Generac Power Systems Quietsource 005012-1 Owner's Manual
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Generac Power Systems Quietsource 005012-1 Owner's Manual

Liquid-cooled, prepackaged standby generator
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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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Summary of Contents for Generac Power Systems Quietsource 005012-1

  • Page 1 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!!

  • Page 2: Introduction

    INTRODUCTION Thank you for purchasing this model of the QuietSource standby generator set product line by Generac Power Systems. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ- ten.

  • Page 3: Table Of Contents

    INTRODUCTION ... IFC Read this Manual Thoroughly ... IFC Operation and Maintenance ... IFC How to Obtain Service ... IFC Authorized Service Dealer Location ... IFC SAFETY RULES ...2 Section 1 — GENERAL INFORMATION ... 4 Generator ...4 Transfer Switch ...4 Automatic System Operation ...4 Generator AC Connection Systems ...4 Main Circuit Breaker ...4...

  • Page 4: Safety Rules

    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. ...

  • Page 5: Electrical Hazards

    • 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.

  • Page 6: Section 1 - General Information

    An Authorized Dealer can supply an appropriate transfer switch for the generator. Model Rating 005012-1 37,000 NG 40,000 LP 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.

  • Page 7: Generator Fuel System

    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. 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.

  • Page 8: Unpacking

    Section 1 — General Information 40kW Liquid-cooled Generators 1.7.3 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.

  • Page 9: Lifting The Generator

    Single-phase rated at 1000 Btu per cubic foot. LP gas is rated at 2520 Btu per cubic foot. Actual fuel consumption 005012-1 obtained may vary depending on such variables as 37 (NG), 40 (LP) applied load, ambient temperature, engine condi- tions and other environmental factors.

  • Page 10: Torque Specifications

    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.

  • Page 11: Generator Location

     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. Only qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system.

  • Page 12: Basic Standby Electric System

    Section 2 — Installation 40kW Liquid-cooled Generators BASIC STANDBY ELECTRIC SYSTEM Figure 2.1 shows a schematic diagram of a basic standby electric system. Both the UTILITY power supply and the STANDBY (GENERATOR) output are connected to an approved transfer switch. The trans- fer switch is required by electrical code and serves the following functions: •...

  • Page 13: Generator Ac Neutral Connections

    GENERATOR AC NEUTRAL 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.

  • Page 14: Preparation Before Start-Up

    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) bicarbon- ate of soda to one gallon (4 liters) of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased.

  • Page 15: Section 3 - Operation

    Make sure the generator battery is fully charged, prop- erly installed and interconnected, and ready for use. Check to ensure that there are no loose electrical con- nections. Restrain any loose wires to keep them clear of any moving generator set components. USING AN ENGINEERED “GTS”...

  • Page 16: Manual Transfer And Startup

    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 crank- ing and startup cannot occur. If the fuse needs to be replaced, use only an identical 15-amp replacement fuse.

  • Page 17: Retransfer And Shutdown

    RETRANSFER AND SHUTDOWN When utility power source voltage has been restored, electrical loads may be transferred back to that source and the generator can be shut down as fol- lows: • Verify that utility power supply voltage to the trans- fer switch has been positively turned OFF , using whatever means provided (such as utility main line circuit breaker).

  • Page 18: Section 4 - Maintenance

    Section 4 — Maintenance 40kW Liquid-cooled Generators MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES EVERY THREE MONTHS 1. Check battery state of charge and condition. 2. Inspect and test fuel system. 3. Check transfer switch. 4. Inspect exhaust system. 5. Check engine ignition system. 6.

  • Page 19: Maintenance Owner/Operator Can Perform

    • 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.

  • Page 20: Miscellaneous Maintenance

    Section 4 — Maintenance 40kW Liquid-cooled Generators 7. Start engine and check for oil leaks. Figure 4.2 - Oil Filter Oil Filter 4.5.11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner, (part number 0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover.
  • Page 21 • 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.

  • Page 22: Scheduled Maintenance

    Section 4 — Maintenance 40kW Liquid-cooled Generators 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.
  • Page 23 Maintenance Level 1 Tasks Recom- mended to be done monthly 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. Adjust as necessary. 4. Check the engine coolant thermal protection level.
  • Page 24 Section 4 — Maintenance 40kW Liquid-cooled Generators Maintenance Level 1 Tasks Recom- mended to be done monthly 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...

  • Page 25: Section 5 - Troubleshooting

    TROUBLESHOOTING POINTS PROBLEM Engine won’t crank. Engine cranks, but won't start Engine starts hard, runs rough. Engine starts, then shuts down. AUTO/OFF/MANUAL Switch at OFF, engine continues to run No AC output from generator. Section 5 — Troubleshooting 40kW Liquid-cooled Generators CAUSE 1.

  • Page 26: Section 6 - Electrical Data

    Section 6 - Electrical Data 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8115-A...
  • Page 27 Section 6 - Electrical Data 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8115-A...
  • Page 28 Section 6 - Electrical Data 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E8116-A...
  • Page 29 Section 6 - Electrical Data 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E8116-A...

  • Page 30: Section 7 - Exploded Views And Parts Lists

    Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Mounting Base — Drawing No. 0E8084-C...
  • Page 31 ITEM PART NO. QTY. 0E7331 052860 052251 052257 052252 052259 052891 0536210214 074906 047411 055414 026850 022097 022473 049813 0A1694 025507 0E7359 027482 022129 045771 051756 046526 022131 055934M 049820 059473 061902 058665 REF. 038804D 038805J 021991 036833 022237 022131 0F3976 050331 050331A...
  • Page 32 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Enclosure — Drawing No. 0F4930-C...
  • Page 33 ITEM PART NO. QTY. 0E8418 0E8414 0E8413 0C2454 0E7807 0E5902 0E5903 0E8387 0E5912 0F5570 089961 0A2115 0E8404 0D2538A 0D2538 078115 022097 022473 0E7570 0E7571 070015 0E7662 0D2537A 0D2537 0D2023 0E7869 0E8001 0F5568 0E8798 0D3037A 0C7781 0E5910 0E8052 0D3037 0E5900 0E5901 0F4938A 0E8415 026850...
  • Page 34 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Control Panel — Drawing No. 0E7118-K...
  • Page 35 ITEM PART NO. QTY. DESCRIPTION 0E7195 CONTROL BOX HSB 0E7196 COVER FRONT PANEL HSB 0E7197 COVER TOP PANEL HSB 0E7193 DECAL WARNINGS HSB 0E7194 DECAL CONTROLS HSB 0E4494 SWITCH ROC DPDT ON-OFF-ON 082573 SWITCH ROCKER DPST 125V SPD 032300 HOLDER FUSE 022676 FUSE 15A X AGC15 067682B...
  • Page 36 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Engine — Drawing No. 0E8121-H BAFFLE REAR UPPER "A" "C" "A" "C" D.C. ALTERNATOR BRACKET HARDWARE. COMES WITH ENGINE "B" "B"...
  • Page 37 ITEM PART NO. QTY. DESCRIPTION 0E5048A FLEXPLATE 3.9L HSB 0E7477 MACHINING 3.9L ENGINE ADAPTOR 0E6703 COVER FLYWHEEL ACCESS 0E8336 REWORK 3.9L CHRYSLER ENGINE 0E7841 GASKET THERMOSTAT ADAPTOR 0E7254 MACH THERM ADAPTOR 3.9L CHRY 0E7956 BRACKET IGNITION COIL 0E7953 COIL IGNITION 3.9L CHRYSLER 047411 SCREW HHC M6-1.0 X 16 G8.8 0E8591...
  • Page 38 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Radiator — Drawing No. 0E8102-F...
  • Page 39 ITEM PART NO. QTY. 0D7825A 0D7174C 0E7640 0E7924 0F2853 0D8252 0D8251 0E0726 076749 035685 069860C 058443 0C2454 052250 048031C 029032 0A2111 0E7640A 035461 065852 051756 022131 046526 045772 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Radiator — Drawing No. 0E8102-F DESCRIPTION RADIATOR COPPER BRASS VENTURI,3.9L CRYSLR HSB 22"FAN...
  • Page 40 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Fuel System — Drawing No. 0E8122-H...
  • Page 41 ITEM PART NO. QTY. 033212 075580 0E8365 039253 022145 022129 045771 042907 0C2454 026307 0E1056 0E6584 057822 059194 064945 0D1509 050279 0E7839 0E6586 0E4394 040105 0E6382B 0F2119 0E6376B 042561 0E7929 0A4637 0E6406 0E7702 0A4632A 037561 046580 0E8286 044118 049815 049226 051713 022097 057796...
  • Page 42 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Alternator — Drawing No. 0F5092-B...
  • Page 43 ITEM PART NO. QTY. 0F1659A 0F1657A 0F1655A 0F5073A 0E7413A 0F1660A 0F1658A 0F1656A 0F5074A 0E7412A 0E5706 0E5048 0E5048B 0E5048A 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 092980 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F ROTOR REPLACEMENT PARTS 047248 070892 Section 7 - Exploded Views and Parts...
  • Page 44 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Muffler — Drawing No. 0F4894-B ITEM PART NO. QTY. DESCRIPTION 0F0738 MUFFLER 7"X9"-(2)2"IN/2.5"OUT 0C9748 PLUG M18-1.50 0F0778 PIPE R/H SIDE EXHAUST MILD ST 0F0777 PIPE L/H SIDE EXHAUST MILD ST 0E5914 BRACKET MUFFLER 3.0L FORD 0E0170C...

  • Page 45: Section 8 - Installation Diagram

    Section 8 — Installation Diagram 40kW Liquid-cooled Generators Installation Diagram — Drawing No. 0E8797...

  • Page 46: Section 9 - Notes

    Section 9 - Notes 40kW Liquid-cooled Generators...
  • Page 47 Section 9 - Notes 40kW Liquid-cooled Generators...

  • Page 48: Section 10 - Warranty

    "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Quietsource generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or an Authorized Warranty Service Dealer, is found to be defective.

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