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Generac 37kW NG Portable Generator User Manual

1. LEGEND CONI 1 LEGEND HCT HIGH CUULANT TEMP SWITCH ALT D C CHARGE ALTERNATOR IGNITION COIL 1eVDC BATTERY IGNITION MDDULE Cl CUNNECIUR 1 CENGINED J 1 JUNCTIUN 1 CHN PCB STARTER CONTACTOR J JUNCTION IN IPOD DEG DRIVER ELEC GOVERNOR JB JUNCTIUN BLUCK DIST DISTRIBUTOR LUS DIL PRESSURE SWITCH FS FUEL SULENUTD MP1 MAGNETIC PICK UP GND1 GROUND CSENSING LUW AMP RI 30 WATT RESISTOR GNDe GRUUND CPUWER HIGH AMP SM STARTER MOTOR GOV ELEC GUVERNUR ACTUATOR WLS COULANT LEVEL SWITCH Generac Power Systems Inc 25 Section 7 Electrical Data QUIETSOURCE 40kW Liquid cooled Generators ELECTRICAL I DATA gt Electrical Schematic Engine Drawing No 0E8116 A gt LEGEND AR ALTERNATUR LEGEND CUNT 1 AS ALTERNATOR STATOR Fl FUSE BAT POWER C15A AGC TYPED AVR AUTOMATIC VOLTAGE REGULATOR Fe FUSE B C AGC TYPE BRUSH ASSEMLY GENERATOR ICT TERMINAL BLUCK INTERCONNECT B C BATTERY CHARGER NEUTRAL BLUCK BCW BATTERY CAHRGE WINDING RLI RELAY 1 CIRCUIT BREAKER COUTPUT SW1 SWITCH AUTO ZOFF MANUAL Cho CIRCUIT BREAKER CEXCITATION SWe SWITCH SET EXERCISER D1 DIDDE FIELD BUOUSTI TRL TRANSFORMER 1 56 VA 240 16 VAC DPE DISPLACED PHASE EXCITATION TRANSFURMER 2 6 VA 240 16 VAC Os TIT T S000 ION UI IS COTU POUR
2. 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 o Uo I Generac Power Systems Inc 7 INSTALLATION Section 2 Installation NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made A Dia A Serious injury or damage may occur if not con A figured properly Please consult an authorized Generac Service Dealer with any questions 1 13 TORQUE SPECIFICATIONS Tighten the bolts from the middle out in a criss CrOSS pattern Cylinder Head 50 ft Ib 105 ft Ib 105 Intake Manifold 48 in b 84 in Ib 84 in Ib Exhaust Manifold eene 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 Temperature Above 80 F 27 C Oil Grade Recommended SAE 15W 40 SAE 15W 40 SAE 15W 40 32 to 80 F 1 to 27 C Below 32 F 0 C NOTE 5W 30 full synthet
3. QUIE T SOURCE Owner s Manual Liquid cooled Prepackaged Standby Generators Model No 005012 0 37kW NG 40kW LP This manual should remain with the unit caution amp ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION INTRODUCTION Thank you for purchasing this model of the 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 Generac Authorized Service Dealer for starting 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 person nel to special instructions about a particular service or operation that may be hazardous if performed incor rectly or carelessly Observe them carefully Their defi nitions are as follows A Dita A After this heading read instructions that if not strictly complied with will result in personal injury or property damage wanNiNG amp After this heading read instructions that if not str
4. The engine control board uses a cyclic cranking process 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 is stopped and the overcrank LED turned on 6 Generac Power Systems Inc Section 1 General Information QUIETSOURCE 40kW Liquid cooled Generators 1 747 LOW BATTERY 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 7 8 ALARM RESET If the engine control board shuts down the generator 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 DC FUSE These fuses are located on the front panel of the con trol system They protect the panel wiring and com ponents
5. oee Section 1 7 for further explanation of engine pro tection functions 5 2 5 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 cranking and startup cannot occur If the fuse needs to be replaced use only an identical 15 amp replacement fuse Type AGC 3 2 4 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 opens 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 Generac Power Systems Inc 13 OPERATION Section 3 Operation J gt QUIETSOURCE 40kW Liquid cooled Generators 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 th
6. 42 Sys tin disque aneodesstah ii 15 15 Main Circuit Breaker 4 4 3 Overload Protection for Engine DC 1 6 Generator Fuel System 21222 5 Electrical System 0 01 15 1 7 Engine Protective Devices 4 411 5 4 4 Checking Fluid Levels 16 1 8 Unpacking 6 4 5 Maintenance Owner Operator 1 9 Lifting the Generator 6 C UC POPIOE EU penam rd Hore E oce 16 Spe DICENTE 7 4 6 Miscellaneous Maintenance 18 1 11 Fuel Consumption eee 7 4 7 Scheduled Maintenance 2444244 4 1 19 1 12 Reconfiguring the Fuel System 7 Section 5 TROUBLESHOOTING 22 1 13 Torque Specifications 8 Section 6 INSTALLATION DIAGRAM 23 1 14 Engine Oil Recommendations 8 1 15 Coolant 8 Section 7 ELECTRICAL DATA 24 1 16 Beltore Installation 8 Section 8 EXPLODED VIEWS AND Section 2 INSTALLATION 8 PARTS LISTS 28 2 1 Standby Generator Installation
7. 8 Section 9 E 43 2 4 Generator Locatii 9 2 3 Generator Mounting and Support 9 Section 10 WARRANTY Back Cover 2 4 Basic Standby Electric System 9 2 5 Emergency Circuit Isolation Method 10 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Transfer Switch Start Signal Connections 10 2 10 Battery Installation 11 2 11 Preparation Before 12 Generac Power Systems Inc M SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS QUIETSOURCE 40kW Liquid cooled Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe A A A 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 A A 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 genera tor can operate safely ef
8. BOLT U 5 16 18 X 2 25 SCREW HHC 8 1 25 X 20 G8 8 WASHER FLAT 5 16 M8 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR 42 Generac Power Systems Inc PART NO 002454 052860 052891 0E8816 051769 0E0170 049808 024114 080762 0E8726 039288 0 0170 4 OO 7 9 TO EXHAUST MANIFOLD DESCRIPTION SCREW TH FRM M6 1 X 16 N WA 2 45 NUT TOP LOCK FL M12 1 75 SCREW HHC M12 1 75 X 80 G8 8 FLANGE EXHAUST 2 PIPE WASHER LOCK M12 BLANKET EXHAUST 800MM WASHER FLAT M12 NUT HEX 5 16 24 STEEL BOLT U 3 8 16 X 2 62 STRAP MUFFLER SCREW HHC 8 1 25 X 55 G8 8 EXHAUST BLANKET 988MM Section 9 Notes NOTES QUIETSOURCE 40kW Liquid cooled Generators Generac Power Systems Inc 43 NOTES Section 9 Notes QUIETSOURCE 40kW Liquid cooled Generators 44 Generac Power Systems Inc Section 9 Notes NOTES QUIETSOURCE 40kW Liquid cooled Generators Generac Power Systems Inc 45 Section 10 Warranty WARRANTY QUIETSOURCE 40kW Liquid cooled Generators GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR QUIETSOURCE PREPACKAGED 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 par
9. BRACKET STIFFENER LH FRONT TRIM VINYL SELF GRIPPING 165 5 LG KIT INSULATION 3 9L HSB Al ROOF PANEL 1 Al DOOR PANEL Al CORNER POST PANEL 1 Al CORNER POST PANEL 2 Al SUPPORT LH PANEL Al SUPPORT RH PANEL Al ROOF PANEL 2 WASHER SELF LOCKING DOME ALL ITEMS NOTATED WITH Al ARE COMPONENTS OF 0E8442 age LISTS Generac Power Systems Inc 31 LISTS PARTS Section 8 Exploded Views and Parts QUIETSOURCE 40kW Liquid cooled Generators Control Panel Drawing No 0E7118 H DETAIL 1 RECTIFIER ASSEMBLY SCALE NONE MICA THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR OUTDOOR INSTALLATION ONLY i 2 M 7 s Z A WARNING PANEL MOUNT DETAIL Generac Power Systems Inc ITEM CONDOR N 17 18 19 20 21 22 24 25 27 28 29 30 31 32 34 PART NO QTY 0E7195 0E7196 0E7197 0E7193 0E7194 0E4494 082573 032300 022676 067682B 060015 054199 0C2657 099076 040213 0 9668 0 4905 067680 0 6875 0E6881 005139 005142 0E3161 054450 0D5070A 0 2514 049457 0 7539 046357 0D3719B 057073 0E7283 0E3628 0E3664 0E7539A 0D4698 JJ JJ N cl cl VAY cl ol cl REF REF REF TI 71 DESCRIPTION CONTROL BOX HSB COVER FRONT PANEL HSB COVER TOP PANEL HSB DECAL WARNINGS HSB DECAL CONTROLS HSB SWITCH ROC DPDT ON OFF
10. Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open ee Generac Power Systems Inc CORRECTION 1 2 NOOR gt Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replace fuse Replenish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Clean or replace as needed Unclog fuel line Clean regap or replace plugs Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Contact an Authorized Generac facility Auto reset Wait 5 min and attempt restart INSTALLATION Section 6 Installation Diagram cooled Generators id Installation Diagram Drawing No 0E8797 iqu QUIETSOURCE 40kW L LAILNO 3313308 GO LSOVHX3 14415 NIVad AOdVA 1 5 9 WaANLVN LAINI SNOTLOSNNOO 4351 445 3NIDN3 TSA
11. OJ 224 Oo 00 OO Got 2 Cv LJ L3 lt T I O O gt gt LJ LJ lt lt J Wb G Guo G LJ CY Ww gt gt Lo Li LI oL Eg Le C T 5424o uo DUTPUT TO 23 NE 0 6 TRANSFER SWITCH CUSTOMER CONNECTION LEGEND 1 LEGEND Fe B L C45 Abb TYPE AVR AUTOMATIC VULTAGE REGULATUR ICT INIERCHNNECT TERMINAL BLUCK BRUSH ASSEMLY NEUTRAL BLICK B C BATTERY CHARGER PLI RELAY 4 BULKHEAD CDNNECTDR 1 ENGINE SWITCH CIRCUIT BREAKER CUUTPUT SWe SET EXERCISER SWITCH Be CIRCUIT BREAKER CEXCITATIUN TERMINAL BLICK 1 DI DIODE FIELD BUDSTJ IRANSFDRMER 1 56 VA 240 16 VAC FUSE BAL POWER AGC TYPED TRe TRANSFORMER 2 VA 240 716 VAC 24 Generac Power Systems Inc Section 7 Electrical Data QUIETSOURCE 40kW Liquid cooled Generators ELECTRICAL Wiring Diagram Engine Drawing No 0E8115 A lt DATA 14 4 4 95 766 5 DA 7e7 7 7 E Le dem d 771 9 9 400 768 101110 0 767 11 111 194 gt e 13 GOV 14 CO Q yxp 767 2 765 3 u 770 4 ona te N C 5 766 6 es lt Q SA HCT 85 2385
12. Fuel consumption is given at rated maximum con tinuous 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 consump tion obtained may vary depending on such vari ables as applied load ambient temperature engine conditions and other environmental fac tors 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 models 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 FUEL HOSE BRASS HOSE FITTING LLAT OUT PORT 1 d NY N J NG FUEL SYSTEM LP FUEL SYSTEM 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
13. ON SWITCH ROCKER DPST 125V SPD HOLDER FUSE FUSE 15A X AGC15 FUSE 4A 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 3 9L ASSY PCB HSB CONTRLR 3 0L FORD 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 2A 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 Section 8 Exploded Views and Parts QUIETSOURCE 40kW Liquid cooled Generators ITEMS INCLUDED AS PART OF I N 39 PARTS 9 LISTS Control Panel Drawing No 0E7118 H QTY DESCRIPTION 35 0E7252 1 BRACKET CB 221 5 X 102 36 001229 1 DECAL WARNING ELECTRICAL SHOCK 37 0C1127 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 PHTT 6 32 X 3 8 ZYC 44 0C2323 4 SCREW PHTT 6 32 X 5 8 ZYC 45 022155 15 WASHER LOCK 6 46 002265 4 SCREW PHTT M4 0 7 X 12 ZYC 47 022264 4 WASHER LO
14. call this number 1 800 333 1322 OR Locate us on the web at WWW generac com Table of Contents a CONTENTS QUIETSOURCE 40kW Liquid cooled Generators INTRODUCTION IFC Section 12 Read this Manual Thoroughly M IM IFC 3 1 Using an Engineered GTS Transfer Switch 12 Operation and Maintenance IFC 3 2 Control Console Components 13 How to Obtain Service i eid tuners IFC 3 8 Manual Transfer and 14 Authorized Service Dealer Location IFC 3 4 Engine Governor Adjustments 14 SAFETY 2 3 5 Retransfer and Shutdown eee 14 Section 1 GENERAL INFORMATION 4 o0 Automall 14 ntm 4 MR s 1 2 Transfer SWC uuu ein iir SpA va pau ee PETER A OA 4 Section 4 MAINTENANCE 15 13 Automatic System Operation 4 4 1 Maintenance Performed by Authorized 5 nis eus Arg 15 1 4 Generator AC Connection Systems 4
15. cooled Generators Radiator Drawing 0E8102 E lt O 17 MMMM A p A THERMOSTAT HOUSING 4 36 Generac Power Systems Inc ITEM CONDOR N PART NO 0D7825A 0D7174C 0E7640 0E7924 2853 008252 0D8251 0E0726 076749 035685 069860C 058443 002454 052250 048031C 029032 0A2111 0E7640A 035461 065852 051756 022131 046526 045772 QTY SSS SS Jod r gt Q Section 8 Exploded Views and Parts QUIETSOURCE 40kW Liquid cooled Generators Radiator Drawing No 0E8102 E DESCRIPTION RADIATOR COPPER BRASS VENTURI 3 9L CRYSLR HSB 22 FAN RADIATOR SUPPORT L H SIDE HOSE LOWER RADIATOR HOSE RADIATOR UPPER 3 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 WA Z JS TAPE FOAM 1 X 1 274 CLAMP HOSE BAND 1 4 HOSE 9 32 ID 30 LG SCREW SWAGE 10 32 X 5 16 Z YC RADIATOR SUPPORT R H SIDE BARBED STR 1 4NPT X 3 8 SPRING CLIP HOLDER 37 62 SCREW HHC M10 1 5 X 20 G8 8 WASHER FLAT 3 8 M10 ZINC WASHER LOCK M10 NUT HEX M10 1 5 G8 YEL CHR age LISTS Generac Power Systems Inc 37 CG Section 8 Exploded Views and Parts 0 QUIETSOURCE 40kW Li
16. from leaking exhaust gases fuel leakage oil leakage etc A ELECTRICAL HAZARDS All generators covered by this manual produce dan gerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dan gerous voltages to the transfer switch as well as the standby generator Avoid contact with bare wires ter minals connections etc on the generator as well as the transfer switch if applicable Ensure all appropri ate 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 repairing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC 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 rounding will help prevent dangerous electrical shock that might be caused by a ground fault condi tion in the generator set or by static electricity Never disconnect the ground wire Wire gauge sizes of electric
17. 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 ochedule Section 6 The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 18 Generac Power Systems Inc QUIETSOURCE 40kW Liquid cooled Generators 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer A Dita A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near th
18. 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 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 Section 4 Maintenance 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 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 3 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 Section 1 10 for more information Generac Power Systems Inc 2 11 4 GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper l
19. reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REG ULATE THE DISTANCE 2 5 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 Section 6 for generator major dimensions 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 approved 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 Generac Power Systems Inc 9 INSTALLATION Section 2 Installation QUIETSOURCE 40kW Liquid cooled Generators Figure 2 1 Basic Standby Electric System MAIN LINE CIRCUIT BREAKER UTILITY ue E POWER SUPPLY SWITCH TO LOAD CIRCUITS STANDBY 8 GENERATOR OUTPUT ore MAIN LINE CIRCUIT BREAKER 2 5 EMERGENCY C
20. 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 exer cise The five red LEDs will not flash in this mode The control board will NOT activate the transfer output OPERATION Section 3 Operation QUIETSOURCE 40kW Liquid cooled Generators J gt 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 automat ic features listed in this document 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 posi tion 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 engineere
21. toxic and harmful to the skin and eyes A The battery represents a risk of high short cir cuit 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 caution amp The electrolyte is a dilute sulfuric acid that is A 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 immediately with water Where electrolyte contacts the eyes flush thor oughly and immediately with water and seek med ical attention and Spilled electrolyte is to be 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 fol lowing procedure 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 pe
22. 01 ASAE EP 364 2 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 452 1 AMERICAN NATIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYS TEMS available from the American National Standard Institute 1430 Broadway New York N Y 10018 INSTALLATION Section 2 Installation 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 openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing 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
23. 295 0 7829 0 7829 078115 o RM no NO Po po po A N NP P HSH HS HS PO B Section 8 Exploded Views and Parts QUIETSOURCE 40kW Liquid cooled Generators Enclosure Drawing No 0E8800 B DESCRIPTION DUCT INTAKE MID AL DUCT DISCHARGE RH AL DUCT DISCHARGE LH AL SCREW TH FRM M6 1 X 16 N WA Z JS BAFFLE REAR BOTTOM POST CORNER LH REAR HSB AL POST CORNER RH REAR HSB AL BAFFLE REAR TOP DOOR SIDE HSB AL SUPPORT RH SIDE HSB AL FOAM STRIP 3 4 WIDE X 3 16 THK 40 LG WASHER NYLON 257 BRACKET STIFFENER RH FRONT HINGE LIFT OFF TYPE B KNUCKLE HINGE LIFT OFF TYPE B PIN SCREW HHC M6 1 0 X 12 G8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC GAS SPRING BALL STUD GAS SPRING MOUNT NUT HEX 5 16 18 LOCK SCREW WING M6 1 00 X 25 HINGE LIFT OFF TYPE A KNUCKLE HINGE LIFT OFF TYPE A PIN TRIM VINYL SELF GRIPPING 91 LG BRACKET STIFFENING BACK MUFFLER BOX ROOF HSB AL BRACE FRONT TOP LATCH 1 4 TURN NONLOCKING PAWL DOOR HSB SUPPORT LH SIDE HSB AL MUFFLER BOX TOP LATCH QUARTER TURN LOCKING POST CORNER LH FRONT HSB AL POST CORNER RH FRONT HSB AL BRACE FRONT BOTTOM DUCT DISCHARGE MID AL WASHER SHAKEPROOF EXT 1 4 STL ASSY GRD WIRE 99HSB ASSEMBLY BASE DOOR GROUND WIRE NUT HEX M6 X 1 0 G8 YEL CHR DUCT INTAKE LH AL DUCT INTAKE RH AL
24. 54455 0 8606 0 8642 0 8597 0 8755 0 8731 026076 0 9975 0F1444A 0C2454 043790 069860C 048031J 0 1444 026925 026257 1 a aqa a u pm TI e NT PARTS ib ues 00 DESCRIPTION PLUG STD PIPE 3 8 COUNTER SUNK 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 8 16 X 1 1 2 G8 SPACER 41 X 75 X 39 ST ZNC SCREW SHC 3 8 16 X 1 25 G8 8 Z 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 SHOWN HARNESS IGNITION 3 9L CHRY NOT SHOWN PLATE FLEX DISK SPACER SCREW SHC 3 8 16 X 1 5 G8 8 NZ CAP VINYL 1 4 ID X 1 DP BLK HEAT SHEILD L H SIDE SCREW THF M6 1 X 16 NWA Z JS BARBED EL 90 3 8 NPT X 3 8 HOSE OIL DRAIN ASSY 21 HOSE CLAMP BAND 5 4 HEAT SHIELD R H SIDE PLUG STD PIPE 3 8 STEEL SQ HD SCREW SHC 3 8 16 X 2 G8 8 NZ Generac Power Systems Inc 35 p Section 8 Exploded Views and Parts Cl QUIETSOURCE 40kW Liquid
25. A R REF 2 ee DESCRIPTION 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 X 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 PLUG PIPE 1 4 CSK W VIBRA SL Section 8 Exploded Views and Parts QUIETSOURCE 40kW Liquid cooled Generators Engine Drawing No 0E8121 G ITEM PART NO QTY 031919 022145 030795 051756 046526 0A1232A 0A7801B 045772 022403 0E7950 0E7951 0E8445 0E7415 042568 061652 031578 082120 023645 0E9974 0D3488A 0E7954 0E8309 029187 032712 0
26. ATOR BOSCH 40 GOVERNOR HOSE COOL 2IN ID 20R4 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 M6 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 HEAD ASSY THROTTLE 28MM PCV VALVE 2 5L FORD O RING 47 625 ID X 2 38 WIDTH age LISTS Generac Power Systems Inc 39 n Section 8 Exploded Views and Parts LISTS 0 QUIETSOURCE 40kW Liquid cooled Generators Alternator Drawing No 5146 Generac Power Systems Inc ITEM ROTOR REPLACEMENT PARTS 30 31 PART NO 0E5093A 0E7413A 0E5094A 0E7412A 0E5706 0E5048 0 5048 0 6668 0 6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 092980 052625 0A2602 042558 0A2601 0E7226 045757 052857 051715 038150 077043F 047248 070892 JJ gt QO Mme QTY TI TI Section 8 Exploded Views and Parts QUIETSOURCE 40kW Liquid cooled Generators Alternator Drawing No 0E5146 B DESCRIPTION ROTOR 390 30KW 1P DIR
27. BULKHEAD CONNECTOR BC1 El 00 E3 TRANSFER SWITCH CUSTOMER CONNECTION CONNECTION 120 240V 1 ee Generac Power Systems Inc QUIETSOURCE 40kW Liquid cooled Generators Section 7 Electrical Data Electrical Schematic Engine Drawing No OE8116 A DATA 2 7 oy gt 4 766 769 10 S 14 utr 86 3 1545 p p 2 7 D 28g 9 1 2 14 14 66 C1 1 0 pc 0 4 15 343 6 144 154 OST 9 14 gt ITI Tu GJ O D U1 C aa 66 LEGEND ALT D C CHARGE ALTERNATUR BAT 1evDC BATTERY CUNNECTUR 1 ENGINED STARTER CONTACTOR DEG DRIVER ELEC G VERNUR DIST DISTRIBUTOR FS FUEL SOLENOID GND1 GROUND CSENSING LOW AMP GNDe GROUND CPUWER HIGH AMP GOV ELEC GUVERNUR ACTUATOR 765 2 lt 770 4 n 2 N C 5 K1 olo LEGEND 1 HCT HIGH COULANT TEMP SWITCH IGNITIUN COIL IM IGNITIUN MODULE J 1 JUNCTION 1 PCB JUNCTION Z PCB JB JUNCTIUN BLUCK POWER LUS LOW UIL PRESSURE SWITCH MAGNETIC PICK UP RI 30 WATT RESISTOR SM STARTER MOTOR WLS CUDLANI LEVEL SWITCH Generac Power Systems Inc 27 ELECTRICAL 402 n Section 8 Exploded Views and Parts LISTS gt QUI
28. CK 8 M4 49 020911 2 SCREW PPHM M5 0 8 X 30 ZINC 50 066849 2 SCREW HHTT M5 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 6 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 6 ZINC 66 038750 2 SCREW HHC M6 1 0 X 30 G8 8 67 0A2115 4 WASHER NYLON 257 68 0C2454 4 SCREW THF M6 1 X 16 NWA Z JS Generac Power Systems Inc 33 n Section 8 Exploded Views and Parts LISTS QUIETSOURCE 40kW Liquid cooled Generators Engine Drawing 0E8121 G BAFFLE REAR UPPER SS A CNG e SS D C ALTERNATOR BRACKET HARDWARE 34 Generac Power Systems Inc ITEM CONDOR N 30 31 32 33 34 35 36 37 38 39 PART NO QTY 0 5048 0 7477 0 6703 0 8336 0E7841 0E7254 0E7956 0E7953 047411 8591 7921 0E7749 022097 022473 049721 049813 036833 022131 022237 0E6729 022129 049821 057073 052677 066849 056739 0D2244M 087599 0 0992 0 0992 0 7754 0 7854 0 7855 0 7952 0E0561 035606 061012 0A8584 050873
29. ECT HSB ROTOR 390 40KW 1P DIRECT HSB STR 390 35AD1 HSB 382MM LONG 3 0LFORD STR 390 40AD HSB 433MM LONG 3 9L CHRYSLER REAR BEARING CARRIER 390 DRCT FLEXPLATE 3 0L FORD FLEXPLATE 3 9L HSB FLYWHEEL ASSY 3 0L HSB LG GEAR REVCOR FAN 10 75 X 2 WIPRESS DIS WASHER LOCK M10 SCREW HHC M10 1 5 X 16 G8 8 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD STUD M14 2 0 X 540 G5 ZINC 3 9L CHRYSLER WASHER LOCK M14 NUT HEX M14 2 0 G8 YEL CHR ASSY BRUSH HOLDER 390 HSB WASHER SHAKEPROOF INT 8 SCREW PPHM M4 0 7 X 25 SCREW SHC M10 1 5 X 35 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 GUARD STATOR 390 SCREW HHC M6 1 0 X 25 G8 8 NUT TOP LOCK FL M6 1 0 NUT HEX M4 0 7 G8 YEL CHR WASHER FLAT 8 ZINC CONDUIT FLEX 1 1 4 30 LG BALL BEARING 45 MM SLIP RING MACHINED age LISTS Generac Power Systems Inc 41 PARTS ITEM CON O CO 9 10 11 12 LISTS OG PART NO QTY 0 8616 1081 0 1087 0 8026 0E5914 0E8702 0E8727 036797 039253 022145 022129 045771 Section 8 Exploded Views and Parts QUIETSOURCE 40kW Liquid cooled Generators Muffler Drawing No OE8068 F TO EXHAUST MANIFOLD 1 N O DESCRIPTION MUFFLER 7 X 9 X 21 2 5 IN amp OUT WYE PIPE 3 91 CHRYSLER PIPE R H SIDE 3 9L CHRYSLER PIPE L H EXHAUST MANIFOLD BRACKET MUFFLER 30 LG PIPE MUFFLER INLET PIPE MUFFLER OUT
30. ETSOURCE 40kW Liquid cooled Generators Mounting Base Drawing 0E8084 A REAR BEARING CARRIER HARNESS ee Generac Power Systems Inc ITEM PART NO QTY 1 0E7331 1 2 052860 4 3 052251 4 4 052257 4 5 052252 4 6 052259 4 7 052891 4 8 0536210214 1 9 074906 1 10 047411 1 11 055414 1 12 026850 2 13 022097 1 14 022473 1 15 049813 1 16 0A1694 4 18 025507 3 19 0E7359 2 20 027482 2 21 022129 1 22 045771 1 23 051756 1 24 046526 1 2 022131 1 26 055934 1 27 049820 2 28 059473 1 29 061902 1 30 058665 REF 31 038804D 1 32 038805J 1 33 021991 1 34 036833 6 35 022237 6 36 022131 6 37 075763 1 38 050331 1 39 050331A 1 40 0A4010 2 41 052858 2 42 065852 1 43 045764 1 SHOWN USED TO HOLD DOWN 32 Section 8 Exploded Views and Parts QUIETSOURCE 40kW Liquid cooled Generators Mounting Base Drawing No OE8084 A DESCRIPTION WELDMENT MTG BASE 3 9L CRYSLR NUT FLANGED HEX M12 1 75 DAMPENER VIBRATION 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 M6 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 M8 1 25 G8 YEL CHR SCR
31. EW HHC M10 1 5 X 20 G8 8 WASHER LOCK M10 WASHER FLAT 3 8 M10 ZINC CLAMP VINYL 75 X 343Z NUT HEX LOCK M8 1 25 NY INS HOLD DOWN BATTERY HOLD DOWN BATTERY BATT 12VDC 90 AH 27F CABLE BATT 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 BOOT BATTERY CABLE BATTERY POST COVWER BLACK BATTERY POST COVWER RED SCREW 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 PARTS LISTS OG Generac Power Systems Inc 29 n Section 8 Exploded Views and Parts LISTS 0 QUIETSOURCE 40kW Liquid cooled Generators Enclosure Drawing 0E8800 B SEE LATCH REQUIRE INSULATION TYPICAL OF ROOF PANEL THAT SECURE AS SHOWN STATES FOAM IS ON FAR SIDE e D lt LLi O 22 lt O LL N lt gt a LATCH DETAIL Generac Power Systems Inc ITEM CONDOR N PART NO 0E8418 0E8414 0E8413 002454 0E7807 0E5902 0E5903 0E8387 0E5912 0E5911 089961 0A2115 0E8404 0D2538A 0D2538 043116 022097 022473 0E7570 0E7571 070015 0E7662 0D2537A 0D2537 0D2023 0E7869 0 8001 0E5913 0E8798 0D3037A 067781 0 5910 0 8052 003037 0 5900 0 5901 0 8799 0 8415 026850 0912970063 0912970064 049813 0 8416 0 8417 0 8665 002023 0 8442 0 7829 0 7829 0 7829 0 7829 0 78
32. IRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage amperage capacity of the generator If the generator is powering only crit ical loads within the wattage amperage capacity dur ing utility power outages consider using the emer gency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are with in the wattage amperage capacity of the generator set When this method is used it is difficult to overload the generator The transfer switch must meet the fol lowing requirements It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit Have it installed between the buildings 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 gener ator 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 utility service entrance and the building distribution panel By code and approved me
33. LLATION A DIG A Standby generators 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 possible 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 Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery INSTALLATION Section 2 Installation A Battery electrolyte fluid is an extremely caustic 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 A A Do not dispose of the battery in a fire The bat A tery is capable of exploding Do not open or mutilate the battery Released A electrolyte can be
34. NT LEVEL See Checking Fluid Levels in Section 4 4 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 4 5 8 CHECK FAN BELT 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 governor QUIETSOURCE 40kW Liquid cooled Generators A Dita A A 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 incorrect frequency and or voltage Only quali fied service technicians should
35. NVd 58422 4015 INIddlLOO4 3SV8 L v 19309GST 30415 AY 14 v NUILO3NNDO 471 JD SVO WANLVN 7 916 60 5011 DNIGNLS9 6 3001 TIVS3ALD INTadlO04 3SV8 L EEI S 9v8 S3HONIJ uw m O 501 29211 INR 9190 3015 1 131 1304 210S 19130 1291 13NVd 1 SIND2 met TIV33AU 7 335 31UN 335 171401 Ee 1 it T TL x i HION31 T1 V33AB0 O9NILNQUNW 1 3ONV3V319 X000 c 31UN 435 dAL Z I8J908 61118106 QVSHASAD 1 96871 11 IAA cl TANVd ANI INIVW 5 Ad3l1V8 2 492 06 AO 92 85 HVGZ 14 31IVOIDWWUOOV 1 TIIM AVAL 8 8 X S 1 S vaga X G eve SNOISNAWIC JCISNI 1 11 W3ISAS IN ODSO 3AI1953N LIDA el Ce TANVd WALNOO NI G3aIAUSd 14915 31DN39 HOLIMS 345 941 54931 YOI 99 A04 SLNIOd NOILOANNOD SALON L 6 01J9 lt 5214 t S3 DH ONILNAOW L ES 09 S ET9 dn dNls 61 21 LETEIVEL 23 Generac Power Systems Inc Section 7 Electrical Data QUIETSOURCE 40kW Liquid cooled Generators ELECTRICAL DATA ud Wiring Diagram Engine Drawing No 0E8115 A
36. This generator system is intended to be used with a Generac transfer switch It will be available 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 A Install the transfer switch on a firm sturdy sup porting structure To prevent switch distortion level the switch if nec essary 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 A Generac Authorized Dealer can supply an appro priate transfer switch for the generator Section 1 General Information QUIETSOURCE 40kW Liquid cooled Generators 1 5 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 source voltage has been restored the switch re transfers back
37. adjust the gov erned speed 4 5 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized serv ice dealers for engine oil and filter change frequen cies 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 from 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 CAP and re install into its retaining clip 4 Turn OIL FILTER Figure 4 2 counterclockwise and remove Dispose of old filter Figure 4 2 Oil Filter LA fes Z NS SAS 90 NLS I 12 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 FULL MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters MAINTENANCE 0 9 Section 4 Maintenance caution amp A After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 7 Start engine and check for oil leaks 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
38. al 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 ofa 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 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 automat ic start up and possible injury to personnel disable the generator s 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 accident caused by electric shock immedi ately shut down the source of electrical power If this is not possible attempt to free the victim from the l
39. amiliar 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 caution amp After the system has been installed do nothing that might render the installation in noncompli ance with such codes standards and regula tions 2 1 1 NFPA 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 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES NFPA No 76A ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES NFPA No 220 STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No 68 GUIDE FOR EXPLOSION VENTING NFPA No 70 NATIONAL ELECTRICAL CODE NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 2 1 2 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following infor mation pertaining to the installation and use of standby electric systems is available Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John otreet New York N Y 10038 AGRICULTURAL WIRING HANDBOOK obtainable from the Food and Energy Council 909 University Avenue Columbia MO 652
40. 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 14 Generac Power Systems Inc Figure 3 2 Engine Governor Adjustment LI m R I ja EDI Es Gg SW HM R40 D6 R57 R58 R59 a Deu s s a J2 ir i L deed BRL LH L D DL 1 L 1 TT T E meum C26 tit 1 PRERRE TEZELE PON GAIN DIFFERENTIAL DIP SWITCH STABILITY POSITION 1 POSITION 2 PUNUSED 50 60 HZ GTS ATS Select 1 e ON 50HZ ON GTS 2 GTS ATS S OFF ATS standard mode 4 m 50 60 Hz OFF 60 HZ 3 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 as follows Verif
41. ans of service disconnect must be located between the incoming utility serv ice and the transfer switch Generac Power Systems Inc 2 7 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 gener ator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations A DX 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 in the event of a ground fault condi tion in the generator or in connected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded devices Figure 2 2 Generator Grounding Lug typical 7 GROUNDING LUG 2 8 GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED neutral Grounding is recommended only at the main service entrance If the neutral wire is grounded and one of the phase loads becomes grounded the excessive current opens the load circuit breaker or collapses the generator field The actual result depends on the electrical characteristics of the particular installed generat
42. d GTS type transfer switch refer to the applicable transfer switch manual for exact oper ating parameters and timing sequences 3 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 7 RED LEDs SET EXECISER GREEN LED TIME SWITCH AUTO OFF MANUAL AA FUSE SWITCH BATTERY 15A FUSE CHARGER MAIN POWER 521 AUTO OFF MANUAL SWITCH Use this three position switch as follows Set the switch to AUTO for fully automatic opera tion See Automatic Operation Section 3 5 Set switch to MANUAL position to crank and start the generator engine Set switch to OFF position to shut down an oper ating engine With OFF selected operation will not be possible A DIG A A With switch set to AUTO engine can crank and start suddenly without warning Such automat ic 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 con trol console 5 2 2 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
43. e battery A Battery electrolyte fluid is an extremely caustic 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 A Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging wanNiNG amp A 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 BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 27F 700 Q 0 deg F NOTE The BCI number should be located directly on the battery PERIODIC REPLACEMENT PARTS Part Name Generac s Part Number Oil Filter 0E7415 Radiator Cap 046627 Air Cleaner 0A4637 Spark Plug Champion RC12LC4 Section 4 Maintenance QUIETSOURCE 40kW Liquid cooled Generators MAINTENANCE 4 7 SCHEDULED MAINTENANCE Following is a r
44. e 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 5 MANUAL TRANSFER AND START UP To transfer electrical loads to the Standby EMER GENCY power source side and start the engine man ually 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 governor has been set by the factory during 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 STABILI TY 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
45. e unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary Test the engine and transfer switch safety devices Correct and or adjust as necessary eo Generac Power Systems Inc Task Comp Date Initials 13 14 15 17 18 19 20 21 Section 4 Maintenance QUIETSOURCE 40kW Liquid cooled Generators MAINTENANCE 2 0 Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task mended Comp be done Comp Ito be done Comp Required to be done Date 3months Date Semi Date to 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 BP Change the engine oll 16 e filter s filter s 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
46. ecommended maintenance schedule for QuietSource 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 appli cation 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 An early 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 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 condi tion from burning out sensitive contr
47. ect any leaks immediately 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 Generac Power Systems Inc 3 GENERAL INFORMATION 1 1 GENERATOR This equipment is a liquid cooled engine driven gen erator set The generator is designed to supply elec trical 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 oper ation of 120 and or 240VAC single phase loads warnings amp 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 transfer switch The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating NEC 701 Failure to isolate an electrical system by such means results in damage to the generator and may also result in injury or even death to utility power work ers due to backfeed of electrical energy 1 2 TRANSFER SWITCH
48. evel the dipstick FULL mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications Section 1 10 and Engine Oil Recommendations Section 1 14 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 Section 1 10 and Coolant Section 1 15 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 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 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 Generac GTS type automatic transfer switch In this application
49. ficiently and reliably only if it is properly installed operated and maintained Many acci dents are caused by failing to follow simple and funda mental rules or precautions Generac cannot anticipate every possible circumstance that might involve a hazard The warnings in this man ual and on tags and decals affixed to the unit are there fore not all inclusive If using a procedure work method or operating technique that Generac does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operat ing technique chosen does not render the generator unsafe A DIG A 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 main tain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running gen erators 2 Generac Power Systems Inc 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 shou
50. 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 colli sion etc 1 8 2 INSPECTION After unpacking carefully 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 warning amp 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 Single phase Model 005012 0 Rated Max Cont AC Power Output kW Rated voltage volts 120 240 37 NG 40 LP No of Rotor Poles 4 Driven Speed of Rotor 1800 Rotor Excitation System Direct excited brush type Type of Stator 4 Wire Rotor Stator Insulation Class F H 1 10 2 ENGINE SPECIFICATIONS Make c Chrysler Displacemen
51. ic oil is highly recommended in any element with temperatures above 90 F or below 30 F caution amp Any attempt to crank or start the engine before A 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 recommended coolant mixture When adding coolant always add the recommended 50 50 mix ture 8 Generac Power Systems Inc QUIETSOURCE 40kW Liquid cooled Generators caution amp A Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chromi umhydroxide green slime forms and will cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating It is also recommend that any soluble 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 Sections 2 5 a
52. ictly complied with may result in personal injury or property damage caution amp 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 A tion that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard Generac Power Systems Inc The operator is responsible for proper and safe use of the equipment Generac strongly recommends that the operator read this Owner s Manual and thor oughly understand all instructions before using this equipment Generac also strongly 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 a
53. ity 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 or 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 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 warrant
54. ive 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 X EXPLOSION HAZARDS Z 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 Generac generator sets may operate using one of sev eral types of fuels All fuel types are potentially FLAM MABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the units fuel system frequently and corr
55. ld be followed during installation and maintenance of the generator and batteries A GENERAL HAZARDS For safety reasons Generac recommends that this equipment be installed serviced and repaired by a Generac Authorized Service Dealer or other compe tent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations Installation 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 electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the gener ator 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 reason ade quate 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 ani
56. ll safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Authorized Service Dealer Normal maintenance serv ice 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 Generac Authorized Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by a Generac 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 a Generac Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting a Generac 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 CARD affixed to the unit AUTHORIZED SERVICE DEALER LOCATION To locate the nearest GENERAC AUTHORIZED SERVICE DEALER please
57. mals 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 operating 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 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS QUIETSOURCE 40kW Liquid cooled Generators 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 stress and break parts and may result in dangerous operating conditions
58. nd 2 6 The generator s 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 Generac GTS type transfer switch if necessary 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 1 STANDBY GENERATOR INSTALLATION A DX A A Connecting this generator to an electrical sys tem normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the electric system from the utility distri bution system when the generator is operating Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy A Ifan open bottom is used the engine genera f tor is to be installed over non combustible materials and should be located such that com bustible materials are not capable of accumu lating under the generator set QUIETSOURCE 40kW Liquid cooled Generators Only qualified competent installation contractors or electricians thoroughly f
59. nd burn from the heat of the exhaust system 4 5 OVERLOAD PROTECTION FOR ENGINE DC 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 If a circuit breaker opens or a fuse element A melts find the cause of the overload before resetting the circuit breaker or replacing the fuse Generac Power Systems Inc 15 OPERATION Section 4 Maintenance J gt QUIETSOURCE 40kW Liquid cooled Generators 4 4 CHECKING FLUID LEVELS 4 4 1 CHECK ENGINE OIL Check engine crankcase oil level Figure 4 1 at least every 20 hours of operation 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 Section 1 14 for recom mended oils Figure 4 1 Oil Dipstick and Oil Fill Cap Oil Dipstick Oil Fill e 2 0 O Sess 0 0 00 0 5 Oil Filter 0 4 4 22 BATTERY FLUID Check battery electrolyte fluid at least once weekly Fluid should cover separators in all batte
60. oft 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 a Generac 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 BATTERY All lead acid storage batteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery 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 in 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
61. ol 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 Generac Service Dealer 3 An operational 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 Generac Service Dealer 4 A mid level 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 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
62. operational run of the unit looking for any post service oroblems Return the unit to standby setup for operation when required Task Comp Date Initials Generac Power Systems Inc 21 TROUBLESHOOTING Section 5 Troubleshooting QUIETSOURCE 40kW Liquid cooled Generators TROUBLESHOOTING POINTS CAUSE PROBLEM Engine won t crank Engine cranks but won t start Engine starts hard runs rough Engine starts then shuts down AUTO OFF MANUAL Switch at OFF engine continues to run No AC output from generator 1 2 NOOR 15 fuse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery 4 amp fuse blown Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Air cleaner plugged or damaged Plugged fuel line Defective spark plugs Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch Defective AUTO OFF MANUAL switch Open disconnected wire 15A between AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board
63. or 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 QUIETSOURCE 40kW Liquid cooled Generators Setting switch two to OFF allows the control PCB to perform the ATS control functions Control system interconnections consist of 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 on the length of the wire as recommended below MAXIMUM WIRE LENGTH RECOMMENDED WIRE SIZE 461 to 730 feet 223m 731 to 1 160 feet 354m 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 Generac GTS type switch it is necessary 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 Section 3 1 for further explanation 2 10 BATTERY INSTA
64. pect exhaust system Check engine ignition system Check fan belts S OPI I Is MAINTENANCE 2 0 Section 4 Maintenance ONCE EVERY SIX MONTHS Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY Test engine governor Adjust or repair if needed Clean inspect generator Flush cooling system FIRST 100 OPERATING HOURS Change engine oil and oil filter After initial change service engine oil and filter at 150 oper ating hours or 6 months whichever comes first 2 Retorque cylinder head See Torque Specs Section 1 13 3 Retorque intake and exhaust manifold See Torque Specs Section 1 13 EVERY 500 OPERATING HOURS Service air cleaner Check starter 3 Check engine DC alternator 4 2 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 m Io S u Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See Section 6 for installation drawings and vent locations WARNING 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 a
65. 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 Section 1 General Information QUIETSOURCE 40kW Liquid cooled Generators 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 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 temper ature low coolant level LED Figure 1 6 on page 6 Generac Power Systems Inc 5 1 74 OVERSPEED SHUTDOWN The engine control board receives AC frequency sig nals from an engine run winding in the alternator Should AC frequenc
66. quid cooled Generators Fuel System Drawing 8122 gt 25 g2 31 45 8 38 Generac Power Systems Inc TO ENGINE MANIFOLD ITEM CONDOR N PART NO 033212 075580 0E8365 039253 022145 022129 045771 042907 002454 026307 0E1056 0 6584 057822 059194 064945 0D1509 050279 0E7839 0 6586 0 4394 040105 0 6382 0 2119 0 6376 042561 0 7929 0 4637 0 6406 0 7702 0 4632 037561 046580 0 8286 044118 049815 049226 051713 022097 057796 057795 052223 061012 0 9295 0 3994 0 7121 qn HR HS HS NS B OO PO Section 8 Exploded Views Parts QUIETSOURCE 40kW Liquid cooled Generators Fuel System Drawing No 0E8122 H DESCRIPTION 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 G8 8 SCREW TH FRM M6 1 X 16 NWA Z JS 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 ACTU
67. re 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 warninc amp Gaseous fuels such as natural and LP A propane gas are highly explosive Even the slightest spark can ignite such fuels and cause an explosion 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 fol lowing conditions low oil pressure high coolant tem perature engine overspeed low coolant level or over crank Figure 1 3 Figure 1 3 Engine Protective Devices Low Oil Pressure Switch High Coolant Temperature Switch EDA _ f M u h oN 2 T JS Al li NA bh y ey Low Coolant Level Sensor l 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 drop below about 8 10
68. rformed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries For recommended batteries see Section 4 6 4 All batteries must be at 100 percent state of charge before they are installed on the generator Generac Power Systems Inc 11 OPERATION Section 3 Operation J gt QUIETSOURCE 40kW Liquid cooled Generators When using maintenance free batteries it is not nec essary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in Section 4 Maintenance A negative 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 stand by generator has been properly installed serviced 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 equipment 2 11 1 PRIOR TO INITIAL START UP caution amp A Prior to initially starting the generator
69. ry 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 Section 1 10 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 Generac Service Dealer Inspect cooling system and coolant recovery system for leaks 16 Generac Power Systems Inc 4 5 MAINTENANCE OWNER OPERATOR CAN PERFORM 4 5 1 CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels in Section 4 4 4 5 2 CHECK BATTERY Check battery fluid level 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 otart the generator engine at least once every seven days and let it run at least 20 minutes See Section 3 6 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 COOLA
70. sure it is positioned properly before reattaching the cover See the Service Schedule Section 6 for air cleaner maintenance 4 5 12 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary See Section 6 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 com mercial solvent Do not blast the spark plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Service Schedule Section 6 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 enis VS 5 4 5 13 COOLANT CHANGE Every year have an authorized service dealer drain flush and refill the cooling system See SPECIFICA TIONS Section 1 10 for cooling system recommen dations Generac Power Systems Inc 17 MAINTENANCE S O Section 4 Maintenance 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 s
71. t 0 440 000000 nnns 3 9 liters Cylinder V 6 Valve Arrangement Overhead Valve Firing Order essere 1 6 5 4 3 2 Number of Main Bearings J a 4 Compression Ratio 9 1 to 1 of Teeth on Flywheel nnne 164 Ignition Timing at 1800 rpm 30 degrees BTDC Spark Plug Gap 1 01mm 0 040 in Recommended Spark Plugs Champion sess RC12LC4 Oil Pressure 30 80 psi Crankcase Oil Capacity 4 0 U S quarts 3 8 liters Recommended Engine Oil SAE 15W 40 Type of Cooling System Pressurized closed recovery Cooling Fan essen Pusher Type 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 1 11 FUEL CONSUMPTION Natural Gas of Load 25 50 75 100 m3 hr 4 1 7 7 11 0 14 2 ftS hr 143 1 271 1 388 5 502 0 LP Vapor of Load 25 50 75 100 ms hr 1 7 3 3 4 7 6 0 ft3 hr 60 7 115 0 164 9 213 0 Section 1 General Information QUIETSOURCE 40kW Liquid cooled Generators NOTE
72. t 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 100 one hundred percent transferable coverage on 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 performed 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 util
73. to accomplish and should be performed only by an authorized Generac Service Dealer NOTE If the generator experiences heavy use the maintenance intervals should be reduced so that procedures are performed more frequently Generac Power Systems Inc 19 Section 4 Maintenance MAINTENANCE QUIETSOURCE 40kW Liquid cooled Generators 5 10 Check the engine 11 12 Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task mended Comp be done Comp be done Comp Hequired Date 3 months Date Semi Date be done Initials Break in Initials annually Initials Annually Disable the unit from operating per the first page warning Check the engine oil level Adjust as necessary Check the engine coolant level Adjust as necessary Check the engine coolant thermal protection level Correct as necessary Check the natural gas delivery system on gas engine driven units Tighten connections as necessary Check the air inlets and J l f necessary Check the battery electrolyte level if accessible Adjust as necessary x cables and charger for loose connections corrosion and proper operation Correct as necessary Check the unit wiring for loose connections corrosion and damage Correct as necessary accessory drive belts for wear weather cracking and damage Replace as necessary Visually inspect th
74. to exercise set the weekly exercise cycle as fol lows 1 Place the AUTO OFF MANUAL switch in the AUTO position 2 Press and hold the Set Exercise switch for three seconds then release 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 gener ator will still start and run in manual mode or auto matically 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 id 15A BAT MAIN CHARGER AUTO OFF ON SET MANUAL EXERCISE TIME s lt 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 Ins
75. 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 supply 120VAC 60 Hertz When the two windings are con nected 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 junc tion of Wires 22 and 33 The NEUTRAL is not grounded Figure 1 1 Generator AC Connection System 240 VOLTS CIRCUIT BREAKER 1 5 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 0 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 e Generac Power Systems Inc 1 6 GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using a natural gas fuel system If propane LP gas is neces sary refer to Section 1 12 for conversion instructions Fuel pressu
76. y exceed about 72 Hertz for three 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 eae ere tls eo aTh R58 R59 3 J2 A44 nnt 1 D6 R57 T TT TT se EMO 7 er hy R44 ITTT zx 02 e x TT T staae ee Ll gt T E i Lg e 9 LE m om LiT J e e e BS s UB e e le e s I _ IT T LEN 022 m 9 em Le eT Le V3R 800530 809 D18 D19 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 1 76 OVERCRANK SHUTDOWN
77. y 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 BOX 297 WHITEWATER WI 53190 Revision 2 05 Part No OESOd2 Revision E 03 15 05 Printed in U S A
78. y that utility power supply voltage to the trans fer switch has been positively turned OFF 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 AUTO OFF MANUAL switch to OFF 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 utility 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 5 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 QUIETSOURCE 40kW Liquid cooled Generators On the day and at the time of day chosen for the gen erator

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