Generac 37Kw Ng Owners Manual 0E9042RevE
37kW NG to the manual 575f314d-9125-453b-a9da-afa287943d32
2015-01-05
: Generac Generac-37Kw-Ng-Owners-Manual-166149 generac-37kw-ng-owners-manual-166149 generac pdf
Open the PDF directly: View PDF .
Page Count: 48
![](asset-1.png)
Owner’s Manual
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
This manual should remain with the unit.
Liquid-cooled, Prepackaged
Standby Generators
Model No: 005012-0
37kW NG, 40kW LP
![](asset-2.png)
Generac®Power Systems, Inc.
INTRODUCTION
Thank you for purchasing this model of the
QuietSource standby generator set product line by
Generac Power Systems.
Every effort was expended to make sure that the
information and instructions in this manual are both
accurate and current at the time the manual was writ-
ten. However, the manufacturer reserves the right to
change, alter or otherwise improve this product(s) at
any time without prior notice.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, con-
tact the nearest Generac Authorized Service Dealer
for starting, operating and servicing procedures.
Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert person-
nel to special instructions about a particular service or
operation that may be hazardous if performed incor-
rectly or carelessly. Observe them carefully. Their defi-
nitions are as follows:
After this heading, read instructions that, if not
strictly complied with, will result in personal injury
or property damage.
After this heading, read instructions that, if not
strictly complied with, may result in personal injury
or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compli-
ance with the special instructions while performing the
service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:
This symbol points out important safety informa-
tion that, if not followed, could endanger personal
safety and/or property of others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use
of the equipment. Generac strongly recommends that
the operator read this Owner's Manual and thor-
oughly understand all instructions before using this
equipment. Generac also strongly recommends
instructing other users to properly start and operate
the unit. This prepares them if they need to operate
the equipment in an emergency.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by a Generac
Authorized Service Dealer. Normal maintenance serv-
ice and replacement of parts are the responsibility of
the owner/operator and, as such, are not considered
defects in materials or workmanship within the terms
of the warranty. Individual operating habits and usage
contribute to the need for maintenance service.
Proper maintenance and care of the generator ensures
a minimum number of problems and keep operating
expenses at a minimum. See the Generac Authorized
Service Dealer for service aids and accessories.
Operating instructions presented in this manual
assume that the standby electric system has been
installed by a Generac Authorized Service Dealer or
other competent, qualified contractor. Installation of
this equipment is not a “do-it-yourself” project.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
contact a Generac Authorized Service Dealer for
assistance. Service technicians are factory-trained
and are capable of handling all service needs.
When contacting a Generac Authorized Service
Dealer about parts and service, always supply the
complete model number of the unit as given on the
front cover of this manual or on the DATA CARD
affixed to the unit.
!
DANGER
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest GENERAC AUTHORIZED
SERVICE DEALER, please call this number:
1-800-333-1322
OR
Locate us on the web at:
www.generac.com
![](asset-3.png)
Table of Contents
QUIETSOURCE
™
40kW Liquid-cooled Generators
Generac®Power Systems, Inc. 1
INTRODUCTION................................................IFC
Read this Manual Thoroughly......................................IFC
Operation and Maintenance ........................................IFC
How to Obtain Service ................................................IFC
Authorized Service Dealer Location ............................IFC
SAFETY RULES ....................................................2
Section 1 — GENERAL INFORMATION ............4
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 ............................................6
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 ..............................9
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......................10
2.9 Transfer Switch Start Signal Connections ..........10
2.10 Battery Installation ..............................................11
2.11 Preparation Before Start-Up ................................12
Section 3 — OPERATION ................................12
3.1 Using an Engineered “GTS” Transfer Switch ......12
3.2 Control Console Components..............................13
3.3 Manual Transfer and Startup..............................14
3.4 Engine Governor Adjustments ............................14
3.5 Retransfer and Shutdown....................................14
3.6 Automatic Operation ..........................................14
3.7 Weekly Exercise Cycle..........................................14
Section 4 — MAINTENANCE ..........................15
4.1 Maintenance Performed by Authorized
Service Facilities ..................................................15
4.2 Cooling System....................................................15
4.3 Overload Protection for Engine DC
Electrical System ................................................15
4.4 Checking Fluid Levels ........................................16
4.5 Maintenance Owner/Operator
Can Perform ........................................................16
4.6 Miscellaneous Maintenance ................................18
4.7 Scheduled Maintenance ......................................19
Section 5 — TROUBLESHOOTING ..................22
Section 6 — INSTALLATION DIAGRAM ..........23
Section 7 — ELECTRICAL DATA ....................24
Section 8 — EXPLODED VIEWS AND
PARTS LISTS ..............................28
Section 9 — NOTES ........................................43
Section 10 — WARRANTY .................Back Cover
![](asset-4.png)
2 Generac®Power 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. Many acci-
dents are caused by failing to follow simple and funda-
mental rules or precautions.
Generac cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this man-
ual, and on tags and decals affixed to the unit are, there-
fore, not all-inclusive. If using a procedure, work
method or operating technique that Generac does not
specifically recommend, ensure that it is safe for others.
Also make sure the procedure, work method or operat-
ing technique chosen does not render the generator
unsafe.
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 main-
tain 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
during operation. Exercise care near running gen-
erators.
GENERAL HAZARDS
• For safety reasons, Generac recommends that this
equipment be installed, serviced and repaired by a
Generac Authorized Service Dealer or other compe-
tent, qualified electrician or installation technician
who is familiar with applicable codes, standards and
regulations. 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 electrical
and building codes. Comply with regulations the
Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the gener-
ator 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, ade-
quate 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 operating.
• 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.
• Keep the area around the generator clean and unclut-
tered. Remove any materials that could become haz-
ardous.
• When working on this equipment, remain alert at all
times. Never work on the equipment when physically
or mentally fatigued.
!
!
!
!
DANGER
IMPORTANT SAFETY INSTRUCTIONS
QUIETSOURCE
™
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.
!
!
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
!!
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:
!!
![](asset-5.png)
Generac®Power 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. 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.
ELECTRICAL HAZARDS
• All generators covered by this manual produce dan-
gerous electrical voltages and can cause fatal electrical
shock. Utility power delivers extremely high and dan-
gerous voltages to the transfer switch as well as the
standby generator. Avoid contact with bare wires, ter-
minals, connections, etc., on the generator as well as
the transfer switch, if applicable. Ensure all appropri-
ate 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.
• 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 repairing
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.
• 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.
• 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 automat-
ic 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.
• In case of accident caused by electric shock, immedi-
ately 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.
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.
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.
• Generac generator sets may operate using one of sev-
eral types of fuels. All fuel types are potentially FLAM-
MABLE 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 immediately. 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.
IMPORTANT SAFETY INSTRUCTIONS
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-6.png)
4 Generac®Power Systems, Inc.
1.1 GENERATOR
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. 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 oper-
ation of 120 and/or 240VAC, single-phase loads.
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 transfer switch. The transfer switch must
effectively isolate the electric system from the
utility distribution system when the generator
is operating (NEC 701). Failure to isolate an
electrical system by such means results in
damage to the generator and may also result
in injury or even death to utility power work-
ers due to backfeed of electrical energy.
1.2 TRANSFER SWITCH
This generator system is intended to be used with a
Generac transfer switch. It will be available 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:
• Install the transfer switch on a firm, sturdy sup-
porting structure.
• To prevent switch distortion, level the switch if nec-
essary. 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.
A Generac Authorized Dealer can supply an appro-
priate transfer switch for the 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.
When utility source voltage has been restored, the
switch re-transfers back to the UTILITY source volt-
age and the generator then shuts down.
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 supply
120VAC, 60 Hertz. When the two windings are con-
nected 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 junc-
tion of Wires 22 and 33. The NEUTRAL is not
grounded.
Figure 1.1 - Generator AC Connection System
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.
!
Section 1 - General Information
QUIETSOURCE
™
40kW Liquid-cooled Generators
Model Rating Phase Actual Current C/B Rating* Circuit Breaker
005012-0 37,000 NG 1 154.2 200 200A QN2
40,000 LP 1 166.7 200 200A QN2
* Amp Rating of C/B structured under model.
Figure 1.2 - Main Circuit Breaker
![](asset-7.png)
Generac®Power Systems, Inc. 5
1.6 GENERATOR FUEL SYSTEM
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.
Fuel pressure for a natural gas set up should be five
inches to 14 inches of water column (0.18 to 0.5
psi) at all load ranges.
Fuel pressure for an LP vapor set up should be 11
inches to 14 inches of water column (0.4 to 0.5
psi) at all load ranges.
NOTE:
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 explosion. 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 fol-
lowing conditions: low oil pressure, high coolant tem-
perature, engine overspeed, low coolant level or over-
crank (Figure 1.3).
Figure 1.3 - Engine Protective Devices
1.7.1 LOW OIL PRESSURE SWITCH
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).
NOTE:
The Low Oil Pressure, High Coolant Temperature
and Low Coolant Level are not monitored for the
first 10 seconds of engine run time.
Figure 1.4 - Low Oil Pressure Switch
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 1.5- High Coolant Temperature Switch
1.7.3 LOW COOLANT LEVEL SWITCH
Should engine coolant level drop below the level of
the high coolant temperature switch, it is possible for
the engine to overheat without automatic shutdown.
To prevent such overheating without automatic shut
down, the engine has a low coolant level sensor. If the
engine coolant drops too low, the engine automatical-
ly shuts down and turns on the high coolant temper-
ature/low coolant level LED (Figure 1.6 on page 6).
Low Coolant
Level Sensor
Low Oil Pressure Switch
High Coolant
Temperature Switch
!
Section 1 - General Information
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-8.png)
6 Generac®Power Systems, Inc.
Figure 1.6 - Low Coolant Level Sensor
1.7.4 OVERSPEED SHUTDOWN
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. Should
AC frequency exceed about 72 Hertz, circuit board
action will automatically shutdown the engine (Figure
1.7).
Figure 1.7 - Printed Circuit Board Assembly
1.7.5 RPM SENSOR LOSS
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.
1.7.6 OVERCRANK SHUTDOWN
The engine control board uses a cyclic cranking
process 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.
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.
Battery voltage is NOT monitored during the crank
cycle.
1.7.8 ALARM RESET
If the engine control board shuts down the generator
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.
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).
1.8 UNPACKING
1.8.1 UNPACKING PRECAUTIONS
Handle shipping cartons and crates with care. Use
care to avoid damage from dropping, bumping, colli-
sion, etc..
1.8.2 INSPECTION
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.
1.9 LIFTING THE GENERATOR
When lifting or hoisting equipment is used,
be careful not to touch overhead power lines.
The generators weight of more than 900
pounds requires proper tools, equipment, and
qualified personnel to be used in all phases of
handling and unpacking.
!
PC
B#
0
E4
906
REV
.
R4
9
D17
J2
C2
C
2
6
U7
C
2
7
R44
Q2
D1
9
C30
RL1
2
L
3
LE
D
1
C4
R
2
5
C9
C
2
1
D
1
0
J1
R4
8
R1
U1
RL2
Section 1 — General Information
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-9.png)
1.10 SPECIFICATIONS
1.10.1 GENERATOR SPECIFICATIONS
1.10.2 ENGINE SPECIFICATIONS
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
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.
1.11 FUEL CONSUMPTION
Natural Gas:
% of Load 25% 50% 75% 100%
m3/hr 4.1 7.7 11.0 14.2
ft3/hr 143.1 271.1 388.5 502.0
LP Vapor:
% of Load 25% 50% 75% 100%
m3/hr 1.7 3.3 4.7 6.0
ft3/hr 60.7 115.0 164.9 213.0
NOTE:
Fuel consumption is given at rated maximum con-
tinuous 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 consump-
tion obtained may vary depending on such vari-
ables as applied load, ambient temperature,
engine conditions and other environmental fac-
tors.
Fuel pressure for a natural gas set up should be five
inches to 14 inches of water column (0.18 to 0.5
psi) at all load ranges.
Fuel pressure for an LP vapor set up should be 11
inches to 14 inches of water column (0.4 to 0.5
psi) at all load ranges.
1.12 RECONFIGURING THE FUEL
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).
Figure 1.8 — Reconfigure the Fuel System
3. Remove the brass hose fitting from the outlet port
(Port 1) of the demand regulator.
4. Remove pipe plug from Port 2.
5. Install brass hose fitting into Port 2.
6. Install pipe plug into Port 1.
7. Connect carburetor gas hose to brass fitting.
8. Tighten all clamps and plugs.
9. Make sure fuel supply is of the proper pressure
and type for configuration.
10. Reverse the procedure to convert back to natural
gas.
NG FUEL SYSTEM LP FUEL SYSTEM
Port 1 Port 2
FUEL HOSE
BRASS HOSE
FITTING
HOUSING
PORTS
OUT
PORT 2
PLUG
FUEL HOSE
BRASS HOSE
FITTING
HOUSING
PORTS
PLUG
OUT
PORT 1
Section 1 — General Information
QUIETSOURCE
™
40kW Liquid-cooled Generators
Generac®Power Systems, Inc. 7
Single-phase
Model 005012-0
Rated Max. Cont. 37 (NG), 40 (LP)
AC Power Output (kW)
Rated voltage (volts) 120/240
No. of Rotor Poles 4
Driven Speed of Rotor 1800
Rotor Excitation System Direct excited brush type
Type of Stator 4 Wire
Rotor/Stator Insulation Class F/H
![](asset-a.png)
8 Generac®Power Systems, Inc.
NOTE:
Port 1 is for NG only and Port 2 is for LP vapor
only. No provision for dual fuel has been made.
Serious injury or damage may occur if not con-
figured properly. Please consult an authorized
Generac Service Dealer with any questions.
1.13 TORQUE SPECIFICATIONS
Tighten the bolts from the middle out, in a criss-
cross pattern.
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.
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:
NOTE:
5W-30 full synthetic oil is highly recommended in
any element with temperatures above 90° F or
below 30° F.
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.
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 recommended coolant mixture. When adding
coolant, always add the recommended 50-50 mix-
ture.
Do not use any chromate base rust inhibitor
with ethylene glycol base anti-freeze or chromi-
umhydroxide (“green slime”) forms and will
cause overheating. Engines that have been
operated with a chromate base rust inhibitor
must be chemically cleaned before adding eth-
ylene glycol base anti-freeze. Using any high
silicate anti-freeze boosters or additives will
also cause overheating. It is also recommend
that any soluble oil inhibitor is NOT USED for
this equipment.
1.16 BEFORE INSTALLATION
Before installing this equipment, check the ratings of
both the generator and the transfer switch. Read
“Emergency Isolation Method” and “Total Circuit
Isolation Method” Sections 2.5 and 2.6.
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.
This generator can be installed in conjunction with
an engineered Generac “GTS” type transfer switch, if
necessary.
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.
2.1 STANDBY GENERATOR
INSTALLATION
Connecting this generator to an electrical sys-
tem normally supplied by an electric utility
shall be by means of a transfer switch, so as to
isolate the electric system from the utility distri-
bution 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.
If an open bottom is used, the engine-genera-
tor is to be installed over non-combustible
materials and should be located such that com-
bustible materials are not capable of accumu-
lating under the generator set.
DANGER
!
!
!
DANGER
Section 2 — Installation
QUIETSOURCE
™
40kW Liquid-cooled Generators
Temperature Oil Grade (Recommended)
Above 80° F (27° C) SAE 15W-40
32° to 80° F (-1° to 27° C) SAE 15W-40
Below 32° F (0° C) SAE 15W-40
![](asset-b.png)
Generac®Power 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.
After the system has been installed, do nothing
that might render the installation in noncompli-
ance with such codes, standards and regula-
tions.
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:
• NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES.
• NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-
TEMS 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.
2.1.2 OTHER PUBLISHED STANDARDS
In addition to NFPA standards, the following infor-
mation pertaining to the installation and use of
standby electric systems is available:
• 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.
• ASAE EP-364.2, INSTALLATION AND MAINTE-
NANCE 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 SYS-
TEMS, available from the American National
Standard Institute, 1430 Broadway, New York, N.Y.
10018.
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:
• Install the unit where air inlet and outlet openings
will not become obstructed by leaves, grass, snow,
etc. If prevailing winds will cause blowing or drift-
ing, consider using a windbreak to protect the unit.
• 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.
• 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 REG-
ULATE THE DISTANCE.
2.3 GENERATOR MOUNTING AND
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 Section 6 for generator
major dimensions.
2.4 BASIC STANDBY ELECTRIC
SYSTEM
Figure 2.1 shows a schematic diagram of a basic
standby electric system. Both the UTILITY power
supply and the STANDBY (GENERATOR) output are
connected to an approved transfer switch. The trans-
fer switch is required by electrical code and serves
the following functions:
• Allows the LOAD circuits to be connected to only
one power supply at a time.
• 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.
!
Section 2 — Installation
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-c.png)
10 Generac®Power Systems, Inc.
Figure 2.1 – Basic Standby Electric System
2.5 EMERGENCY CIRCUIT ISOLATION
METHOD
This prevents overloading the generator by keeping
electrical loads below the wattage/amperage capacity
of the generator. If the generator is powering only crit-
ical loads, within the wattage/amperage capacity, dur-
ing utility power outages, consider using the emer-
gency circuit isolation method.
Critical electrical loads are grouped together and
wired into a separate “Emergency Distribution
Panel.” Load circuits powered by that panel are with-
in the wattage/amperage capacity of the generator set.
When this method is used, it is difficult to overload
the generator. The transfer switch must meet the fol-
lowing requirements:
• 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.
2.6 TOTAL CIRCUIT ISOLATION
METHOD
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 gener-
ator to be overloaded when this isolation method is
employed. The following apply to the transfer switch
in this type of system.
• Ampere rating of the transfer switch must equal
the ampere rating of the normal incoming utility
service.
• The transfer switch is installed between the utility
service entrance and the building distribution
panel.
• By code and approved means of service disconnect
must be located between the incoming utility serv-
ice and the transfer switch.
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 gener-
ator mounting base. Consult a qualified electrician
for grounding requirements in the area. Grounding
procedures must meet local regulations.
Do not connect the ground wire to any pipe
that carries a flammable or explosive substance
– FIRE or an EXPLOSION may result.
Proper grounding helps protect personnel against
electrical shock in the event of a ground fault condi-
tion in the generator or in connected electrical
devices. In addition, grounding helps dissipate static
electricity that often builds up in ungrounded
devices.
Figure 2.2 – Generator Grounding Lug (typical)
2.8 GENERATOR AC NEUTRAL
CONNECTIONS
Generac uses an UNGROUNDED AC neutral.
Grounding is recommended only at the main service
entrance. If the neutral wire is grounded and one of
the phase loads becomes grounded, the excessive
current opens the load circuit breaker or collapses
the generator field. The actual result depends on the
electrical characteristics of the particular installed
generator.
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.
G
R
OU
NDIN
G
L
UG
DANGER
Section 2 — Installation
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-d.png)
Generac®Power Systems, Inc. 11
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:
2.9.2 GTS-TYPE ENGINEERED TRANSFER
SWITCH
If the generator is to be installed with an engineered
transfer switch, such as a Generac GTS-type switch,
it is necessary to connect the two-wire start control
system.
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
Section 3.1 for further explanation.)
2.10 BATTERY INSTALLATION
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 possible
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
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the gas
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks or any spark
producing tools or equipment near the battery.
Battery electrolyte fluid is an extremely caustic
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.
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
and eyes.
The battery represents a risk of high short cir-
cuit current. When working on the battery,
always remove watches, rings or other metal
objects, and only use tools that have insulated
handles.
2.10.1 VENTED BATTERIES
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:
• 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 med-
ical attention, and
• 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.
Lead acid batteries present a risk of fire
because they generate hydrogen gas. The fol-
lowing procedure 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.
For recommended batteries, see Section 4.6.4. All
batteries must be at 100 percent state-of-charge
before they are installed on the generator.
!
!
!
!
DANGER
Section 2 — Installation
QUIETSOURCE
™
40kW Liquid-cooled Generators
MAXIMUM WIRE LENGTH RECOMMENDED WIRE
SIZE
460 feet (140m) No. 18 AWG.
461 to 730 feet (223m) No. 16 AWG.
731 to 1,160 feet (354m) No. 14 AWG.
1,161 to 1,850 feet (565m) No. 12 AWG.
![](asset-e.png)
12 Generac®Power 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. 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.
NOTE:
Damage will result if the battery connections are
made in reverse.
2.11 PREPARATION BEFORE START-UP
The instructions in this section assume that the stand-
by generator has been properly installed, serviced,
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) equipment.
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.
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 Section 4, “Maintenance.”
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.
2.11.3 FUEL SYSTEM
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” (Section 1.10) for more information.
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”
(Section 1.10) and “Engine Oil Recommendations”
(Section 1.14).
NOTE:
This engine is shipped from the manufacturer
with 15W-40 oil. This oil should be changed after
30 hours of operation.
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”
(Section 1.10) and “Coolant” (Section 1.15).
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).
2.11.7 ELECTRICAL SYSTEM
Make sure the generator is properly connected to an
approved earth ground and/or ground rod.
Make sure the generator battery is fully charged, prop-
erly installed and interconnected, and ready for use.
Check to ensure that there are no loose electrical con-
nections. Restrain any loose wires to keep them clear
of any moving generator set components.
3.1 USING AN ENGINEERED “GTS”
TRANSFER SWITCH
When required, the pre-packaged standby generator
can be installed with an engineered Generac “GTS”
type automatic transfer switch.
In this application, the GTS is responsible for utility
sensing, weekly exercising, and load transferring.
Position two of the four-position dip switch is used to
turn over this control to the GTS.
Pos2 ON — GTS Application
• The control board will NOT monitor utility.
• The control board will NOT perform a weekly exer-
cise. (The five red LEDs will not flash in this
mode.)
• The control board will NOT activate the transfer
output.
!
Section 3 — Operation
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-f.png)
Generac®Power 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 ATS Application
• The control board will perform all of the automat-
ic features listed in this document.
• The two-wire start connections should NOT be
used.
GTS Mode Operation
When in GTS mode, the control board will respond
as follows based on the AUTO/OFF/MANUAL switch
position.
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 posi-
tion.
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.
NOTE:
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.
3.2 CONTROL CONSOLE
COMPONENTS
The components of a home standby generator control
console (Figure 3.1) are as follows:
Figure 3.1 - Home Standby Generator Panel
3.2.1 AUTO/OFF/MANUAL SWITCH
Use this three-position switch as follows:
• Set the switch to AUTO for fully automatic opera-
tion. See “Automatic Operation” (Section 3.5).
• Set switch to MANUAL position to crank and start
the generator engine.
• Set switch to OFF position to shut down an oper-
ating engine. With OFF selected, operation will not
be possible.
With switch set to AUTO, engine can crank and
start suddenly without warning. Such automat-
ic 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 con-
trol console.
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
• Low Battery
• Overspeed/RPM Sensor Loss
• High Coolant Temperature/Low Coolant Level
See Section 1.7 for further explanation of engine pro-
tection functions.
3.2.3 15 AMP FUSE
This fuse protects the control console’s DC control
circuit against electrical overload. If the fuse has
melted open because of an overload, engine cranking
and startup cannot occur. If the fuse needs to be
replaced, use only an identical 15-amp replacement
fuse. (Type AGC)
3.2.4 4.0 AMP INLINE FUSE
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).
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.”
!
DANGER
(
SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS
)
5
FLA
S
HIN
G
RED LED'
S
= EXER
C
I
S
ER N
O
T
S
E
T
FLA
S
HIN
G
G
REEN LED = N
O
U
TILITY
S
EN
SE
TO SET EXERCISER TIME
1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.
(
IN AUTO MODE ONLY
)
SOLID GREEN LED = SYSTEM READY, UTILITY POWER O
N
OFF
EXER
C
I
SE
TIME
ON
S
E
T
4A
LED INDI
C
AT
O
R
S:
RED LED'
S
= INDIVID
U
AL FA
U
L
T
L
O
W BATTER
Y
S
Y
S
TEM READ
Y
M
AN
U
A
L
O
F
F
A
U
T
O
0E7194
O
VER
C
RAN
K
A
U
T
O/O
FF
/
MAN
U
A
L
S
WIT
CH
1
5
A F
USE
MAI
N
P
O
WE
R
4A F
USE
BATTERY
C
HAR
G
E
R
S
E
T
EXE
C
I
S
E
R
TIME
S
WIT
CH
RED LED
s
G
REEN LE
D
Section 3 - Operation
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-10.png)
14 Generac®Power Systems, Inc.
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.
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.
This secondary function is only available with dip
switch two in the OFF position (standard ATS appli-
cation).
3.3 MANUAL TRANSFER AND
START-UP
To transfer electrical loads to the Standby (EMER-
GENCY) power source side and start the engine man-
ually, refer to the Owner’s Manual of the particular
transfer switch.
3.4 ENGINE GOVERNOR
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 governor
has been set by the factory during final testing of the
generator and, in most cases, should not be adjusted.
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):
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.
4. Under full load condition, increase the STABILI-
TY 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.
Figure 3.2 — Engine Governor Adjustment
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 follows:
• 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.
3.6 AUTOMATIC OPERATION
To set the system for fully automatic operation, pro-
ceed as follows:
• Check that load circuits are connected to the
utility power supply.
• Set the AUTO/OFF/MANUAL switch to its AUTO
position.
• Set the generator main circuit breaker to its ON or
CLOSED position.
3.7 WEEKLY EXERCISE CYCLE
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.
PCB# 0E4906 REV.
R4
9
D17
J2
C2
C
2
6
U7
C
2
7
R44
Q2
D1
9
C30
RL1
2
L
3
LE
D
1
C4
R
2
5
C9
C
2
1
D
1
0
J1
R4
8
R1
U1
RL2
1
2
3
4
UNUSED
GTS/ATS
50/60 HZ
POSITION 1
50/60 HZ
ON = 50 HZ
OFF = 60 HZ
POSITION 2
GTS/ATS Select
ON = GTS
OFF = ATS (standard mode)
STABILITY
DIFFERENTIAL DIP SWITCH
0
0
Section 3 — Operation
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-11.png)
Generac®Power 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 AUTO/OFF/MANUAL switch in the
AUTO position.
2. Press and hold the “Set Exercise” switch for three
seconds, then release.
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.
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 gener-
ator will still start and run in manual mode, or auto-
matically start and run if UTILITY is lost while in
AUTO mode, but it will not perform a weekly exercise
cycle.
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
4.1 MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE FACILITIES
A. 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.
B. ONCE EVERY SIX MONTHS
1. Test Engine Safety Devices (low oil pressure, low
coolant level, high coolant temperature).
C. ONCE ANNUALLY
1. Test engine governor. Adjust or repair, if needed.
2. Clean, inspect generator.
3. Flush cooling system.
D. FIRST 100 OPERATING HOURS
1. Change engine oil and oil filter. (After initial
change, service engine oil and filter at 150 oper-
ating hours or 6 months, whichever comes first.)
2. Retorque cylinder head. (See Torque Specs,
Section 1.13.)
3. Retorque intake and exhaust manifold. (See
Torque Specs, Section 1.13.)
E. EVERY 500 OPERATING HOURS
1. Service air cleaner.
2. Check starter.
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 Section 6 for installation drawings
and vent locations.)
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.
4.3 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.
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.
!
E
E
U
S
F
F
S
U
S
E
E
U
S
F
F
U
S
F
U
S
BAT.
F
USE
C
HAR
G
E
R
ON
O
F
F
EXER
C
I
SE
TIME
S
E
T
4A
MAN
U
A
L
A
U
T
O
O
F
F
F
USE
1
5A
MAIN
Section 4 — Maintenance
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-12.png)
16 Generac®Power Systems, Inc.
4.4 CHECKING FLUID LEVELS
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.
• Remove oil dipstick and wipe dry with a clean,
lint-free cloth.
• 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 Section 1.14 for recom-
mended oils.
Figure 4.1 - Oil Dipstick and Oil Fill Cap
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.
4.4.3 ENGINE COOLANT
Check coolant level in coolant recovery bottle. See
Specifications, Section 1.10.
• 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
Generac Service Dealer. Inspect cooling system
and coolant recovery system for leaks.
4.5 MAINTENANCE OWNER/
OPERATOR CAN PERFORM
4.5.1 CHECK ENGINE OIL LEVEL
Refer to “Checking Fluid Levels” in Section 4.4.
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 Section
3.6, “Weekly Exercise Cycle”.
4.5.4 INSPECT COOLING SYSTEM
• 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.
4.5.5 CHECK ENGINE COOLANT LEVEL
See “Checking Fluid Levels” in Section 4.4.
4.5.6 PERFORM VISUAL INSPECTION
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.
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.
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.
Oil Dipstick Oil Fill
Oil Filter
Section 4 — Maintenance
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-13.png)
Generac®Power 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 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
incorrect frequency and/or voltage. Only quali-
fied service technicians should adjust the gov-
erned speed.
4.5.10 CHANGING ENGINE OIL
Refer to maintenance performed by authorized serv-
ice dealers for engine oil and filter change frequen-
cies.
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:
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. Turn OIL FILTER (Figure 4.2) counterclockwise
and remove. Dispose of old filter.
Figure 4.2 - Oil Filter
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).
After refilling the crankcase with oil, always
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
7. Start engine and check for oil leaks.
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.
See the “Service Schedule,” Section 6, for air cleaner
maintenance.
4.5.12 SPARK PLUGS
Reset the spark plug gap or replace the spark plugs
as necessary. See Section 6.
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 com-
mercial solvent. Do not blast the spark plugs to
clean.
2. Remove the spark plugs and check the condition.
Replace the spark plugs if worn or if reuse is
questionable. See the “Service Schedule,” Section
6, 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).
Figure 4.3 – Setting the Spark Plug Gap
4.5.13 COOLANT CHANGE
Every year, have an authorized service dealer drain,
flush and refill the cooling system. See SPECIFICA-
TIONS (Section 1.10) for cooling system recommen-
dations.
!
Oil Filter
!
DANGER
Section 4 — Maintenance
QUIETSOURCE
™
40kW Liquid-cooled Generators
SET PLUG GAP AT 1.01 mm
(0.040 inch)
![](asset-14.png)
18 Generac®Power Systems, Inc.
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.
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.
Once each year, have the generator cleaned and
inspected by a Generac 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.
Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
excessively low, the generator may require drying.
4.6.2 BATTERY
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.
• Always wear safety glasses, rubber apron and
gloves when handling a battery.
• Batteries give off explosive hydrogen gas while
charging. The gas can form an explosive mixture
around the battery for several hours after charging.
Any spark, heat or flames can ignite the gas and
cause an explosion which can shatter the battery,
causing blindness or other serious injury.
4.6.3 BATTERY MAINTENANCE
The battery should be inspected per the “Service
Schedule,” Section 6. The following procedure
should be followed 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 BATTERIES.
3. Have the state of charge and condition checked.
This should be done with an automotive-type bat-
tery hydrometer.
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the gas
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks or any spark
producing tools or equipment near the battery.
Battery electrolyte fluid is an extremely caustic
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 bat-
tery to crank and start the generator engine. If
the battery has completely discharged, remove
it from the generator for recharging.
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.
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.
4.6.4 BATTERY REPLACEMENT
When replacing batteries, use the same number and
the type of battery that follows:
NOTE:
The BCI number should be located directly
on the battery.
!
!
!
DANGER
Section 4 — Maintenance
QUIETSOURCE
™
40kW Liquid-cooled Generators
BCI Group No. CCA
27F 700 @ 0 deg. F
PERIODIC REPLACEMENT PARTS
Part Name Generac’s Part Number
Oil Filter # 0E7415
Radiator Cap # 046627
Air Cleaner # 0A4637
Spark Plug Champion # RC12LC4
![](asset-15.png)
Generac®Power Systems, Inc. 19
Section 4 — Maintenance
QUIETSOURCE
™
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 appli-
cation. 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:
1An 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 condi-
tion 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.
2A 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 Generac Service Dealer.
3An 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 Generac Service Dealer.
4A 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 Generac Service Dealer.
NOTE:
If the generator experiences heavy use, the maintenance intervals should be reduced so that procedures are
performed more frequently.
![](asset-16.png)
20 Generac®Power Systems, Inc.
Section 4 — Maintenance
QUIETSOURCE
™
40kW Liquid-cooled Generators
Maintenance Level 1 Level 2 Level 3 Level 4
Tasks Recom- Task Required Task Required Task Task
mended Comp. to be done Comp. to be done Comp. Required Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date-
monthly Initials) Break-in Initials) annually Initials) 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.
![](asset-17.png)
Generac®Power Systems, Inc. 21
Section 4 — Maintenance
QUIETSOURCE
™
40kW Liquid-cooled Generators
Maintenance Level 1 Level 2 Level 3 Level 4
Tasks Recom- Task Required Task Required Task Task
mended Comp. to be done Comp. to be done Comp. Required Comp.
to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date-
monthly Initials) Break-in Initials) annually Initials) 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.
![](asset-18.png)
22 Generac®Power Systems, Inc.
Section 5 — Troubleshooting
QUIETSOURCE
™
40kW Liquid-cooled Generators
TROUBLESHOOTING POINTS
PROBLEM CAUSE CORRECTION
Engine won’t crank. 1. 15-amp fuse blown. 1. Replace fuse.
2. Loose or corroded or defective 2. Tighten, clean or replace
battery cables. battery cables as necessary.
3. Defective starter contactor. 3. Replace contactor.
4. Defective starter motor. 4. Replace starter motor.
5. Dead or Defective Battery. 5. Remove, change or replace battery.
6. 4-amp fuse blown. 6. Replace fuse.
Engine cranks, but won't start 1. Out of fuel. 1. Replenish fuel.
2. Fuel solenoid (FS) is defective 2. Replace solenoid.
3. Open Wire #14 from Engine Control 3. Reconnect wire.
circuit board.
4. Spark plugs defective. 4. Clean, regap or replace plugs.
Engine starts hard, runs rough. 1. Air cleaner plugged or damaged. 1. Clean or replace as needed.
2. Plugged fuel line. 2. Unclog fuel line.
3. Defective spark plugs. 3. Clean, regap or replace plugs.
Engine starts, then shuts down. 1. Engine oil level is low. 1. Check oil and add oil as needed.
2. Engine is overheated. 2. Check cooling system for leaks.
3. Defective Low Oil Pressure Switch 3. Replace switch.
4. Defective Coolant Temperature Switch 4. Replace switch.
5. Defective Control Module circuit board. 5. Replace board.
6. Coolant Level is Low. 6. Repair leak - Add coolant.
7. Defective Low Coolant Level Switch 7. Replace Switch.
AUTO/OFF/MANUAL Switch at 1. Defective AUTO/OFF/MANUAL switch 1. Replace switch.
OFF, engine continues to run 2. Open/disconnected wire #15A between 2. Reconnect/close wire.
AUTO/OFF/MANUAL switch and Control
Module circuit board.
3. Defective Control Module circuit board 3. Replace board.
No AC output from generator. 1. Check main line circuit breaker. 1. Reset to ON or CLOSED.
2. Check circuit breaker & fuses. 2. Reset and replace, if necessary.
3. Transfer switch set to NORMAL position 3. Set to GENERATOR position.
4. Generator internal failure. 4. Contact an Authorized Generac
facility.
5. Thermal circuit breaker open. 5. Auto-reset - Wait 5 min. and
attempt restart.
![](asset-19.png)
Generac®Power Systems, Inc. 23
Section 6 — Installation Diagram
QUIETSOURCE
™
40kW Liquid-cooled Generators
Installation Diagram — Drawing No. 0E8797
![](asset-1a.png)
24 Generac®Power Systems, Inc.
Section 7 - Electrical Data
QUIETSOURCE
™
40kW Liquid-cooled Generators
Wiring Diagram — Engine — Drawing No. 0E8115-A
![](asset-1b.png)
Generac®Power Systems, Inc. 25
Section 7 - Electrical Data
QUIETSOURCE
™
40kW Liquid-cooled Generators
Wiring Diagram — Engine — Drawing No. 0E8115-A
![](asset-1c.png)
26 Generac®Power Systems, Inc.
Section 7 - Electrical Data
QUIETSOURCE
™
40kW Liquid-cooled Generators
Electrical Schematic — Engine — Drawing No. 0E8116-A
![](asset-1d.png)
Generac®Power Systems, Inc. 27
Section 7 - Electrical Data
QUIETSOURCE
™
40kW Liquid-cooled Generators
Electrical Schematic — Engine — Drawing No. 0E8116-A
![](asset-1e.png)
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®Power Systems, Inc.
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Mounting Base — Drawing No. 0E8084-A
![](asset-1f.png)
ITEM PART NO. QTY. DESCRIPTION
1 0E7331 1 WELDMENT MTG BASE 3.9L CRYSLR
2 052860 4 NUT FLANGED HEX M12-1.75
3 052251 4 DAMPENER VIBRATION 40 BLUE
4 052257 4 SPACER .49 X .62 X 1.87 PWDR/ZNC
5 052252 4 DAMPENER VIBRATION
6 052259 4 WASHER FLAT M12
7 052891 4 SCREW HHC M12-1.75 X 80 G8.8
8 0536210214 1 ASSY WIRE 15.0"
9 074906 1 SCREW HHTT M6-1.0 X 20 BP
10 047411 1 SCREW HHC M6-1.0 X 16 BP
11 055414 1 LUG SLDLSS #2-#8 X 17/64 CU
12 026850 2 WASHER SHAKEPROOF EXT 1/4 STL
13 022097 1 WASHER LOCK M6-1/4
14 022473 1 WASHER FLAT M6-1/4 ZINC
15 049813 1 NUT HEX M6 -1.0 G8 YEL CHR
16 0A1694 4 1-1/2" BUTTON PLUG
18 025507 3 WASHER SHAKEPROOF EXT 7/16 STL
19 0E7359 2 ENGINE MOUNT (3.9L CHRYSLER)
20 027482 2 WASHER SHAKEPROOF EXT 5/16 STL
21 022129 1 WASHER LOCK M8-5/16
22 045771 1 NUT HEX M8-1.25 G8 YEL CHR
23* 051756 1 SCREW HHC M10-1.5 X 20 G8.8
24* 046526 1 WASHER LOCK M10
25* 022131 1 WASHER FLAT 3/8-M10 ZINC
26* 055934M 1 CLAMP VINYL .75 X .343 Z
27 049820 2 NUT HEX LOCK M8-1.25 NY INS
28 059473 1 HOLD DOWN BATTERY
29 061902 1 HOLD DOWN BATTERY
30 058665 REF. BATT 12VDC 90-AH 27F
31 038804D 1 CABLE BATT RED #4 X 20.00
32 038805J 1 CABLE BATT BLK #1 X 30.00
33 021991 1 EARTH STRAP
34 036833 6 SCREW HHC 3/8-16 X 1 G8
35 022237 6 WASHER LOCK 3/8
36 022131 6 WASHER FLAT 3/8 ZINC
37 075763 1 BOOT BATTERY CABLE
38 050331 1 BATTERY POST COVWER (BLACK)
39 050331A 1 BATTERY POST COVWER (RED)
40 0A4010 2 SCREW HHC M8-1.25 X 60 G8.8 FT
41 052858 2 NUT TOP LOCK FL M8-1.25
42 065852 1 SPRING CLIP HOLDER .37-.62
43 045764 1 SCREW HHTT M4-0.7 X 8 BP
*NOT SHOWN-USED TO HOLD DOWN I/N 32.
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Mounting Base — Drawing No. 0E8084-A
Generac®Power Systems, Inc. 29
![](asset-20.png)
30 Generac®Power 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.
R
E
Q
UIRE INSULATION.
T
YPI
C
AL
O
F R
OO
F PANEL THAT
4
53
35
R
ADIAT
OR
33
4
46
55
53
4
36
4
57
5
5
5
5
18
4
26
4
8
4
"A
"
22
9
12
13
16
17
5
2
"B
"
20
53
10
15
14
19
5
1
21
58
28
43
4
1
(
2-PLCS
)
TO
"B"
17
16
40
17
18
23
57
57
5
5
5
41
26
4
4
10
39
18
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Enclosure — Drawing No. 0E8800-B
![](asset-21.png)
Generac®Power Systems, Inc. 31
ITEM PART NO. QTY. DESCRIPTION
1 0E8418 1 DUCT INTAKE 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 WA Z/JS
5 0E7807 1 BAFFLE REAR BOTTOM
6 0E5902 1 POST CORNER LH REAR HSB AL
7 0E5903 1 POST CORNER RH REAR HSB AL
8 0E8387 1 BAFFLE REAR TOP
9 0E5912 2 DOOR SIDE HSB AL
10 0E5911 1 SUPPORT RH SIDE HSB AL
11 089961 2 FOAM STRIP 3/4" WIDE X 3/16" THK (40" LG)
12 0A2115 4 WASHER NYLON .257
13 0E8404 1 BRACKET STIFFENER RH FRONT
14 0D2538A 1 HINGE LIFT OFF TYPE B KNUCKLE
15 0D2538 1 HINGE LIFT OFF TYPE B PIN
16 043116 8 SCREW HHC M6-1.0 X 12 G8.8
17 022097 12 WASHER LOCK M6-1/4
18 022473 12 WASHER FLAT 1/4-M6 ZINC
19 0E7570 2 GAS SPRING
20 0E7571 4 BALL STUD GAS SPRING MOUNT
21 070015 4 NUT HEX 5/16-18 LOCK
22 0E7662 4 SCREW WING M6-1.00 X 25
23 0D2537A 1 HINGE LIFT OFF TYPE A KNUCKLE
24 0D2537 1 HINGE LIFT OFF TYPE A PIN
25 0D2023 2 TRIM VINYL SELF GRIPPING (91" LG)
26 0E7869 2 BRACKET STIFFENING BACK
27 0E8001 1 MUFFLER BOX
28 0E5913 1 ROOF HSB AL
29 0E8798 1 BRACE, FRONT TOP
30 0D3037A 1 LATCH 1/4 TURN NONLOCKING
31 0C7781 2 PAWL DOOR HSB
32 0E5910 1 SUPPORT LH SIDE HSB AL
33 0E8052 1 MUFFLER BOX TOP
34 0D3037 1 LATCH QUARTER TURN LOCKING
35 0E5900 1 POST CORNER LH FRONT HSB AL
36 0E5901 1 POST CORNER RH FRONT HSB AL
37 0E8799 1 BRACE, FRONT BOTTOM
38 0E8415 1 DUCT DISCHARGE MID AL
39 026850 4 WASHER SHAKEPROOF EXT 1/4 STL
40 0912970063 2 ASSY GRD WIRE 99HSB
41 0912970064 2 ASSEMBLY,BASE-DOOR GROUND WIRE
42 049813 2 NUT HEX M6 X 1.0 G8 YEL CHR
43 0E8416 1 DUCT INTAKE LH AL
44 0E8417 1 DUCT INTAKE RH AL
45 0E8665 1 BRACKET STIFFENER LH FRONT
46 0D2023 1 TRIM VINYL SELF GRIPPING (165.5"LG)
50 * 0E8442 1 KIT INSULATION 3.9L HSB
51 0E7829A 1 AI ROOF PANEL 1
52 0E7829B 2 AI DOOR PANEL
53 0E7829P 4 AI CORNER POST PANEL 1
54 0E7829R 2 AI CORNER POST PANEL 2
55 0E7829S 1 AI SUPPORT LH PANEL
56 0E7829T 1 AI SUPPORT RH PANEL
57 0E7829N 2 AI ROOF PANEL 2
58 078115 8 WASHER SELF LOCKING DOME
* ALL ITEMS NOTATED WITH "AI" ARE COMPONENTS OF 0E8442
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Enclosure — Drawing No. 0E8800-B
![](asset-22.png)
32 Generac®Power Systems, Inc.
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Control Panel — Drawing No. 0E7118-H
![](asset-23.png)
Generac®Power Systems, Inc. 33
ITEM PART NO. QTY. DESCRIPTION
1 0E7195 1 CONTROL BOX HSB
2 0E7196 1 COVER FRONT PANEL HSB
3 0E7197 1 COVER TOP PANEL HSB
4 0E7193 1 DECAL WARNINGS HSB
5 0E7194 1 DECAL CONTROLS HSB
6 0E4494 1 SWITCH ROC DPDT ON-OFF-ON
7 082573 1 SWITCH ROCKER DPST 125V SPD
8 032300 2 HOLDER FUSE
9 022676 1 FUSE 15A X AGC15
10 067682B 1 FUSE 4A SLO BLO GLASS
11 060015 1 FITTING CONDUIT 90D 3/8"
12 054199 1 DECAL DANGER HIGH VOLTAGE
13 0C2657 1 TRANSFRMR 16V 6VA
14 099076 1 TRANSFORMER 16V 56VA
15 040213 2 PCB SUPPORT SNAP-IN 1/4"
16 0E9668 1 ASSY PCB HSB CONTROLLER 3.9L
0E4905 1 ASSY PCB HSB CONTRLR 3.0L
FORD
17 067680 1 ASSY VOLTAGE REGULATOR 60HZ
18 0E6875A 1 RELAY 12VDC C FORM W/DIODE
19 0E6881 * REF. SOCKET RELAY
20 0C5139 * REF. CONN DEUTSCH RECEPT GY/FLN
21 0C5142 * REF. CONN DEUTSCH RECEPT WDGE
BLKHD
22 0E3161 1 ASSY BOSCH GOV DRIVER
23 054450 1 CIRCT BRK 5.5 X 1 ETA 46-500-P
24 0D5070A 1 ASSY 2A 12V UL BATTERY
CHARGER
25 0E2514 1 FITTING CONDUIT STR 1-1/2"
26 0A9457 1 DECAL NEUTRAL
27 0E7539 1 DECALCUSTOMER CNNCTN XFER
SW
28 046357 * REF. BLOCK TERM 20A 6 X 6 X 1100V
29 0D3719B 1 DECAL CUSTOMER CNNCTN
30 057073 1 JUNCTION BLOCK 3/8-16
31 0E7283 1 CB 0150A2P240V S QN2 LL
0E3628 1 CB 0200A2P240V S QN2 LL
32 0E3664 1 BASE QN CIRCUIT BREAKER
33 0E7539A 1 DECAL TB1 HSB CONTROL PANEL
34 0D4698 * REF. BLOCK TERM 20A 6 X 3 X 1100V
ITEM PART NO. QTY. DESCRIPTION
35 0E7252 1 BRACKET CB 221.5 X 102
36 0C1229 1 DECAL WARNING ELECTRICAL
SHOCK
37 0C1127 1 DECAL AVR COVER
38 0A1441B 1 COVER PLATE, AVR
39 0E7128 1 HARNESS CNTRL PNL (NOT
SHOWN)
40 0E7358 8 SCREW PPPH HI-LO #4-24 X 3/8
41 074908 6 SCREW HHTT M5-0.8 X 10 BP
42 0C5141 1 CONN DEUTSCH GASKET 8/12 POS
DT
43 0C2699 11 SCREW PHTT #6-32 X 3/8 ZYC
44 0C2323 4 SCREW PHTT #6-32 X 5/8 ZYC
45 022155 15 WASHER LOCK #6
46 0C2265 4 SCREW PHTT M4-0.7 X 12 ZYC
47 022264 4 WASHER LOCK #8-M4
49 020911 2 SCREW PPHM M5-0.8 X 30 ZINC
50 066849 2 SCREW HHTT M5-0.8 X 16
51 022152 4 WASHER LOCK #10
52 023897 3 WASHER FLAT #10 ZINC
53 051716 2 NUT HEX M5-0.8 G8 YEL CHR
54 090388 2 SCREW HHTT M6-1.0 X 12 ZINC
55 042568 4 SCREW HHC M6-1.0 X 20 G8.8
56 022097 8 WASHER LOCK M6-1/4
57 022473 6 WASHER FLAT 1/4-M6 ZINC
58 0441140187 2 WIRE ASSY 3" X (2) 3/16" TABS
59 070370 2 WASHER MICA .203
60 023762 1 WASHER SHAKEPROOF EXT #10
STL
61 055444 1 HEATSINK
62 030468 1 WASHER STEP NYLON .20
63 049939 1 RECTIFIER MSC 12A 600V 1N1206R
64 022158 1 NUT HEX #10-32 STEEL
65 022985 1 WASHER FLAT #6 ZINC
66 038750 2 SCREW HHC M6-1.0 X 30 G8.8
67 0A2115 4 WASHER NYLON .257
68 0C2454 4 SCREW THF M6-1 X 16 N WA Z/JS
* ITEMS INCLUDED AS PART OF I/N 39
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Control Panel — Drawing No. 0E7118-H
![](asset-24.png)
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Engine — Drawing No. 0E8121-G
34 Generac®Power Systems, Inc.
![](asset-25.png)
ITEM PART NO. QTY. DESCRIPTION
1 0E5048A 1 FLEXPLATE 3.9L HSB
2 0E7477 1 MACHINING 3.9L ENGINE ADAPTOR
3 0E6703 1 COVER FLYWHEEL ACCESS
4 0E8336 REF REWORK 3.9L CHRYSLER ENGINE
5 0E7841 2 GASKET THERMOSTAT ADAPTOR
6 0E7254 1 MACH THERM ADAPTOR 3.9L CHRY
7 0E7956 1 BRACKET IGNITION COIL
8 0E7953 1 COIL IGNITION 3.9L CHRYSLER
9 047411 4 SCREW HHC M6-1.0 X 16 G8.8
10 0E8591 6 BOLT AUTO TRANS CRANKSHAFT
11 0E7921 1 BRACKET ALTERNATOR
12 0E7749 1 FAN SPACER ENGINE COOLING
13 022097 7 WASHER LOCK M6-1/4
14 022473 10 WASHER FLAT 1/4-M6 ZINC
15 049721 2 SCREW HHC M6-1.0 X 35 G8.8 BLK
16 049813 3 NUT HEX M6 X 1.0 G8 YEL CHR
17 036833 11 SCREW HHC 3/8-16 X 1 G8
18 022131 21 WASHER FLAT 3/8-M10 ZINC
19 022237 14 WASHER LOCK 3/8
20 0E6729 1 STARTER DELCO-REMY 12V
21 022129 11 WASHER LOCK M8-5/16
22 049821 3 SCREW SHC M8-1.25 X 30 G12.9
23 057073 1 JUNCTION BLOCK 3/8-16
24 052677 1 WASHER NYLON .50 X .87 X .06
25 066849 2 SCREW HHTT M5-0.8 X 16
26 056739 1 RELAY SOLENOID 12VDC PNL MNT
27 0D2244M 1 ASSY MAGPICKUP (3/8-24 MALE)
28 087599 1 PLUG PLASTIC 3/8 NPT
29 0E0992B REF PLUG EXPANSION 21/32" OD
(WATER PUMP) (QTY 1)
30 0E0992A REF PLUG EXPANSION 14.1 OD
(INJCTOR HOLE) (QTY 6)
31 0E7754 1 COOLING FAN 10-BLADE (KYSAIR)
32 0E7854 1 CLUTCH COOLING FAN
33 0E7855 1 TENSIONER W/BRACKET
34 0E7952 1 PULLEY CRANKSHAFT 3.9L
CRYSLR
35 0E0561 1 ASSY WATER LEVEL SENSOR C/E
PL
36 035606 1 SENSOR HI COOLANT SHUTDOWN
37 061012 1 PLUG STD PIPE 1/8 SOCKET HEAD
38 0A8584 1 SWITCH OIL PRESSURE10 PSI
2POL
39 050873A 1 PLUG PIPE 1/4 CSK W/ VIBRA SL
ITEM PART NO. QTY. DESCRIPTION
40 031919 1 PLUG STD PIPE 3/8 COUNTER-
SUNK
41 022145 6 WASHER FLAT 5/16-M8 ZINC
42 030795 6 SCREW HHC 5/16-18 X 1 G5
43 051756 5 SCREW HHC M10-1.5 X 20 G8.8
44 046526 6 WASHER LOCK M10
45 0A1232A 1 ASSEMBLY, D.C. ALTERNATOR
46 0A7801B 1 PULLEY POLY-V 82 OD
47 045772 1 NUT HEX M10-1.5 G8 YEL CHR
48 022403 2 SCREW HHC 5/16-18 X 2 G5
49 0E7950 1 TUBE DIPSTICK 3.9L CHRYSLER
50 0E7951 1 DIPSTICK OIL LEVEL 3.9L CRYSLR
51 0E8445 1 BRACKET DIPSTICK TUBE
52 0E7415 1 OIL FILTER 3.9L CHRYSLER
53 042568 1 SCREW HHC M6-1.0 X 20 G8.8
54 061652 1 SCREW HHC M10-1.5 X 85 G8.8
55 031578 1 SCREW HHC 3/8-16 X 1-1/2 G8
56 082120 1 SPACER .41 X .75 X .39 ST/ZNC
57 023645 5 SCREW SHC 3/8-16 X 1.25 G8.8 Z
58 0E9974 2 CAP VINYL 3/8" ID X 1" DP BLK
59 0D3488A 1 BELT SERPENTINE 69.39"
60 0E7954 1 CABLE IGN COIL 3.9L CHRYSLER
61 0E8309 1 ASSY IGNITION MODULE 3.9L
62 029187 2 SPACER .19 X .31 X .50 PL
63 032712 2 SCREW HHTT #10-32 X 1.75 CZ
64 054455 1 ADP OIL DRN 1/2-20
65 0E8606 2 SCREW PPH TAPPING #4 X 3/8" LG
66 0E8642 REF ASSEMBLY RESISTOR
67 0E8597 1 HARNESS 3.9L CHRYSLER ENGINE
(NOT SHOWN)
68 0E8755 1 HARNESS IGNITION 3.9L CHRY
(NOT SHOWN)
69 0E8731 1 PLATE FLEX DISK SPACER
70 026076 1 SCREW SHC 3/8-16 X 1.5 G8.8 NZ
71 0E9975 1 CAP VINYL 1/4" ID X 1" DP BLK
72 0F1444A 2 HEAT SHEILD L/H SIDE
73 0C2454 2 SCREW THF M6-1 X 16 N WA Z/JS
74 043790 1 BARBED EL 90 3/8 NPT X 3/8
75 069860C 1 HOSE OIL DRAIN ASSY 21"
76 048031J REF HOSE CLAMP BAND 5/8"
77 0F1444 1 HEAT SHIELD R/H SIDE
78 026925 1 PLUG STD PIPE 3/8 STEEL SQ HD
79 026257 1 SCREW SHC 3/8-16 X 2 G8.8 NZ
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Engine — Drawing No. 0E8121-G
Generac®Power Systems, Inc. 35
![](asset-26.png)
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 Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Radiator — Drawing No. 0E8102-E
36 Generac®Power Systems, Inc.
![](asset-27.png)
ITEM PART NO. QTY. DESCRIPTION
1 0D7825A 1 RADIATOR COPPER BRASS
2 0D7174C 1 VENTURI,3.9L CRYSLR HSB 22"FAN
3 0E7640 1 RADIATOR SUPPORT L/H SIDE
4 0E7924 1 HOSE LOWER RADIATOR
5 0F2853 1 HOSE, RADIATOR UPPER, 3.9L
6 0D8252 1 FAN GUARD, TOP
7 0D8251 1 FAN GUARD, BOTTOM
8 0E0726 1 BRACKET, WATER BOTTLE 1.5L MIT
9 076749 1 TANK COOLANT RECOVERY
10 035685 4 CLAMP HOSE #28 1.32-2.25
13 069860C 1 HOSE OIL DRAIN ASSY 21"
14 058443 17 SCREW CRIMPTITE 1/4-20 X 5/8
15 0C2454 5 SCREW TH-FRM M6-1X16 N WA Z/JS
16 052250 2 TAPE FOAM 1 X 1 (27"LG)
17 048031C 1 CLAMP HOSE BAND 1/4
18 029032 1 HOSE 9/32 ID (30" LG)
19 0A2111 1 SCREW SWAGE 10-32 X 5/16 Z/YC
20 0E7640A 1 RADIATOR SUPPORT R/H SIDE
21 035461 1 BARBED STR 1/4NPT X 3/8
22 065852 1 SPRING CLIP HOLDER .37-.62
23 051756 4 SCREW HHC M10-1.5 X 20 G8.8
24 022131 8 WASHER FLAT 3/8-M10 ZINC
25 046526 4 WASHER LOCK M10
26 045772 4 NUT HEX M10-1.5 G8 YEL CHR
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Radiator — Drawing No. 0E8102-E
Generac®Power Systems, Inc. 37
![](asset-28.png)
38 Generac®Power 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 Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Fuel System — Drawing No. 0E8122-H
![](asset-29.png)
Generac®Power Systems, Inc. 39
ITEM PART 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 WASHER FLAT 5/16 ZINC
6 022129 8 WASHER LOCK M8-5/16
7 045771 2 NUT HEX M8-1.25 G8 YEL CHR
8 042907 2 SCREW HHC M8-1.25 X 16 G8.8
9 0C2454 2 SCREW TH-FRM M6-1 X 16 N WA Z/JS
10 026307 1 ELBOW 90D STREET 3/4
11 0E1056 1 FUEL HOSE ASSY NAT.GAS/L.P.V.
12 0E6584 1 BRACKET REGULATOR 3.0L FORD HSB
13 057822 2 CLAMP HOSE #8 .53-1.00
14 059194 1 HOSE 5/8 ID LPG & NG (36" LG)
15 064945 1 GASKET CARB ADAPTOR
16 0D1509 1 DECAL INLET PRESSURE
17 050279 1 DECAL FUEL INLET NG
18 0E7839 1 MACHINING, CARBURETOR ADAPTOR
19 0E6586 2 GASKET BOSCH 32 & 40
20 0E4394 1 ACTUATOR BOSCH 40 GOVERNOR
21 040105 1 HOSE COOL 2IN ID 20R4 (2" LG)
22 0E6382B 1 VENTURI HOLDER W/40MM ACTUATOR
23 0F2119 1 O-RING 45.63 ID X 2.62 WIDTH
24 0E6376B 1 VENTURI 28 ID THROTTLE W/CHOK
25 042561 2 CLAMP HOSE #36 1.88-2.75
27 0E7929 1 BASE AIR CLEANER PLATE
28 0A4637 1 FILTER AIR 11.5" CA326
29 0E6406 1 HOLDER VENTURI
30 0E7702 1 HOLD DOWN AIR CLEANER
31 0A4632A 1 PLATE AIR CLEANER TOP
32 037561 1 NUT WING 1/4-20 NYLK
33 046580 4 SCREW SHC M6-1.0 X 45 G12.9
34 0E8286 1 STREET EL 45DEG 1/2" NPT BRASS
35 044118 1 BARBED STR 1/2NPT X 5/8
36 049815 4 SCREW HHC M5-0.8 X 16 G8.8
37 049226 4 WASHER LOCK M5
38 051713 4 WASHER FLAT M5
39 022097 4 WASHER LOCK M6-1/4
40 057796 1 GROMMET
41 057795A 1 BARBED EL 90 3/4 PLASTIC
42 052223 1 HOSE 1/2 ID SAE-30R2 FUEL/OIL
43 061012 1 PLUG STD PIPE 1/8 SOCKET HEAD
44 0E9295 1 ASSY THROTTLE 28MM
45 0F3994 1 PCV VALVE 2.5L FORD
46 0E7121 1 O-RING 47.625 ID X 2.38 WIDTH
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Fuel System — Drawing No. 0E8122-H
![](asset-2a.png)
40 Generac®Power 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 Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Alternator — Drawing No. 0E5146-B
![](asset-2b.png)
Generac®Power Systems, Inc. 41
ITEM PART NO. QTY. DESCRIPTION
1 0E5093A 1 ROTOR 390 30KW 1P DIRECT HSB
0E7413A 1 ROTOR 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 CHRYSLER)
3 0E5706 1 REAR BEARING CARRIER 390/DRCT
4 0E5048 REF FLEXPLATE 3.0L FORD
0E5048A REF FLEXPLATE 3.9L HSB
5 0E6668 1 FLYWHEEL ASSY 3.0L HSB LG GEAR
6 0E6076 1 REVCOR FAN 10.75 X 2 W/PRESS DIS
7 046526 8 WASHER LOCK M10
8 051755 4 SCREW HHC M10-1.5 X 16 G8.8
9 04576100BK 4 STUD M14-2.0 X 490 G5 ZINC (3.0L FORD)
04576100BF 4 STUD M14-2.0 X 540 G5 ZINC (3.9L CHRYSLER)
10 043123 4 WASHER LOCK M14
11 051779 4 NUT HEX M14-2.0 G8 YEL CHR
12 0E7587 1 ASSY BRUSH HOLDER 390/HSB
13 023365 5 WASHER SHAKEPROOF INT #8
14 092980 4 SCREW PPHM M4-0.7 X 25
15 052625 4 SCREW SHC M10-1.5 X 35 G12.9
16 0A2602 1 WASHER FLAT .688 ID X 3.25 OD
17 042558 1 KEY SQ 3/8 X 1 STEEL
18 0A2601 1 SCREW HHC M16-2.0 X 45 G8.8
19 0E7226 1 GUARD STATOR 390
20 045757 2 SCREW HHC M6-1.0 X 25 G8.8
21 052857 2 NUT TOP LOCK FL M6-1.0
22 051715 4 NUT HEX M4-0.7 G8 YEL CHR
23 038150 4 WASHER FLAT #8 ZINC
24 077043F 1 CONDUIT FLEX 1-1/4" (30" LG)
ROTOR REPLACEMENT PARTS
30 047248 1 BALL BEARING-45 MM
31 070892 1 SLIP RING -MACHINED-
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Alternator — Drawing No. 0E5146-B
![](asset-2c.png)
ITEM PART NO. QTY. DESCRIPTION
1 0E8616 1 MUFFLER 7" X 9" X 21" 2.5" IN &
OUT
2 0F1081 1 WYE, PIPE 3.9L CHRYSLER
3 0F1087 1 PIPE R/H SIDE 3.9L CHRYSLER
4 0E8026 1 PIPE L/H EXHAUST MANIFOLD
5 0E5914 1 BRACKET MUFFLER 30" LG
6 0E8702 1 PIPE MUFFLER INLET
7 0E8727 1 PIPE MUFFLER OUT
8 036797 3 BOLT U 5/16-18 X 2.25
9 039253 2 SCREW HHC M8-1.25 X 20 G8.8
10 022145 6 WASHER FLAT 5/16-M8 ZINC
11 022129 9 WASHER LOCK M8-5/16
12 045771 3 NUT HEX M8-1.25 G8 YEL CHR
ITEM PART NO. QTY. DESCRIPTION
13 0C2454 4 SCREW TH-FRM M6-1 X 16 N WA
Z/JS
14 052860 4 NUT TOP LOCK FL M12-1.75
15 052891 4 SCREW HHC M12-1.75 X 80 G8.8
16 0E8816 2 FLANGE EXHAUST 2" PIPE
17 051769 4 WASHER LOCK M12
18 0E0170 1 BLANKET EXHAUST 800MM
19 049808 8 WASHER FLAT M12
20 024114 6 NUT HEX 5/16-24 STEEL
21 080762 2 BOLT U 3/8-16 X 2.62
22 0E8726 2 STRAP MUFFLER
23 039288 1 SCREW HHC M8-1.25 X 55 G8.8
24 0E0170A 1 EXHAUST BLANKET 988MM
T
O
EXHA
UST
MANIF
O
L
D
14
19
1
5
1
9
17
4
11
8
2
0
9
1
0
1
0
2
3
22
21
1
21
3
1
8
11
8
2
8
11
2
0
1
3
6
2
0
22
7
11
1
0
12
1
5
1
3
1
0
CO
MPARTMEN
T
T
O
5
1
9
1
1
12
1
9
17
14
24
T
O
EXHA
UST
MANIF
O
L
D
1
6
42 Generac®Power Systems, Inc.
Section 8 - Exploded Views and Parts
QUIETSOURCE
™
40kW Liquid-cooled Generators
Muffler — Drawing No. 0E8068-F
![](asset-2d.png)
Section 9 - Notes
QUIETSOURCE
™
40kW Liquid-cooled Generators
Generac®Power Systems, Inc. 43
![](asset-2e.png)
44 Generac®Power Systems, Inc.
Section 9 - Notes
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-2f.png)
Generac®Power Systems, Inc. 45
Section 9 - Notes
QUIETSOURCE
™
40kW Liquid-cooled Generators
![](asset-30.png)
Part No. 0E9042 Revision E (03/15/05) Printed in U.S.A.
Section 10 – Warranty
QUIETSOURCE
™
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)