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
on the electrical characteristics of the particular
installed generator.
Standby generators installed with automatic
transfer switches will crank and 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
Failure to connect the generator neutral proper-
gas. This gas can form an explosive mixture
ly will result in unbalanced line-to-neutral volt-
around the battery for several hours after charg-
ing. The slightest spark can ignite the gas and
cause an explosion. Such an explosion can shat-
ter the battery and cause blindness or other
injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smok-
ing, open flame, sparks or any spark producing
tools or equipment near the battery.
ages. Resulting high voltages will cause equip-
ment damage.
2.9 TRANSFER SWITCH SIGNAL
CONNECTIONS
‹
2.9.1 PRE-PACKAGED ATS
If the generator is to be installed with a pre-packaged
transfer switch, it is necessary to connect the control
wires to the generator and set position two of the
four-position dip switch to OFF.
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 fluid is spilled, flush the
affected area immediately with clear water.
Setting switch two to OFF allows the control PCB to
perform the ATS control functions.
Control system interconnections consist of N1 and
N2, and leads 23 and 194. Control system intercon-
nection leads must be run in a conduit that is sepa-
rate from the AC power lead. Recommended wire
gauge sizes for this wiring depends on the length of
the wire, as recommended below:
Do not dispose of the battery in a fire. The bat-
tery is capable of exploding.
Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
MAXIMUM WIRE LENGTH
RECOMMENDED WIRE
SIZE
and eyes.
460 feet (140m)
No. 18 AWG.
No. 16 AWG.
No. 14 AWG.
No. 12 AWG.
The battery represents a risk of high short circuit
461 to 730 feet (223m)
731 to 1,160 feet (354m)
1,161 to 1,850 feet (565m)
current. When working on the battery, always
remove watches, rings or other metal objects,
and only use tools that have insulated handles.
‹
2.9.2 GTS-TYPE ENGINEERED TRANSFER
SWITCH
‹
2.10.1 VENTED BATTERIES
If the generator is to be installed with an engineered
transfer switch, such as a GTS-type switch, it is nec-
essary to connect the two-wire start control system.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following proce-
dures are to be observed:
Connect the two-wire start signal from the automatic
transfer switch to the automatic start connection,
which is located in the middle, on the bottom, inside
the control panel. Match wires 178 and 183 in the
transfer switch to 178 and 183 on the terminal strip
in the control panel. The conductors for the two-wire
start circuit must be in their own conduit. (See "Using
an Engineered GTS Transfer Switch" for further
explanation.)
• Wear full eye protection and protective clothing,
• Where electrolyte contacts the skin, wash it off
immediately with water,
• Where electrolyte contacts the eyes, flush thor-
oughly and immediately with water and seek
medical attention, and
11
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Section 2 — Installation
40kW Liquid-cooled Generators
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.
• 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. The
resulting liquid is to be flushed with water and the
area dried.
‹
2.11.2 TRANSFER SWITCH
If this generator is used to supply power to any elec-
trical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents elec-
trical backfeed between two different electrical sys-
tems (for additional information, see the applicable
transfer switch manual for this unit). The transfer
switch, as well as the generator and other standby
components, must be properly located and mounted
in strict compliance with applicable codes, standards
and regulations.
Lead acid batteries present a risk of fire because
they generate hydrogen gas. The following pro-
cedure are to be followed:
• DO NOT SMOKE when near batteries,
• DO NOT cause flame or spark in battery area, and
• Discharge static electricity from body before touch-
ing batteries by first touching a grounded metal
surface.
Servicing of batteries is to be performed or super-
vised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized person-
nel away from batteries.
‹
2.11.3 FUEL SYSTEM
For recommended batteries, see the Maintenance
section. All batteries must be at 100 percent state-of-
charge before they are installed on the generator.
Make sure the fuel supply system to the generator (a)
delivers the correct fuel at the correct pressure and (b)
is properly purged and leak tested according to code.
No fuel leakage is permitted. See “Specifications” for
more information.
When using maintenance-free batteries, it is not
necessary to check the specific gravity or electrolyte
level. Have these procedures performed at the inter-
vals specified in the Maintenance section. A nega-
tive ground system is used. Battery connections are
shown on the wiring diagrams. Make sure all batter-
ies are correctly connected and terminals are tight.
Observe battery polarity when connecting batteries to
the generator set.
‹
2.11.4 GENERATOR SET LUBRICATION
Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level
below the dipstick “ADD” mark. See “Specifications”
and “Engine Oil Recommendations”.
NOTE:
NOTE:
Damage will result if the battery connections are
This engine is shipped from the manufacturer
with 15W-40 oil. This oil should be changed after
30 hours of operation.
made in reverse.
2.11 PREPARATION BEFORE START-UP
The instructions in this section assume that the
standby generator has been properly installed, ser-
viced, tested, adjusted and otherwise prepared for
use by a competent, qualified installation contractor.
Be sure to read the “Safety Rules” on pages 2 and 3,
as well as all other safety information in this manual,
before attempting to operate this (and related) equip-
ment.
‹
2.11.5 ENGINE COOLANT
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
for leaks and other problems. See “Specifications”
and “Coolant”.
‹
2.11.6 BELT TENSION
Check-the engine-fan belt tension and condition prior
to placing the unit into service and at recommended
intervals. Belt tension is correct when a force of
approximately 22 pounds (10 kg), applied midway
between pulleys, deflects the belt about 3/8- to 5/8 of
an inch (10 to 16 mm).
‹
2.11.1 PRIOR TO INITIAL START-UP
Prior to initially starting the generator, it must
be properly prepared for use. Any attempt to
crank 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.
‹
2.11.7 ELECTRICAL SYSTEM
Make sure the generator is properly connected to an
approved earth ground and/or ground rod.
12
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Section 3 - Operation
40kW Liquid-cooled Generators
Make sure the generator battery is fully charged, prop-
erly installed and interconnected, and ready for use.
3.2 CONTROL CONSOLE
COMPONENTS
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.
The components of a home standby generator control
console (Figure 3.1) are as follows:
Figure 3.1 - Home Standby Generator Panel
3.1 USING AN ENGINEERED “GTS”
TRANSFER SWITCH
LED INDICATORS:
FLASHING GREEN LED
=
=
NO UTILITY SENSE
EXERCISER NOT SET
5
FLASHING RED LED'S
(IN AUTO MODE ONLY) SOLID GREEN LED
RED LED'S INDIVIDUAL FAULT
=
SYSTEM READY, UTILITY POWER ON
When required, the pre-packaged standby generator
can be installed with an engineered “GTS” type auto-
matic transfer switch.
=
(SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS)
OVER CRANK
RED LEDs
LOW BATTERY
SYSTEM READY
4A
AUTO
OFF
In this application, the GTS is responsible for utility
sensing, weekly exercising, and load transferring.
OFF
ON
SET
EXECISER
TIME
SET
EXERCISE
TIME
MANUAL
GREEN LED
TO SET EXERCISER TIME
1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.
Position two of the four-position dip switch is used to
turn over this control to the GTS.
0E7194
SWITCH
Pos2 ON — GTS Application
AUTO/OFF/MANUAL
SWITCH
• The control board will NOT monitor utility.
• The control board will NOT perform a weekly
exercise. (The five red LEDs will not flash in this
mode.)
4A FUSE
BATTERY
CHARGER
15A FUSE
MAIN
POWER
• The control board will NOT activate the transfer
‹
3.2.1 AUTO/OFF/MANUAL SWITCH
output.
• The control board WILL monitor all engine condi-
tions and shut down on all the faults listed in this
document.
Use this three-position switch as follows:
• Set the switch to AUTO for fully automatic opera-
tion. See “Automatic Operation”.
Pos2 OFF — Prepackaged ATS Application
• Set switch to MANUAL position to crank and start
the generator engine.
• The control board will perform all of the automatic
• Set switch to OFF position to shut down an operat-
ing engine. With OFF selected, operation will not
be possible.
features listed in this document.
• The two-wire start connections should NOT be
used.
DANGER
GTS Mode Operation
When in GTS mode, the control board will respond
as follows based on the AUTO/OFF/MANUAL switch
position.
With switch set to AUTO, engine can crank and
start suddenly without warning. Such automatic
start up normally occurs when utility source
voltage drops below a pre-set level. To prevent
possible injury that might be caused by such
sudden starts, set AUTO/OFF/MANUAL switch
to OFF before working on or around the unit.
Then, place a “DO NOT OPERATE” tag on control
console.
OFF — The generator will not start and run in this
position.
MANUAL — The control board will start and run
the generator whenever the switch is in the manual
position.
AUTO — The control board will monitor the two-wire
start circuit. When a two-wire start is sent, the con-
trol board will immediately start and run the genera-
tor. When the two-wire start is removed, the control
board will immediately stop the generator.
‹
3.2.2 FAULT INDICATOR LED
This LED goes ON when one or more of the following
engine faults occurs and when engine shuts down.
• Low Oil Pressure
• Overcrank
NOTE:
• Low Battery
• Overspeed/RPM Sensor Loss
• High Coolant Temperature/Low Coolant Level
See "Engine Protective Devices" for further explana-
tion of engine protection functions.
If the generator is installed in conjunction with an
engineered GTS type transfer switch, refer to the
applicable transfer switch manual for exact oper-
ating parameters and timing sequences.
13
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Section 3 — Operation
40kW Liquid-cooled Generators
‹
3.2.3 15 AMP FUSE
3.4 ENGINE GOVERNOR
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. (Type AGC)
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 testing
of the generator and, in most cases, should not be
adjusted.
‹
3.2.4 4.0 AMP INLINE FUSE
If, however, adjustments are necessary, or a new
engine control board is installed in the generator, the
following procedure should be followed (Figure 3.2):
This fuse protects the battery charger against electri-
cal overload. If the fuse needs to be replaced, use only
an identical 4-amp replacement fuse (type AG).
1. Set all three potentiometers (pots) fully counter-
clockwise.
2. Under no load condition, increase the GAIN pot
as much as possible without causing instability.
3. Apply 1/4, 1/2, 3/4 and full load to the unit.
Decrease the GAIN pot if there is instability at any
load point.
NOTE:
This fuse will not remove the + battery input
power from the PCB when it opens. This means
the exercise timer will not be reset.
‹
3.2.5 SET EXERCISE TIME SWITCH
This switch allows programming the generator to
start and exercise automatically. “See Weekly Exercise
Cycle.”
4. Under full load condition, increase the stability
pot until the unit returns to 60 Hertz (or 50 Hertz
in 50 Hertz applications).
5. Reduce load to 3/4, 1/2, 1/4 and no load. Decrease
the STABILITY pot if there is instability at any
load point.
6. Adjust differential pot to make the recovery to
load changes even faster and minimize load
change undershoot and overshoot. If it is set too
high, it may introduce oscillations at some load.
It can be set to zero (full CCW) if a small amount
causes oscillations at some load.
‹
3.2.6 SYSTEM READY LED
The System Ready LED (green) has two main pro-
poses. First, the LED will be ON when the AUTO/
OFF/MANUAL switch is in the AUTO position, utility
is present, and there are no system alarms. This ON
state indicates the system is fully ready for automatic
operation.
The system ready LED will be OFF when the switch
is in the MANUAL or OFF positions.
Figure 3.2 — Engine Governor Adjustment
The system ready LED is also used to indicate the
presence of utility sensing at the PCB when the switch
is either in the AUTO or MANUAL modes. The LED
will flash at the rate of 1/2 second on, 1/2 second off
if the utility sensing level is below the transfer back
threshold.
R44
LED1
C27
Q2
C9
J2
C26
U7
C4
D10
This secondary function is only available with dip
switch two in the OFF position (standard ATS appli-
cation).
C21
C30
C2
RL1
RL2
R1
R48
D17
3.3 MANUAL TRANSFER AND
R49
START-UP
To transfer electrical loads to the Standby
(EMERGENCY) power source side and start the
engine manually, refer to the Owner’s Manual of the
particular transfer switch.
U1
J1
L3
D19
0
DIP SWITCH
DIFFERENTIAL
STABILITY
POSITION 1
50/60 HZ
POSITION 2
GTS/ATS Select
ON = GTS
1
3
2
4
UNUSED
ON = 50 HZ
GTS/ATS
OFF = ATS (standard mode)
OFF = 60 HZ
50/60 HZ
14
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Section 3 - Operation
40kW Liquid-cooled Generators
At this time all five red LEDs will flash for approxi-
mately 10 seconds, then the engine will start and run
for it’s 12 minute exercise period, then shut down.
The generator will now start and run each week at
the same time.
3.5 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:
If DC power to the control board is lost, the weekly
exercise setting will be lost. This is indicated by all
five red LEDs continually flashing. In this state the
generator will still start and run in manual mode, or
automatically start and run if UTILITY is lost while in
AUTO mode, but it will not perform a weekly exercise
cycle.
• 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).
• Set the generator’s main circuit breaker to its OFF
or OPEN position.
• Let the generator engine run at no-load for a few
minutes, to stabilize internal unit temperatures.
• On the generator console, set the AUTO/OFF/
MANUAL switch to OFF. Wait for engine to come to
a complete stop.
• For transfer to utility position, refer to the Owner’s
Manual of the particular transfer switch.
• Turn on the utility power supply to the transfer
switch, using whatever means provided (such as a
utility main line circuit breaker). The utility power
source now powers the loads.
If a failure occurs while running in this mode, the five
red LEDs will stop flashing, the individual fault LED
will turn on and the engine will shut down. Once the
AUTO/OFF/MANUAL switch has been switch to OFF,
the individual fault LED will turn OFF and the five
red LEDs will begin flashing to show exercise has still
not been set.
Figure 3.2 - “Set Exercise” Switch
3.6 AUTOMATIC OPERATION
To set the system for fully automatic operation, pro-
ceed as follows:
FUSE
FUSE
4A
BAT.
CHARGER
15A
MAIN
• Check that load circuits are connected to the utility
power supply.
AUTO
• Set the AUTO/OFF/MANUAL switch to its AUTO
OFF
OFF
ON
position.
• Set the generator main circuit breaker to its ON or
CLOSED position.
SET
EXERCISE
TIME
MANUAL
3.7 WEEKLY EXERCISE CYCLE
The engine control board will start and run the gen-
erator once every seven days for approximately 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 three
seconds, then release.
15
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Section 4 — Maintenance
40kW Liquid-cooled Generators
4.1 MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE FACILITIES
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 protection devices
will open if the circuit is overloaded.
‹
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. Check fan belts.
If a circuit breaker opens or a fuse element
melts, find the cause of the overload before
resetting the circuit breaker or replacing the
fuse.
‹
ONCE EVERY SIX MONTHS
1. Test Engine Safety Devices (low oil pressure, low
coolant level, high coolant temperature).
4.4 CHECKING FLUID LEVELS
‹
ONCE ANNUALLY
‹
4.4.1 CHECK ENGINE OIL
Check engine crankcase oil level (Figure 4.1) at least
every 20 hours of operation, or prior to use.
1. Test engine governor. Adjust or repair, if needed.
2. Clean, inspect generator.
3. Flush cooling system.
• Remove oil dipstick and wipe dry with a clean, lint-
free cloth.
‹
FIRST 100 OPERATING HOURS
• Install oil dipstick, then remove again.
• Oil should be between FULL and ADD marks.
• If oil level is below the dipstick ADD mark,
remove oil fill cap. Add the recommended oil to
bring oil level up to the FULL mark. DO NOT
FILL ABOVE THE “FULL” MARK. See "Engine Oil
Recommendations" for recommended oils.
1. Change engine oil and oil filter. (After initial
change, service engine oil and filter at 150 operat-
ing hours or 6 months, whichever comes first.)
2. Retorque cylinder head. (See Torque Specs.)
3. Retorque intake and exhaust manifold. (See
Torque Specs.)
‹
EVERY 500 OPERATING HOURS
Figure 4.1 - Oil Dipstick and Oil Fill Cap
1. Service air cleaner.
2. Check starter.
Oil Dipstick
Oil Fill
3. Check engine DC alternator.
4.2 COOLING SYSTEM
Air intake and outlet openings in the generator com-
partment must be open and unobstructed for contin-
ued proper operation. This includes such obstruc-
tions as high grass, weeds, brush, leaves and snow.
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to shut down. (See the Mounting Dimensions drawing
for installation and vent locations.)
Oil Filter
‹
4.4.2 BATTERY FLUID
Check battery electrolyte fluid at least once weekly.
Fluid should cover separators in all battery cells. If
fluid level is low, add distilled water to cover tops of
separators. DO NOT USE TAP WATER IN BATTERY.
The exhaust system parts from this product get
extremely hot and remain hot after 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.
‹
4.4.3 ENGINE COOLANT
Check coolant level in coolant recovery bottle. See
Specifications.
16
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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.
‹
4.5.8 CHECK FAN BELT
• Inspect fan belts every three months. Replace any
damaged, deteriorated, worn or otherwise 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.
4.5 MAINTENANCE OWNER/
OPERATOR CAN PERFORM
DANGER
Do not attempt to adjust the governor. Only
qualified service facilities should adjust the
‹
4.5.1 CHECK ENGINE OIL LEVEL
Refer to “Checking Fluid Levels”.
governor. Excessively high operating speeds
are dangerous and increase the risk of personal
injury. Low speeds impose a heavy load on the
engine when adequate engine power is not
available and may shorten engine life. Correct
rated frequency and voltage are supplied only
at the proper governed speed. Some connected
electrical load devices may be damaged by incor-
rect frequency and/or voltage. Only qualified
service technicians should adjust the governed
speed.
‹
4.5.2 CHECK BATTERY
• Check battery fluid level each week as outlined
under “Check Fluid Levels”.
• Check battery cables for condition, tightness, cor-
rosion or damage. Clean, tighten or replace as
necessary.
‹
4.5.3 EXERCISE SYSTEM
Start the generator engine at least once every seven
days and let it run at least 20 minutes. See “Weekly
Exercise Cycle”.
‹
4.5.10 CHANGING ENGINE OIL
Refer to maintenance performed by authorized service
dealers for engine oil and filter change frequencies.
‹
4.5.4 INSPECT COOLING SYSTEM
Drain the oil while the engine is still warm from run-
ning. This means warm up the engine, shut it down
and drain immediately as follows:
• Inspect engine cooling system at least once each
month.
• Check hoses for damage, deterioration, leaks, etc.
Correct any discrepancies found.
• Check hose clamps for tightness.
1. Remove OIL DRAIN HOSE from its retaining
clip.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain
oil completely into suitable container.
3. When all oil has drained, install and tighten OIL
DRAIN HOSE CAP, and re-install into its retaining
clip.
‹
4.5.5 CHECK ENGINE COOLANT LEVEL
See “Checking Fluid Levels”.
4. Turn OIL FILTER (Figure 4.2) counterclockwise
‹
4.5.6 PERFORM VISUAL INSPECTION
and remove. Dispose of old filter.
Complete a thorough visual inspection of the entire
engine-generator monthly. Look for obvious damage,
loose, missing or corroded nuts, bolts and other fas-
teners. Look for fuel, oil or coolant leaks.
5. Apply light coating of new engine oil to seal of new
oil filter.-Install FILTER and tighten by hand only.
DO NOT OVERTIGHTEN.
6. Remove OIL FILL CAP. Add recommended oil (see
SPECIFICATIONS). DO NOT FILL ABOVE THE
DIPSTICK “FULL” MARK. Crankcase oil capacity
is 4.0 U.S. quarts (3.8 liters).
‹
4.5.7 INSPECT EXHAUST SYSTEM
Inspect the exhaust system at least once every three
months. Check all exhaust system pipes, mufflers,
clamps, etc. for condition, tightness, leaks, security,
damage.
After refilling the crankcase with oil, always
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
17
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Section 4 — Maintenance
40kW Liquid-cooled Generators
7. Start engine and check for oil leaks.
‹
4.5.13 COOLANT CHANGE
Every year, have an authorized service deal-
er drain, flush and refill the cooling system. See
SPECIFICATIONS for cooling system recommenda-
tions.
Figure 4.2 - Oil Filter
4.6 MISCELLANEOUS MAINTENANCE
‹
4.6.1 CLEANING THE GENERATOR
Keep the generator as clean and as dry as possible.
Dirt and moisture that accumulates on internal gen-
erator windings have an adverse effect on insulation
resistance.
Oil Filter
Periodically clean generator exterior 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.
‹
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.
Once each year, have the generator cleaned and
inspected by an Authorized Service Dealer. That
dealer will use dry, low pressure air to clean internal
windings. Parts inside the control console should be
cleaned and inspected at this time as well.
See the “Service Schedule,” for air cleaner mainte-
nance.
Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
excessively low, the generator may require drying.
‹
4.5.12 SPARK PLUGS
Reset the spark plug gap or replace the spark plugs
as necessary.
‹
4.6.2 BATTERY
1. Clean the area around the base of the spark plugs
to keep dirt and debris out of the engine. Clean
by scraping or washing using a wire brush and
commercial solvent. Do not blast the spark plugs
to clean.
2. Remove the spark plugs and check the condi-
tion. Replace the spark plugs if worn or if reuse
is questionable. See the “Service Schedule, for
recommended inspection.
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 1.01 mm (0.040 inch)
by carefully bending the ground electrode (Figure
4.3).
All lead-acid storage batteries discharge when not in
use. Refer to specific instructions and warnings that
accompany the battery. If such information is not
available, observe the following precautions when
handling a battery:
• DO NOT use jumper cables and a booster battery
to crank or start the generator engine.
• DO NOT recharge a weak battery while it is
installed in the generator. Remove battery from
generator and recharge in a well-ventilated area,
away from fuel vapors, sparks, heat or flames.
• Battery electrolyte fluid is an extremely caustic
sulfuric solution that can cause severe burns. DO
NOT permit fluid to contact eyes, skin, clothing,
painted surfaces, wiring insulation, etc. If any bat-
tery fluid is spilled, flush the affected area with
clear water immediately.
Figure 4.3 – Setting the Spark Plug Gap
SET PLUG GAP AT 1.01 mm
(0.040 inch)
• Always wear safety glasses, rubber apron and
gloves when handling a battery.
18
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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.
Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as the
battery cables are connected.
‹
4.6.3 BATTERY MAINTENANCE
Be sure the UTILITY power supply is turned OFF,
or sparking may occur at the battery posts as
the cables are attached and cause an explosion.
The battery should be inspected per the “Service
Schedule”. The following procedure should be fol-
lowed for inspection:
1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with DISTILLED WATER
ONLY. DO NOT USE TAP WATER IN BATTER-
IES.
‹
4.6.4 BATTERY REPLACEMENT
When replacing batteries, use the same number and
the type of battery that follows:
BCI Group No.
CCA
27F
700 @ 0 deg. F
3. Have the state of charge and condition checked.
This should be done with an automotive-type bat-
tery hydrometer.
NOTE:
The BCI number should be located directly on the
battery.
DANGER
Storage batteries give off explosive hydrogen
‹
PERIODIC REPLACEMENT PARTS
Part Number
gas. This gas can form an explosive mixture
Part Name
around the battery for several hours after charg-
ing. The slightest spark can ignite the gas and
cause an explosion. Such an explosion can shat-
ter the battery and cause blindness or other
injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smok-
ing, open flame, sparks or any spark producing
tools or equipment near the battery.
Oil Filter
# 0E7415
# 046627
# 0A4637
Radiator Cap
Air Cleaner
Spark Plug
Champion # RC12LC4
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 immediately with clear water.
Do not use any jumper cables or booster battery
to crank and start the generator engine. If the
battery has completely discharged, remove it
from the generator for recharging.
19
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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. Use calendar time from the previous maintenance interval to determine the next required maintenance
interval.
Service Maintenance Interval Information:
The various service maintenance intervals are designated by interval numbers as follows:
1 An early inspection of the generator set to ensure it is ready to operate when required and to identify any poten-
tial problem areas.
Performed monthly, this procedure requires approximately .5 man-hours per unit to complete.
This inspection may be performed by the end user providing the following safety steps are taken to prevent
the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
• Disable the generator set from starting and/or connecting to the load by setting the control panel AUTO/
OFF/MANUAL switch to the “OFF” position.
• Remove the control panel fuse.
• Turn off the battery charger.
• Remove the negative battery cable.
The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition
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 first three months after purchase of the unit and requires approxi-
mately 2.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
3 An operational 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 semi-annually, this procedure requires approximately 1.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
4 A mid-level 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 annually, this procedure requires approximately 4.0 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an Authorized Service Dealer.
NOTE:
If the generator experiences heavy use, the maintenance intervals should be reduced so that procedures are
performed more frequently.
20
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Section 4 — Maintenance
40kW Liquid-cooled Generators
Maintenance
Tasks
Level 1
Recom-
mended
Level 2
Required
Level 3
Required
Level 4
Task
Task
Task
Task
Comp.
Comp. to be done Comp. to be done Comp.
Required
to be done (Date-
monthly Initials)
3 months/
Break-in
(Date-
Initials)
Semi-
annually
(Date-
Initials)
to be done (Date-
Annually
Initials)
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.
Correct as necessary.
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 connections,
corrosion, and damage.
Correct as necessary.
10. Check the engine
accessory drive belts for
wear, weather cracking,
and damage. Replace as
necessary.
11. Visually inspect the unit
looking for leaks, wear or
damage, loose connections
or components, and
corrosion. Correct as
necessary.
12. Test the engine and
transfer switch safety
devices. Correct and/or
adjust as necessary.
21
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Section 4 — Maintenance
40kW Liquid-cooled Generators
Maintenance
Tasks
Level 1
Recom-
mended
Level 2
Required
Level 3
Required
Level 4
Task
Task
Task
Task
Comp.
Comp. to be done Comp. to be done Comp.
Required
to be done (Date-
monthly Initials)
3 months/
Break-in
(Date-
Initials)
Semi-
annually
(Date-
Initials)
to be done (Date-
Annually Initials)
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.
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 engine
driven units and re-prime
the fuel system.
19. Check the engine spark
plugs on gas engine driven
units. Clean and re-gap or
replace as necessary.
20. Perform a 5 minute no-load
operational run of the unit
looking for any post service
problems.
21. Return the unit to standby
setup for operation when
required.
22
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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.
1. Replace fuse.
2. Tighten, clean or replace
battery cables as necessary.
3. Replace contactor.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
6. 4-amp fuse blown.
4. Replace starter motor.
5. Remove, change or replace battery.
6. Replace fuse.
Engine cranks, but won't start
1. Out of fuel.
1. Replenish fuel.
2. Replace solenoid.
3. Reconnect wire.
2. Fuel solenoid (FS) is defective
3. Open Wire #14 from Engine Control
circuit board.
4. Spark plugs defective.
4. Clean, regap or replace plugs.
Engine starts hard, runs rough.
Engine starts, then shuts down.
1. Air cleaner plugged or damaged.
2. Plugged fuel line.
3. Defective spark plugs.
1. Clean or replace as needed.
2. Unclog fuel line.
3. Clean, regap or replace plugs.
1. Engine oil level is low.
2. Engine is overheated.
1. Check oil and add oil as needed.
2. Check cooling system for leaks.
3. Replace switch.
3. Defective Low Oil Pressure Switch
4. Defective Coolant Temperature Switch
5. Defective Control Module circuit board.
6. Coolant Level is Low.
4. Replace switch.
5. Replace board.
6. Repair leak - Add coolant.
7. Replace Switch.
7. Defective Low Coolant Level Switch
AUTO/OFF/MANUAL Switch at
OFF, engine continues to run
1. Defective AUTO/OFF/MANUAL switch
2. Open/disconnected wire #15A between
AUTO/OFF/MANUAL switch and Control
Module circuit board.
1. Replace switch.
2. Reconnect/close wire.
3. Defective Control Module circuit board
3. Replace board.
No AC output from generator.
1. Check main line circuit breaker.
2. Check circuit breaker & fuses.
3. Transfer switch set to NORMAL position
4. Generator internal failure.
1. Reset to ON or CLOSED.
2. Reset and replace, if necessary.
3. Set to GENERATOR position.
4. Contact an Authorized facility.
5. Auto-reset - Wait 5 min. and
attempt restart.
5. Thermal circuit breaker open.
23
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Section 6 - Electrical Data
40kW Liquid-cooled Generators
Wiring Diagram — Engine — Drawing No. 0E8115-A
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Section 6 - Electrical Data
40kW Liquid-cooled Generators
Wiring Diagram — Engine — Drawing No. 0E8115-A
25
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Section 6 - Electrical Data
40kW Liquid-cooled Generators
Electrical Schematic — Engine — Drawing No. 0E8116-A
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Section 6 - Electrical Data
40kW Liquid-cooled Generators
Electrical Schematic — Engine — Drawing No. 0E8116-A
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Mounting Base — Drawing No. 0E8084-C
28
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Mounting Base — Drawing No. 0E8084-C
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
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
038804D
038805J
021991
036833
022237
022131
0F3976
050331
050331A
0A4010
052858
065852
045764
1
4
4
4
4
4
4
1
1
1
1
2
1
1
1
4
3
2
2
1
1
1
1
1
1
2
1
1
REF.
1
1
1
6
6
6
1
1
1
2
2
1
1
WELDMENT MTG BASE 3.9L CRYSLR
NUT FLANGED HEX M12-1.75
DAMPENER VIBRATION 40 BLUE
SPACER .49 X .62 X 1.87 PWDR/ZNC
DAMPENER VIBRATION
3
4
5
6
WASHER FLAT M12
SCREW HHC M12-1.75 X 80 G8.8
ASSY WIRE 15.0”
7
8
9
SCREW HHTT M6-1.0 X 20 BP
SCREW HHC M6-1.0 X 16 BP
LUG SLDLSS #2-#8 X 17/64 CU
WASHER SHAKEPROOF EXT 1/4 STL
WASHER LOCK M6-1/4
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
WASHER FLAT M6-1/4 ZINC
NUT HEX M6 -1.0 G8 YEL CHR
1-1/2” BUTTON PLUG
WASHER SHAKEPROOF EXT 7/16 STL
ENGINE MOUNT (3.9L CHRYSLER)
WASHER SHAKEPROOF EXT 5/16 STL
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC M10-1.5 X 20 G8.8
WASHER LOCK M10
WASHER FLAT 3/8-M10 ZINC
CLAMP VINYL .75 X .343 Z
NUT HEX LOCK M8-1.25 NY INS
HOLD DOWN BATTERY
HOLD DOWN BATTERY
BATT 12VDC 90-AH 27F (NOT INCLUDED)
CABLE BATT RED #4 X 20.00
CABLE BATT BLK #1 X 30.00
EARTH STRAP
SCREW HHC 3/8-16 X 1 G8
WASHER LOCK 3/8
WASHER FLAT 3/8 ZINC
BOOT, CONTACTOR CABLES
BATTERY POST COVWER (BLACK)
BATTERY POST COVWER (RED)
SCREW HHC M8-1.25 X 60 G8.8 FT
NUT TOP LOCK FL M8-1.25
SPRING CLIP HOLDER .37-.62
SCREW HHTT M4-0.7 X 8 BP
* NOT SHOWN-USED TO HOLD DOWN I/N 32.
29
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Enclosure — Drawing No. 0F4930-C
30
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Enclosure — Drawing No. 0F4930-C
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
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
0912970063
0912970064
049813
0E8416
0E8417
0E8665
0D2023
0E7829N
0E7829T
0E7829S
0E8442
0E7829A
0E7829B
0E7829P
0E7829R
043116
1
1
1
62
1
1
1
1
2
1
2
4
1
1
1
8
12
12
2
4
4
4
1
1
2
2
1
1
1
1
2
1
1
1
1
1
1
1
4
2
2
2
1
1
1
1
2
1
1
1
1
2
4
2
8
DUCT INTAKE MID AL
DUCT DISCHARGE RH AL
DUCT DISCHARGE LH AL
3
4
SCREW TH-FRM M6-1 X 16 N WA Z/JS
BAFFLE REAR BOTTOM
5
6
POST CORNER LH REAR HSB AL
POST CORNER RH REAR HSB AL
BAFFLE REAR TOP
7
8
9
DOOR SIDE HSB AL
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
SUPPORT RH SIDE HSB AL
FOAM STRIP 3/4” WIDE X 3/16” THK (40” LG)
WASHER NYLON .257
BRACKET STIFFENER RH FRONT
HINGE LIFT OFF TYPE B KNUCKLE
HINGE LIFT OFF TYPE B PIN
WASHER SELF LOCKING DOME
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
GAS SPRING
BALL STUD GAS SPRING MOUNT
NUT HEX 5/16-18 LOCK
SCREW WING M6-1.00 X 25
HINGE LIFT OFF TYPE A KNUCKLE
HINGE LIFT OFF TYPE A PIN
TRIM VINYL SELF GRIPPING (91” LG)
BRACKET STIFFENING BACK
MUFFLER BOX
ROOF HSB AL ACOUSTIC
BRACE, FRONT TOP
LATCH 1/4 TURN NONLOCKING
PAWL DOOR HSB
SUPPORT LH SIDE HSB AL
MUFFLER BOX TOP
LATCH QUARTER TURN LOCKING
POST CORNER LH FRONT HSB AL
POST CORNER RH FRONT HSB AL
BRACE FRONT BOTTOM
DUCT DISCHARGE MID AL
WASHER SHAKEPROOF EXT 1/4 STL
ASSY WIRE 14AWG 7.5 #0 GRN/YEL
ASSY WIRE 14AWG 7.5 #0 GRN/YEL
NUT HEX M6 X 1.0 G8 YEL CHR
DUCT INTAKE LH AL
DUCT INTAKE RH AL
BRACKET STIFFENER LH FRONT
TRIM VINYL SELF GRIPPING (165.5” LG)
AI ROOF PANEL 2
AI SUPPORT RH PANEL
AI SUPPORT LH PANEL
KIT INSULATION 3.9L HSB
AI ROOF PANEL 1
AI DOOR PANEL
AI CORNER POST PANEL 1
AI CORNER POST PANEL 2
SCREW HHC M6-1.0 X 12 G8.8
* ALL ITEMS NOTATED WITH “AI” ARE COMPONENTS OF 0E8442
31
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Control Panel — Drawing No. 0E7118-K
32
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Control Panel — Drawing No. 0E7118-K
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
0E7195
0E7196
0E7197
0E7193
0E7194
0E4494
082573
032300
022676
067682B
060015
054199
0C2657
099076
040213
0E9668
067680
0E6875A
0E6881 *
0C5139 *
0C5142 *
1
CONTROL BOX HSB
37
38
39
0C1127
0A1441B
0E7128
1
1
1
DECAL AVR COVER
COVER PLATE, AVR
1
COVER FRONT PANEL HSB
COVER TOP PANEL HSB
DECAL WARNINGS HSB
DECAL CONTROLS HSB
SWITCH ROC DPDT ON-OFF-ON
SWITCH ROCKER DPST 125V SPD
HOLDER FUSE
3
1
HARNESS CNTRL PNL (NOT
SHOWN)
4
1
5
1
40
41
42
0E7358
074908
0C5141
8
6
1
SCREW PPPH HI-LO #4-24 X 3/8
SCREW HHTT M5-0.8 X 10 BP
CONN DEUTSCH GASKET 8/12 POS
DT
6
1
7
1
8
2
9
1
FUSE 15A X AGC15
43
44
45
46
47
49
50
51
52
53
54
55
56
57
58
59
60
0C2699
0C2323
022155
0C2265
022264
020911
066849
022152
023897
051716
090388
042568
022097
022473
0441140187
070370
023762
11
4
SCREW PHTT #6-32 X 3/8 ZYC
SCREW PHTT #6-32 X 5/8 ZYC
WASHER LOCK #6
10
11
12
13
14
15
16
17
18
19
20
21
1
FUSE 4A SLO BLO GLASS
FITTING CONDUIT 90D 3/8"
DECAL DANGER HIGH VOLTAGE
TRANSFRMR 16V 6VA
1
15
4
1
1
SCREW PHTT M4-0.7 X 12 ZYC
WASHER LOCK #8-M4
4
1
TRANSFORMER 16V 56VA
PCB SUPPORT SNAP-IN 1/4"
ASSY PCB HSB CONTROLLER
ASSY VOLTAGE REGULATOR 60HZ
RELAY 12VDC C FORM W/DIODE
SOCKET RELAY
2
SCREW PPHM M5-0.8 X 30 ZINC
SCREW HHTT M5-0.8 X 16
WASHER LOCK #10
2
2
1
4
1
3
WASHER FLAT #10 ZINC
NUT HEX M5-0.8 G8 YEL CHR
SCREW HHTT M6-1.0 X 12 ZINC
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M6-1/4
WASHER FLAT 1/4-M6 ZINC
WIRE ASSY 3" X (2) 3/16" TABS
WASHER MICA .203
1
2
REF.
REF.
REF.
2
CONN DEUTSCH RECEPT GY/FLN
CONN DEUTSCH RECEPT WDGE
BLKHD
4
8
6
22
23
24
0E3161
054450
0D5070A
1
1
1
ASSY BOSCH GOV DRIVER
CIRCT BRK 5.5 X 1 ETA 46-500-P
ASSY 2A 12V UL BATTERY
CHARGER
2
2
1
WASHER SHAKEPROOF EXT #10
STL
HEATSINK
25
26
27
0E2514
0A9457
0E7539
1
1
1
FITTING CONDUIT STR 1-1/2"
DECAL NEUTRAL
61
62
63
64
65
66
67
68
69
055444
030468
049939
022158
022985
038750
0A2115
0C2454
0F6146
1
1
1
1
1
2
4
4
1
WASHER STEP NYLON .20
RECTIFIER MSC 12A 600V 1N1206R
NUT HEX #10-32 STEEL
WASHER FLAT #6 ZINC
SCREW HHC M6-1.0 X 30 G8.8
WASHER NYLON .257
DECALCUSTOMER CNNCTN XFER
SW
28
29
30
31
046357 *
0D3719B
057073
REF.
BLOCK TERM 20A 6 X 6 X 1100V
DECAL CUSTOMER CNNCTN
JUNCTION BLOCK 3/8-16
CB 0150A2P240V S QN2 LL
CB 0200A2P240V S QN2 LL
BASE QN CIRCUIT BREAKER
DECAL TB1 HSB CONTROL PANEL
BLOCK TERM 20A 6 X 3 X 1100V
BRACKET CB 221.5 X 102
DECAL WARNING ELECTRICAL
SHOCK
1
1
0E7283
0E3628
0E3664
0E7539A
0D4698 *
0E7252
0C1229
1
SCREW THF M6-1 X 16 N WA Z/JS
HANG TAG 2 WIRE START (NOT
SHOWN)
1
32
33
34
35
36
1
1
REF.
1
* ITEMS INCLUDED AS PART OF I/N 39
1
33
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Engine — Drawing No. 0E8121-H
48
21
47
COMES WITH
ENGINE
44
18
11
56
62
61
5
6
43
36
78
44
18
35
18
63
54
BAFFLE
REAR UPPER
37
66
46
40
39
65
18
45
23
19
5
17
25
30
18
26
19
43
"B"
44
55
73
18
31
29
12
75
24
64
76
52
34
32
74
41
21
42
33
17
"A"
19
TO
"B"
18
38
58
59
16
50
14
70
18
49
19
13
19
18
17
14
77
13
53
51
4
9
18
19
27
14
17
"C"
28
79
19
18
19
60
2
57
TO
"A"
15
69
14
18
19
8
1
17
3
7
14
13
16
TO
"C"
10
22
21
20
USE
D.C. ALTERNATOR
BRACKET HARDWARE.
18
19
17
72
34
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Engine — Drawing No. 0E8121-H
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
0E5048A
0E7477
0E6703
0E8336
0E7841
0E7254
0E7956
0E7953
047411
0E8591
0E7921
0E7749
022097
022473
049721
049813
036833
022131
022237
0E6729
022129
049821
057073
052677
066849
056739
0D2244M
087599
0E0992B
1
1
FLEXPLATE 3.9L HSB
39
40
050873A
031919
1
1
PLUG PIPE 1/4 CSK W/ VIBRA SL
PLUG STD PIPE 3/8
COUNTERSUNK
MACHINING 3.9L ENGINE ADAPTOR
COVER FLYWHEEL ACCESS
REWORK 3.9L CHRYSLER ENGINE
GASKET THERMOSTAT ADAPTOR
MACH THERM ADAPTOR 3.9L CHRY
BRACKET IGNITION COIL
COIL IGNITION 3.9L CHRYSLER
SCREW HHC M6-1.0 X 16 G8.8
BOLT AUTO TRANS CRANKSHAFT
BRACKET ALTERNATOR
3
1
4
REF
2
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
022145
030795
051756
046526
0A1232A
0A7801B
045772
022403
0E7950
0E7951
0E8445
0E7415
042568
061652
031578
082120
023645
0E9974
0D3488A
0E7954
0E8309
029187
032712
054455
0E8606
0E8642
0E8597
6
6
WASHER FLAT 5/16-M8 ZINC
SCREW HHC 5/16-18 X 1 G5
SCREW HHC M10-1.5 X 20 G8.8
WASHER LOCK M10
5
6
1
5
7
1
6
8
1
1
ASSEMBLY, D.C. ALTERNATOR
PULLEY POLY-V 82 OD
9
4
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
6
1
NUT HEX M10-1.5 G8 YEL CHR
SCREW HHC 5/16-18 X 2 G5
TUBE DIPSTICK 3.9L CHRYSLER
DIPSTICK OIL LEVEL 3.9L CRYSLR
BRACKET DIPSTICK TUBE
OIL FILTER 3.9L CHRYSLER
SCREW HHC M6-1.0 X 20 G8.8
SCREW HHC M10-1.5 X 85 G8.8
SCREW HHC 3/8-16 X 1-1/2 G8
SPACER .41 X .75 X .39 ST/ZNC
SCREW SHC 3/8-16 X 1.25 G8.8 Z
CAP VINYL 3/8” ID X 1” DP BLK
BELT SERPENTINE 69.39”
CABLE IGN COIL 3.9L CHRYSLER
ASSY IGNITION MODULE 3.9L
SPACER .19 X .31 X .50 PL
SCREW HHTT #10-32 X 1.75 CZ
ADP OIL DRN 1/2-20
1
2
1
FAN SPACER ENGINE COOLING
WASHER LOCK M6-1/4
1
7
1
10
2
WASHER FLAT 1/4-M6 ZINC
SCREW HHC M6-1.0 X 35 G8.8 BLK
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW HHC 3/8-16 X 1 G8
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK 3/8
1
1
3
1
11
21
14
1
1
1
1
STARTER DELCO-REMY 12V
WASHER LOCK M8-5/16
5
11
3
1
SCREW SHC M8-1.25 X 30 G12.9
JUNCTION BLOCK 3/8-16
1
1
1
1
WASHER NYLON .50 X .87 X .06
SCREW HHTT M5-0.8 X 16
RELAY SOLENOID 12VDC PNL MNT
ASSY MAGPICKUP (3/8-24 MALE)
PLUG PLASTIC 3/8 NPT
1
2
2
1
2
1
1
1
REF
2
SCREW PPH TAPPING #4 X 3/8” LG
ASSEMBLY RESISTOR
PLUG EXPANSION 21/32” OD
(WATER PUMP) (QTY 1)
REF
1
HARNESS 3.9L CHRYSLER ENGINE
(NOT SHOWN)
30
0E0992A
REF
PLUG EXPANSION 14.1 OD
(INJCTOR HOLE) (QTY 6)
68
0E8755
1
HARNESS IGNITION 3.9L CHRY
(NOT SHOWN)
31
32
33
34
0E7754
0E7854
0E7855
0E7952
1
1
1
1
COOLING FAN 10-BLADE (KYSAIR)
CLUTCH COOLING FAN
69
70
72
73
74
75
76
77
78
79
0E8731
026076
0F1444A
0C2454
043790
069860C
048031J
0F1444
026925
026257
1
1
PLATE FLEX DISK SPACER
SCREW SHC 3/8-16 X 1.5 G8.8 NZ
HEAT SHEILD L/H SIDE
TENSIONER W/BRACKET
PULLEY CRANKSHAFT 3.9L
CRYSLR
2
2
SCREW THF M6-1 X 16 N WA Z/JS
BARBED EL 90 3/8 NPT X 3/8
HOSE OIL DRAIN ASSY 21”
HOSE CLAMP BAND 5/8”
35
0E0561
1
ASSY WATER LEVEL SENSOR C/E
PL
1
1
36
37
38
035606
061012
0A8584
1
1
1
SENSOR HI COOLANT SHUTDOWN
PLUG STD PIPE 1/8 SOCKET HEAD
SWITCH OIL PRESSURE10 PSI
2POL
REF
1
HEAT SHIELD R/H SIDE
PLUG STD PIPE 3/8 STEEL SQ HD
SCREW SHC 3/8-16 X 2 G8.8 NZ
1
1
35
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Radiator — Drawing No. 0E8102-F
36
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Radiator — Drawing No. 0E8102-F
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0D7825A
0D7174C
0E7640
0E7924
0F2853
0D8252
0D8251
0E0726
076749
035685
069860C
058443
0C2454
052250
048031C
029032
0A2111
0E7640A
035461
065852
051756
022131
046526
045772
1
1
1
1
1
1
1
1
1
4
1
17
5
2
1
1
1
1
1
1
4
8
4
4
RADIATOR COPPER BRASS
VENTURI,3.9L CRYSLR HSB 22"FAN
RADIATOR SUPPORT L/H SIDE
HOSE LOWER RADIATOR
3
4
5
HOSE, RADIATOR UPPER, 3.9L
FAN GUARD, TOP
FAN GUARD, BOTTOM
6
7
8
BRACKET, WATER BOTTLE 1.5L MIT
TANK COOLANT RECOVERY
CLAMP HOSE #28 1.32-2.25
HOSE OIL DRAIN ASSY 21"
SCREW CRIMPTITE 1/4-20 X 5/8
SCREW TH-FRM M6-1X16 N WA Z/JS
TAPE FOAM 1 X 1 (27"LG)
9
10
13
14
15
16
17
18
19
20
21
22
23
24
25
26
CLAMP HOSE BAND 1/4
HOSE 9/32 ID (30" LG)
SCREW SWAGE 10-32 X 5/16 Z/YC
RADIATOR SUPPORT R/H SIDE
BARBED STR 1/4NPT X 3/8
SPRING CLIP HOLDER .37-.62
SCREW HHC M10-1.5 X 20 G8.8
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
NUT HEX M10-1.5 G8 YEL CHR
37
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Fuel System — Drawing No. 0E8122-H
38
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Fuel System — Drawing No. 0E8122-H
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
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
057795A
052223
061012
0E9295
0F3994
0E7121
4
1
1
2
2
8
2
2
2
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
4
1
1
4
4
4
4
1
1
1
1
1
1
1
SCREW HHC 5/16-18 X 1-1/4 G5
FLANGE FUEL INLET
3
ASSY REG. 3.9L N/G-LPV 1800RPM
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
4
5
6
WASHER LOCK M8-5/16
7
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC M8-1.25 X 16 G8.8
SCREW TH-FRM M6-1 X 16 N WA Z/JS
ELBOW 90D STREET 3/4
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
FUEL HOSE ASSY NAT.GAS/L.P.V.
BRACKET REGULATOR 3.0L FORD HSB
CLAMP HOSE #8 .53-1.00
HOSE 5/8 ID LPG & NG (36" LG)
GASKET CARB ADAPTOR
DECAL INLET PRESSURE
DECAL FUEL INLET NG
MACHINING, CARBURETOR ADAPTOR
GASKET BOSCH 32 & 40
ACTUATOR BOSCH 40 GOVERNOR
HOSE COOL 2IN ID 20R4 (2" LG)
VENTURI HOLDER W/40MM ACTUATOR
O-RING 45.63 ID X 2.62 WIDTH
VENTURI 28 ID THROTTLE W/CHOK
CLAMP HOSE #36 1.88-2.75
BASE AIR CLEANER PLATE
FILTER AIR 11.5" CA326
HOLDER VENTURI
HOLD DOWN AIR CLEANER
PLATE AIR CLEANER TOP
NUT WING 1/4-20 NYLK
SCREW SHC M6-1.0 X 45 G12.9
STREET EL 45DEG 1/2" NPT BRASS
BARBED STR 1/2NPT X 5/8
SCREW HHC M5-0.8 X 16 G8.8
WASHER LOCK M5
WASHER FLAT M5
WASHER LOCK M6-1/4
GROMMET
BARBED EL 90 3/4 PLASTIC
HOSE 1/2 ID SAE-30R2 FUEL/OIL
PLUG STD PIPE 1/8 SOCKET HEAD
ASSY THROTTLE 28MM
PCV VALVE 2.5L FORD
O-RING 47.625 ID X 2.38 WIDTH
39
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Alternator — Drawing No. 0F5092-B
40
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Alternator — Drawing No. 0F5092-B
ITEM
PART NO.
QTY.
DESCRIPTION
1
0F1659A
0F1657A
0F1655A
0F5073A
0E7413A
0F1660A
0F1658A
0F1656A
0F5074A
0E7412A
0E5706
1
ROTOR 390 15KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390 20KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390 25KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390__30AD1 HSB TECUM
1
1
1
1
RTR 390 40KW 1P DIRECT HSB
2
1
STR 390 15AD HSB (382MM LONG) (2.5L FORD)
STR 390 20AD HSB (382MM LONG) (2.5L FORD)
STR 390 25AD HSB (382MM LONG) (2.5L FORD)
STR-390__30AD1 HSB TECUM
1
1
1
1
STR-390--40AD HSB (433MM LONG)
REAR BEARING CARRIER 390/DRCT
FLEXPLATE 3.0L FORD
3
4
1
REF
0E5048
0E5048B
REF
FLEXPLATE 2.5L FORD
0E5048A
0E6668
0E6076
046526
REF
1
FLEXPLATE HSB 3.9L CHRYSLER
FLYWHEEL ASSY 3.0L HSB LG GEAR
REVCOR FAN 10.75 X 2 W/PRESS DIS
WASHER LOCK M10
5
6
7
8
9
1
8
051755
4
SCREW HHC M10-1.5 X 16 G8.8
STUD M14-2.0 X 490 G5 ZINC (3.0L FORD & 2.5L FORD)
STUD M14-2.0 X 540 G5 ZINC
04576100BK
04576100BF
043123
4
4
10
11
12
13
14
15
16
17
18
19
20
21
4
WASHER LOCK M14
051779
4
NUT HEX M14-2.0 G8 YEL CHR
ASSY BRUSH HOLDER 390/HSB
WASHER SHAKEPROOF INT #8
SCREW PPHM M4-0.7 X 25
0E7587
023365
092980
1
1
4
057192
0A2602
042558
4
SCREW SHC M10-1.5 X 30 G12.9
WASHER FLAT .688 ID X 3.25 OD
KEY SQ 3/8 X 1 STEEL
1
1
0A2601
022264
038150
1
SCREW HHC M16-2.0 X 45 G8.8
WASHER LOCK #8-M4
WASHER FLAT #8 ZINC
4
4
077043F
077043F
1
CONDUIT FLEX 1-1/4” (30” LG - 3.0L FORD & 3.9L CHRYSLER)
CONDUIT FLEX 1-1/4” (18” LG – 2.5L FORD)
1
ROTOR REPLACEMENT PARTS
30
31
047248
070892
1
1
BALL BEARING-45 MM
SLIP RING -MACHINED-
41
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Section 7 - Exploded Views and Parts
40kW Liquid-cooled Generators
Muffler — Drawing No. 0F4894-B
7
21
13
12
11
10
5
1
22
10
11
10
12
23
13
22
TO
COMPARTMENT
9
20
14
17
19
8
10
11
11
20
8
TO EXHAUST
MANIFOLD
24
19
8
15
17
19
14
16
3
11
TO
EXHAUST
MANIFOLD
19
15
25
8
2
18
6
11
20
4
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
3
4
5
0F0738
0C9748
0F0778
0F0777
0E5914
1
1
1
1
1
MUFFLER 7"X9"-(2)2"IN/2.5"OUT
PLUG M18-1.50
14
15
16
17
18
19
20
21
22
23
24
25
052860
052891
0E8816
051769
0E0170B
049808
022259
080762
0E8726
039288
0F5612
0F6262
4
4
1
4
1
8
8
1
2
1
1
1
NUT TOP LOCK FL M12-1.75
SCREW HHC M12-1.75 X 80 G8.8
EXHAUST FLANGE 2" PIPE
WASHER LOCK M12
PIPE R/H SIDE EXHAUST MILD ST
PIPE L/H SIDE EXHAUST MILD ST
BRACKET MUFFLER 3.0L FORD
HSB
EXHAUST BLANKET 800MM
WASHER FLAT M12
6
7
0E0170C
0F6258
036797
039253
022145
022129
045771
0C2454
1
1
EXHAUST BLANKET 675MM
PIPE MUFFLER OUT
BOLT U 5/16-18 X 2.25
NUT HEX 5/16-18 STEEL
BOLT U 3/8-16 X 2.62
STRAP MUFFLER
8
4
9
2
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW TH-FRM M6-1 X 16 N WA
Z/JS
SCREW HHC M8-1.25 X 55 G8.8
PIPE R/H SIDE EXHAUST MILD ST
PIPE L/H SIDE EXHAUST MILD ST
10
11
12
13
6
11
3
4
42
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Section 8 — Installation Diagram
40kW Liquid-cooled Generators
Installation Diagram — Drawing No. 0E8797
43
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Section 9 - Notes
40kW Liquid-cooled Generators
44
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Section 9 - Notes
40kW Liquid-cooled Generators
45
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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. 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. Any equipment that the purchaser/owner claims to be defective must be examined by
the nearest Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are
to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac Quietsource prepackaged emergency
automatic standby generators sold and rated for use in "Standby" applications.
WARRANTY SCHEDULE
YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase
and maintenance is required):
Engine - All Components
Alternator - All Components
Transfer System - All Components
All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat
Rate Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Quietsource generators that utilize non-Generac replacement parts.
• Quietsource generators utilizing non-Generac automatic transfer switches.
• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by
Generac Power Systems.
• Any Quietsource generators used as rental or trailer mounted applications.
• Units used for prime power in place of existing utility power where utility power is present or in place of utility power where
utility power service does not normally exist.
• Costs of normal maintenance, adjustments, installation and start-up.
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.
• 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, theft, vandalism, riot or wars, nuclear holocaust, fire,
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent and/or insect infestation.
• Products that are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or
replacement of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit
warranty period.
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)
• Overnight freight costs for replacement part(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some
states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO
EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH
DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
®
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Revision (2.05)
Part No. 0F4946
Revision E (09/02/05)
Printed in U.S.A.
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