standby generator owner's manual - Zabatt

Standby Generator SetsTable of ContentsSECTIONPAGESAFETY RULES ................................................ 1-1INTRODUCTION .....................................................1-3Read this Manual Thoroughly ...................................1-3Operation and Maintenance ......................................1-3How to Obtain Service ..............................................1-3IDENTIFICATION RECORD .....................................2-1Data Label ................................................................2-1EQUIPMENT DESCRIPTION ...................................3-1Equipment Description ................................................3-1Engine Oil Recommendations ......................................3-1Coolant Recommendations...........................................3-1ENGINE PROTECTIVE DEVICES ............................4-1High Coolant Temperature Switch ............................4-1Low Coolant Level Sensor .........................................4-1Low Oil Pressure Switch ...........................................4-1Overcrank Shutdown ................................................4-1Overspeed Shutdown ................................................4-1RPM Sensor Loss Shutdown .....................................4-1DC Fuse ....................................................................4-1FUEL SYSTEMS .....................................................5-1Fuel Requirements ....................................................5-1Natural Gas Fuel System ..........................................5-1Propane Vapor Withdrawal Fuel System....................5-1LP Fuel System .........................................................5-1SPECIFICATIONS ...................................................6-1Generator .................................................................6-1Engine.......................................................................6-1Cooling System .........................................................6-1Fuel System ..............................................................6-1Electrical System ......................................................6-1Cold Weather Kit .......................................................6-2Reconfiguring the Fuel System ..................................6-2GENERAL INFORMATION .......................................7-1Generator AC Lead Connections ..................................7-1Four-lead, Single-phase Stator ..................................7-1Alternator Power Winding Connections ........................7-13-phase Alternators ..................................................7-1INSTALLATION .......................................................8-1Installation ...................................................................8-1Preparation Before Start-up .........................................8-1Transfer Switch ........................................................8-1Fuel System ..............................................................8-1Generator Set Lubrication ........................................8-1Prior to Initial Start-up .............................................8-1Engine Coolant .........................................................8-1Belt Tension ..............................................................8-1Electrical System ......................................................8-1Initial Inspection for QT Genset Start-up .....................8-1Start-up Checklist ........................................................8-2Preparation for Start-up............................................8-2Start-up Inspection ...................................................8-2OPERATION ...........................................................9-1Generator Control and Operation ................................9-1Operating Unit with Manual Transfer Switch ...............9-1Engine Start-up and Transfer ...................................9-1Retransfer and Shutdown .........................................9-1Operating Unit with Automatic Transfer Switch ...........9-1MAINTENANCE .....................................................10-1Maintenance Performed by AuthorizedService Facilities .....................................................10-1Every Three Months ...............................................10-1Once Every Six Months ...........................................10-1Once Annually .........................................................10-1First 100 Operating Hours ......................................10-1Every 500 Operating Hours ....................................10-1Every 800 Operating Hours ....................................10-1Exhaust Manifold Procedure ......................................10-1Intake Manifold Procedure .........................................10-1Cylinder Head Procedure ...........................................10-1Cooling System ..........................................................10-2Overload Protection for Engine DCElectrical System ....................................................10-2Checking Fluid Levels ................................................10-2Check Engine Oil ....................................................10-2Battery Fluid ...........................................................10-2Engine Coolant .......................................................10-2Maintenance Owner/Operator Can Perform ................10-3Check Engine Oil Level ...........................................10-3Check Battery .........................................................10-3Exercise System ......................................................10-3Inspect Cooling System ...........................................10-3Check Engine Coolant Level....................................10-3Perform Visual Inspection .......................................10-3Inspect Exhaust System ..........................................10-3Check Fan Belt ........................................................10-3Inspect Engine Governor ........................................10-3Changing Engine Oil ...............................................10-3Changing the Engine Air Cleaner ............................10-3Spark Plugs ............................................................10-4Coolant Change .......................................................10-4Miscellaneous Maintenance ........................................10-4Cleaning the Generator ...........................................10-4Battery ....................................................................10-4Battery Maintenance ...............................................10-4Battery Replacement ...............................................10-5SERVICE SCHEDULE ...........................................11-1TROUBLESHOOTING ...........................................12-1Troubleshooting Guide ...............................................12-1NOTESEXPLODED VIEWS & PARTS LISTSWIRING DIAGRAMS & SCHEMATICSWARRANTYContent004 Rev. 0 09/05