Instruction/ maintenance manual of the product 40kW LP Generac
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Owner’ s Man ual ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!! This manual should remain with the unit. Liquid-cooled, Prepac kaged Standb y Generators Model No: 00501.
Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the QuietSource standby generator set product line by Generac P ower Systems. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ- ten.
T able of Contents QUIET SOURCE ™ 40kW Liquid-cooled Generators Generac ® Pow er Systems, Inc. 1 INTRODUCTION ................................................ IFC Read this Manual Thoroughly ......................................IFC Operation and Maintenance .
2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The genera- tor can operate safely , efficiently and reliably only if it is properly installed, operated and maintained.
Generac ® Pow er Systems, Inc. 3 • Inspect the generator regularly , and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. • Before performing any maintenance on the generator , disconnect its battery cables to prevent accidental start -up.
4 Generac ® Pow er Systems, Inc. 1.1 GEN ER A T OR This equipment is a liquid- cooled, engine - driven gen- erator set. The generator is designed to supply elec- trical power that operates critical electrical loads during utility power failure.
Generac ® Pow er Systems, Inc. 5 1.6 GEN ER A T OR F U EL SY S TEM The unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is neces- sary , refer to Section 1.12 for conversion instructions. F uel pressure for a natural gas set up should be five inches to 14 inches of water column (0.
6 Generac ® Pow er Systems, Inc. Figure 1.6 - Low Coolant Level Sensor 1.7 .4 O VERSPEED SH UTDOWN The engine control board receives AC frequency sig- nals from an engine run winding in the alternator . Should AC frequency exceed about 72 Hertz for three seconds or 75 Hertz instantaneously , the engine shuts down and the overspeed LED turns on.
1.1 0 SP ECIF ICA TIONS 1.1 0.1 GEN ER A T OR SP ECIF ICA TIONS 1.1 0.2 ENGI N E SP E CI F ICA TIONS Make ................................................................................Chrysler Displacement ...........................................
8 Generac ® Pow er Systems, Inc. NOTE: P ort 1 is for NG only and P ort 2 is for LP vapor only . No provision for dual fuel has been made. Serious injury or damage may occur if not con- figured pr operly . Please consult an authorized Generac Service Dealer with any questions.
Generac ® Pow er Systems, Inc. 9 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.
10 Generac ® Pow er Systems, Inc. Figure 2.1 – Basic Standby Electric System 2.5 EM ERGENCY CI RCU IT IS OL A TION M E THOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator .
Generac ® Pow er Systems, Inc. 11 Setting switch two to OFF allows the control PCB to perform the A TS 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.
12 Generac ® Pow er Systems, Inc. When using maintenance -free batteries, it is not nec- essary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in Section 4, “Maintenance.” A negative ground system is used.
Generac ® Pow er Systems, Inc. 13 • The control board WILL monitor all engine condi- tions and shut down on all the faults listed in this document. Pos2 OFF — Prepackaged A TS Application • The control board will perform all of the automat- ic features listed in this document.
14 Generac ® Pow er Systems, Inc. 3.2.6 SY S TEM READ Y LED The System Ready LED (green) has two main pro- poses. First, the LED will be ON when the A UTO/OFF/MANU AL switch is in the A UTO position, utility is present, and there are no system alarms.
Generac ® Pow er Systems, Inc. 15 On the day , and at the time of day chosen for the gen- erator to exercise, set the weekly exercise cycle as fol- lows: 1. Place the A UTO/OFF/MANU AL switch in the A UTO position. 2. Press and hold the “Set Exercise” switch for three seconds, then release.
16 Generac ® Pow er Systems, Inc. 4.4 CH E CKI NG F L U I D LEVEL S 4.4.1 CH E CK ENGI NE OI L Check engine crankcase oil level (Figure 4.1) at least every 20 hours of operation, or prior to use. • Remove oil dipstick and wipe dry with a clean, lint -free cloth.
Generac ® Pow er Systems, Inc. 17 Do not attempt to adjust the governor . Only qualified service facilities should adjust the governor . Excessively high operating speeds are dangerous and incr ease 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.
18 Generac ® Pow er Systems, Inc. 4.6 M IS CELL AN EOUS MAINTENANCE 4.6.1 CLEAN ING TH E GEN ER A T OR 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.
Generac ® Pow er Systems, Inc. 19 Section 4 — Maintenance QUIET SOURCE ™ 40kW Liquid-cooled Generators 4.7 S CH EDU LED MAI NTENANCE F ollowing is a recommended maintenance schedule for QuietSource small standby and residential generator sets.
20 Generac ® Pow er Systems, Inc. Section 4 — Maintenance QUIET SOURCE ™ 40kW Liquid-cooled Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp .
Generac ® Pow er Systems, Inc. 21 Section 4 — Maintenance QUIET SOURCE ™ 40kW Liquid-cooled Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp .
22 Generac ® Pow er Systems, Inc. Section 5 — T roubleshooting QUIET SOURCE ™ 40kW Liquid-cooled Generators TROU B LE SHOO TI NG POI NTS P ROBLEM CAUSE CORR E CTION Engine won’t crank. 1. 15-amp fuse blown. 1. Replace fuse . 2. Loose or corroded or defectiv e 2.
Generac ® Pow er Systems, Inc. 23 Section 6 — Installation Diagram QUIET SOURCE ™ 40kW Liquid-cooled Generators Installation Diagram — Drawing No.
24 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data QUIET SOURCE ™ 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No.
Generac ® Pow er Systems, Inc. 25 Section 7 - Electrical Data QUIET SOURCE ™ 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No.
26 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data QUIET SOURCE ™ 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No.
Generac ® Pow er Systems, Inc. 27 Section 7 - Electrical Data QUIET SOURCE ™ 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No.
CONTACTOR WIRE H ARNE SS 4 3 35 13 12 9 34 TO MOU NT E N G INE 18 8 6 7 5 16 3 4 43 42 2 36 41 40 16 6 7 5 19 16 30 27 35 3 4 36 33 27 29 22 20 3 2 38 18 31 20 21 TO S TARTER S TARTER BO LT TO E N G INE B L OC K 18 TO 11 1 12 10 1 4 R EAR BEARIN G 15 3 7 13 C ARRIER 3 4 16 2 28 Generac ® Pow er Systems, Inc.
ITEM P ART NO . QTY . DESCRIPTION 1 0E7331 1 WELDMENT MTG BASE 3.9L CR YSLR 2 052860 4 NUT FLANGED HEX M12-1.75 3 052251 4 DAMPENER VIBRA TION 40 BLUE 4 052257 4 SP ACER .49 X .62 X 1.87 PWDR/ZNC 5 052252 4 DAMPENER VIBRA TION 6 052259 4 W ASHER FLA T M12 7 052891 4 SCREW HHC M12-1.
30 Generac ® Pow er Systems, Inc. S TATE S F O AM I S O N NEAR S IDE S TATE S F O AM I S O N FAR S IDE 3 7 17 L AT C H DETAIL 30 1 3 1 3 4 38 3 2 3 45 18 27 41 4 2 S EE LAT CH 7 DETAIL 25 "B" 5 2 11 9 4 6 53 5 5 4 TO "A" S E CU RE A S S H O WN.
Generac ® Pow er Systems, Inc. 31 ITEM P ART NO . QTY . DESCRIPTION 1 0E8418 1 DUCT INT AKE MID AL 2 0E8414 1 DUCT DISCHARGE RH AL 3 0E8413 1 DUCT DISCHARGE LH AL 4 0C2454 62 SCREW TH-FRM M6-1 X 16 N.
32 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts QUIET SOURCE ™ 40kW Liquid-cooled Generators Control Panel — Drawing No. 0E7 11 8-H.
Generac ® Pow er Systems, Inc. 33 ITEM P ART NO . QTY . DESCRIPTION 1 0E7195 1 CONTROL BO X HSB 2 0E7196 1 CO VER FR ONT P ANEL HSB 3 0E7197 1 CO VER TOP P ANEL HSB 4 0E7193 1 DECAL W ARNINGS HSB 5 0.
Section 8 - Exploded Views and P arts QUIET SOURCE ™ 40kW Liquid-cooled Generators Engine — Drawing No. 0E81 21 -G 34 Generac ® Pow er Systems, Inc.
ITEM P ART NO . QTY . DESCRIPTION 1 0E5048A 1 FLEXPLA TE 3.9L HSB 2 0E7477 1 MA CHINING 3.9L ENGINE AD APT OR 3 0E6703 1 CO VER FL YWHEEL ACCESS 4 0E8336 REF REWORK 3.9L CHR YSLER ENGINE 5 0E7841 2 GASKET THERMOST A T ADAPT OR 6 0E7254 1 MA CH THERM AD APT OR 3.
17 WATER PUMP 24 23 26 24 25 21 3 "A" 13 1 15 19 22 TO T HERM OS TAT HOUS IN G 10 4 10 20 0 5 16 16 2 14 8 15 7 14 18 6 9 1 7 14 O "A" Section 8 - Exploded Views and P arts QUIET SOURCE ™ 40kW Liquid-cooled Generators Radiator — Drawing No.
ITEM P ART NO . QTY . DESCRIPTION 1 0D7825A 1 RADIA T OR COPPER BRASS 2 0D7174C 1 VENTURI,3.9L CR YSLR HSB 22"F AN 3 0E7640 1 RADIA TOR SUPPOR T L/H SIDE 4 0E7924 1 HOSE LOWER RADIA T OR 5 0F2853 1 HOSE, RADIA TOR UPPER, 3.9L 6 0D8252 1 F AN GUARD , T OP 7 0D8251 1 F AN GUARD , BO TT OM 8 0E0726 1 BRACKET , W A TER BO TTLE 1.
38 Generac ® Pow er Systems, Inc. 46 21 24 23 TO EN G INE 2 16 17 4 5 6 45 42 40 11 41 9 8 12 6 3 15 2 13 27 3 1 14 19 29 30 3 2 "B " TO "B " 13 36 3 7 38 20 19 18 35 3 4 M ANIF O LD INTAKE TO 44 43 25 22 6 1 39 33 Section 8 - Exploded Views and P arts QUIET SOURCE ™ 40kW Liquid-cooled Generators Fuel Syst em — Drawing No.
Generac ® Pow er Systems, Inc. 39 ITEM P ART NO . QTY . DESCRIPTION 1 033212 4 SCREW HHC 5/16-18 X 1-1/4 G5 2 075580 1 FLANGE FUEL INLET 3 0E8365 1 ASSY REG. 3.9L N/G-LPV 1800RPM 4 039253 2 SCREW HHC M8-1.25 X 20 G8.8 5 022145 2 W ASHER FLA T 5/16 ZINC 6 022129 8 W ASHER LOCK M8-5/16 7 045771 2 NUT HEX M8-1.
40 Generac ® Pow er Systems, Inc. 4 15 7 17 8 7 1 18 20 3 1 30 5 21 19 L EAD S 6 2 14 12 24 9 22 * 2 3 13* 3 10 13 11 Section 8 - Exploded Views and P arts QUIET SOURCE ™ 40kW Liquid-cooled Generators Alternator — Drawing No.
Generac ® Pow er Systems, Inc. 41 ITEM P ART NO . QTY . DESCRIPTION 1 0E5093A 1 RO T OR 390 30KW 1P DIRECT HSB 0E7413A 1 RO T OR 390 40KW 1P DIRECT HSB 2 0E5094A 1 STR-390--35AD1 HSB (382MM LONG)(3.0LFORD) 0E7412A 1 STR-390--40AD HSB (433MM LONG)(3.9L CHR YSLER) 3 0E5706 1 REAR BEARING CARRIER 390/DRCT 4 0E5048 REF FLEXPLA TE 3.
ITEM P ART NO . QTY . DESCRIPTION 1 0E8616 1 MUFFLER 7" X 9" X 21" 2.5" IN & OUT 2 0F1081 1 WYE, PIPE 3.9L CHR YSLER 3 0F1087 1 PIPE R/H SIDE 3.9L CHR YSLER 4 0E8026 1 PIPE L/H EXHA UST MANIFOLD 5 0E5914 1 BRA CKET MUFFLER 30" LG 6 0E8702 1 PIPE MUFFLER INLET 7 0E8727 1 PIPE MUFFLER OUT 8 036797 3 BOL T U 5/16-18 X 2.
Section 9 - Notes QUIET SOURCE ™ 40kW Liquid-cooled Generators Generac ® Pow er Systems, Inc. 43.
44 Generac ® Pow er Systems, Inc. Section 9 - Notes QUIET SOURCE ™ 40kW Liquid-cooled Generators.
Generac ® Pow er Systems, Inc. 45 Section 9 - Notes QUIET SOURCE ™ 40kW Liquid-cooled Generators.
Part No. 0E9042 Revision E (03/15/05) Printed in U.S.A. Section 1 0 – W arranty QUIET SOURCE ™ 40kW Liquid-cooled Generators GENER AC PO WER SY STEMS "TWO YEAR" LIMITED WARR ANTY FOR QU .
An important point after buying a device Generac 40kW LP (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Generac 40kW LP yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Generac 40kW LP - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Generac 40kW LP you will learn all the available features of the product, as well as information on its operation. The information that you get Generac 40kW LP will certainly help you make a decision on the purchase.
If you already are a holder of Generac 40kW LP, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Generac 40kW LP.
However, one of the most important roles played by the user manual is to help in solving problems with Generac 40kW LP. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Generac 40kW LP along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
