Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Model No: 005012-1
37kW NG, 40kW LP
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
Table of Contents
40kW Liquid-cooled Generators
INTRODUCTION ...............................................IFC
Read this Manual Thoroughly..................................... IFC
Operation and Maintenance ........................................ IFC
How to Obtain Service................................................. IFC
Authorized Service Dealer Location ............................ IFC
Section 3 — OPERATION................................ 13
3.1 Using an Engineered “GTS” Transfer Switch ......13
3.2 Control Console Components..............................13
3.3 Manual Transfer and Startup..............................14
3.4 Engine Governor Adjustments ............................14
3.5 Retransfer and Shutdown ...................................15
3.6 Automatic Operation ...........................................15
3.7 Weekly Exercise Cycle .........................................15
Section 4 — MAINTENANCE........................... 16
SAFETY RULES....................................................2
Section 1 — GENERAL INFORMATION............. 4
1.1 Generator..............................................................4
1.2 Transfer Switch.....................................................4
1.3 Automatic System Operation.................................4
1.4 Generator AC Connection Systems........................4
1.5 Main Circuit Breaker.............................................4
1.6 Generator Fuel System..........................................5
1.7 Engine Protective Devices......................................5
1.8 Unpacking.............................................................6
1.9 Lifting the Generator.............................................7
1.10 Specifications........................................................7
1.11 Fuel Consumption.................................................7
1.12 Reconfiguring the Fuel System ..............................7
1.13 Torque Specifications............................................8
1.14 Engine Oil Recommendations ...............................8
1.15 Coolant Recommendations....................................8
1.16 Before Installation.................................................8
Section 2 — INSTALLATION............................. 8
2.1 Standby Generator Installation .............................8
2.2 Generator Location ...............................................9
2.3 Generator Mounting and Support .........................9
2.4 Basic Standby Electric System............................10
2.5 Emergency Circuit Isolation Method ...................10
2.6 Total Circuit Isolation Method.............................10
2.7 Grounding the Generator....................................10
2.8 Generator AC Neutral Connections .....................11
2.9 Transfer Switch Start Signal Connections...........11
2.10 Battery Installation..............................................11
2.11 Preparation Before Start-Up................................12
4.1 Maintenance Performed by Authorized
Service Facilities..................................................16
4.2 Cooling System....................................................16
4.3 Overload Protection for Engine DC
Electrical System.................................................16
4.4 Checking Fluid Levels .........................................16
4.5 Maintenance Owner/Operator
Can Perform........................................................17
4.6 Miscellaneous Maintenance.................................18
4.7 Scheduled Maintenance.......................................20
Section 5 — TROUBLESHOOTING ................. 23
Section 6 — ELECTRICAL DATA.................... 24
Section 7 — EXPLODED VIEWS AND
PARTS LISTS ............................. 28
Section 8 — INSTALLATION DIAGRAM.......... 43
Section 9 — NOTES........................................ 44
Section 10 — WARRANTY .................Back Cover
1
IMPORTANT SAFETY INSTRUCTIONS
40kW Liquid-cooled Generators
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas. Safety should be stressed to all
operators, potential operators, and service and repair technicians for this equipment.
SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be
followed during installation and maintenance of the generator and batteries.
WARNING:
GENERAL HAZARDS
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
• For safety reasons, the manufacturer recommends
that this equipment be installed, serviced and repaired
by an Authorized Service Dealer or other competent,
qualified electrician or installation technician who is
familiar with applicable codes, standards and regula-
tions. The operator also must comply with all such
codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electri-
cal and building codes. Comply with regulations
the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the genera-
tor is installed, operated and serviced in accordance
with the manufacturer’s instructions and recommen-
dations. Following installation, do nothing that might
render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regula-
tions.
• The engine exhaust fumes contain carbon monoxide
gas, which can be DEADLY. This dangerous gas,
if breathed in sufficient concentrations, can cause
unconsciousness or even death. For that reason,
adequate ventilation must be provided. Exhaust
gases must be piped safely away from any building
or enclosure that houses the generator to an area
where people, animals, etc., will not be harmed. This
exhaust system must be installed properly, in strict
compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive belts,
fans, and other moving or hot parts. Never remove
any drive belt or fan guard while the unit is operat-
ing.
• Adequate, unobstructed flow of cooling and ventilat-
ing air is critical to prevent buildup of explosive gases
and to ensure correct generator operation. Do not
alter the installation or permit even partial blockage
of ventilation provisions, as this can seriously affect
safe operation of the generator.
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar
with this Owner’s Manual and with the unit. The gen-
erator can operate safely, efficiently and reliably only if
it is properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and fun-
damental rules or precautions.
The manufacturer cannot anticipate every possible cir-
cumstance that might involve a hazard. The warnings in
this manual, and on tags and decals affixed to the unit
are, therefore, not all-inclusive. If using a procedure,
work method or operating technique that the manufac-
turer does not specifically recommend, ensure that it
is safe for others. Also make sure the procedure, work
method or operating technique chosen does not render
the generator unsafe.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or maintain
this equipment.
Potentially lethal voltages are generated by these
machines. Ensure all steps are taken to render the
machine safe before attempting to work on the
generator.
Parts of the generator are rotating and/or hot dur-
• Keep the area around the generator clean and unclut-
tered. Remove any materials that could become haz-
ardous.
ing operation. Exercise care near running genera-
tors.
• When working on this equipment, remain alert at all
times. Never work on the equipment when physically
or mentally fatigued.
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IMPORTANT SAFETY INSTRUCTIONS
40kW Liquid-cooled Generators
• Inspect the generator regularly, and promptly repair • Generators installed with an automatic transfer
switch will crank and start automatically when NOR-
MAL (UTILITY) source voltage is removed or is below
an acceptable preset level. To prevent such automatic
start-up and possible injury to personnel, disable the
generator’s automatic start circuit (battery cables,
etc.) before working on or around the unit. Then,
place a “Do Not Operate” tag on the generator control
panel and on the transfer switch.
or replace all worn, damaged or defective parts using
only factory-approved parts.
• Before performing any maintenance on the generator,
disconnect its battery cables to prevent accidental
start-up. Disconnect the cable from the battery post
indicated by a NEGATIVE, NEG or (–) first. Reconnect
that cable last.
• Never use the generator or any of its parts as a step.
Stepping on the unit can stress and break parts, and
may result in dangerous operating conditions from
leaking exhaust gases, fuel leakage, oil leakage, etc.
• In case of accident caused by electric shock, imme-
diately shut down the source of electrical power. If
this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement, such
as a dry rope or board, to free the victim from the live
conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric
shock, or may get caught in moving components
causing injury.
ELECTRICAL HAZARDS
• All generators covered by this manual produce dan-
gerous electrical voltages and can cause fatal electri-
cal shock. Utility power delivers extremely high and
dangerous voltages to the transfer switch as well as
the standby generator. Avoid contact with bare wires,
terminals, connections, etc., on the generator as well
as the transfer switch, if applicable. Ensure all appro-
priate covers, guards and barriers are in place before
operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface
to reduce shock hazard.
FIRE HAZARDS
• Keep a fire extinguisher near the generator at all
times. Do NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid can
deteriorate wiring insulation. Keep the extinguisher
properly charged and be familiar with its use. If there
are any questions pertaining to fire extinguishers,
consult the local fire department.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• If people must stand on metal or concrete while
installing, operating, servicing, adjusting or repair-
ing this equipment, place insulative mats over a dry
wooden platform. Work on the equipment only while
standing on such insulative mats.
• The National Electrical Code (NEC), Article 250
requires the frame and external electrically conduc-
tive parts of the generator to be connected to an
approved earth ground and/or grounding rods. This
grounding will help prevent dangerous electrical
shock that might be caused by a ground fault condi-
tion in the generator set or by static electricity. Never
disconnect the ground wire.
EXPLOSION HAZARDS
• Properly ventilate any room or building housing the
generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel
or oil spills immediately. Ensure that no combustible
materials are left in the generator compartment, or
on or near the generator, as FIRE or EXPLOSION
may result. Keep the area surrounding the generator
clean and free from debris.
• These generator sets may operate using one of
several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulating
the storage and handling of fuels. Inspect the unit’s
fuel system frequently and correct any leaks imme-
diately. Fuel supply lines must be properly installed,
purged and leak tested according to applicable fuel-
gas codes before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids
such as natural gas and liquid propane (LP) gas are
extremely EXPLOSIVE. Natural gas is lighter than air,
and LP gas is heavier than air; install leak detectors
accordingly.
• Wire gauge sizes of electrical wiring, cables and cord
sets must be adequate to handle the maximum elec-
trical current (ampacity) to which they will be sub-
jected.
• Before installing or servicing this (and related) equip-
ment, make sure that all power voltage supplies are
positively turned off at their source. Failure to do so
will result in hazardous and possibly fatal electrical
shock.
• Connecting this unit to an electrical system normally
supplied by an electric utility shall be by means of a
transfer switch so as to isolate the generator electric
system from the electric utility distribution system
when the generator is operating. Failure to isolate the
two electric system power sources from each other
by such means will result in damage to the generator
and may also result in injury or death to utility power
workers due to backfeed of electrical energy.
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