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Section 9 - Notes
40kW Liquid-cooled Generators
Page 1: ...wner s Manual ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model No 005012 1 37kW NG 40kW LP ...
Page 2: ...l explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly recommends instructing oth...
Page 3: ...ctric System 10 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 11 2 9 Transfer Switch Start Signal Connections 11 2 10 Battery Installation 11 2 11 Preparation Before Start Up 12 Section 3 OPERATION 13 3 1 Using an Engineered GTS Transfer Switch 13 3 2 Control Console Components 13 3 3 Manual Trans...
Page 4: ...re that the genera tor is installed operated and serviced in accordance with the manufacturer s instructions and recommen dations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient co...
Page 5: ... 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 accepta...
Page 6: ...t construction grit and cor rosive vapors An Authorized Dealer can supply an appropriate transfer switch for the generator 1 3 AUTOMATIC SYSTEM OPERATION When this generator along with a transfer switch has been installed and interconnected a circuit board in the generator panel constantly monitors UTILITY power source voltage Should that voltage drop below a preset value and remain at such a low ...
Page 7: ...e the engine to automatically shut down under the following conditions low oil pressure high coolant temperature engine overspeed low coolant level or overcrank Figure 1 3 Figure 1 3 Engine Protective Devices Low Coolant Level Sensor Low Oil Pressure Switch High Coolant Temperature Switch 1 7 1 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure durin...
Page 8: ...fter all six attempts the start attempt is stopped and the overcrank LED turned on 1 7 7 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 wil...
Page 9: ...Fuel consumption is given at rated maximum continuous power output when using natural gas rated at 1000 Btu per cubic foot LP gas is rated at 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient temperature engine condi tions and other environmental factors Fuel pressure for a natural gas set up should be five inches to 14 inches of ...
Page 10: ...d coolant mixture When adding coolant always add the recommended 50 50 mixture Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chro miumhydroxide green slime forms and will cause overheating Engines that have been oper ated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti freeze Using any high silicate anti ...
Page 11: ...ANDBOOK obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 364 2 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 A52 1 AMERICAN NATIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYSTEMS available from the American National Standard Institute 1430...
Page 12: ...ding s main dis tribution panel and the emergency distribution panel 2 6 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed use the Total Circuit Isolation Method It is possible for the gen erator to be overloaded when this isolation method is employed The following apply to the transfer switch in this type of system Ampere ra...
Page 13: ...nd start automati cally when NORMAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and pos sible injury to personnel do not connect battery cables until certain that normal source voltage at the transfer switch is correct and the system is ready to be placed into operation Storage batteries give off explosive hydrogen gas This gas can fo...
Page 14: ...ank 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 the Maintenance section 2 11 2 TRANSFER SWITCH...
Page 15: ...lled in conjunction with an engineered 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 SEE OWNER S MANUAL FOR COMPLETE LED DETAILS 5 FLASHING RED LED S EXERCISER NOT S...
Page 16: ...by EMERGENCY power source side and start the engine manually refer to the Owner s Manual of the particular transfer switch 3 4 ENGINE GOVERNOR ADJUSTMENTS Engine speed governing is also controlled by the engine control board Connector J2 on the engine control board interfaces with a governor driver mod ule and the Bosch throttle body The engine gover nor has been set by the factory during final te...
Page 17: ...ximately 12 minutes If utility should fail during this exercise period the engine control board will transfer the load to the generator output and continue to run until util ity returns On the day and at the time of day chosen for the generator to exercise set the weekly exercise cycle as follows 1 Place the AUTO OFF MANUAL switch in the AUTO position 2 Press and hold the Set Exercise switch for t...
Page 18: ...er shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system 4 3 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 protec...
Page 19: ...wise 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 DANGER Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase t...
Page 20: ...rior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer That dealer will use dry low pressure air to clean...
Page 21: ...ot allow smok ing open flame sparks or any spark producing tools or equipment near the battery Battery electrolyte fluid is an extremely caus tic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If the fluid is spilled flush the affected area immed...
Page 22: ...dition from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to ensure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ONLY ONCE following the fi...
Page 23: ...sary 5 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiring for loose conne...
Page 24: ...ting conditions Correct as necessary 14 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 15 Change the engine oil 16 Replace the engine oil filter s 17 Replace the engine air filter s 18 Replace the engine fuel filter s on diesel...
Page 25: ...or replace plugs Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defective Low Coolan...
Page 26: ...24 Section 6 Electrical Data 40kW Liquid cooled Generators Wiring Diagram Engine Drawing No 0E8115 A ...
Page 27: ...25 Section 6 Electrical Data 40kW Liquid cooled Generators Wiring Diagram Engine Drawing No 0E8115 A ...
Page 28: ...26 Section 6 Electrical Data 40kW Liquid cooled Generators Electrical Schematic Engine Drawing No 0E8116 A ...
Page 29: ...27 Section 6 Electrical Data 40kW Liquid cooled Generators Electrical Schematic Engine Drawing No 0E8116 A ...
Page 30: ...3 2 35 36 41 40 16 6 7 5 19 16 28 30 27 35 34 39 36 33 27 29 22 20 32 38 18 31 20 21 STARTER TO STARTER BOLT TO BLOCK ENGINE 18 TO 11 1 12 10 14 REAR BEARING 15 37 13 CARRIER 3 4 16 2 Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Mounting Base Drawing No 0E8084 C ...
Page 31: ...1 WASHER LOCK M8 5 16 22 045771 1 NUT HEX M8 1 25 G8 YEL CHR 23 051756 1 SCREW HHC M10 1 5 X 20 G8 8 24 046526 1 WASHER LOCK M10 25 022131 1 WASHER FLAT 3 8 M10 ZINC 26 055934M 1 CLAMP VINYL 75 X 343 Z 27 049820 2 NUT HEX LOCK M8 1 25 NY INS 28 059473 1 HOLD DOWN BATTERY 29 061902 1 HOLD DOWN BATTERY 30 058665 REF BATT 12VDC 90 AH 27F NOT INCLUDED 31 038804D 1 CABLE BATT RED 4 X 20 00 32 038805J 1...
Page 32: ...ECURE AS SHOWN REQUIRE INSULATION TYPICAL OF ROOF PANEL THAT 4 53 35 SUPPORT RADIATOR 4 33 4 4 46 49 53 32 4 36 4 47 18 29 4 26 4 8 4 A 22 9 12 13 55 17 48 52 54 B 20 53 11 10 15 14 19 51 21 20 16 28 43 4 1 2 PLCS TO B 24 17 42 41 21 18 39 17 55 18 23 47 40 17 4 26 44 10 39 18 Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Enclosure Drawing No 0F4930 C ...
Page 33: ...K 27 0E8001 1 MUFFLER BOX 28 0F5568 1 ROOF HSB AL ACOUSTIC 29 0E8798 1 BRACE FRONT TOP 30 0D3037A 1 LATCH 1 4 TURN NONLOCKING 31 0C7781 2 PAWL DOOR HSB 32 0E5910 1 SUPPORT LH SIDE HSB AL 33 0E8052 1 MUFFLER BOX TOP 34 0D3037 1 LATCH QUARTER TURN LOCKING 35 0E5900 1 POST CORNER LH FRONT HSB AL 36 0E5901 1 POST CORNER RH FRONT HSB AL 37 0F4938A 1 BRACE FRONT BOTTOM 38 0E8415 1 DUCT DISCHARGE MID AL ...
Page 34: ...32 Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Control Panel Drawing No 0E7118 K ...
Page 35: ...OL PANEL 34 0D4698 REF BLOCK TERM 20A 6 X 3 X 1100V 35 0E7252 1 BRACKET CB 221 5 X 102 36 0C1229 1 DECAL WARNING ELECTRICAL SHOCK ITEM PART NO QTY DESCRIPTION 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 PHT...
Page 36: ...PPER 61 A 26 75 64 74 76 38 17 24 25 73 23 B 66 63 62 E OIL ENGIN 9 1 14 13 28 27 2 10 57 19 19 18 17 44 43 5 40 18 70 4 19 18 B TO 39 30 35 37 6 19 77 18 33 17 5 78 36 21 48 FRONT 42 12 59 16 51 14 41 34 21 14 49 50 13 19 29 18 18 44 43 18 17 53 55 19 18 31 56 47 18 44 11 45 54 Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Engine Drawing No 0E8121 H ...
Page 37: ...E10 PSI 2POL ITEM PART NO QTY DESCRIPTION 39 050873A 1 PLUG PIPE 1 4 CSK W VIBRA SL 40 031919 1 PLUG STD PIPE 3 8 COUNTERSUNK 41 022145 6 WASHER FLAT 5 16 M8 ZINC 42 030795 6 SCREW HHC 5 16 18 X 1 G5 43 051756 5 SCREW HHC M10 1 5 X 20 G8 8 44 046526 6 WASHER LOCK M10 45 0A1232A 1 ASSEMBLY D C ALTERNATOR 46 0A7801B 1 PULLEY POLY V 82 OD 47 045772 1 NUT HEX M10 1 5 G8 YEL CHR 48 022403 2 SCREW HHC 5...
Page 38: ... ENGINE 23 24 26 25 24 21 3 A 13 1 15 19 22 HOUSING THERMOSTAT TO 10 4 10 20 10 5 16 16 2 14 15 8 7 14 17 17 6 9 14 18 TO A Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Radiator Drawing No 0E8102 F ...
Page 39: ...E OIL DRAIN ASSY 21 14 058443 17 SCREW CRIMPTITE 1 4 20 X 5 8 15 0C2454 5 SCREW TH FRM M6 1X16 N WA Z JS 16 052250 2 TAPE FOAM 1 X 1 27 LG 17 048031C 1 CLAMP HOSE BAND 1 4 18 029032 1 HOSE 9 32 ID 30 LG 19 0A2111 1 SCREW SWAGE 10 32 X 5 16 Z YC 20 0E7640A 1 RADIATOR SUPPORT R H SIDE 21 035461 1 BARBED STR 1 4NPT X 3 8 22 065852 1 SPRING CLIP HOLDER 37 62 23 051756 4 SCREW HHC M10 1 5 X 20 G8 8 24 ...
Page 40: ... 4 5 6 45 42 40 11 41 9 8 12 6 3 15 2 13 27 31 14 19 29 30 32 B TO B 13 36 37 38 20 19 18 35 34 MANIFOLD INTAKE TO 44 43 25 22 6 1 39 33 Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Fuel System Drawing No 0E8122 H ...
Page 41: ... HOSE COOL 2IN ID 20R4 2 LG 22 0E6382B 1 VENTURI HOLDER W 40MM ACTUATOR 23 0F2119 1 O RING 45 63 ID X 2 62 WIDTH 24 0E6376B 1 VENTURI 28 ID THROTTLE W CHOK 25 042561 2 CLAMP HOSE 36 1 88 2 75 27 0E7929 1 BASE AIR CLEANER PLATE 28 0A4637 1 FILTER AIR 11 5 CA326 29 0E6406 1 HOLDER VENTURI 30 0E7702 1 HOLD DOWN AIR CLEANER 31 0A4632A 1 PLATE AIR CLEANER TOP 32 037561 1 NUT WING 1 4 20 NYLK 33 046580 ...
Page 42: ...40 3 LOCKTIGHT LOCKTIGHT 7 15 17 8 7 6 18 4 16 LEADS 5 2 9 13 21 19 20 14 10 11 12 30 1 31 Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Alternator Drawing No 0F5092 B ...
Page 43: ...COR FAN 10 75 X 2 W PRESS DIS 7 046526 8 WASHER LOCK M10 8 051755 4 SCREW HHC M10 1 5 X 16 G8 8 9 04576100BK 4 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD 2 5L FORD 04576100BF 4 STUD M14 2 0 X 540 G5 ZINC 10 043123 4 WASHER LOCK M14 11 051779 4 NUT HEX M14 2 0 G8 YEL CHR 12 0E7587 1 ASSY BRUSH HOLDER 390 HSB 13 023365 1 WASHER SHAKEPROOF INT 8 14 092980 4 SCREW PPHM M4 0 7 X 25 15 057192 4 SCREW SHC M10 ...
Page 44: ... BLANKET 675MM 7 0F6258 1 PIPE MUFFLER OUT 8 036797 4 BOLT U 5 16 18 X 2 25 9 039253 2 SCREW HHC M8 1 25 X 20 G8 8 10 022145 6 WASHER FLAT 5 16 M8 ZINC 11 022129 11 WASHER LOCK M8 5 16 12 045771 3 NUT HEX M8 1 25 G8 YEL CHR 13 0C2454 4 SCREW TH FRM M6 1 X 16 N WA Z JS ITEM PART NO QTY DESCRIPTION 14 052860 4 NUT TOP LOCK FL M12 1 75 15 052891 4 SCREW HHC M12 1 75 X 80 G8 8 16 0E8816 1 EXHAUST FLAN...
Page 45: ...43 Section 8 Installation Diagram 40kW Liquid cooled Generators Installation Diagram Drawing No 0E8797 ...
Page 46: ...44 Section 9 Notes 40kW Liquid cooled Generators ...
Page 47: ...45 Section 9 Notes 40kW Liquid cooled Generators ...
Page 48: ...mounts 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 the...
