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3

•  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 from 
leaking exhaust gases, fuel leakage, oil leakage, etc.

 ELECTRICAL HAZARDS 

• All generators covered by this manual produce dan-

gerous electrical voltages and can cause fatal electri-
cal shock. Utility power delivers extremely high and 
dangerous voltages to the transfer switch as well as 
the standby generator. Avoid contact with bare wires, 
terminals, connections, etc., on the generator as well 
as the transfer switch, if applicable. Ensure all appro-
priate covers, guards and barriers are in place before 
operating the generator. If work must be done around 
an operating unit, stand on an insulated, dry surface 
to reduce shock hazard.

• Do not handle any kind of electrical device while 

standing in water, while barefoot, or while hands or 
feet are wet. 

DANGEROUS ELECTRICAL SHOCK 

MAY RESULT.

• If people must stand on metal or concrete while 

installing, operating, servicing, adjusting or repair-
ing this equipment, place insulative mats over a dry 
wooden platform. Work on the equipment only while 
standing on such insulative mats.

• The National Electrical Code (NEC), Article 250 

requires the frame and external electrically conduc-
tive parts of the generator to be connected to an 
approved earth ground and/or grounding rods. This 
grounding will help prevent dangerous electrical 
shock that might be caused by a ground fault condi-
tion in the generator set or by static electricity. Never 
disconnect the ground wire.

•  Wire gauge sizes of electrical wiring, cables and cord 

sets must be adequate to handle the maximum elec-
trical current (ampacity) to which they will be sub-
jected.

•  Before installing or servicing this (and related) equip-

ment, make sure that all power voltage supplies are 
positively turned off at their source. Failure to do so 
will result in hazardous and possibly fatal electrical 
shock.

•  Connecting this unit to an electrical system normally 

supplied by an electric utility shall be by means of a 
transfer switch so as to isolate the generator electric 
system from the electric utility distribution system 
when the generator is operating. Failure to isolate the 
two electric system power sources from each other 
by such means will result in damage to the generator 
and may also result in injury or death to utility power 
workers due to backfeed of electrical energy.

• Generators installed with an automatic transfer 

switch will crank and start automatically when NOR-

MAL (UTILITY) source voltage is removed or is below 

an acceptable preset level. To prevent such automatic 

start-up and possible injury to personnel, disable the 

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, imme-

diately shut down the source of electrical power. If 

this is not possible, attempt to free the victim from 

the live conductor. 

AVOID DIRECT CONTACT WITH 

THE VICTIM.

 Use a nonconducting implement, such 

as a dry rope or board, to free the victim from the live 

conductor. If the victim is unconscious, apply first aid 

and get immediate medical help.

•  Never wear jewelry when working on this equipment. 

Jewelry can conduct electricity resulting in electric 

shock, or may get caught in moving components 

causing injury.

 FIRE HAZARDS 

• Keep a fire extinguisher near the generator at all 

times. Do NOT use any carbon tetra-chloride type 
extinguisher. Its fumes are toxic, and the liquid can 
deteriorate wiring insulation. Keep the extinguisher 
properly charged and be familiar with its use. If there 
are any questions pertaining to fire extinguishers, 
consult the local fire department.

 EXPLOSION HAZARDS 

• Properly ventilate any room or building housing the 

generator to prevent build-up of explosive gas.

•  Do not smoke around the generator. Wipe up any fuel 

or oil spills immediately. Ensure that no combustible 
materials are left in the generator compartment, or 
on or near the generator, as FIRE or EXPLOSION 
may result. Keep the area surrounding the generator 
clean and free from debris.

• These generator sets may operate using one of 

several types of fuels. All fuel types are potentially 
FLAMMABLE and/or EXPLOSIVE and should be 
handled with care. Comply with all laws regulating 
the storage and handling of fuels. Inspect the unit’s 
fuel system frequently and correct any leaks imme-
diately. Fuel supply lines must be properly installed, 
purged and leak tested according to applicable fuel-
gas codes before placing this equipment into service.

•  Diesel fuels are highly FLAMMABLE. Gaseous fluids 

such as natural gas and liquid propane (LP) gas are 
extremely EXPLOSIVE. Natural gas is lighter than air, 
and LP gas is heavier than air; install leak detectors 
accordingly.

IMPORTANT SAFETY INSTRUCTIONS

40kW Liquid-cooled Generators

Содержание Quietsource 005012-1

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 26: ...24 Section 6 Electrical Data 40kW Liquid cooled Generators Wiring Diagram Engine Drawing No 0E8115 A ...

Страница 27: ...25 Section 6 Electrical Data 40kW Liquid cooled Generators Wiring Diagram Engine Drawing No 0E8115 A ...

Страница 28: ...26 Section 6 Electrical Data 40kW Liquid cooled Generators Electrical Schematic Engine Drawing No 0E8116 A ...

Страница 29: ...27 Section 6 Electrical Data 40kW Liquid cooled Generators Electrical Schematic Engine Drawing No 0E8116 A ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 34: ...32 Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Control Panel Drawing No 0E7118 K ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 45: ...43 Section 8 Installation Diagram 40kW Liquid cooled Generators Installation Diagram Drawing No 0E8797 ...

Страница 46: ...44 Section 9 Notes 40kW Liquid cooled Generators ...

Страница 47: ...45 Section 9 Notes 40kW Liquid cooled Generators ...

Страница 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...

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