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Generac Power Systems 005012-1 Portable Generator User Manual

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2. n LL i i i ATL e 80308899 DIFFERENTIAL STABILITY DIP SWITCH POSITION1 POSITION 2 e UNUSED GTS ATS Select N GTS ON 50HZ ON OFF 60HZ OFF ATS standard mode J gt 5 5 RETRANSFER AND SHUTDOWN When utility power source voltage has been restored electrical loads may be transferred back to that source and the generator can be shut down fol lows Verify that utility power supply voltage to the trans fer switch has been positively turned using whatever means provided such as utility main line circuit breaker Set the generator s main circuit breaker to its OFF or OPEN position Let the generator engine run at no load for a few minutes to stabilize internal unit temperatures On the generator console set the Auro OFF MANUAL switch to OFE Wait for engine to come to a complete stop For transfer to utility position refer to the Owner s Manual of the particular transfer switch Turn on the utility power supply to the transfer switch using whatever means provided such as a ut
3. EXHAUST MANIFOLD DESCRIPTION NUT TOP LOCK FL M12 1 75 SCREW HHC M12 1 75 X 80 G8 8 EXHAUST FLANGE 2 PIPE WASHER LOCK M12 EXHAUST BLANKET 800MM WASHER FLAT M12 NUT HEX 5 16 18 STEEL BOLT U 3 8 16 X 2 62 STRAP MUFFLER SCREW HHC M8 1 25 X 55 G8 8 PIPE R H SIDE EXHAUST MILD ST PIPE L H SIDE EXHAUST MILD ST INSTALLATION Section 8 Installation Diagram 1311100 3313308 131100 ISQVHX3 DNAd 13315 NIvad 110 ldNr E AOdVA 1 549 WaANLYN 137 1 15 1124 2 323IAB3S 3NION3 I3AUW33 TANVd 5839993 M3IA 3015 gr 5 o EN im 004 3SV8 L amp 193098 p p 3015 393 14 5 M dVA 599 WANLYN 7 15 6 U bo IS3HONIJ wu SLINA ps 3 591 29211 64 2 6 LINN 1 8 VIVI 3015 3 F AU s 9 2105 3 28
4. J24 ae DEG IM JB 0 1 Li 4 766 75 5 8 9 5 768 E 5 m 14 4 4 9 e 7 766 5 5 70606 e 79 6 ze y Pay 5 B6 I 771 9 4 15 r 768 10 110 0 4 23 767 11 11 194 ny 769 12 12 6 0 vs lt 7 GOV 14 25 8 239 771 1 9 767 2 10 15 765 3 R1 O QJ 11 85 770 4 12 14A N C S i 13 225 r 66 6 rd 14 66 lt C 1 0 e 0 3 0 4 0A 5 13 6 14 7 __15 DIST 8 15 9 14 25 0 1 oe 10 224 9 11 225 e 12 239 IC 86 0 23 FRONT LEGEND CUNT 1 LEGEND HIGH COOLANT TEMP SWITCH ALT D C CHARGE ALTERNATOR IGNITION COIL BAT 12700 BATTERY IGNITION MODULE Cl CONNECTOR 1 ENGINE J 1 JUNCTION 1 ON PCB CC STARTER CONTACTOR J 2 JUNCTION 2 ON PCB DEG DRIVER ELEC GOVERNOR JB JUNCTION BLOCK RUN POWER DIST DISTRIBUTOR LOS LOW OIL PRESSURE SWITCH FS FUEL SOLENOID P1 MAGNETIC PICK UP GND1 GROUND SENSING LOW AMP RI 50 WATT RESISTOR GND2 GROUND AMP SM STARTER MOTOR GOV ELEC GOVERNOR ACTUATOR WLS COOLANT LEVEL SWITCH 25 Section 6 Electrical Data 40kW Liquid cooled Generators ELECTRICAL DAA 7 Electrical Schematic Engine Drawing N
5. RC12LC4 Oil Pressure nettes 30 80 psi Crankcase Oil Capacity 4 0 U S quarts 3 8 liters Recommended Engine SAE 15W 40 of Cooling System Pressurized closed recovery Cooling Cooling System Capacity 5 0 U S gallons 19 3 liters Recommended Coolant Use a 50 50 mixture of ethylene glycol base and de ionized water Section 1 General Information GENERAL 40kW Liquid cooled Generators INFORMATION 1 11 FUEL CONSUMPTION Natural Gas 95 of Load 2596 5096 7596 10096 m3 hr 4 1 7 7 11 0 14 2 ft8 hr 143 1 271 1 388 5 502 0 LP Vapor of Load 25 50 75 100 m hr 1 7 3 3 4 7 6 0 ft8 hr 60 7 115 0 164 9 213 0 NOTE Fuel consumption is given at rated maximum continuous power output when using natural gas rated at 1000 Btu per cubic foot LP gas is rated at 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient temperature engine condi tions and other environmental factors Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges 1 12 RECONFIGURING THE FUEL SYSTEM NOTE All m
6. 05 ES S E 19130 3293 13NVd 7081405 noct SL O RE B rr 1 K z I 310 335 335 i 5 i fide EEEEEE i 9 9 5 q 2 H19N31 1636 8061 370 39 59375 4004 31DN 335 7 L ZTE1908 7 L Z v3 9681 E J i 7031409 SII 4 5 gt 5370 gt Y 0 SNILNDDW gt dAl LETEI6L S gt 8 4393884 1102412 3NITNIVW H AB3IIVS 2 89 906 AD 92 0 HVGZ N3HlI3 TIIA AVAL 8 X 5 11 S X ISNOISN3WIC 34015 AVAL AB3LIIVH W31SAS ONNOAD 3 11993 LIDA 1 r I 7051409 NI 1591 310W33 NV 1 du d HOLIMS BN3JSNVal 50941 404 SINIDd 123 2 I LTZJES ee SALON 8074 v1 v3av S310H ONTLNNOW pee LEGOSISEIS 1 5 44 Section 9 Notes 40kW Liquid cooled Generators Section 9 Notes 40kW Liquid cooled Generators NOTES 45 Section 10 Warranty WARRANTY 40kW Liquid cooled Generators GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR QUIETSOURCE PREPACKA
7. RECTIFIER ASSEMBLY SCALE NONE MICA e J ITEM PART NO DESCRIPTION ak 4 CO C 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 0 7195 0 7196 0 7197 0 7193 0 7194 0 4494 082573 032300 022676 067682 060015 054199 0 2657 099076 040213 0 9668 067680 0 6875 0E6881 0C5139 0 5142 0E3161 054450 0D5070A 0E2514 0A9457 0E7539 046357 0D3719B 0570
8. NOTE The BCI number should be located directly on the battery Part Name Part Number Oil Filter 0E7415 046627 0A4637 Champion RC12LC4 Radiator Cap Air Cleaner Spark Plug 19 Section 4 Maintenance MAINTENANCE 40kW Liquid cooled Generators 2 09 4 7 SCHEDULED MAINTENANCE Following is a recommended maintenance schedule for small standby and residential generator sets 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 previous maintenance interval to determine the next required maintenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 Anearly inspection of the generator set to ensure it is ready to operate when required and to identify any poten tial problem areas Performed monthly this procedure requires approximately 5 man hours per unit to complete This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load
9. 059194 064945 001509 050279 0 7839 0 6586 0 4394 040105 0E6382B 0 2119 0 6376 042561 0 7929 044637 0 6406 0 7702 0A4632A 037561 046580 0E8286 044118 049815 049226 051713 022097 057796 057795A 052223 061012 0E9295 0F3994 0E7121 k ik k E k ES S cx k x Wy IND es NY amp x SCREW HHC 5 16 18 X 1 1 4 G5 FLANGE FUEL INLET ASSY REG 3 9L N G LPV 1800RPM SCREW HHC 8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK 8 5 16 NUT HEX M8 1 25 G8 YEL CHR SCREW HHC 8 1 25 X 16 08 8 SCREW TH FRM M6 1 X 16 N WA Z US ELBOW 90D STREET 3 4 FUEL HOSE ASSY NAT GASIL PV BRACKET REGULATOR 3 0L FORD HSB CLAMP HOSE 8 53 1 00 HOSE 5 8 ID LPG amp NG 36 LG GASKET CARB ADAPTOR DECAL INLET PRESSURE DECAL FUEL INLET NG MACHINING CARBURETOR ADAPTOR GASKET BOSCH 32 amp 40 ACTUATOR BOSCH 40 GOVERNOR HOSE COOL 2IN ID 2084 2 LG VENTURI HOLDER W 40MM ACTUATOR O RING 45 63 ID X 2 62 WIDTH VENTURI 28 ID THROTTLE W CHOK CLAMP HOSE 36 1 88 2 75 BASE AIR CLEANER PLATE FILTER AIR 11 5 CA326 HOLDER VENTURI HOLD DOWN AIR CLEANER PLATE AIR CLEANER TOP NUT WING 1 4 20 NYLK SCREW SHC 6 1 0 X 45 G12 9 STREET EL 45DEG 1 2 NPT BRASS BARBED STR 1 2NPT X 5 8 SCREW HHC M5 0 8 X 16 G8 8 WASHER LOCK M5 WASHER FLAT M5 WASHER LOCK 6 1 4 GROMMET BARBED EL 90 3 4 PLASTIC HOSE 1 2 ID SAE 30R2 FUEL OIL PLUG STD PIPE 1 8 SOCKET HEA
10. 30 31 32 33 34 35 36 37 38 0 5048 0 7477 0 6703 0 8336 0 7841 0 7254 0 7956 0 7953 047411 0 8591 0 7921 0 7749 022097 022473 049721 049813 036833 022131 022237 0 6729 022129 049821 057073 052677 066849 056739 002244 087599 0E0992B 0E0992A 0E7754 0E7854 0E7855 0E7952 0E0561 035606 061012 0A8584 FLEXPLATE 3 9L HSB MACHINING 3 9L ENGINE ADAPTOR COVER FLYWHEEL ACCESS REWORK 3 9L CHRYSLER ENGINE GASKET THERMOSTAT ADAPTOR MACH THERM ADAPTOR 3 9L CHRY BRACKET IGNITION COIL COIL IGNITION 3 9L CHRYSLER SCREW HHC M6 1 0 X 16 G8 8 BOLT AUTO TRANS CRANKSHAFT BRACKET ALTERNATOR FAN SPACER ENGINE COOLING WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW HHC M6 1 0 X 35 G8 8 BLK NUT HEX M6 X 1 0 G8 YEL CHR SCREW HHC 3 8 16 X 1 G8 WASHER FLAT 3 8 M10 ZINC WASHER LOCK 3 8 STARTER DELCO REMY 12V WASHER LOCK 8 5 16 SCREW SHC 8 1 25 X 30 G12 9 JUNCTION BLOCK 3 8 16 WASHER NYLON 50 X 87 06 SCREW HHTT M5 0 8 X 16 RELAY SOLENOID 12VDC PNL MNT ASSY MAGPICKUP 3 8 24 MALE PLUG PLASTIC 3 8 NPT PLUG EXPANSION 21 32 OD WATER PUMP QTY 1 PLUG EXPANSION 14 1 OD INJCTOR HOLE QTY 6 COOLING FAN 10 BLADE KYSAIR CLUTCH COOLING FAN TENSIONER W BRACKET PULLEY CRANKSHAFT 3 9L CRYSLR ASSY WATER LEVEL SENSOR C E PL SENSOR HI COOLANT SHUTDOWN PLUG STD PIPE 1 8 SOCKET HEAD SWITCH OIL PRESSURE10 PSI 2POL Section 7 Exploded Views and Parts 40kW Liquid co
11. 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiring for loose connections corrosion and damage Correct as necessary 10 Check the engine accessory drive belts for wear weather cracking and damage Replace as necessary 11 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 12 Test the engine and transfer switch safety devices Correct and or adjust as necessary 21 Section 4 Maintenance MAINTENANCE 40kW Liquid cooled Generators 13 14 15 16 17 19 20 21 Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task mended Comp to done Comp lto done Comp Required to be Date 3 months Date Semi Date be done monthly Initials Break in Initials annually Initials Annually Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 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 Chang
12. Exhaust Manifold 25 ft lb 1 14 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE SE Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Above 80 27 C 15W 40 15W 40 SAE 15W 40 32 to 80 F 1 to 27 C Below 32 F 0 C NOTE 5W 30 full synthetic oil is highly recommended in any element with temperatures above 90 F or below 30 F caution Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure 1 15 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and half de ionized water Cooling system capacity is about 20 U S quarts 19 3 liters Use only de ionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolant mixture When adding coolant always add the recommended 50 50 mixture caution 4 AN Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chro miumhydroxide green slime forms and will cause overheating Engines that have been oper at
13. J 414 1 225 12 239 ic x 2 0 0 2 23 66 FRONT LEGEND LCUNT 1 LEGEND HIGH COOLANT TEMP SWITCH ALT D C CHARGE ALTERNATUR IGNITION COIL BAT 12 0 BATTERY IM IGNITION MODULE C1 CONNECTOR 1 ENGINE J 1 JUNCTION 1 UN PCB STARTER CONTACTOR J e JUNCTION DEG DRIVER ELEC GOVERNOR JB JUNCTION BLOCK RUN POWER DIST DISTRIBU LOS LOW PRESSURE SWITCH FS FUEL SOLENOID P1 MAGNETIC PICK UP GND1 GROUND CSENSING LDW AMP R1 50 WATT RESISTOR GNDe GROUND CPUWER HIGH AMP SM STARTER GOV ELEC GOVERNOR ACTUATOR WLS COOLANT LEVEL SWITCH 27 4 S 4 l 8 x INNON E gt J 3NON3 77 S HOLOVINOO CA HALHVIS le 8 OL Section 7 Exploded Views and Parts Mounting Base Drawing 028084 40kW Liquid cooled Generators a v 1108 7 2 H31HVLS A OL x X 61 ve e 32018 x 9 o Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Mounting Base Drawing No OE8084 C age LISTS 1 PO ask O CO no C co 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
14. drifting consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it This genset must be installed on a level surface The base frame must be level within 1 2 inch all around Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow five feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install the generator as close as possible to the transfer switch This reduces the length of wiring and conduit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE 2 3 GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a concrete slab with 1 4 inch masonry type anchor bolts Be sure the bolts are long enough to retain the compartment The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides See Mounting Dimensions for generator major dimensions INSTALLATION Section 2 Installation 40kW Liquid cooled Generators 2 4 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic diagram of a basic standby electric system Both the UTILITY power supply and the STANDBY GENERATOR output are connected to an appro
15. 9L FAN GUARD TOP FAN GUARD BOTTOM BRACKET WATER BOTTLE 1 5L MIT TANK COOLANT RECOVERY CLAMP HOSE 28 1 32 2 25 HOSE OIL DRAIN ASSY 21 SCREW CRIMPTITE 1 4 20 X 5 8 SCREW TH FRM M6 1X16 N Z JS TAPE FOAM 1 X 1 2740 CLAMP HOSE BAND 1 4 HOSE 9 32 ID 30 LG SCREW SWAGE 10 32 X 5 16 Z YC RADIATOR SUPPORT SIDE BARBED STR 1 4NPT X 3 8 SPRING CLIP HOLDER 37 62 SCREW HHC 10 1 5 X 20 G8 8 WASHER FLAT 3 8 M10 ZINC WASHER LOCK M10 NUT HEX 10 1 5 G8 YEL CHR 37 G 1O3INVIN p N E 6 8 59 2 52 80 2 55 5 95 o lt 5 vv 5 5 gt 5 N LISTS 00 PARTS 9 3NION3 OL 090909090 905090000 56000000000000000000090 4660000050000000000000000 5050505050505050000000 a Le Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Fuel System Drawing No 0E8122 H age LISTS 1 P 4 GD 02 O1 OO O1 CO O O1 CO C O1 CO n9 cO 033212 075580 0 8365 039253 022145 022129 045771 042907 0 2454 026307 0 1056 0 6584 057822
16. AR 5 213 4 4 4 4 4 AVR B C RUP is 6 5 e 5H 5 9 6 224A 224 T 6 Lau 2 2 162 2054 ees DPE AAA 00090700 0 2 od 42 3 8 44 i SW2 5 MEN 44 6 23 11 154 7 5 mS Se ae 11000422 33 49 44 178 79 41 224 10 S CL 1 1 54 225 11 pet Ae 5 1239 239 12 5 Z 194 SW SHOWN 00 UL 183 POSITION NB IRANSFER SWITCH 1 178 CUSTOMER CONNECTION 20 240V 1 PHASE Section 6 Electrical Data 40kW Liquid cooled Generators 5 ELECTRICAL Electrical Schematic Engine Drawing No 0 8116 DATA H A 14 Di 9 0 79 0 SLD 402 0 194 ON 25 a x a QJ ON lt 1 2 3 4 6 7 DIST 8 0 7 6 9 5 5 0 224
17. OFF TYPE A KNUCKLE 24 0D2537 1 HINGE LIFT OFF TYPE A PIN 25 0D2023 2 TRIM VINYL SELF GRIPPING 91 LG 26 0E7869 2 BRACKET STIFFENING BACK 27 0 8001 1 MUFFLER BOX 28 0F5568 1 ROOF HSB AL ACOUSTIC 29 0E8798 1 BRACE FRONT TOP 30 0D3037A 1 LATCH 1 4 TURN NONLOCKING 31 0C7781 2 PAWL DOOR HSB 32 0E5910 1 SUPPORT LH SIDE HSB AL 33 0E8052 1 MUFFLER BOX TOP 34 0D3037 1 LATCH QUARTER TURN LOCKING 35 0E5900 1 POST CORNER LH FRONT HSB AL 36 0E5901 1 POST CORNER RH FRONT HSB AL 37 0F4938A 1 BRACE FRONT BOTTOM 38 0E8415 1 DUCT DISCHARGE MID AL 39 026850 4 WASHER SHAKEPROOF EXT 1 4 STL 40 0912970063 2 ASSY WIRE 14AWG 7 5 0 GRN YEL 41 0912970064 2 ASSY WIRE 14AWG 7 5 0 GRN YEL 42 049813 2 NUT HEX M6 X 1 0 G8 YEL CHR 43 0E8416 1 DUCT INTAKE LH AL 44 0E8417 1 DUCT INTAKE RH AL 45 0 8665 1 BRACKET STIFFENER LH FRONT 46 0D2023 1 TRIM VINYL SELF GRIPPING 165 5 LG 47 0E7829N 2 AI ROOF PANEL 2 48 0E7829T 1 SUPPORT RH PANEL 49 0E7829S 1 SUPPORT LH PANEL 50 0 8442 1 KIT INSULATION 3 9L HSB 51 0 7829 1 PANEL 1 52 0E7829B 2 Al DOOR PANEL 53 0E7829P 4 AI CORNER POST PANEL 1 54 0E7829R 2 CORNER POST PANEL 2 55 043116 8 SCREW HHC 6 1 0 X 12 G8 8 ALL ITEMS NOTATED WITH AI ARE COMPONENTS OF 0E8442 31 Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Drawing No 0E7118 K Control Panel E TAIL 1
18. See Torque Specs EVERY 500 OPERATING HOURS 1 Service air cleaner 2 Check starter 3 Check engine DC alternator 42 COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling ventilating air flow the engine generator quickly overheats which causes it to shut down See the Mounting Dimensions drawing for installation and vent locations warninc amp 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 ignite and burn from the heat of the exhaust system 16 4 3 OVERLOAD PROTECTION FOR ENGINE ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via a 15 amp fuse These overcurrent protection devices will open if the circuit is overloaded caution If a circuit breaker opens fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse 44 CHECKING FLUID LEVELS 441 CHECK ENGINE Check engine crankcase oil level Figure 4 1 at least every 20 hours of operatio
19. ZYC 44 0C2323 4 SCREW PHTT 46 32 X 5 8 ZYC 45 022155 15 WASHER LOCK 6 46 0C2265 4 SCREW PHTT M4 0 7 X 12 ZYC 47 022264 4 WASHER 8 M4 49 020911 2 SCREW 5 0 8 X 30 ZINC 50 066849 2 SCREW 5 0 8 X 16 51 022152 4 WASHER LOCK 10 52 023897 3 WASHER FLAT 10 ZINC 53 051716 2 NUT HEX M5 0 8 G8 YEL CHR 54 090388 2 SCREW HHTT M6 1 0 X 12 ZINC 55 042568 4 SCREW HHC M6 1 0 X 20 G8 8 56 022097 8 WASHER LOCK M6 1 4 57 022473 6 WASHER FLAT 1 4 M6 ZINC 58 0441140187 2 WIRE ASSY 3 X 2 3 16 TABS 59 070370 2 WASHER MICA 203 60 023762 1 WASHER SHAKEPROOF EXT 10 STL 61 055444 1 HEATSINK 62 030468 1 WASHER STEP NYLON 20 63 049939 1 RECTIFIER MSC 12A 600V 1N1206R 64 022158 1 NUT HEX 10 32 STEEL 65 022985 1 WASHER FLAT 46 ZINC 66 038750 2 SCREW HHC M6 1 0 X 30 G8 8 67 0A2115 4 WASHER NYLON 257 68 002454 4 SCREW THF M6 1 X 16 N WA Z JS 69 0F6146 1 HANG TAG 2 WIRE START NOT SHOWN ITEMS INCLUDED AS PART 39 33 PARTS 5 LISTS Section 7 Exploded Views and Parts 40kW Liquid cooled Generators 0 Engine Drawing 0 8121 5 WITH ENGINE BAFFLE REAR UPPER NS Z VE lt D C ALTERNATOR BRACKET HARDWARE ITEM PART NO DESCRIPTION gt RD PO PP e CO QC O1 C
20. approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 of an inch 10 to 16 mm 2 11 7 ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground and or ground rod Section 3 Operation 40kW Liquid cooled Generators ix Make sure the generator battery is fully charged prop erly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components 3 1 USING AN ENGINEERED GTS TRANSFER SWITCH When required the pre packaged standby generator can be installed with an engineered GTS type auto matic transfer switch In this application the GTS is responsible for utility sensing weekly exercising and load transferring Position two of the four position dip switch is used to turn over this control to the GTS Pos2 ON GTS Application The control board will NOT monitor utility The control board will NOT perform a weekly exercise The five red LEDs will not flash in this mode The control board will NOT activate the transfer output The control board WILL monitor all engine condi tions and shut down on all the faults listed in this document Pos2 OFF Prepackaged ATS Application The control board will perform all of the automatic features listed in this docume
21. be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks imme diately Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detectors accordingly Section 1 General Information 40kW Liquid cooled Generators 1 1 GENERATOR This equipment is a liquid cooled engine driven generator set The generator is designed to supply electrical power that operates critical electrical loads during utility power failure The unit has been facto ry installed in a weather resistant all metal enclosure and is intended for outdoor installation only Use this generator as a source of electrical power for the operation of 120 and or 240VAC single phase loads warninc AN If this generator is used to power electrical load circuits normally powered by a utility power source it is required by code to install a trans fer switch The transfer switch must effectively isolate the electric system from the utility distri bution system when the generator is operating NEC 701 Failure to isolate an electrical system by such means results in damage to
22. ing The slightest spark can ignite the gas and cause an explosion Such an explosion can shat ter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smok ing open flame sparks or any spark producing tools or equipment near the battery AN Battery electrolyte fluid is an extremely caus tic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If the fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster battery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging MAINTENANCE Section 4 Maintenance 40kW Liquid cooled Generators wanNING Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the UTILITY power supply is turned OFF or sparking may occur at the battery posts as the cables are attached and cause an explosion 4 6 4 BAITERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 27F 700 0 deg F
23. lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator AN Parts of the generator are rotating and or hot dur ing operation Exercise care near running genera tors N GENERAL HAZARDS For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by an Authorized Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regula tions The operator also must comply with all such codes standards and regulations Installation operation servicing and repair of this and related equipment must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electri cal and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the genera tor is installed operated and serviced in accordance with the manufacturer s instructions and recommen dations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions 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 reas
24. or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Revision 2 05 Part No OF4946 Revis
25. the genera tor and may also result in injury or even death to utility power workers due to backfeed of electrical energy 1 2 TRANSFER SWITCH This generator system is intended to be used with the manufacturer s transfer switch It will be avail able in either a NEMA 1 enclosure or a NEMA 3R enclosure The NEMA 1 enclosure is intended for indoor use only The NEMA 3R enclosure is weather proof and can be used indoors or outdoors Follow these rules Install the transfer switch on a firm sturdy sup porting structure To prevent switch distortion level the switch if necessary This can be done by placing washers between the switch enclosure and the mounting surface Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors An Authorized Dealer can supply an appropriate transfer switch for the generator 1 3 AUTOMATIC SYSTEM OPERATION When this generator along with a transfer switch has been installed and interconnected a circuit board in the generator panel constantly monitors UTILITY power source voltage Should that voltage drop below a preset value and remain at such a low state for a preset amount of time the generator cranks and starts After the generator starts the transfer switch transfers load circuits so the generator can power them When utility sourc
26. 41 42 43 SHOWN USED TO HOLD DOWN 32 0E7331 052860 052251 052257 052252 052259 052891 0536210214 074906 047411 055414 026850 022097 022473 049813 0A1694 025507 0E7359 027482 022129 045771 051756 046526 022131 055934M 049820 059473 061902 058665 038804D 038805J 021991 036833 022237 022131 0F3976 050331 050331A 0A4010 052858 065852 045764 a PES RUE C CUTE MR by TY WELDMENT MTG 3 9L CRYSLR FLANGED 12 1 75 DAMPENER 40 BLUE SPACER 49 X 62 X 1 87 PWDR ZNC DAMPENER VIBRATION WASHER FLAT M12 SCREW HHC M12 1 75 X 80 G8 8 ASSY WIRE 15 0 SCREW HHTT M6 1 0 X 20 BP SCREW HHC M6 1 0 X 16 BP LUG SLDLSS 2 8 X 17 64 CU WASHER SHAKEPROOF EXT 1 4 STL WASHER LOCK 6 1 4 WASHER FLAT M6 1 4 ZINC NUT HEX M6 1 0 G8 YEL CHR 1 1 2 BUTTON PLUG WASHER SHAKEPROOF EXT 7 16 STL ENGINE MOUNT 3 9L CHRYSLER WASHER SHAKEPROOF EXT 5 16 STL WASHER LOCK M8 5 16 NUT HEX 8 1 25 G8 YEL CHR SCREW HHC M10 1 5 X 20 G8 8 WASHER LOCK M10 WASHER FLAT 3 8 M10 ZINC CLAMP VINYL 75 X 343 2 NUT HEX LOCK M8 1 25 NY INS HOLD DOWN BATTERY HOLD DOWN BATTERY BATT 12VDC 90 AH 27F NOT INCLUDED CABLE RED 4 X 20 00 CABLE BATT BLK 1 X 30 00 EARTH STRAP SCREW HHC 3 8 16 X 1 G8 WASHER LOCK 3 8 WASHER FLAT 3 8 ZINC CONTACTOR CABLES BATTERY POST COVWER BLACK BATTERY POST COVWER RED SC
27. 73 0 7283 0E3628 0E3664 0E7539A 0D4698 0E7252 001229 icem R AS ek ek REF REF REF CONTROL BOX HSB COVER FRONT PANEL HSB COVER TOP PANEL HSB DECAL WARNINGS HSB DECAL CONTROLS HSB SWITCH ROC DPDT ON OFF ON SWITCH ROCKER DPST 125V SPD HOLDER FUSE FUSE 15 X AGC15 FUSE 4 SLO BLO GLASS FITTING CONDUIT 90D 3 8 DECAL DANGER HIGH VOLTAGE TRANSFRMR 16V 6VA TRANSFORMER 16V 56VA PCB SUPPORT SNAP IN 1 4 ASSY PCB HSB CONTROLLER ASSY VOLTAGE REGULATOR 60HZ RELAY 12VDC C FORM W DIODE SOCKET RELAY CONN DEUTSCH RECEPT GY FLN CONN DEUTSCH RECEPT WDGE BLKHD ASSY BOSCH GOV DRIVER CIRCT BRK 5 5 X 1 ETA 46 500 P ASSY 2 12V UL BATTERY CHARGER FITTING CONDUIT STR 1 1 2 DECAL NEUTRAL DECALCUSTOMER CNNCTN XFER SW BLOCK TERM 20A 6 X 6 X 1100V DECAL CUSTOMER CNNCTN JUNCTION BLOCK 3 8 16 CB 0150A2P240V S QN2 LL CB 0200A2P240V S QN2 LL BASE QN CIRCUIT BREAKER DECAL TB1 HSB CONTROL PANEL BLOCK TERM 20A 6 X 3 X 1100V BRACKET CB 221 5 X 102 DECAL WARNING ELECTRICAL SHOCK Section 7 Exploded Views and Parts 40kW Liquid cooled Generators PARTS 5 LISTS Control Panel Drawing No 0E7118 K 0 37 001127 1 DECAL AVR COVER 38 0A1441B 1 COVER PLATE AVR 39 0E7128 1 HARNESS CNTRL PNL NOT SHOWN 40 0E7358 8 SCREW PPPH HI LO 4 24 X 3 8 41 074908 6 SCREW HHTT M5 0 8 X 10 BP 42 0C5141 1 CONN DEUTSCH GASKET 8 12 POS DT 43 0C2699 11 SCREW 6 32 X 3 8
28. 9 12 lt 44 E NB lt lt 23 23 H 66 66 CUS LEGEND CENT 1 LEGEND FUSE B C 4 AGC TYPE AVR AUTOMATIC VOLTAGE REGULATOR ICT INTERCONNECT TERMINAL BLOCK BRUSH ASSEMLY GENERATOR NB NEUTRAL BLOCK B C BATTERY CHARGER RLI RELAY 1 BULKHEAD CONNECTOR 1 ENGINE SW1 AUTO OFF MANUAL SWITCH CIRCUIT BREAKER OUTPUT SET EXERCISER SWITCH CIRCUIT BREAKER EXCITATION TBI TERMINAL BLOCK 1 DI DIODE FIELD BOOST TRANSFORMER 1 56 VA 240 16 VAC FI FUSE POWER 15 AGC TYPE TRe TRANSFORMER 2 6 VA 240 16 VAC Section 6 Electrical Data 40kW Liquid cooled Generators 42 ELECTRICAL Wiring Diagram Engine Drawing No 0E8115 A
29. A nega tive ground system is used Battery connections are shown on the wiring diagrams Make sure all batter ies are correctly connected and terminals are tight Observe battery polarity when connecting batteries to the generator set NOTE Damage will result if the battery connections are made in reverse 2 11 PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed ser viced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules on pages 2 and 3 as well as all other safety information in this manual before attempting to operate this and related equip ment 2 11 1 PRIOR TO INITIAL START UP caution Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure 12 Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information and or service intervals please refer to the Maintenance section 2 11 2 TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires
30. D ASSY THROTTLE 28MM PCV VALVE 2 5L FORD O RING 47 625 ID X 2 38 WIDTH PARTS 40kW Liquid cooled Generators 0 Alternator Drawing 5092 LOCKTIGHT JA I y 4 Lr N E j 5 k E Z E 5 PARTS Section 7 Exploded Views and Parts 50 LISTS 40kW Liquid cooled Generators Alternator Drawing No 0F5092 B 0 11 12 13 14 15 16 17 18 19 20 21 ROTOR REPLACEMENT PARTS 30 31 0 1659 0 1657 0 1655 0 5073 0E7413A OF1660A 0 1658 0 1656 0 5074 0E7412A 0E5706 0 5048 0 5048 0 6668 0 6076 046526 051755 045761008 04576100 043123 051779 0E7587 023365 092980 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F 047248 070892 TA k amp sk sk k 1 REF 0E5048B ROTOR 390 15KW 1 DIRECT HSB 2 5L FORD ROTOR 390 20KW DIRECT HSB 2 5L FORD ROTOR 390 25KW 1 DIRECT HSB 2 5L FORD ROTOR 390 0 1 HSB TECUM RTR 390 40KW 1P DIRECT HSB STR 390 15AD HSB 382 LONG 2 51 FORD STR 390 20AD HSB 382MM LONG 2 5L FORD STR 390 25AD HSB 382MM LONG 2 5L FORD STR 390__30AD1 HSB TECUM STR 390 40AD HSB 433MM LONG REAR BEARING CARRIER 390 DRCT FLEXPLATE 3 0L FORD REF FLEXPLATE 2 5L FORD FLEXPLATE HSB 3 9L CHRYSLER FLYWHEEL ASSY 3 0L HSB LG
31. GEAR REVCOR FAN 10 75 X 2 W PRESS DIS WASHER LOCK M10 SCREW HHC 10 1 5 X 16 08 8 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD amp 2 5L FORD STUD M14 2 0 X 540 G5 ZINC WASHER LOCK M14 NUT HEX M14 2 0 G8 YEL CHR ASSY BRUSH HOLDER 390 HSB WASHER SHAKEPROOF INT 48 SCREW PPHM 4 0 7 X 25 SCREW SHC M10 1 5 X 30 G12 9 WASHER FLAT 688 ID X 3 25 OD KEY SQ 3 8 X 1 STEEL SCREW HHC M16 2 0 X 45 G8 8 WASHER LOCK 8 4 WASHER FLAT 48 ZINC CONDUIT FLEX 1 1 4 307 3 0L FORD amp 3 9L CHRYSLER CONDUIT FLEX 1 1 4 18 LG 2 5L FORD BALL BEARING 45 MM SLIP RING MACHINED 41 Gi ITEM NO 1 0F0738 2 0C9748 3 0F0778 4 0F0777 5 0 5914 6 0 0170 7 0F6258 8 036797 9 039253 10 022145 11 022129 12 045771 13 0C2454 42 LISTS Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Muffler Drawing No 0F4894 B TY 1 1 1 1 1 ro gt DESCRIPTION MUFFLER 7 X9 2 2 IN 2 5 OUT PLUG M18 1 50 PIPE R H SIDE EXHAUST MILD ST PIPE L H SIDE EXHAUST MILD ST BRACKET MUFFLER 3 0L FORD HSB EXHAUST BLANKET 675MM PIPE MUFFLER OUT BOLT U 5 16 18 X 2 25 SCREW HHC 8 1 25 X 20 8 8 WASHER FLAT 5 16 M8 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR SCREW TH FRM M6 1 X 16 N WA ZJS ITEM APART NO 14 052860 15 052891 16 0 8816 17 051769 18 0E0170B 19 049808 20 022259 21 080762 22 0E8726 23 039288 24 0 5612 25 0 6262
32. GED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the date of original sale Generac Power Systems Inc Generac warrants that its Quietsource generator will be free from defects in material and workmanship for the items and period set forth below Generac will at its option repair or replace any part which upon examination inspection and testing by Generac or an Authorized Warranty Service Dealer is found to be defective Any equipment that the purchaser owner claims to be defective must be examined by the nearest Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Quietsource prepackaged emergency automatic standby generators sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS ONE and TWO 10095 one hundred percent transferable coverage Labor and Part s listed proof of purchase and maintenance is required Engine All Components Alternator All Components Transfer System All Components All warranty expense allowances are subject to the conditions defined in Generac s Warranty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Quietsource generators that utilize non Generac replacement parts Quietsource generators utilizing non Generac automatic transfer switches Repairs or diagnostics perfor
33. N HARNESS IGNITION 3 9L CHRY NOT SHOWN PLATE FLEX DISK SPACER SCREW SHC 3 8 16 X 1 5 G8 8 NZ HEAT SHEILD L H SIDE SCREW THF M6 1 X 16 N WA Z JS BARBED EL 90 3 8 NPT X 3 8 HOSE OIL DRAIN ASSY 21 HOSE CLAMP BAND 5 8 HEAT SHIELD SIDE PLUG STD PIPE 3 8 STEEL SQ HD SCREW SHC 3 8 16 X 2 68 8 NZ 35 PARTS 5 LISTS Section 7 Exploded Views and Parts 40kW Liquid cooled Generators 0 Radiator Drawing No 0 8102 TO A 17 18 14 4 o 7 N E AQ 4 7 us SS 16 4 ENGINE Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Radiator Drawing No 0 8102 age LISTS ND 4 O O1 O cO 0D7825A 007174 0E7640 0E7924 0F2853 0D8252 0D8251 0E0726 076749 035685 069860 058443 0 2454 052250 048031 029032 0A2111 0E7640A 035461 065852 051756 022131 046526 045772 ds L cx E C DA cas ck RADIATOR BRASS VENTURI 3 9L CRYSLR HSB 22 FAN RADIATOR SUPPORT L H SIDE HOSE LOWER RADIATOR HOSE RADIATOR UPPER 3
34. ONAL ELECTRICAL CODE No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 2 1 2 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following informa tion pertaining to the installation and use of standby electric systems is available NOTE It is essential to use the latest version of any stan dard to ensure correct and current information Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOR obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 INSTALLATION Section 2 Installation ASAE EP 364 2 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRIC available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 A52 1 AMERICAN NATIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYSTEMS available from the American National Standard Institute 1430 Broadway New York N Y 10018 2 2 GENERATOR LOCATION Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air always is available Consider these factors Install the unit where air inlet and outlet open ings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or
35. REW HHC 8 1 25 X 60 G8 8 FT NUT TOP LOCK FL M8 1 25 SPRING CLIP HOLDER 37 62 SCREW HHTT M4 0 7 X 8 BP LISTS Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Enclosure Drawing No 0F4930 C SEE LATCH REQUIRE INSULATION SECURE AS SHOWN a LLI E Y o a 5 m E E MMMM 5 LATCH DETAIL Section 7 Exploded Views and Parts CG urs 40kW Liquid cooled Generators Enclosure Drawing No 0F4930 C 0 1 0 8418 1 DUCT INTAKE AL 2 0 8414 1 DUCT DISCHARGE RH AL 3 0E8413 1 DUCT DISCHARGE LH AL 4 002454 62 SCREW TH FRM 6 1 X 16 Z JS 5 0E7807 1 BAFFLE REAR BOTTOM 6 0 5902 1 POST CORNER LH REAR HSB AL 7 0E5903 1 POST CORNER RH REAR HSB AL 8 0E8387 1 BAFFLE REAR TOP 9 0E5912 2 DOOR SIDE HSB AL 10 0 5570 1 SUPPORT RH SIDE HSB AL 11 089961 2 FOAM STRIP 3 4 WIDE X 3 16 THK 40 LG 12 0A2115 4 WASHER NYLON 257 13 0 8404 1 STIFFENER 14 0D2538A 1 HINGE LIFT OFF TYPE B KNUCKLE 15 0D2538 1 HINGE LIFT OFF TYPE B PIN 16 078115 8 WASHER SELF LOCKING DOME 17 022097 12 WASHER LOCK M6 1 4 18 022473 12 WASHER FLAT 1 4 M6 ZINC 19 0E7570 2 GAS SPRING 20 0E7571 4 BALL STUD GAS SPRING MOUNT 21 070015 4 NUT HEX 5 16 18 LOCK 22 0E7662 4 SCREW WING M6 1 00 X 25 23 0D2537A 1 HINGE LIFT
36. WOUIETSOURCE Owner s Manual Liquid cooled Prepackaged Standby Generators Model No 005012 1 37kW NG 40kW LP OUIETSOURCE This manual should remain with the unit ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION INTRODUCTION Thank you for purchasing this model ofthe QuietSource standby generator set product line by Generac Power Systems Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ ten However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest Authorized Service Dealer for start ing operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to spe cial instructions about a particular service or opera tion that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows A DIE A After this heading read instructions that if not strictly complied with will result in personal injury or property damage WARNING amp After this heading read instructions that if n
37. by setting the control panel AUTO OFF MANUAL switch to the OFF position Remove the control panel fuse Turn off the battery charger Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to ensure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ONLY ONCE following the first three months after purchase of the unit and requires approxi mately 2 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer 3 Anoperational inspection of the generator set to ensure it is ready to operate and carry the load when required and to identify any potential problem areas Performed semi annually this procedure requires approximately 1 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer 4 A mid level inspection of the generat
38. c Operatiori 1 conterere reti one 15 3 7 Weekly Exercise Cycle eem retten tene 15 Section 4 16 4 1 Maintenance Performed by Authorized Service Facilities 4 2 Cooling 4 3 Overload Protection for Engine DC Electrical SyStem uuu uu 16 4 4 Checking Fluid Levels 16 4 5 Maintenance Owner Operator uei perisse Sua Cu E eer RR UPS 17 4 6 Miscellaneous Maintenance 18 4 7 Scheduled Maintenance 20 Section 5 TROUBLESHOOTING 23 Section 6 ELECTRICAL DATA 24 Section 7 EXPLODED VIEWS AND PARTS LISTS 28 Section 8 INSTALLATION DIAGRAM 43 Section 9 NOTES 44 Section 10 WARRANTY Back Cover RULES 40kW Liquid cooled Generators 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 SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenanc
39. capacity is 4 0 U S quarts 3 8 liters caon After refilling the with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 17 MAINTENANCE 2 09 Section 4 Maintenance 40kW Liquid cooled Generators 7 Start engine and check for oil leaks Figure 4 2 Oil Filter 4 5 11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 0A4637 remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover See the Service Schedule for air cleaner mainte nance 4 5 12 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plugs to clean 2 Remove the spark plugs and check the condi tion Replace the spark plugs if worn or if reuse is questionable See the Service Schedule for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 1 01 mm 0 040 inch by carefully bending the ground electrode Figure 4 3 Figure 4 3 Setting the Spark Plug Gap SET PLUG GAP AT 1 01 mm 0 040 inch CONT 4 5 13 COOLANT CHANGE Every year have an authorize
40. d service deal er drain flush and refill the cooling system See SPECIFICATIONS for cooling system recommenda tions 4 6 MISCELLANEOUS MAINTENANCE 4 6 1 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 resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer That dealer will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying 4 6 2 BAITERY 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 DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed i
41. e of the generator and batteries WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The gen erator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fun damental rules or precautions The manufacturer cannot anticipate every possible cir cumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique that the manufac turer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique chosen does not render the generator unsafe DIE A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to install operate or maintain this equipment AN Potentially
42. e the engine oil Le J C Replace the engine oil filter s Replace the engine air filter s 18 Replace the engine fuel filter s on diesel engine driven units and re prime the fuel system Check the engine spark plugs on gas engine driven units Clean and re gap or replace as necessary Perform a 5 minute no load operational run of the unit looking for any post service problems Return the unit to standby setup for operation when required Task Comp Date Initials Section 5 Troubleshooting TROUBLESHOOTING 40kW Liquid cooled Generators TROUBLESHOOTING POINTS PROBLEM Engine won t crank Engine cranks but won t start Engine starts hard runs rough CAUSE 1 2 15 fuse blown Loose or corroded or defective battery cables CORRECTION i 2 Replace fuse Tighten clean or replace battery cables as necessary 3 Defective starter contactor 3 Replace contactor 4 Defective starter motor 4 Replace starter motor 5 Dead or Defective Battery 5 Remove change or replace battery 6 4 amp fuse blown 6 Replace fuse Out of fuel Replenish fuel 2 Fuel solenoid FS is defective 2 Replace solenoid 3 Open Wire 14 from Engine Control 3 Reconnect wire circuit board 4 Spark plugs defective 4 Clean regap or replace plugs Air cleaner plugged or damaged Clean or replace as needed 2 Plugg
43. e voltage has been restored the switch re transfers back to the UTILITY source volt age and the generator then shuts down Please reference the transfer switch manual for spe cific information 1 4 GENERATOR AC CONNECTION SYSTEMS The generator was shipped from the factory with its stator AC output leads connected in a single phase three wire generator AC connection system Figure 1 1 The stator assembly in this system consists of a pair of stationary windings with two leads brought out of each winding Each single winding can sup ply 120VAC 60 Hertz When the two windings are connected in series a 240VAC 60 Hertz AC output results Typically the two HOT leads in the circuit are wires 11 and 44 The NEUTRAL leads are the junction of Wires 22 and 33 The NEUTRAL is not grounded Figure 1 1 Generator AC Connection System 240 VOLTS CIRCUIT BREAKER 1 5 MAIN CIRCUIT BREAKER The generator s main circuit breaker is included with the unit as shipped from the factory The breaker for this unit is described in Figure 1 2 Figure 1 2 Main Circuit Breaker Model Rating Phase Actual Current C B Rating Circuit Breaker 005012 1 37 000 NG 1 154 2 200 200A QN2 40 000 LP 1 166 7 200 200A QN2 Amp Rating of C B structured under model 1 6 GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using a natural gas fuel system If propane LP gas is nec essary refer to Reconfiguring the Fuel System for c
44. ed fuel line 2 Unclog fuel line 3 Defective spark plugs 3 Clean regap or replace plugs Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defective Low Coolant Level Switch 7 Replace Switch AUTO OFF MANUAL Switch at 1 Defective AUTO OFF MANUAL switch 1 Replace switch OFF engine continues to run 2 Open disconnected wire 15A between 2 Reconnect close wire AUTO OFF MANUAL switch and Control Module circuit board 3 Defective Control Module circuit board 3 Replace board No AC output from generator 1 Check main line circuit breaker 1 Reset to ON or CLOSED 2 Check circuit breaker amp fuses 2 Reset and replace if necessary 3 Transfer switch set to NORMAL position 3 Setto GENERATOR position 4 Generator internal failure 4 Contact an Authorized facility 5 Thermal circuit breaker open 5 Auto reset Wait 5 min and attempt restart Section 6 Electrical Data 40kW Liquid cooled Generators ELECTRICAL Sk Wiring Diagram Engine Drawing No OE8115 A
45. ed with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating It is also recommend that any solu ble oil inhibitor is NOT USED for this equipment 1 16 BEFORE INSTALLATION Before installing this equipment check the ratings of both the generator and the transfer switch Read Emergency Isolation Method and Total Circuit Isolation Method The generators rated wattage amperage capacity must be adequate to handle all electrical loads that the unit will power The critical essential loads may need to be grouped together and wired into a sepa rate emergency distribution panel This generator can be installed in conjunction with an engineered GTS type transfer switch if neces sary The standard transfer switch has no sensing or con trolling circuit boards Instead the generator control console houses a Printed Circuit Board Assembly which controls all phases of operation including engine start up and load transfer 2 STANDBY GENERATOR INSTALLATION DIG A Connecting this generator to electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the electric system from the utility distribution system when the generator is operating Failure to isolate the electric system by these means will result in dama
46. ely with water Where electrolyte contacts the eyes flush thor oughly and immediately with water and seek medical attention and 11 INSTALLATION Section 2 Installation 40kW Liquid cooled Generators Spilled electrolyte 15 to washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbon ate of soda to one gallon 4 liters of water The bicarbonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The following pro cedure are to be followed DO NOT SMOKE when near batteries DO NOT cause flame or spark in battery area and Discharge static electricity from body before touch ing batteries by first touching a grounded metal surface Servicing of batteries is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries For recommended batteries see the Maintenance section All batteries must be at 100 percent state of charge before they are installed on the generator When using maintenance free batteries it is not necessary to check the specific gravity or electrolyte level Have these procedures performed at the inter vals specified in the Maintenance section
47. final testing of the generator and in most cases should not be adjusted If however adjustments are necessary or a new engine control board is installed in the generator the following procedure should be followed Figure 3 2 1 Set all three potentiometers pots fully counter clockwise 2 Under no load condition increase the GAIN pot as much as possible without causing instability 3 Apply 1 4 1 2 3 4 and full load to the unit Decrease the GAIN pot if there is instability at any load point 4 Under full load condition increase the stability pot until the unit returns to 60 Hertz or 50 Hertz in 50 Hertz applications 5 Reduce load to 3 4 1 2 1 4 and no load Decrease the STABILITY pot if there is instability at any load point 6 Adjust differential pot to make the recovery to load changes even faster and minimize load change undershoot and overshoot If it is set too high it may introduce oscillations at some load It can be set to zero full CCW if a small amount causes oscillations at some load Figure 3 2 Engine Governor Adjustment s lun Teese 97999 vlee ES mii essssssss 99998924 pes 4 000000 ttot fe 4 222520 0 Til 3 BB FEL 10 1 1
48. ge to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy 40kW Liquid cooled Generators If an open bottom is used the engine generator is to be installed over non combustible materi als and should be located such that combustible materials are not capable of accumulating under the generator set Only qualified competent installation contractors or electricians thoroughly familiar with applicable codes standards and regulations should install this standby electric power system The installation must comply strictly with all codes standards and regula tions pertaining to the installation After the system has been installed do nothing that might render the installation in noncompli ance with such codes standards and regulations 2 1 1 STANDARDS The following published standards booklets pertain ing to standby electric systems are available form the National Fire Protection Association NFPA Batterymarch Park Quincy MA 02269 NOTE It is essential to use the latest version of any stan dard to ensure correct and current information No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES No 220 STANDARD TYPES OF BUILDING CONSTRUCTION No 68 GUIDE FOR EXPLOSION VENTING No 70 NATI
49. hree seconds or 75 Hertz instantaneously the engine shuts down and the overspeed LED turns on Should AC frequency exceed about 72 Hertz circuit board action will automatically shutdown the engine Figure 1 7 Figure 1 7 Printed Circuit Board Assembly see ee 4 E 24444555 ses Hn s iz 3 1 2 DELLI eee e e 6 4 2 TT jee TN N97 jee L1 Le elle oleae a d 80830 899 ou Lj 1 75 RPM SENSOR LOSS If the engine control board does not receive a proper rpm signal from the starter during cranking or run ning it shuts down the engine on rpm sensor loss and flashes the overspeed LED Section 1 General Information 176 SHUTDOWN The engine control board uses a cyclic cranking pro cess when attempting to start the engine The first crank cycle is a 15 second crank followed by a seven second rest This is followed by five more crank cycles each with a seven second crank followed by a seven second rest If the engine fails to start after all six attempts the start attempt i
50. ility main line circuit breaker The utility power source now powers the loads 3 6 AUTOMATIC OPERATION To set the system for fully automatic operation pro ceed as follows Check that load circuits are connected to the utility power supply Set the AUTO OFF MANUAL switch to its AUTO position Set the generator main circuit breaker to its ON or CLOSED position 3 7 WEEKLY EXERCISE CYCLE The engine control board will start and run the gen erator once every seven days for approximately 12 minutes If utility should fail during this exercise period the engine control board will transfer the load to the generator output and continue to run until util ity returns On the day and at the time of day chosen for the generator to exercise set the weekly exercise cycle as follows 1 Place the AUTO OFF MANUAL switch in the AUTO position 2 Press and hold the Set Exercise switch for three seconds then release Section 3 Operation OPERATION 40kW Liquid cooled Generators Wes At this time all five red LEDs will flash for approxi mately 10 seconds then the engine will start and run for its 12 minute exercise period then shut down The generator will now start and run each week at the same time If DC power to the control board is lost the weekly exercise setting will be lost This is indicated by all five red LEDs continually flashing In this state the generator will still start and run in manual mode or aut
51. in the event of a ground fault condi tion in the generator or in connected electrical devic es In addition grounding helps dissipate static elec tricity that often builds up in ungrounded devices Figure 2 2 Generator Grounding Lug typical GROUNDING LUG 2 8 GENERATOR AC NEUTRAL CONNECTIONS The manufacturer uses an UNGROUNDED AC neu tral Grounding is recommended only at the main service entrance If the neutral wire is grounded and one of the phase loads becomes grounded the exces sive current opens the load circuit breaker or col lapses the generator field The actual result depends on the electrical characteristics of the particular installed generator warninc Failure to connect the generator neutral proper ly will result in unbalanced line to neutral volt ages Resulting high voltages will cause equip ment damage 2 9 TRANSFER SWITCH SIGNAL CONNECTIONS 2 9 1 PRE PACKAGED ATS If the generator is to be installed with a pre packaged transfer switch it is necessary to connect the control wires to the generator and set position two of the four position dip switch to OFF Setting switch two to OFF allows the control PCB to perform the ATS control functions Control system interconnections consist of N1 and N2 and leads 23 and 194 Control system intercon nection leads must be run in a conduit that is sepa rate from the AC power lead Recommended wire gauge sizes for this wiring depends
52. ion E 09 02 05 Printed in U S A
53. l each week as outlined under Check Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary 4 5 5 EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 20 minutes See Weekly Exercise Cycle 4 5 4 INSPECT COOLING SYSTEM Inspect engine cooling system at least once each month Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness 4 5 5 CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels 4 5 6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks 4 5 7 INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks security damage MAINTENANCE Section 4 Maintenance 458 CHECK FAN Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 of an inch Adjust belt tension as required 4 5 9 INSPECT ENGINE GOVERNOR Visually inspect electronic gover
54. lly inspect the generator for any damage that may have occurred during ship ment If loss or damage is noted at the time of deliv ery have the person s making delivery note all dam age on the freight bill or affix their signature under the consignor s memo of loss or damage 1 9 LIFTING THE GENERATOR wanNING AN When lifting or hoisting equipment is used be careful not to touch overhead power lines The generators weight of more than 900 pounds requires proper tools equipment and qualified personnel to be used in all phases of handling and unpacking 1 10 SPECIFICATIONS 1 10 1 GENERATOR SPECIFICATIONS 005012 1 37 40 LP Rated Max Cont AC Power Output kW Rated voltage volts 120 240 No of Rotor Poles Driven Speed of Rotor Rotor Excitation System Direct excited brush type ype of Stator Rotor Stator Insulation 1 10 2 ENGINE SPECIFICATIONS Class F H sipinmi in Oud dn EE E IDE Chrysler Displacement u 3 9 liters Cylinder Arrangement senes V 6 Valve Arrangement sse Overhead Valve ge cm 1 6 5 4 3 2 Number of Main Bearings 4 Compression 9 1 to 1 No of Teeth on Flywheel 164 Ignition Timing at 1800 rpm 30 degrees BTDC Spark Plug 1 01mm 0 040 in Recommended Spark Plugs
55. med by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems Any Quietsource generators used as rental or trailer mounted applications Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist Costs of normal maintenance adjustments installation and start up Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access
56. n or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Engine Oil Recommendations for recommended oils Figure 4 1 Oil Dipstick and Oil Fill Cap Oil Dipstick Oil Fill Oil Filter 40 442 BAITERY FLUID Check battery electrolyte fluid at least once weekly Fluid should cover separators in all battery cells If fluid level is low add distilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY 4 4 5 ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications 40kW Liquid cooled Generators Add recommended coolant mixture as necessary Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radiator filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact an Authorized Service Dealer Inspect cooling system and coolant recovery system for leaks 45 MAINTENANCE OWNER OPERATOR CAN PERFORM 45 1 CHECK ENGINE LEVEL Refer to Checking Fluid Levels 4 5 2 CHECK BATTERY Check battery fluid leve
57. n the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury 4 6 5 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 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTER IES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer DIE A A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charg
58. ng engine With OFF selected operation will not be possible A With switch set to AUTO engine can and start suddenly without warning Such automatic start up normally occurs when utility source voltage drops below a pre set level To prevent possible injury that might be caused by such sudden starts set AUTO OFF MANUAL switch to OFF before working on or around the unit Then place a DO NOT OPERATE tag on control console 522 FAULT INDICATOR LED This LED goes ON when one or more of the following engine faults occurs and when engine shuts down Low Oil Pressure Overcrank Low Battery Overspeed RPM Sensor Loss High Coolant Temperature Low Coolant Level See Engine Protective Devices for further explana tion of engine protection functions 13 Section 3 Operation ix 40kW Liquid cooled Generators 3 2 3 15 AMP FUSE This fuse protects the control console s DC control circuit against electrical overload If the fuse has melted open because of an overload engine crank ing and startup cannot occur If the fuse needs to be replaced use only an identical 15 amp replacement fuse Type AGC 524 4 0 AMP INLINE FUSE This fuse protects the battery charger against electri cal overload If the fuse needs to be replaced use only an identical 4 amp replacement fuse type AG NOTE This fuse will not remove the battery input power from the PCB when it ope
59. nor A AN Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incor rect frequency and or voltage Only qualified service technicians should adjust the governed speed 4 5 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized service dealers for engine oil and filter change frequencies Drain the oil while the engine is still warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE its retaining clip 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil completely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE and re install into its retaining clip 4 Turn OIL FILTER Figure 4 2 counterclockwise and remove Dispose of old filter 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVERTIGHTEN 6 Remove OIL FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK MARK Crankcase oil
60. ns This means the exercise timer will not be reset 5 2 5 SET EXERCISE TIME SWITCH This switch allows programming the generator to start and exercise automatically See Weekly Exercise Cycle 3 2 6 SYSTEM READY LED The System Ready LED green has two main pro poses First the LED will be ON when the AUTO OFF MANUAL switch is in the AUTO position utility is present and there are no system alarms This ON state indicates the system is fully ready for automatic operation The system ready LED will be OFF when the switch is in the MANUAL or OFF positions The system ready LED is also used to indicate the presence of utility sensing at the PCB when the switch is either in the AUTO or MANUAL modes The LED will flash at the rate of 1 2 second on 1 2 second off if the utility sensing level is below the transfer back threshold This secondary function is only available with dip switch two in the OFF position standard ATS appli cation 3 3 MANUAL TRANSFER AND START UP To transfer electrical loads to the Standby EMERGENCY power source side and start the engine manually refer to the Owner s Manual of the particular transfer switch 3 4 ENGINE GOVERNOR ADJUSTMENTS Engine speed governing is also controlled by the engine control board Connector J2 on the engine control board interfaces with a governor driver mod ule and the Bosch throttle body The engine gover nor has been set by the factory during
61. nt The two wire start connections should NOT be used GTS Mode Operation When in GTS mode the control board will respond as follows based on the AUTO OFF MANUAL switch position OFF The generator will not start and run in this position MANUAL The control board will start and run the generator whenever the switch is in the manual position AUTO The control board will monitor the two wire start circuit When a two wire start is sent the con trol board will immediately start and run the genera tor When the two wire start is removed the control board will immediately stop the generator NOTE If the generator is installed in conjunction with an engineered GTS type transfer switch refer to the applicable transfer switch manual for exact oper ating parameters and timing sequences 5 2 CONTROL CONSOLE COMPONENTS The components of a home standby generator control console Figure 3 1 are as follows Figure 3 1 Home Standby Generator Panel RED LEDs sEr EXECISER GREEN LED TIME SWITCH AUTO OFF MANUAL 4A FUSE SWITCH BATTERY 15A FUSE CHARGER MAIN POWER 3 2 1 AUTO OFF MANUAL SWITCH Use this three position switch as follows Set the switch to AUTO for fully automatic opera tion See Automatic Operation Set switch to MANUAL position to crank and start the generator engine Set switch to OFF position to shut down an operat i
62. o 8116 LEGEND AR ALTERNATDR ROTOR EGEND CUNT 1 5 ALTERNATOR STATOR 1 FUSE BAT POWER lt 15 TYPE AVR AUTOMATIC VOLTAGE REGULATOR 2 FUSE B C 4A AGC TYPE BA BRUSH ASSEMLY GENERATOR CT TERMINAL BLOCK INTERCONNECT B C BATTERY CHARGER B NEUTRAL BLOCK BCW BATTERY CAHRGE WINDING RELAY 1 CIRCUIT BREAKER OUTPUT W1 SWITCH AUTO OFF MANUAL CIRCUIT BREAKER EXCITATION We SWITCH SET EXERCISER RI TRANSFORMER 1 56 VA 240 16 VAC Re TRANSFORMER 2 6 VA 240 16 VAC Di DIODE FI DPE DISPLACED LD BOOST HASE EXCITATION e eS St E 66 0 RL1 0 14 ___ 15 18 BCW 15 B 5 14 55 66 m F2 E 1 DA ____ B
63. ocate us on the web at www generac com INTRODUCTION Read this Manual Thoroughly Operation and Maintenance How to Obtain Service Authorized Service Dealer Location SAFETY RULES Section 1 GENERAL INFORMATION Transfer Switch Automatic System Operation Generator AC Connection Systems Main Circuit Breaker Generator Fuel System Engine Protective Devices Lifting the Generator Specifications Fuel Consumption Reconfiguring the Fuel System Torque Specifications Engine Oil Recommendations Coolant Recommendations Before Installation Section 2 INSTALLATION Standby Generator Installation rn Generator Location Generator Mounting and Support Basic Standby Electric System Emergency Circuit Isolation Method Total Circuit Isolation Method Grounding the Generator Generator AC Neutral Connections Transfer Switch Start Signal Connections Battery Installation Preparation Before Start Up Table of Contents Ex ENT F 40kW Liquid cooled Generators CONTENTS Section 3 OPERATION 13 3 1 Using an Engineered GTS Transfer Switch 13 3 2 Control Console Components 13 3 3 Manual Transfer and Startup 14 3 4 Engine Governor Adjustments 14 3 5 Retransfer and Shutdown eese 15 3 0 Automati
64. odels are configured for natural gas from the factory To reconfigure the fuel system from NG to LP vapor follow these steps 1 Turn the main gas supply off 2 Remove the carburetor fuel hose from the outlet port Port 1 of the demand regulator Figure 1 8 Figure 1 8 Reconfigure the Fuel System Port 1 Port 2 mC FUEL HOSE BRASS HOSE FITTING OUT PORT 1 le NG FUEL SYSTEM LP FUEL SYSTEM INSTALLATION Section 2 Installation 40kW Liquid cooled Generators m Remove the brass hose fitting from the outlet port Port 1 of the demand regulator Remove pipe plug from Port 2 Install brass hose fitting into Port 2 Install pipe plug into Port 1 Connect carburetor gas hose to brass fitting Tighten all clamps and plugs Make sure fuel supply is of the proper pressure and type for configuration 10 Reverse the procedure to convert back to natural gas CANO NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made DIE A Serious injury or damage may occur if not con figured properly Please consult an Authorized Service Dealer with any questions 1 15 TORQUE SPECIFICATIONS Tighten the bolts from the middle out in a criss cross pattern Cylinder Head 50 ft Ib 105 ft lb 105 ft lb Intake Manifold 48 in lb 84 in Ib 84 in lb
65. oled Generators Engine Drawing No 0E8121 H PARTS 00 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 72 78 74 75 76 77 78 79 050873A 031919 022145 030795 051756 046526 0A1232A 0A7801B 045772 022403 0E7950 0E7951 0 8445 0 7415 042568 061652 031578 082120 023645 0 9974 003488 0 7954 0E8309 029187 032712 054455 0E8606 0E8642 0E8597 0E8755 0E8731 026076 0F1444A 0C2454 043790 069860 0480314 0F1444 026925 026257 MO ORE ERE RE MES E 20 i i FT PLUG 1 4 CSK W VIBRA SL PLUG STD PIPE 3 8 COUNTERSUNK WASHER FLAT 5 16 M8 ZINC SCREW HHC 5 16 18 X 1 G5 SCREW HHC M10 1 5 X 20 G8 8 WASHER LOCK M10 ASSEMBLY D C ALTERNATOR PULLEY POLY V 82 OD NUT HEX M10 1 5 G8 YEL CHR SCREW HHC 5 16 18 X 2 G5 TUBE DIPSTICK 3 9L CHRYSLER DIPSTICK OIL LEVEL 3 9L CRYSLR BRACKET DIPSTICK TUBE OIL FILTER 3 9L CHRYSLER SCREW HHC M6 1 0 X 20 G8 8 SCREW HHC M10 1 5 X 85 G8 8 SCREW HHC 3 6 16 X 1 1 2 G8 SPACER 44 X 75 X 39 ST ZNC SCREW SHC 3 8 16 X 1 25 08 87 CAP VINYL 3 8 ID X 1 DP BLK BELT SERPENTINE 69 39 CABLE IGN COIL 3 9L CHRYSLER ASSY IGNITION MODULE 3 9L SPACER 19 X 31 X 50 PL SCREW HHTT 10 32 X 1 75 CZ ADP OIL DRN 1 2 20 SCREW PPH TAPPING 4 X 3 8 LG ASSEMBLY RESISTOR HARNESS 3 9L CHRYSLER ENGINE NOT SHOW
66. omatically start and run if UTILITY is lost while in AUTO mode but it will not perform a weekly exercise cycle If a failure occurs while running in this mode the five red LEDs will stop flashing the individual fault LED will turn on and the engine will shut down Once the AUTO OFF MANUAL switch has been switch to OFF the individual fault LED will turn OFF and the five red LEDs will begin flashing to show exercise has still not been set Figure 3 2 Set Exercise Switch FUSE FUSE 15A BAT MAIN CHARGER AUTO MANUAL EXERCISE TIME 15 OPERATION Section 4 Maintenance ix 40kW Liquid cooled Generators 4 1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES EVERY THREE MONTHS Check battery state of charge and condition Inspect and test fuel system Check transfer switch Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY 1 Test engine governor Adjust or repair if needed 2 Clean inspect generator 3 Flush cooling system FIRST 100 OPERATING HOURS 1 Change engine oil and oil filter After initial change service engine oil and filter at 150 operat ing hours or 6 months whichever comes first 2 Retorque cylinder head See Torque Specs 3 Retorque intake and exhaust manifold
67. on adequate ventilation must be provided Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people animals etc will not be harmed This exhaust system must be installed properly in strict compliance with applicable codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operat ing Adequate unobstructed flow of cooling and ventilat ing air is critical to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator Keep the area around the generator clean and unclut tered Remove any materials that could become haz ardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts Before performing any maintenance on the generator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stre
68. on the length of the wire as recommended below MAXIMUM WIRE LENGTH RECOMMENDED WIRE SIZE 460 feet 140m 461 to 730 feet 223m No 12 AWG 1 161 to 1 850 feet 565m 2 9 2 GTS TYPE ENGINEERED TRANSFER SWITCH If the generator is to be installed with an engineered transfer switch such as a GTS type switch it is nec essary to connect the two wire start control system Connect the two wire start signal from the automatic transfer switch to the automatic start connection which is located in the middle on the bottom inside the control panel Match wires 178 and 183 in the transfer switch to 178 and 183 on the terminal strip in the control panel The conductors for the two wire start circuit must be in their own conduit See Using an Engineered GTS Transfer Switch for further explanation INSTALLATION Section 2 Installation 40kW Liquid cooled Generators 2 10 BATTERY INSTALLATION Standby 5 installed with automatic transfer switches will crank and start automati cally when NORMAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and pos sible injury to personnel do not connect battery cables until certain that normal source voltage at the transfer switch is correct and the system is ready to be placed into operation A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixt
69. onversion instructions Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges NOTE A seperate gas line and regulator may be needed to assure proper gas pressure to the generator Improper gas pressure can cause hard starting and affect engine durability WARNING amp AN Gaseous fuels such as natural and LP propane gas are highly explosive Even the slightest spark can ignite such fuels and cause an explo sion No leakage of fuel is permitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas 1 7 ENGINE PROTECTIVE DEVICES The engine has several safety switches which cause the engine to automatically shut down under the following conditions low oil pressure high coolant temperature engine overspeed low coolant level or overcrank Figure 1 3 Figure 1 3 Engine Protective Devices Low Oil Pressure Switch High Coolant Temperature Switch Low Coolant Level Sensor Section 1 General Information 40kW Liquid cooled Generators GENERAL INFORMATION 1 71 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure dr
70. op below about 8 10 psi 55 68 kPa the switch contacts close the engine shuts down automatically and the low oil pressure LED is turned ON Figure 1 4 NOTE The Low Oil Pressure High Coolant Temperature and Low Coolant Level are not monitored for the first 10 seconds of engine run time Figure 1 4 Low Oil Pressure Switch 1 72 HIGH COOLANT TEMPERATURE SWITCH This normally open N O thermostatic switch has sensing tip which is immersed in captive coolant Should coolant temperature exceed about 230 F 110 C the switch contacts close This causes the engine to shut down automatically and turns on the high coolant temperature low coolant level LED Figure 1 5 Figure 1 5 High Coolant Temperature Switch 40kW Liquid cooled Generators 1 75 LOW COOLANT LEVEL SWITCH Should engine coolant level drop below the level of the high coolant temperature switch it is possible for the engine to overheat without automatic shutdown To prevent such overheating without automatic shut down the engine has a low coolant level sensor If the engine coolant drops too low the engine automatical ly shuts down and turns on the high coolant tempera ture low coolant level LED Figure 1 6 on page 6 Figure 1 6 Low Coolant Level Sensor 1 74 OVERSPEED SHUTDOWN The engine control board receives AC frequency signals from an engine run winding in the alterna tor Should AC frequency exceed about 72 Hertz for t
71. or set to ensure it is ready to operate and carry the load when required and to identify any potential problem areas Performed annually this procedure requires approximately 4 0 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer NOTE If the generator experiences heavy use the maintenance intervals should be reduced so that procedures are performed more frequently eo Section 4 Maintenance 40kW Liquid cooled Generators MAINTENANCE Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp done Comp to be done Comp Required Comp to be done Date 3 months Date Semi Date to be done Date monthly Initials Initials annually Initials Annually Initials 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 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary
72. ot strictly complied with may result in personal injury or property damage caution After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety informa tion that if not followed could endanger personal safety and or property of others A This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safe
73. ricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maximum elec trical current ampacity to which they will be sub jected Before installing or servicing this and related equip ment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in hazardous and possibly fatal electrical shock Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS 40kW Liquid cooled Generators Generators installed with an automatic transfer switch will crank and start automatically when NOR MAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel disable the generators automatic start circuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and on the transfer switch In case of acciden
74. s stopped and the overcrank LED turned on 1 77 LOW BAITERY The engine control board continually monitors the battery voltage and turns on the low battery LED if the battery voltage falls below 11 0 VDC for one minute Low battery voltage is a non latching alarm which will automatically clear if the battery voltage rises above 11 0 VDC The control system will not attempt to start the engine if there is a low battery condition however if the engine is already running when the low battery condition occurs the engine will continue to run as long as possible Battery voltage is NOT monitored during the crank cycle 1 78 ALARM RESET If the engine control board shuts down the genera tor for any of the above reasons the engine remains stopped until the alarm is cleared by placing the AUTO OFF MANUAL switch into the OFF position 1 79 FUSE These fuses located front panel of the trol system They protect the panel wiring and com ponents from damaging overload Always remove the 15 amp main fuse before working on the generator The unit will not start or crank if this fuse is blown Replace the fuse with one of the same size type and rating main AGC 15 battery charger AG4 1 8 UNPACKING 1 8 1 UNPACKING PRECAUTIONS Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping col lision etc 1 8 2 INSPECTION After unpacking carefu
75. ss and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS All generators covered by this manual produce dan gerous electrical voltages and can cause fatal electri cal shock Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the standby generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appro priate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT If people must stand on metal or concrete while installing operating servicing adjusting or repair ing 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 Article 250 requires the frame and external electrically conduc tive parts of the generator to be connected to an approved earth ground and or grounding rods This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condi tion in the generator set or by static elect
76. t caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS A Properly ventilate any room or building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris These generator sets may operate using one of several types of fuels fuel types are potentially FLAMMABLE and or EXPLOSIVE and should
77. that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems for additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with applicable codes standards and regulations 2 11 5 FUEL SYSTEM Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and b is properly purged and leak tested according to code No fuel leakage is permitted See Specifications for more information 2 11 4 GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULL mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications and Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with 15W 40 oil This oil should be changed after 30 hours of operation 2 11 5 ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications and Coolant 2 11 6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of
78. tion panel circuit Have it installed between the building s main dis tribution panel and the emergency distribution panel 2 6 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed use the Total Circuit Isolation Method It is possible for the gen erator to be overloaded when this isolation method is employed The following apply to the transfer switch in this type of system Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service The transfer switch is installed between the util ity service entrance and the building distribution panel By code and approved means of service disconnect must be located between the incoming utility ser vice and the transfer switch 2 1 GROUNDING THE GENERATOR The National Electrical Code requires the frame and external electrically conductive parts of this equip ment to be properly connected to an approved earth ground and or grounding rods For that purpose a GROUND LUG Figure 2 2 is provided on the gen erator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations DIG A Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against electrical shock
79. ty checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized Service Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See the Authorized Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by an Authorized Service Dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs contact an Authorized Service Dealer for assistance Service technicians are factory trained and are capa ble of handling all service needs When contacting an Authorized Service Dealer about parts and service always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit AUTHORIZED SERVICE DEALER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 OR L
80. ure around the battery for several hours after charg ing The slightest spark can ignite the gas and cause an explosion Such an explosion can shat ter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smok ing open flame sparks or any spark producing tools or equipment near the battery AN Battery electrolyte fluid is an extremely caus tic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water warninc Do not dispose of the battery in a fire The bat tery is capable of exploding Do not open or mutilate the battery Released electrolyte can be toxic and harmful to the skin and eyes AN The battery represents a risk of high short circuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles 2 10 1 VENTED BATTERIES 4 The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following proce dures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediat
81. ved transfer switch The trans fer switch is required by electrical code and serves the following functions Allows the LOAD circuits to be connected to only one power supply at a time Prevents electrical backfeed between the generator and the UTILITY power circuits Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker Figure 2 1 Basic Standby Electric System MAIN LINE CIRCUIT BREAKER UTILITY r POWER SUPPLY TRANSFER SWITCH 1 1 E TO LOAD CIRCUITS 1 1 STANDBY DESEE GENERATOR DUTPUT MAIN LINE 2 5 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage amperage capac ity of the generator If the generator is powering only critical loads within the wattage amperage capac ity during utility power outages consider using the emergency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are within the wattage amperage capacity of the generator set When this method is used it is difficult to overload the gen erator The transfer switch must meet the following requirements It must have an ampere rating equal to the total amperage rating of the emergency distribu

Generac Power Systems 005012-1 Portable Generator User Manual

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