instructions in this section assume that the crank or start the engine before it has been standby generator has been properly installed, ser- properly serviced with the recommended types viced, tested, a
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Standby Generator Sets Installation � Check voltage at the generator terminals. START-UP CHECKLIST � 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 generator, ensure the fol- � Check for coolant, fuel, oil, and exhaust leaks. lowing: � Close the generators main line circuit breaker. � The AUTO/OFF/MANUAL switch is in the OFF � Turn the generator set off. position. � Connect
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Standby Generator Sets Operation GENERATOR CONTROL AND OPERATION Do not crank the engine continuously for longer Refer to the appropriate control panel operator’s than 30 seconds, or the heat may manual for this unit. damage the starter motor. � Let engine stabilize and warm up. OPERATING UNIT WITH MANUAL � Check all applicable instrument and gauge read- ings. When certain that all readings are correct, TRANSFER SWITCH move the transfer switch manual handle to its If the generator was
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Standby Generator Sets Maintenance MAI NTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES The exhaust system parts from this product get extremely hot and remain hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may Before working on the generator, ensure the fol- ignite and burn from the heat of the exhaust lowing: system. � The AUTO/OFF/MANUAL switch is in the OFF position. CHECKING FLUID LEVELS � The 15A fuse has been
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Standby Generator Sets Maintenance ENGINE COOLANT CHECK FAN BELT Check coolant level in coolant recovery bottle. See the � Inspect fan belts every three months. Replace any “Specifications” section. damaged, deteriorated, worn or otherwise defec- tive belt. � Add recommended coolant mixture as necessary. � Check fan belt tension. Thumb pressure, exerted � Periodically remove radiator pressure cap to make midway between pulleys, should deflect about 3/8 sure the coolant recovery system is f
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Standby Generator Sets Maintenance 7. Start engine and check for oil leaks. COOLANT CHANGE Every year, have an Authorized Service Facility Figure 10.2 - Oil Filter drain, flush and refill the cooling system. See the “Specifications” section for cooling system recom- mendations. 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 resistanc
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Standby Generator Sets Maintenance BATTERY MAINTENANCE The battery should be inspected per the “Service Be sure the AUTO/OFF/MANUAL switch is set to Schedule” section. The following procedure should the OFF position before connecting the battery be followed for inspection: cables. If the switch is set to AUTO or MANUAL, 1. Inspect the battery posts and cables for tightness the generator can crank and start as soon as the and corrosion. Tighten and clean as necessary. battery cables a
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Standby Generator Sets 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. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use calendar time, from the
