Generac Power Systems Portable Generator 005012 1 User Manual

Owner’s Manual  
Liquid-cooled, Prepackaged  
Standby Generators  
Model No: 005012-1  
37kW NG, 40kW LP  
This manual should remain with the unit.  
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS  
SHOULD ATTEMPT INSTALLATION!!  
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Table of Contents  
40kW Liquid-cooled Generators  
INTRODUCTION ...............................................IFC  
Read this Manual Thoroughly..................................... IFC  
Operation and Maintenance ........................................ IFC  
How to Obtain Service................................................. IFC  
Authorized Service Dealer Location ............................ IFC  
Section 3 OPERATION................................ 13  
3.1 Using an Engineered “GTS” Transfer Switch ......13  
3.2 Control Console Components..............................13  
3.3 Manual Transfer and Startup..............................14  
3.4 Engine Governor Adjustments ............................14  
3.5 Retransfer and Shutdown ...................................15  
3.6 Automatic Operation ...........................................15  
3.7 Weekly Exercise Cycle .........................................15  
Section 4 — MAINTENANCE........................... 16  
SAFETY RULES....................................................2  
Section 1 — GENERAL INFORMATION............. 4  
1.1 Generator..............................................................4  
1.2 Transfer Switch.....................................................4  
1.3 Automatic System Operation.................................4  
1.4 Generator AC Connection Systems........................4  
1.5 Main Circuit Breaker.............................................4  
1.6 Generator Fuel System..........................................5  
1.7 Engine Protective Devices......................................5  
1.8 Unpacking.............................................................6  
1.9 Lifting the Generator.............................................7  
1.10 Specifications........................................................7  
1.11 Fuel Consumption.................................................7  
1.12 Reconfiguring the Fuel System ..............................7  
1.13 Torque Specifications............................................8  
1.14 Engine Oil Recommendations ...............................8  
1.15 Coolant Recommendations....................................8  
1.16 Before Installation.................................................8  
Section 2 — INSTALLATION............................. 8  
2.1 Standby Generator Installation .............................8  
2.2 Generator Location ...............................................9  
2.3 Generator Mounting and Support .........................9  
2.4 Basic Standby Electric 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  
4.1 Maintenance Performed by Authorized  
Service Facilities..................................................16  
4.2 Cooling System....................................................16  
4.3 Overload Protection for Engine DC  
Electrical System.................................................16  
4.4 Checking Fluid Levels .........................................16  
4.5 Maintenance Owner/Operator  
Can Perform........................................................17  
4.6 Miscellaneous Maintenance.................................18  
4.7 Scheduled Maintenance.......................................20  
Section 5 — TROUBLESHOOTING ................. 23  
Section 6 — ELECTRICAL DATA.................... 24  
Section 7 — EXPLODED VIEWS AND  
PARTS LISTS ............................. 28  
Section 8 — INSTALLATION DIAGRAM.......... 43  
Section 9 — NOTES........................................ 44  
Section 10 — WARRANTY .................Back Cover  
1
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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.  
SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be   
followed during installation and maintenance of the generator and batteries.  
WARNING:  
GENERAL HAZARDS  
The engine exhaust from this product  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
For safety reasons, the manufacturer recommends  
that this equipment be installed, serviced and repaired  
by an Authorized Service Dealer or other competent,  
qualified electrician or installation technician who is  
familiar with applicable codes, standards and regula-  
tions. The operator also must comply with all such  
codes, standards and regulations.  
• Installation, operation, servicing and repair of this  
(and related) equipment must always comply with  
applicable codes, standards, laws and regulations.  
Adhere strictly to local, state and national electri-  
cal and building codes. Comply with regulations  
the Occupational Safety and Health Administration  
(OSHA) has established. Also, ensure that the genera-  
tor is installed, operated and serviced in accordance  
with the manufacturer’s instructions and recommen-  
dations. Following installation, do nothing that might  
render the unit unsafe or in noncompliance with the  
aforementioned codes, standards, laws and regula-  
tions.  
• The engine exhaust fumes contain carbon monoxide  
gas, which can be DEADLY. This dangerous gas,  
if breathed in sufficient concentrations, can cause  
unconsciousness or even death. For that reason,  
adequate ventilation must be provided. Exhaust  
gases must be piped safely away from any building  
or enclosure that houses the generator to an area  
where people, animals, etc., will not be harmed. This  
exhaust system must be installed properly, in strict  
compliance with applicable codes and standards.  
• Keep hands, feet, clothing, etc., away from drive belts,  
fans, and other moving or hot parts. Never remove  
any drive belt or fan guard while the unit is operat-  
ing.  
• Adequate, unobstructed flow of cooling and ventilat-  
ing air is critical to prevent buildup of explosive gases  
and to ensure correct generator operation. Do not  
alter the installation or permit even partial blockage  
of ventilation provisions, as this can seriously affect  
safe operation of the generator.  
WARNING:  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
Study these SAFETY RULES carefully before installing,  
operating or servicing this equipment. Become familiar  
with this Owner’s Manual and with the unit. The gen-  
erator can operate safely, efficiently and reliably only if  
it is properly installed, operated and maintained. Many  
accidents are caused by failing to follow simple and fun-  
damental rules or precautions.  
The manufacturer cannot anticipate every possible cir-  
cumstance that might involve a hazard. The warnings in  
this manual, and on tags and decals affixed to the unit  
are, therefore, not all-inclusive. If using a procedure,  
work method or operating technique that the manufac-  
turer does not specifically recommend, ensure that it  
is safe for others. Also make sure the procedure, work  
method or operating technique chosen does not render  
the generator unsafe.  
DANGER  
Despite the safe design of this generator,  
operating this equipment imprudently, neglecting  
its maintenance or being careless can cause  
possible injury or death. Permit only responsible  
and capable persons to install, operate or maintain  
this equipment.  
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 dur-  
• Keep the area around the generator clean and unclut-  
tered. Remove any materials that could become haz-  
ardous.  
ing operation. Exercise care near running genera-  
tors.  
• When working on this equipment, remain alert at all  
times. Never work on the equipment when physically  
or mentally fatigued.  
2
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IMPORTANT SAFETY INSTRUCTIONS  
40kW Liquid-cooled Generators  
• Inspect the generator regularly, and promptly repair • 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.  
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.  
• 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.  
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.  
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.  
• 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.  
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.  
• 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.  
3
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Section 1 - General Information  
40kW Liquid-cooled Generators  
1.1 GENERATOR  
1.3 AUTOMATIC SYSTEM OPERATION  
When this generator, along with a transfer switch, has  
been installed and interconnected, a circuit board  
in the generator panel constantly monitors UTILITY  
power source voltage. Should that voltage drop below  
a preset value, and remain at such a low state for  
a preset amount of time, the generator cranks and  
starts. After the generator starts, the transfer switch  
transfers load circuits so the generator can power  
them.  
This equipment is a liquid-cooled, engine-driven  
generator set. The generator is designed to supply  
electrical power that operates critical electrical loads  
during utility power failure. The unit has been facto-  
ry-installed in a weather resistant, all metal enclosure  
and is intended for outdoor installation only. Use  
this generator as a source of electrical power for the  
operation of 120 and/or 240VAC, single-phase loads.  
When utility source voltage has been restored, the  
switch re-transfers back to the UTILITY source volt-  
age and the generator then shuts down.  
If this generator is used to power electrical load  
circuits normally powered by a utility power  
source, it is required by code to install a trans-  
fer switch. The transfer switch must effectively  
isolate the electric system from the utility distri-  
bution system when the generator is operating  
(NEC 701). Failure to isolate an electrical system  
by such means results in damage to the genera-  
tor and may also result in injury or even death  
to utility power workers due to backfeed of  
electrical energy.  
Please reference the transfer switch manual for spe-  
cific information.  
1.4 GENERATOR AC CONNECTION  
SYSTEMS  
The generator was shipped from the factory with its  
stator AC output leads connected in a single-phase,  
three-wire generator AC connection system (Figure  
1.1). The stator assembly in this system consists of  
a pair of stationary windings, with two leads brought  
out of each winding. Each single winding can sup-  
ply 120VAC, 60 Hertz. When the two windings are  
connected in series, a 240VAC, 60 Hertz AC output  
results. Typically the two HOT leads in the circuit  
are wires 11 and 44. The NEUTRAL leads are the  
junction of Wires 22 and 33. The NEUTRAL is not  
grounded.  
1.2 TRANSFER SWITCH  
This generator system is intended to be used with  
the manufacturer's transfer switch. It will be avail-  
able in either a NEMA 1 enclosure or a NEMA 3R  
enclosure. The NEMA 1 enclosure is intended for  
indoor use only. The NEMA 3R enclosure is weather  
proof and can be used indoors or outdoors. Follow  
these rules:  
Figure 1.1 - Generator AC Connection System  
• Install the transfer switch on a firm, sturdy sup-  
porting structure.  
To prevent switch distortion, level the switch if  
necessary. This can be done by placing washers  
between the switch enclosure and the mounting  
surface.  
• Never install the switch where water or any corro-  
sive substance might drip onto the enclosure.  
• Protect the switch at all times against excessive  
moisture, dust, dirt, lint, construction grit and cor-  
rosive vapors.  
An Authorized Dealer can supply an appropriate  
transfer switch for the generator.  
1.5 MAIN CIRCUIT BREAKER  
The generator’s main circuit breaker is included with  
the unit as shipped from the factory. The breaker for  
this unit is described in Figure 1.2.  
Figure 1.2 - Main Circuit Breaker  
Model  
005012-1  
Rating  
37,000 NG  
40,000 LP  
Phase  
Actual Current  
154.2  
C/B Rating*  
Circuit Breaker  
200A QN2  
1
1
200  
200  
166.7  
200A QN2  
* Amp Rating of C/B structured under model.  
4
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Section 1 - General Information  
40kW Liquid-cooled Generators  
1.7.1 LOW OIL PRESSURE SWITCH  
1.6 GENERATOR FUEL SYSTEM  
The unit has been factory tested and adjusted using  
a natural gas fuel system. If propane (LP) gas is nec-  
essary, refer to "Reconfiguring the Fuel System" for  
conversion instructions.  
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 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).  
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.  
NOTE:  
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.  
The Low Oil Pressure, High Coolant Temperature  
and Low Coolant Level are not monitored for the  
first 10 seconds of engine run time.  
NOTE:  
Figure 1.4 - Low Oil Pressure Switch  
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.  
Gaseous fuels such as natural and LP (propane)  
gas are highly explosive. Even the slightest  
spark can ignite such fuels and cause an explo-  
sion. No leakage of fuel is permitted. Natural  
gas, which is lighter than air, tends to collect in  
high areas. LP gas is heavier than air and tends  
to settle in low areas.  
1.7 ENGINE PROTECTIVE DEVICES  
The engine has several safety switches which cause  
the engine to automatically shut down under the  
following conditions: low oil pressure, high coolant  
temperature, engine overspeed, low coolant level or  
overcrank (Figure 1.3).  
1.7.2 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 1.3 - Engine Protective Devices  
Low Oil Pressure Switch  
High Coolant  
Temperature Switch  
Figure 1.5- High Coolant Temperature Switch  
Low Coolant  
Level Sensor  
5
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Section 1 — General Information  
40kW Liquid-cooled Generators  
1.7.3 LOW COOLANT LEVEL SWITCH  
1.7.6 OVERCRANK SHUTDOWN  
Should engine coolant level drop below the level of  
the high coolant temperature switch, it is possible for  
the engine to overheat without automatic shutdown.  
To prevent such overheating without automatic shut  
down, the engine has a low coolant level sensor. If the  
engine coolant drops too low, the engine automatical-  
ly shuts down and turns on the high coolant tempera-  
ture/low coolant level LED (Figure 1.6 on page 6).  
The engine control board uses a cyclic cranking pro-  
cess when attempting to start the engine. The first  
crank cycle is a 15-second crank followed by a seven-  
second rest. This is followed by five more crank  
cycles each with a seven-second crank followed by a  
seven-second rest.  
If the engine fails to start after all six attempts, the  
start attempt is stopped and the overcrank LED  
turned on.  
Figure 1.6 - Low Coolant Level Sensor  
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 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.  
1.7.4 OVERSPEED SHUTDOWN  
The engine control board receives AC frequency  
signals from an engine run winding in the alterna-  
tor. Should AC frequency exceed about 72 Hertz for  
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).  
Battery voltage is NOT monitored during the crank  
cycle.  
1.7.8 ALARM RESET  
If the engine control board shuts down the genera-  
tor for any of the above reasons, the engine remains  
stopped until the alarm is cleared by placing the  
AUTO/OFF/MANUAL switch into the OFF position.  
Figure 1.7 - Printed Circuit Board Assembly  
1.7.9 DC FUSE  
These fuses are located on the front panel of the con-  
trol system. They protect the panel wiring and com-  
ponents from damaging overload. Always remove the  
15 amp main fuse before working on the generator.  
The unit will not start or crank if this fuse is blown.  
Replace the fuse with one of the same size, type, and  
rating (main AGC-15, battery charger AG4).  
R44  
LED1  
C27  
Q2  
C9  
J2  
C26  
U7  
C4  
D10  
C21  
C30  
C2  
1.8 UNPACKING  
RL1  
RL2  
R1  
R48  
D17  
1.8.1 UNPACKING PRECAUTIONS  
R49  
Handle shipping cartons and crates with care. Use  
care to avoid damage from dropping, bumping, col-  
lision, etc..  
U1  
J1  
L3  
D19  
.
R E V 9 0 6 E 0 4 B #  
1.8.2 INSPECTION  
1.7.5 RPM SENSOR LOSS  
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.  
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.  
6
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Section 1 — General Information  
40kW Liquid-cooled Generators  
1.9 LIFTING THE GENERATOR  
1.11 FUEL CONSUMPTION  
Natural Gas  
% of Load  
m3/hr  
ft3/hr  
25%  
4.1  
50%  
7.7  
75%  
11.0  
100%  
14.2  
When lifting or hoisting equipment is used, be  
careful not to touch overhead power lines. The  
143.1  
271.1  
388.5  
502.0  
generators weight of more than 900 pounds  
requires proper tools, equipment, and qualified  
personnel to be used in all phases of handling  
and unpacking.  
LP Vapor  
% of Load  
m3/hr  
25%  
1.7  
50%  
3.3  
75%  
4.7  
100%  
6.0  
ft3/hr  
60.7  
115.0  
NOTE:  
164.9  
213.0  
1.10 SPECIFICATIONS  
1.10.1 GENERATOR SPECIFICATIONS  
Single-phase  
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.  
Model  
Rated Max. Cont.  
AC Power Output (kW)  
Rated voltage (volts)  
No. of Rotor Poles  
005012-1  
37 (NG), 40 (LP)  
120/240  
4
1800  
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.  
Driven Speed of Rotor  
Rotor Excitation System Direct excited brush type  
Type of Stator  
Rotor/Stator Insulation  
4 Wire  
Class F/H  
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.  
1.10.2 ENGINE SPECIFICATIONS  
1.12 RECONFIGURING THE FUEL  
Make................................................................................ Chrysler  
Displacement...................................................................3.9 liters  
Cylinder Arrangement ............................................................. V-6  
Valve Arrangement.............................................. Overhead Valve  
Firing Order .................................................................1-6-5-4-3-2  
Number of Main Bearings ...........................................................4  
Compression Ratio........................................................... 9.1 to 1  
No. of Teeth on Flywheel.........................................................164  
Ignition Timing at 1800 rpm..............................30 degrees BTDC  
Spark Plug Gap.............................................. 1.01mm (0.040 in.)  
Recommended Spark Plugs  
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).  
Champion ....................................................................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 ...............................................................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.  
Figure 1.8 — Reconfigure the Fuel System  
Port 1  
Port 2  
FUEL HOSE  
FUEL HOSE  
BRASS HOSE  
FITTING  
BRASS HOSE  
FITTING  
PLUG  
PLUG  
OUT  
PORT 1  
OUT  
PORT 2  
HOUSING  
PORTS  
HOUSING  
PORTS  
NG FUEL SYSTEM  
LP FUEL SYSTEM  
7
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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.  
1.15 COOLANT RECOMMENDATIONS  
Use a mixture of half low silicate ethylene glycol base  
anti-freeze and half de-ionized water. Cooling system  
capacity is about 20 U.S. quarts (19.3 liters). Use only  
de-ionized water and only low silicate anti-freeze. If  
desired, add a high quality rust inhibitor to the rec-  
ommended coolant mixture. When adding coolant,  
always add the recommended 50-50 mixture.  
10. Reverse the procedure to convert back to natural  
gas.  
Do not use any chromate base rust inhibitor  
NOTE:  
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-freeze boosters or additives will also cause  
overheating. It is also recommend that any solu-  
ble oil inhibitor is NOT USED for this equipment.  
Port 1 is for NG only and Port 2 is for LP vapor  
only. No provision for dual fuel has been made.  
DANGER  
Serious injury or damage may occur if not con-  
figured properly. Please consult an Authorized  
Service Dealer with any questions.  
1.16 BEFORE INSTALLATION  
1.13 TORQUE SPECIFICATIONS  
Tighten the bolts from the middle out, in a criss-  
cross pattern.  
Before installing this equipment, check the ratings  
of both the generator and the transfer switch. Read  
“Emergency Isolation Method” and “Total Circuit  
Isolation Method”.  
Cylinder Head.....................................50 ft.lb./105 ft.lb./105 ft.lb.  
Intake Manifold .................................... 48 in.lb./84 in.lb./84 in.lb.  
Exhaust Manifold .............................................................25 ft.lb.  
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.  
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, SF.” 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:  
This generator can be installed in conjunction with  
an engineered “GTS” type transfer switch, if neces-  
sary.  
The standard transfer switch has no sensing or con-  
trolling circuit boards. Instead, the generator control  
console houses a “Printed Circuit Board Assembly”,  
which controls all phases of operation, including  
engine start up and load transfer.  
Temperature  
Above 80° F (27° C)  
32° to 80° F (-1° to 27° C)  
Below 32° F (0° C)  
Oil Grade (Recommended)  
SAE 15W-40  
SAE 15W-40  
SAE 15W-40  
2.1 STANDBY GENERATOR  
INSTALLATION  
NOTE:  
5W-30 full synthetic oil is highly recommended  
in any element with temperatures above 90° F or  
below 30° F.  
DANGER  
Connecting this generator to an electrical system  
normally supplied by an electric utility shall be  
by means of a transfer switch, so as to isolate  
the electric system from the utility distribution  
system when the generator is operating. Failure  
to isolate the electric system by these means  
will result in damage to the generator and may  
also result in injury or death to utility workers  
due to backfeed of electrical energy.  
Any attempt to crank or start the engine before  
it has been properly serviced with the recom-  
mended oil may result in an engine failure.  
8
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Section 2 — Installation  
40kW Liquid-cooled Generators  
• ASAE  
EP-364.2,  
INSTALLATION  
AND  
If an open bottom is used, the engine-generator  
is to be installed over non-combustible materi-  
als and should be located such that combustible  
materials are not capable of accumulating under  
the generator set.  
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 Broadway, New York, N.Y.  
10018.  
Only qualified, competent installation contractors  
or electricians thoroughly familiar with applicable  
codes, standards and regulations should install this  
standby electric power system. The installation must  
comply strictly with all codes, standards and regula-  
tions pertaining to the installation.  
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:  
After the system has been installed, do nothing  
that might render the installation in noncompli-  
• Install the unit where air inlet and outlet open-  
ings will not become obstructed by leaves, grass,  
snow, etc. If prevailing winds will cause blowing or  
drifting, consider using a windbreak to protect the  
unit.  
ance with such codes, standards and regulations.  
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:  
• 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.  
NOTE:  
• Allow sufficient room on all sides of the generator  
for maintenance and servicing. A good rule is to  
allow five feet of space on all sides.  
• Where strong prevailing winds blow from one  
direction, face the generator air inlet openings into  
the prevailing winds.  
• Install the generator as close as possible to the  
transfer switch. This reduces the length of wiring  
and conduit.  
• Install the generator as close as possible to  
the fuel supply, to reduce the length of piping.  
HOWEVER, REMEMBER THAT LAWS OR CODES  
MAY REGULATE THE DISTANCE.  
It is essential to use the latest version of any stan-  
dard to ensure correct and current information.  
• NFPA No. 37, STATIONARY COMBUSTION  
ENGINES AND GAS TURBINES.  
• NFPA No. 76A, ESSENTIAL ELECTRICAL  
SYSTEMS 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.  
2.3 GENERATOR MOUNTING AND  
2.1.2 OTHER PUBLISHED STANDARDS  
SUPPORT  
Retain the generator compartment to a concrete slab  
with 1/4-inch masonry type anchor bolts. Be sure the  
bolts are long enough to retain the compartment. The  
slab should be at least six inches thick and should  
extend beyond the enclosure to a distance of at least  
three inches on all sides. See "Mounting Dimensions"  
for generator major dimensions.  
In addition to NFPA standards, the following informa-  
tion pertaining to the installation and use of standby  
electric systems is available:  
NOTE:  
It is essential to use the latest version of any stan-  
dard to ensure correct and current information.  
• Article X, NATIONAL BUILDING CODE, available  
from the American Insurance Association, 85 John  
Street, New York, N.Y. 10038.  
• AGRICULTURAL WIRING HANDBOOK, obtainable  
from the Food and Energy Council, 909 University  
Avenue, Columbia, MO, 65201.  
9
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Section 2 — Installation  
40kW Liquid-cooled Generators  
2.4 BASIC STANDBY ELECTRIC  
2.6 TOTAL CIRCUIT ISOLATION  
SYSTEM  
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. The trans-  
fer switch is required by electrical code and serves  
the following functions:  
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.  
• Allows the LOAD circuits to be connected to only  
one power supply at a time.  
• Ampere rating of the transfer switch must equal  
the ampere rating of the normal incoming utility  
service.  
• The transfer switch is installed between the util-  
ity service entrance and the building distribution  
panel.  
• By code and approved means of service disconnect  
must be located between the incoming utility ser-  
vice and the transfer switch.  
• Prevents electrical backfeed between the generator  
and the UTILITY power circuits.  
Notice that both the STANDBY and the UTILITY  
power supplies to the transfer switch are protected  
against overload by a main line circuit breaker.  
Figure 2.1 – Basic Standby Electric System  
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 gen-  
erator mounting base. Consult a qualified electrician  
for grounding requirements in the area. Grounding  
procedures must meet local regulations.  
DANGER  
Do not connect the ground wire to any pipe  
that carries a flammable or explosive substance  
– FIRE or an EXPLOSION may result.  
2.5 EMERGENCY CIRCUIT ISOLATION  
Proper grounding helps protect personnel against  
electrical shock in the event of a ground fault condi-  
tion in the generator or in connected electrical devic-  
es. In addition, grounding helps dissipate static elec-  
tricity that often builds up in ungrounded devices.  
METHOD  
This prevents overloading the generator by keeping  
electrical loads below the wattage/amperage capac-  
ity of the generator. If the generator is powering only  
critical loads, within the wattage/amperage capac-  
ity, during utility power outages, consider using the  
emergency circuit isolation method.  
Figure 2.2 – Generator Grounding Lug (typical)  
Critical electrical loads are grouped together and  
wired into a separate “Emergency Distribution Panel.”  
Load circuits powered by that panel are within the  
wattage/amperage capacity of the generator set. When  
this method is used, it is difficult to overload the gen-  
erator. The transfer switch must meet the following  
requirements:  
GROUNDING  
LUG  
• It must have an ampere rating equal to the total  
amperage rating of the emergency distribution  
panel circuit.  
• Have it installed between the building’s main dis-  
tribution panel and the emergency distribution  
panel.  
10  
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Section 2 — Installation  
40kW Liquid-cooled Generators  
2.8 GENERATOR AC NEUTRAL  
2.10 BATTERY INSTALLATION  
DANGER  
CONNECTIONS  
The manufacturer uses an UNGROUNDED AC neu-  
tral. Grounding is recommended only at the main  
service entrance. If the neutral wire is grounded and  
one of the phase loads becomes grounded, the exces-  
sive current opens the load circuit breaker or col-  
lapses the generator field. The actual result depends