Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model No: 005012-1 37kW NG, 40kW LP This manual should remain with the unit.
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 written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.
Table of Contents 40kW Liquid-cooled Generators INTRODUCTION ............................................... IFC Section 3 — OPERATION ................................ 13 Read this Manual Thoroughly ..................................... IFC 3.1 Operation and Maintenance ........................................ IFC 3.2 Control Console Components..............................13 How to Obtain Service................................................. IFC 3.3 Manual Transfer and Startup ................
IMPORTANT SAFETY INSTRUCTIONS 40kW Liquid-cooled Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. followed during installation and maintenance of the generator and batteries.
IMPORTANT SAFETY INSTRUCTIONS 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.
Section 1 - General Information 40kW Liquid-cooled Generators 1.1 GENERATOR 1.3 This equipment is a liquid-cooled, engine-driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been factory-installed in a weather resistant, all metal enclosure and is intended for outdoor installation only. Use this generator as a source of electrical power for the operation of 120 and/or 240VAC, single-phase loads.
Section 1 - General Information 40kW Liquid-cooled Generators 1.6 GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is necessary, refer to "Reconfiguring the Fuel System" for conversion instructions. Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges. Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.4 to 0.
Section 1 — General Information 40kW Liquid-cooled Generators 1.7.3 1.7.6 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.
Section 1 — General Information 40kW Liquid-cooled Generators 1.9 LIFTING THE GENERATOR lifting or hoisting equipment is used, be When 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 005012-1 Rated Max. Cont. 37 (NG), 40 (LP) AC Power Output (kW) Rated voltage (volts) 120/240 No.
Section 2 — Installation 40kW Liquid-cooled Generators 3. Remove the brass hose fitting from the outlet port (Port 1) of the demand regulator. 4. Remove pipe plug from Port 2. 5. Install brass hose fitting into Port 2. 6. Install pipe plug into Port 1. 7. Connect carburetor gas hose to brass fitting. 8. Tighten all clamps and plugs. 9. Make sure fuel supply is of the proper pressure and type for configuration. 10. Reverse the procedure to convert back to natural gas.
Section 2 — Installation 40kW Liquid-cooled Generators If an open bottom is used, the engine-generator is to be installed over non-combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set. Only qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system.
Section 2 — Installation 40kW Liquid-cooled Generators 2.4 BASIC STANDBY ELECTRIC SYSTEM 2.6 TOTAL CIRCUIT ISOLATION METHOD 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.
Section 2 — Installation 40kW Liquid-cooled Generators 2.8 GENERATOR AC NEUTRAL CONNECTIONS The manufacturer uses an UNGROUNDED AC 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 generator.
Section 2 — Installation 40kW Liquid-cooled Generators • 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) bicarbonate 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.
Section 3 - Operation 40kW Liquid-cooled Generators Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use. 3.2 Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear of any moving generator set components. The components of a home standby generator control console (Figure 3.1) are as follows: 3.1 USING AN ENGINEERED “GTS” TRANSFER SWITCH CONTROL CONSOLE COMPONENTS Figure 3.
Section 3 — Operation 40kW Liquid-cooled Generators 3.2.3 15 AMP FUSE This fuse protects the control console’s DC control circuit against electrical overload. If the fuse has melted open because of an overload, engine cranking and startup cannot occur. If the fuse needs to be replaced, use only an identical 15-amp replacement fuse. (Type AGC) 3.4 ENGINE GOVERNOR ADJUSTMENTS 3.2.4 4.0 AMP INLINE FUSE Engine speed governing is also controlled by the engine control board.
Section 3 - Operation 40kW Liquid-cooled Generators To set the system for fully automatic operation, proceed as follows: • Check that load circuits are connected to the utility power supply. • Set the AUTO/OFF/MANUAL switch to its AUTO position. • Set the generator main circuit breaker to its ON or CLOSED position. 3.7 WEEKLY EXERCISE CYCLE FUSE 4A BAT. CHARGER F US FUSE 15A MAIN US E F Figure 3.
Section 4 — Maintenance 40kW Liquid-cooled Generators 4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES EVERY THREE MONTHS 1. 2. 3. 4. 5. 6. Check battery state of charge and condition. Inspect and test fuel system. Check transfer switch. Inspect exhaust system. Check engine ignition system. Check fan belts. ONCE EVERY SIX MONTHS 1. Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature). ONCE ANNUALLY 1. Test engine governor.
Section 4 — Maintenance 40kW Liquid-cooled Generators • Add recommended coolant mixture as necessary. • Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact an Authorized Service Dealer. Inspect cooling system and coolant recovery system for leaks. 4.5.
Section 4 — Maintenance 40kW Liquid-cooled Generators 7. Start engine and check for oil leaks. Figure 4.2 - Oil Filter 4.5.13 COOLANT CHANGE Every year, have an authorized service dealer drain, flush and refill the cooling system. See SPECIFICATIONS for cooling system recommendations. 4.6 MISCELLANEOUS MAINTENANCE 4.6.1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible.
Section 4 — Maintenance 40kW Liquid-cooled Generators • 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. 4.6.3 BATTERY MAINTENANCE The battery should be inspected per the “Service Schedule”. The following procedure should be followed for inspection: 1.
Section 4 — Maintenance 40kW Liquid-cooled Generators 4.7 SCHEDULED MAINTENANCE Following is a recommended 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 application.
Section 4 — Maintenance 40kW Liquid-cooled Generators Maintenance Tasks Level 1 Recommended to be done monthly Level 2 Task Comp. (DateInitials) Required to be done 3 months/ Break-in Level 3 Task Comp. (DateInitials) Required to be done Semiannually Level 4 Task Comp. (DateInitials) Required to be done Annually Task Comp. (DateInitials) 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level.
Section 4 — Maintenance 40kW Liquid-cooled Generators Maintenance Tasks 13. 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. 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.
Section 5 — Troubleshooting 40kW Liquid-cooled Generators TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15-amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 4-amp fuse blown. 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor. 4. Replace starter motor. 5. Remove, change or replace battery. 6. Replace fuse.
Section 6 - Electrical Data 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No.
Section 6 - Electrical Data 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No.
Section 6 - Electrical Data 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No.
Section 6 - Electrical Data 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No.
28 16 12 13 9 34 35 18 8 7 6 5 TO ENGINE MOUNT 42 43 2 36 35 34 4 3 16 19 40 34 30 16 28 27 36 39 35 41 38 18 27 32 33 22 29 20 31 21 20 7 6 5 37 15 1 13 12 11 REAR BEARING CARRIER HARNESS WIRE TO STARTER CONTACTOR TO STARTER BOLT TO ENGINE 18 BLOCK 14 16 10 4 3 2 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Mounting Base — Drawing No.
Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Mounting Base — Drawing No. 0E8084-C ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23* 24* 25* 26* 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 PART NO.
30 2 30 32 31 LATCH DETAIL 38 4 31 32 34 18 17 39 45 27 3 40 4 37 4 35 4 4 53 25 RADIATOR SUPPORT 33 4 STATES FOAM IS ON FAR SIDE STATES FOAM IS ON NEAR SIDE 32 46 4 49 53 4 4 9 11 29 13 SEE LATCH DETAIL 26 TO "A" TYPICAL OF ROOF PANEL THAT REQUIRE INSULATION. SECURE AS SHOWN.
Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Enclosure — Drawing No. 0F4930-C ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 * 51 52 53 54 55 PART NO.
Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Control Panel — Drawing No.
Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Control Panel — Drawing No. 0E7118-K ITEM PART NO. QTY. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 0E7195 0E7196 0E7197 0E7193 0E7194 0E4494 082573 032300 022676 067682B 060015 054199 0C2657 099076 040213 0E9668 067680 0E6875A 0E6881 * 0C5139 * 0C5142 * 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 REF. REF. REF.
Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Engine — Drawing No. 0E8121-H 48 COMES WITH ENGINE 62 61 44 18 11 FRONT 5 36 35 63 BAFFLE REAR UPPER 47 21 6 43 44 56 18 18 78 37 66 46 40 39 65 23 18 5 25 45 19 17 30 26 43 "B" 73 18 44 24 64 76 31 12 52 34 74 "A" 38 19 59 70 19 18 18 19 77 9 "C" 19 18 60 15 8 7 14 TO "C" 13 18 19 17 14 28 18 27 19 16 18 72 19 10 21 17 20 50 49 14 1 3 E OIL 17 69 22 USE D.C.
Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Engine — Drawing No. 0E8121-H ITEM PART NO. QTY.
26 25 24 3 21 "A" 36 23 24 1 13 TO ENGINE WATER PUMP 10 10 4 20 10 15 TO THERMOSTAT HOUSING 5 19 16 16 22 2 14 15 8 14 17 9 7 6 17 14 18 TO "A" Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Radiator — Drawing No.
Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Radiator — Drawing No. 0E8102-F ITEM 1 2 3 4 5 6 7 8 9 10 13 14 15 16 17 18 19 20 21 22 23 24 25 26 PART NO. 0D7825A 0D7174C 0E7640 0E7924 0F2853 0D8252 0D8251 0E0726 076749 035685 069860C 058443 0C2454 052250 048031C 029032 0A2111 0E7640A 035461 065852 051756 022131 046526 045772 QTY. 1 1 1 1 1 1 1 1 1 4 1 17 5 2 1 1 1 1 1 1 4 8 4 4 DESCRIPTION RADIATOR COPPER BRASS VENTURI,3.
38 TO ENGINE 45 42 16 2 4 41 40 5 17 11 6 9 13 6 8 12 27 2 3 31 14 19 30 29 32 13 TO "B" 37 38 36 "B" 35 34 15 18 19 20 21 46 23 24 43 6 1 39 33 TO INTAKE MANIFOLD 25 22 44 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Fuel System — Drawing No.
Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Fuel System — Drawing No. 0E8122-H ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 PART NO.
Section 7 - Exploded Views and Parts 12 8 7 5 18 40 LOCKTIGHT 15 7 17 1 4 16 31 30 LEADS 2 6 9 21 13 LOCKTIGHT 3 10 11 20 19 14 40kW Liquid-cooled Generators Alternator — Drawing No.
Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Alternator — Drawing No. 0F5092-B ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART NO. 0F1659A 0F1657A 0F1655A 0F5073A 0E7413A 0F1660A 0F1658A 0F1656A 0F5074A 0E7412A 0E5706 0E5048 0E5048A 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 092980 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F ROTOR REPLACEMENT PARTS 30 047248 31 070892 QTY.
Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Muffler — Drawing No. 0F4894-B 7 21 13 12 11 10 1 5 22 10 11 10 12 23 13 22 9 20 8 10 20 TO COMPARTMENT 14 11 11 17 19 8 TO EXHAUST MANIFOLD 24 19 19 TO EXHAUST MANIFOLD 19 8 15 14 16 25 8 17 15 3 11 2 18 6 11 20 ITEM PART NO. QTY.
Section 8 — Installation Diagram 40kW Liquid-cooled Generators Installation Diagram — Drawing No.
Section 9 - Notes 40kW Liquid-cooled Generators 44
Section 9 - Notes 40kW Liquid-cooled Generators 45
Section 10 – Warranty 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.