Generac 40kW LP, 37kW NG Preparation Before START-UP, Using AN Engineered GTS Transfer Switch

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Section 3 — Operation

QUIETSOURCE™ 40kW Liquid-cooled Generators

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.

‹2.11.4 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 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.

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‹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.

3.1USING 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.

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Contents Liquid-cooled, Prepackaged Standby Generators ‹ HOW to Obtain Service Authorized Service Dealer Location‹ Operation and Maintenance IntroductionTable of Contents General Hazards Electrical Hazards Automatic System Operation Transfer SwitchGenerator Generator AC Connection Systems‹ 1.7.3 LOW Coolant Level Switch ‹ 1.7.1 LOW OIL Pressure Switch‹ 1.7.2 High Coolant Temperature Switch Generator Fuel SystemUnpacking Lifting the Generator‹ 1.10.1 Generator Specifications SpecificationsReconfiguring the Fuel System ‹ 1.10.2 Engine SpecificationsEngine OIL Recommendations Torque SpecificationsBefore Installation Coolant RecommendationsBasic Standby Electric System Generator LocationGenerator Mounting Support ‹ 2.1.1 Nfpa StandardsTotal Circuit Isolation Method Transfer Switch Signal ConnectionsEmergency Circuit Isolation Method Generator AC Neutral Connections‹ 2.10.1 Vented Batteries Battery Installation‹ 2.9.2 GTS-TYPE Engineered Transfer Switch Using AN Engineered GTS Transfer Switch Preparation Before START-UP‹ 3.2.5 SET Exercise Time Switch ‹ 3.2.1 AUTO/OFF/MANUAL Switch‹ 3.2.2 Fault Indicator LED Control Console ComponentsAutomatic Operation Manual Transfer START-UP Engine Governor AdjustmentsRetransfer and Shutdown Weekly Exercise CycleCooling System Overload Protection for Engine DC Electrical SystemChecking Fluid Levels ‹ 4.5.12 Spark Plugs ‹ 4.5.11 Changing the Engine AIR Cleaner‹ 4.5.10 Changing Engine OIL ‹ 4.5.13 Coolant Change‹ 4.6.2 Battery Miscellaneous Maintenance‹ 4.6.1 Cleaning the Generator ‹ 4.6.4 Battery ReplacementScheduled Maintenance Service Maintenance Interval InformationLevel Maintenance Level Troubleshooting Points Problem Cause CorrectionInstallation Diagram Electrical Data Electrical Data Electrical Data Electrical Data Carrier Rear Bearing Boot Battery Cable Assy WireHold Down Battery Battery Post Covwer BlackSee Latch Detail Duct Intake MID AL Assy GRD Wire 99HSBASSEMBLY,BASE-DOOR Ground Wire Duct Discharge RH ALGenerac Power Systems, Inc Cover Front Panel HSB Assy 2A 12V UL BatteryControl BOX HSB Cover TOP Panel HSB ShockGenerac Power Systems, Inc Flexplate 3.9L HSB Cover Flywheel AccessAssembly Resistor SunkPump VENTURI,3.9L Cryslr HSB 22FAN Tank Coolant RecoveryRadiator Copper Brass Radiator Support L/H SideTo Engine Plate AIR Cleaner TOP Base AIR Cleaner PlateHold Down AIR Cleaner Flange Fuel InletLeads STR-390--40AD HSB 433MM LONG3.9L Chrysler Rotor 390 30KW 1P Direct HSBRotor 390 40KW 1P Direct HSB Rear Bearing Carrier 390/DRCTNUT TOP Lock FL M12-1.75 OUTWYE, Pipe 3.9L Chrysler Pipe L/H Exhaust ManifoldQuietsource 40kW Liquid-cooled Generators Quietsource 40kW Liquid-cooled Generators Quietsource 40kW Liquid-cooled Generators This Warranty Shall not Apply to the Following