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Generac Power Systems 43734 User's Manual

1. 23 Generac Power Systems Inc y 11 SI an 9 1 3 rubi 62c a 918 918 g d z SIS LZ r 9918601011 Z vl SL otal FOVLIOA LNdLNO OV YILIN WA ama T SdlH1S TVNIWH3L ZSL LSL im 5 SIS 99110 B La E LL NI VA 2 ONISN3S H3INHOJSNVHL FHL S e lt iag O zH 3SIOH3X3 13S HOLIMS ZMS
2. Lasso 222 _ 0 9 6999 U o O UU UJ SH fs oh gos OP e s E a D G 5 2 PE IN J S B S 34 Generac Power Systems Inc ITEM Section 7 Exploded Views and Parts Lists Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generator PARTS Ce LISTS Control Panel 4 3L Drawing No 0D4995 F 0 PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 0D5488 1 PANEL BTM amp BACK CONTROL 32 070042 1 FREQUENCY METER 240V 55 65HZ PANEL 33 081988 1 DECAL EXERCISE INFO 0D1521A 1 CONTROL PANEL F
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4. Air Cleaner i pi e pa E LL ml Vn EN A I LIH we Q O x m ge A mm 9 9 MN o TRANSPARENT ENCLOSURE FOR CLARITY See the Service Schedule Section 4 12 for recom mended air cleaner maintenance 4 4 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary See Section 4 12 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean the plugs by scraping using a wire brush 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 ques tionable See the Service Schedule Section 4 12 for recommended inspection 3 Check the spark plug gap using a feeler gauge Adjust the gap to 0 045 inch 1 1 mm by carefully bending the ground electrode Figure 4 4 Figure 4 4 Setting the Spark Plug Gap 0 045 inch 1 1 mm DLE AU y SA 4 5 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 4 12 The following procedure should be followed for inspection G f lt 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 ONL
5. 39 3 8 2 Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Compartment Drawing No 0D8992 DESCRIPTION ASSEMBLY M6 HINGE SCREW BHSC M6 1 0 X 16 SS SHAKEPROOF INT M6 SS DOOR SMALL STD WELD CORNER POST LH REAR CORNER POST RH REAR CORNER POST LH FRONT CORNER POST RH FRONT REAR BRACE TOP amp BOTTOM SIDE BRACE TOP amp BOTTOM SIDE SUPPORT ROOF ONE PIECE WLDMT FRONT BRACE TOP PLATE STRIKER SCREW PPHM M4 0 7 X 12 SS PADDLE HANDLE LOCK NUT LOCK HEX M4 0 7 SS NYL INS WASHER FLAT 8 SS RIVET POP 3 16 X 1 4 DUCT FRONT LH DUCT FRONT RH DUCT BOTTOM DUCT FRONT PANEL DUCT FRONT TOP RH ASSEMBLY COVER ACCESS SCREW TH FRM M6 1X16 N WA Z JS WASHER LOCK M8 5 16 SCREW 8 1 25 X 16 G8 8 WASHER FLAT M6 1 4 ZINC WASHER LOCK M6 1 4 NUT HEX 1 4 20 STEEL GASKET DOOR RUBBER SCREW SHOULDER COVER EXHAUST HOLE FASTENER RATCHET STRIP SEALANT 1 8 X 1 WASHER FLAT 5 16 ZINC OPTIONAL COMPARTMENT MATERIALS ALL P N S WITH AN A SUFFIX INDICATEALUMINUM MATERIAL OPTION age LISTS Generac Power Systems Inc 33 us Section 7 Exploded Views and Parts Lists y Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generator 0 Control Panel 4 3L Drawing No 0D4995 F ZZZZZZZZLZZZZZT PANEL FACE
6. 0043733 0043734 0043735 0046262 0046263 0046264 Rated Maximum Continuous AC Power Output WI store 40 Rated Voltage VOWS stan asada 120 240 Rated Maximum Continuous Current at 240 Volts Single phase amrps 167 Number Or Rotor POLES cicxtasicscdsonsiciecnsdetnsecaeseeneeiienideanaetice 4 Driven Speed of Rotor rpm 1 800 Four wire Rotor Excitation System Direct Excited Brush type System Sator Sula uuu pas ps ed uera e tuit nint penas Class H Rotor Insulation etica time Class F Rated power of generator is subject to and limited by such factors as ambient tempera ture altitude engine condition and other factors Engine power will decrease about 3 5 percent for each 1 000 feet above sea level and also will decrease an additional 1 percent for each 6 C 10 F above 15 5 C 60 F ambient Maximum output power of the gener ator is limited by maximum engine power Generac Power Systems Inc 5 Section 1 General Information GENERAL INFORMATION 1 8 2 GENERATOR AND LOAD COMPATIBILITY The generator must be fully compatible with the rated voltage number of phases and frequency of the con nected electrical loads The generator connected elec trical devices or both can be damaged if voltage num ber of phases and frequen
7. 10 Section 5 Troubleshooting MENORES 20 PI MAN UA A ad Section 6 Electrical Data 21 2 8 1 Prior to Initial Start up 11 2 8 2 Transfer Switch 11 Section 7 Exploded Views and 2 8 8 Fuel 11 Parts Lists 30 2 8 4 Generator Set Lubrication 11 Section 8 Notes 58 2 0 0 Engine Coolant 11 _ D o qar O O O a Section 9 Warranty 60 2 8 7 Electrical System 11 2 8 8 Rodent Protection 11 Generac Power Systems Inc 1 SAFETY RULES Important Safety Instructions Guardian Liquid cooled 40 kW Generator 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 and potential operators of this equipment SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries A WARNING A The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm A WARNING A This prod
8. 15 and Recommendations 6 posco E 16 1 9 1 Conversion to LP Gas Vapor 6 4 5 Battery Maintenance 16 1 10 Engine Oil Recommendations 7 4 5 1 Battery Replacement 16 O oleo A o A 7 ALO Cooling sacacasa 17 1 12 Emission Control System 7 4 7 Overload Protection for Section 2 Installation 8 E 2 1 Basic Standby Electric System 8 48 DC Puse ds 17 2 2 Emergency Circuit Isolation Method 9 4 9 Engine Coolant eee nennen 17 2 3 Total Circuit Isolation Method 9 4 10 Miscellaneous Maintenance 17 2 4 Grounding the Generator 9 4 10 1 Cleaning the Generator d 25 Generator AC Neutral Connection oos 9 4 10 2 Rodent Protection u a 17 26 Transfer Switch Start Signal Connections 9 4 11 Out of Service Procedure eene 18 2 6 1 Pre Packaged Type Switch 9 4 11 1 Removal From Service os 18 2 6 2 GTS Type Switch 9 4 1 1 2 Return to 18 2 7 Battery Installation 10 4 12 Service Schedule career ads 19 2 7 1 Vented Batteries
9. ZN c 99 e 681 el a DO vL 0 Zu ez Sg Er v Q o6 vi L 9 9G Y __ c8 un Sg B a e vil ES 3 esl r v gt gt vs vs Bs 2 2 4 d A I I m Odd ELECTRICAL DATA 26 Generac Power Systems Inc 3SV11OA 1 1 0 OV YILIN WA dle 1S WNINYAL 251 ESL VA 9NISN3S ALMILA H3INHOJSNVHL LL 3SIOU3X3 13S HOLIMS ZMS 27 ELECTRICAL DATA Generac Power Systems Inc dO HOLO3NNOO TANVd H3MO1 OL H3 HOLO3NNOO 3NION3 OL AVnNVW 3dO O1nV HO LIMS LMS 9 1 9 1 1SOO8 YOLSIS38 YOLOATAS 3SVHd HOLIMS MSd est est y y3TIOYLNOO H3MOd Odd H3TIOHINOO GHVOE LINOHI
10. cauroN If you switch the Auto Off Manual switch is switched too soon the engine may start If engine does start it will shut down automatically in about two 2 minutes Set the generator s main circuit breaker to its ON or closed position The generator is now programmed to start and exer cise every seven days thereafter on the day and at the time of day the switch was activated 14 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator Place a sign on the generator s control panel and on the transfer switch that indicates the day and time the generator will be exercising NOTE If the battery terminals are disconnected or the con trol panel fuse is removed the exercise timer needs to be reset for automatic exercise operation Figure 3 3 Set Exercise Switch on Control Panel VOLTS SET EXERCISE TIME FAULT AUTO INDICATOR MANUAL 4 1 CHECKING THE ENGINE OIL LEVEL For oil capacities see Specifications Section 1 8 For engine oil recommendations see Section 4 2 1 To check the engine oil level proceed as follows Figure 4 1 1 Remove the dipstick and wipe it dry with a clean cloth 2 Install the dipstick cap then remove it again The oil level should be at the dipstick Full mark If nec essary add oil to the Full mark only DO NOT FILL ABOVE THE FULL MARK 3 Install the dipstick caution amp Neve
11. 4 10 1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulate on internal generator windings have an adverse effect on insulation resist ance Periodically clean the generator s 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 inspect ed by a Generac Guardian Authorized Dealer Service technicians will use dry low pressure air to clean inter nal 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 10 2 RODENT PROTECTION The intrusion of rodents into the generator set can cause a wide range of problems from failure of the unit to start to personal injury and in extreme circum stances short circuit or fire Although the unit was designed to limit this problem further precautions can be taken by the owner to help minimize both the chance of rodent entry and the extent of any damage The fol lowing inspection should be performed 1 The base frame of the unit contains an optional fuel inlet location an
12. HOSE 3 8 ID SINGLE BRAID 10 GASKET CARBURETOR ADAPTOR ASSY THROTTLE PF42 WIRE CONN WASHER LOCK 10 SCREW SHC 10 32 X 5 8 G8 8 NZ GASKET CARB IMPCO 225 SCREW PHM SEMS 12 24 X 5 8 EX NUT HEX 5 16 18 STEEL SADDLE 1 3 8 age LISTS Generac Power Systems Inc 53 ININISAPOV HO JONVNILNIVIA OIdOldAd OL LOALENS LON J8V SWALI ASSHL HO1v1n93u8 SVD ANY SATIVA GION310S H3TIOHLINOO D OILVY T3fid ulV HOSN3S N39AXO HOLAYNEYVO LSATVLVO LSnVHX3 JHL ONIGNIONI W3LSAS SIHL JO 148 Vd d 18VSIGO HO HLIM H3dlNV L LON LOIWLSIG x SC AN3IN3OVNVM ALITVND LSVOO HLNOS JHL ONIGNIONI S13S ONILVYSANSD AON39HU3IA3 03 LINDIAUVAS Joje nBay OL SNOASVD SNOILVINGAY LOILSIC HIV VINHOSIIVO NIV LH3O H LIM A TdIlNOO OL WALSAS TOHLNOD SNOISSIWA LSNVHX 3ALLOV NV HLIM QaddInO3 SI LINN SIH L NOILVINHOJNI SNOISSIIN3 1SAVHX3 LNV LHOdMI Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generators A Section 7 Exploded Views and Parts Lists Exhaust Drawing No 0E1347 LISTS PARTS qe OL ol JNION3 OL LL 8l E duelo 9 Oc amp 54 Generac Power Systems Inc ITEM CONDOR WP Section 7 Exploded Views and Parts Lists Model No 0046262 0046263 amp 004626
13. NIVIN H35 1V3H8 LINDYID 89 YOLVLS SV YOLOY HOLVNHALTV WVYSVIC SNIdIA NOZ L I 3SVHd L AOvc OcL NOILOANNOO YANOLSNO 00 OL 00 OL I3 AOp 3 OL aNao3i 219 vr 3 i o i3 0 918 O 1918 85 s e zz gN 9 9 z c 9 Ji SLO OVH3N3O QHVONVISWOH4 2005 841 NOILOANNOO 1915 Q QO SSL C e a 2 193810 cme ONIHY38 OL 1538010 a x Nu N 19 Y HOLIMS U 1 19 XH H34SNVH1 ZL Ha 3Ovxovd3ud uv S Y ESL ez TS 8 O i vol HOS MIYOS DLN Hsnug 1 L Y v esl dO HOLO3NNOO 13NVd 1OHINOO OL CN TELLA T 8 681 J OLLVIN3HOS s lt IN 1 en 4X 3SVHd A 0rz OcL NST HS NOLLO3NNOO u3io1sno lt 21 0 eJ T L3 M l
14. S D E Qu d X Y 2 o 2 5 5 Y bbbbb G O D 0 2 IN N x 2 o o o 4 5 PS 9 OO Dl T dr OO L Oo Lo A Go 9 p Oo 0 0 o o o o e ES o x 2 ca c o To ej 0 e le _ S ie O d 5 poe o f 0 T amp o a A Fe 36 Generac Power Systems Inc ITEM Section 7 Exploded Views and Parts Lists PARTS Ce LISTS Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generator Control Panel Drawing No 0D6978 C 0 PART QTY DESCRIPTION PART NO QTY DESCRIPTION 0D7397 1 PNL BTM amp BACK CNTL PNL 04626 33 081988 1 DECAL EXERCISE INFO 0D1521A 1 CONTROL PANEL FRONT W SILK 34 001229 1 DECAL CUST CONN BOX SCREEN 35 0D3440 1 CONTROLLER B C DPG 2103 0D1522 1 PANEL SIDE COVER CONTROL 36 0A3968 1 CAPACITOR FILTER ASY PANEL 37 048766 REF BLOCK TERM 20A 2 X 6 X 1100V 067680 1 ASSY VOLTAGE REGULATOR 60HZ 38 0A1441B 1 COVER PLATE AVR 008243 1 WASHER LOCK HDP
15. Turn on the utility power to the transfer switch 10 The generator is now ready for service 4 12 SERVICE SCHEDULE Section 4 Maintenance Guardian Liquid cooled 40 kW Generator MAINTENANCE LD ATTENTION It is recommended that all service work be performed by your nearest Generac Guardian Authorized Dealer SYSTEM COMPONENT PROCEDURE FREQUENCY X Action Inspect Change Clean W Weekly R Replace Adjust as Needed M Monthly Notify Dealer Y Yearly if Repair is Needed H Hours FUEL Fuel lines and connections X EVERY 3M LUBRICATION Oil level X M Oil X FIRST 9 H EVERY 150H 6M Oil filter X FIRST 9 H EVERY 150H 6M Oil line leakage X 100 H COOLING Engine cooling system X M Coolant X Y Enclosure louvers X X W EXHAUST Exhaust system X EVERY 3M Retorque Exhaust Manifold X FIRST 100 H AND EVERY 800 H BATTERY Charge and condition X R X EVERY3M FAN BELT Tension and condition X R EVERY 3M ENGINE Retorque cylinder head X FIRST 100 H AND EVERY 800 H Retorque intake manifold X FIRST 100 H AND EVERY 800 H Starter motor X R EVERY 500 H DC alternator X R EVERY 500 H AND Y Air cleaner X R EVERY 500 H Compression X EVERY 800 H Valve clearance X R EVERY 800 H Governor X R Y Safety devices X R EVERY 6M Spark plugs X R 500 H AND Y Ignition system X R EVERY 3 M GENERAL
16. 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 ventilating air is critical in any room or building housing the gen erator to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventila tion provisions as this can seriously affect safe oper ation 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 Important Safety Instructions SAFETY RULES Guardian Liquid cooled 40 kW Generator 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 electr
17. 090283 QTY O po Ba BR B o R amp fa MH Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators 4 5L Radiator Drawing No 0D7992 D DESCRIPTION RADIATOR COPPER BRASS FAN GUARD BOTTOM FAN GUARD TOP SCREW HHTT 1 4 20 X 1 CZ WASHER LOCK M6 1 4 WASHER FLAT 1 4 ZINC VENTURI 4 3L 22 FAN VENTURI 4 3L 17 FAN RADIATOR HOSE LOWER CLAMP HOSE 28 1 32 2 25 HOSE 3 8 ID SINGLE BRAID CLAMP HOSE 5 5 62 62 DRAINCOCK HOSE 9 32 ID 64 LG TAPE FOAM 1 X 1 29 LG SCREW CRIMPTITE 1 4 20 X 5 8 SCREW HHC 3 8 16 X 1 G5 WASHER LOCK 3 8 WASHER FLAT 3 8 M10 ZINC RADIATOR HOSE UPPER BOTTLE COOLANT RECOVERY WATER BOTTLE BRACKET SCREW HHTT M6 1 0 X 12 YC CLAMP HOSE BAND 1 4 SUPPORT RADIATOR A GRP BRACKET AIR DUCT TOP BOT SUPPORT AIR DUCT RH SIDE SUPPORT AIR DUCT LH SIDE SCREW HHC 1 4 20 X 1 G5 WASHER LOCK M6 1 4 WASHER FLAT 1 4 ZINC SCREEN FRONT SCREW HHTT 1 4 20 X 1 CZ WASHER LOCK M6 1 4 WASHER FLAT 1 4 ZINC CAP RADIATOR 13 PSI FOR SERVICE ONLY age LISTS Generac Power Systems Inc 47 PARTS age LISTS BI TO ENGINE ITEM CON O WP PART NO 059902A 009641 0C9650 004114A 004126 0D5787 0A5215B 0E0699 0E0698 004170 004305 002454 Section 7 Exploded Views and Parts Lists Model No 0043733 0043734 amp 0043735 Guardian Liquid co
18. 5 16 SCREW HHC 5 16 18 X 1 G5 PLUG STD PIPE 3 4 STEEL SQ HD WASHER FLAT 9 16 ZINC SCREW HHC M14 2 0 X 25 G8 8 NIPPLE TOE 3 4 NPT X 2 CLAMP HOSE 16 87 1 50 HOSE 1IN ID LP GAS 42 LG WASHER LOCK M14 NUT HEX M14 2 G8 YEL CHR DECAL FUEL INLET NG NIPPLE CLOSE 3 4 X 1 375 CLAMP VINYL 1 62 X 486 Z SPACER D C ALT 29MM LONG NOT SHOWN DECAL INLET PRESSURE GASKET AIR CLEANER CARB REWORK 4 3L SCREW HHC 3 8 16 X 1 G5 WASHER LOCK 3 8 GASKET CARBURETOR SCREW HHC 5 16 18 X 1 1 4 G5 ADAPTOR CARBURETOR W INLET GASKET CARBURETOR ADAPTOR BARBED ELBOW 90 DEG 1 8 NPT X 3 8 VALVE PCV HOSE 3 8 ID SINGLE BRAID 10 NUT HEX 1 4 28 STEEL WASHER LOCK M6 1 4 ARM THROTTLE REWORK BALL JOINT PLA 25 28 age LISTS Generac Power Systems Inc 51 Ge Section 7 Exploded Views and Parts Lists Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generators 0 4 3L Nat Gas Fuel System Drawing No 0E1338 ATTACH TO Cy FAN SCROLL T d i 29 aC 18 WS SY 24 di DE 2 EN A P S 25 gt L 7 ASSEMBLY P N 0D3509 36 TO INTAKE MANIFOLD 52 Generac Power Systems Inc ITEM YO WP NOT SHOWN Section 7 Exploded Views and Parts Lists Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generators PART NO 065907 026812 076691 007598 026490 026577 0D2758 0 0521
19. 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators 7 q 0 Engine Drawing No 0A4304 L 44 Generac Power Systems Inc ITEM con PART NO 0A9046 0A4084 0A4239 0A4240 0A5640 0A5640A 0A5639 0D3293A 077996 05 823 035579 037065 022302 0A8584 052644 0A4278A 0A4930A 0A4085 0A3927 007947 0A1232 0A7801B 021928 006239 0A4241 002885 0A5737C 022131 077456 044117 057823 057448 022129 022142 048614 022237 029745 042633 033819 022241 0A5768 046526 049814 003756 045772 0D2514 052259 055934D 0A37970001 Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Engine Drawing No 0A4304 L DESCRIPTION ENGINE 4 3L GM MOUNT ENGINE R amp L PULLEY CRANKSHAFT PULLEY WATER PUMP SPACER FAN 50MM 4 3L 35KW UNITS ONLY SPACER FAN 62MM 45KW UNITS ONLY FAN 17 REVRS ROT 35KW UNITS ONLY FAN COOLING 22 DIA REVRS ROT 45KW UNITS ONLY CAP HOSE CLAMP HOSE 10 56 1 06 BUSHING REDUCER 1 4 TO 1 8 SCREW HHC 7 16 20 X 2 1 4 G5 WASHER LOCK 7 16 SWITCH OIL PRESSURE SPACER 5 X 1 5 X 25 STL ZINC BELT SERPENTNE 72 5 HEAT SHIELD LEFT GASKET EXHAUST MANIFOLD MANIFOLD LEFT EXHAUST BOLT U 3 8 16 X 2 50 DC ALTERNATOR ASSEMBLY PULLEY PLOY V 82 OD BRACKET ALT SUPPORT BRACKET MOUNTING WELD ASSEMBLY PULLEY GROOVED IDLER PULLEY TENSIONER SPACER DC ALTERNATOR 34MM WASHER
20. CONTACTOR SM STARTER MOTOR WLS WATER LEVEL SENSOR ONLY USED ON EMISSIONS MODELS Generac Power Systems Inc 29 CH Section 7 Exploded Views and Parts Lists LISTS gt Guardian Liquid cooled 40 kW Generators 0 Mounting Base Drawing No 0E2384 A WwW N D To Oil Drain On Oil Pan 12 19 11 10 TO STARTER SOLENOID 30 Generac Power Systems Inc ITEM YO WP PART NO 003250 0388041 055414 0A4084 022129 045771 022237 029745 023152 043107 022145 027482 055597 052251 052257 052252 052259 052860 0536210098 052251A 044118 05 823 057448 024310 0D4239 0D4239A 0D4239B 038805H 022131 025507 061902 022413 022473 022097 022127 0A4010 052858 058665 059473 049820 075763 QTY PO PO D c c c c c c c c PS ome en5 c5n5 n5 o0 n5nn Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Mounting Base Drawing No 0E2384 A DESCRIPTION ASSEMBLY BASE MOUNTING DIRECT COUPLED CABLE BATT RED 1 X 31 00 LUG SLDLSS 2 8 X 17 64 CU MOUNT ENGINE R amp L WASHER LOCK 8 5 16 NUT HEX M8 1 25 G8 YEL CHR WASHER LOCK 3 8 SCREW HHC 3 8 16 X 1 G5 SCREW HHC 3 8 16 X 3 4 G5 SCREW HHC M8 1 25 X 25 G8 8 WASHER FLAT 5 16 ZINC WASHER SHAKEPROOF EXT 5 16 STL SCREW HHC M12 1 75 X 85 G8 8 DAMPENER VIBRATION 40 BLUE SPACER 49 X 6
21. DEUTSCH 39 083264 1 TFMR ASM CMA 240 12V 008244 1 NUT HDP DEUTSCH 40 0A1441C 1 COVER PLATE EGOV 0A6321 1 PANEL LEFT SIDE E 41 057335 REF BLOCK TERM 20A 20 X 6 X 1100V 048467 1 CIRCT BRK 7 X 1 ETA 46 500 P 42 076061 1 DECAL TERM STRIP 057907 1 RES WW LUG 10R 10 25W 43 029333 6 TIE WRAP 7 4 X 19 NATL UL 064008 1 COVER CON PNL TOP NOT SHOWN 44 040479 4 VIB MNT 1 0 X 1 0 X 1 4 20 0 3550 1 CHASSIS UNIVERSAL 45 022507 4 SCREW HHC 1 4 20 X 1 2 G5 055444 1 HEATSINK 46 022127 4 NUT HEX 1 4 20 STEEL 030468 1 WASHER STEP NYLON 20 47 022097 4 WASHER LOCK M6 1 4 049939 1 RECTIFIER MSC 12A 600V 1N1206R 48 033121 14 SCREW HHC 10 32 X 1 2 070370 1 WASHER MICA 203 49 022152 14 WASHER LOCK 10 022158 1 NUT HEX 10 32 STEEL 50 036902 4 SCREW PPHM 6 32 X 1 2 023762 1 WASHER SHAKEPROOF EXT 10 51 022155 6 WASHER LOCK 6 STL 52 022985 8 WASHER FLAT 6 ZINC 023897 19 WASHER FLAT 10 ZINC 53 036918 8 SCREW PPHM 8 32 X 1 2 076009A 1 PP LOGIC ASM 50 60HZ 94 022264 8 WASHER LOCK M4 040213 4 PCB SUPPORT SNAP IN 1 4 55 038150 8 WASHER FLAT 8 ZINC 0A3394 1 GROMMET 3 4 X 5 32 X 5 16 96 022471 8 NUT HEX 48 32 STEEL 082573 1 SWITCH ROCKER DPST 125V SPD 57 022188 6 NUT HEX 6 32 STEEL 076020 1 SWITCH TOG DPDT 15 10 SP 98 002428 8 SCREW PHTT 6 32 X 1 2 ZYC 032300 1 HOLDER FUSE 99 002323 4 SCREW PHTT 6 32 X 5 8 ZYC 022676 1 FUSE 15A X AGC15 60 0A2284 4 SCREW SWAGE 8 32 X 1 2 Z YC 064009 1 LIGHT 12VDC 02A LED RED PILOT 61 001127 1 DECAL AVR COVER 061945 1 SWITCH SELECT
22. L L M IS zu e zo Z 98 bl vi a A 00 LL 9G Y L 0 jid GL 96 98 LN vi IS is dL aon 9 m 61 ES ZN cg e gS ZS 00 LL SL qaq 8S sts J T n yovga NM 841 m ZN ZN a NM LS ez yovia 99 2 00 IN cel el e 82 Nid sis Q dO EN dVO vi m 9 58 y LN c 98 3 915 vl ei 9 ZN Rae 8888888 ag a zz 2 S gt e ON loe gt gt 9S pl 4 1 0 gt H vi E 39NVHO Q H pl el o e MOTA Z2 tz 21 99 AS m vi o NWOHH 32 Q en yi NDD e e xovi8 96 0 9S 9 681 Sg r r J ama ania ang 821 821 dO HOLO3NNOO TANVd H3MO1 OL 81 81 61 61 FOVLIOA 18110 OV
23. Overall condition X X M Exercise system W COMPLETE TUNE UP TO BE COMPLETED BY A GENERAC Y GUARDIAN AUTHORIZED DEALER Generac Power Systems Inc 19 TROUBLESHOOTING Section 5 Troubleshooting Guardian Liquid cooled 40 kW Generator 5 1 TROUBLESHOOTING GUIDE PROBLEM The engine will not crank CAUSE 1 Fuse blown CORRECTION Replace fuse 2 Loose corroded or defective 2 Tighten clean or replace battery cables as necessary 3 Defective starter contactor oe 4 4 Defective starter motor 4 5 Dead Battery 5 Charge or replace battery The engine cranks but 1 Out of fuel 1 Replenish fuel will not start 2 Defective fuel solenoid FS 2 3 Open Z14 wire from Se 7 engine control board 4 Defective spark plug s 4 Clean re gap or replace plug s 5 Dirty Blocked air filter 5 Clean or replace as required The engine starts hard 1 Air cleaner 1 Check clean or replace air cleaner and runs rough plugged or damaged 2 Defective spark plug s 2 Clean re gap or replace plug s 3 Dirty Blocked air filter 3 Clean or replace as required The engine starts but then 1 Engine oil level low 1 Check oil and add oil as needed shuts down 2 Defective low oil 2 7 pressure switch 3 Defective high temperature uo switch 4 Defective control board 4 5 Low coolant level 5 Check coolant level repair leaks and refill The Auto Off Manual switch 1 Defective switch is s
24. YALA WA ed ed 5 diH LS TVNIINH3L S1 LS VAbZ ONISN3S ALITILN HIWHOJSNY HL LHL ZN ZN D 3SI043X3 13S HOLIMS ZMS IVANVINW 4JO OLNV HOLIMS LMS IN IN 18008 01314 YOLSIS38 LH 84 6 HO10313S 3SVHd HOLIMS MSd 21 21 H3TIOHLNOO LINDHIO 80d 2 HOLVOIQNI Ln v4 HOT 17 841 v6l LL LL k AONANDSYS YILIN ZH r oc YILINENOH WH 1 LINN H3TIOHLNOO HONYSAOD 125 22 mM 3NIT NI Sd 94 390 25 HOLWN LOV Oo SdNV SL 3Snd 14 HONHUHAOS OL 19 o oeo y o vz A009 30010 1 035010 SALVOIGNI X al bh er NOILV LLIOX3 LINOYIO 199 iN y S S IX IGI am o Q HOLIOVdVO dvO eN X x 0 erst o NV o 89 go 35V L10A AY3LLV8 YILIN WAG yOLO3NNOO o O O X rs iad zi H3TIOHLINOO HOLWINDAY JOVLIOA DILVINOLNV HAV ZSL i o o WO 1IN388N9 LNALNO Ov YILIN WV o o ox ea T z X X H2 lt X X oO x 1 2 te gt aNn3931 x x x O 6 2 Lo o 1919 1 150 Z v SLOVLNOO 2 yovga 6 6 NOILISOd ZL oxo oD v9 o e G G LHL gt E 3 3 279 8 es A Le o e LLL m 2 6L eer p 3 LVINSNI NA loe o_o ai 00 S I 3SVHd A80Z SHIM MOTIZA ISN rn gh 91 3SvHd A0FZ an1g ISN no 86 oe IS mM E Q MOVI8 MSd A i gis 915 E er LL HO LI
25. 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 orEXPLOSIVE 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 uel 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 FLAM
26. 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 inter vals please refer to Section 4 Maintenance 2 8 2 TRANSFER SWITCH If this generator is used to supply power to any electri cal system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents electrical backfeed between two different electrical systems 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 compli ance with applicable codes standards and regulations 2 8 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 Section 1 8 Specifications for more information 2 8 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 Section 1 8 Specifications and Section 1 10 Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with
27. l v9 5 gt o m E Cit N 915 n z Aowa 3 340 1VANVWOLNV HOLIMS LMS x 18009 01315 HOLSISSY LH e 59 Sl 289 HO 0313S 3SVHd HOLIMS MSd ON ZMS VSZ2 H3TIOHLNOO QHVOS LINDHID 80d Y HOLVOIQNI LIV 1 911 11 59 vk vk NOLLO3NNOO TANWd H3MO1 291 LL LL AON3hO3H YILIN ZH e Odud im 2 ZL ZL YSLSWYNOH WH iud LINN HONH3AOO NOD D Tz O VSL 3NITNI 94 ISNA VS 38N3 14 TT Panas o5 NOLLO3NNOO SS3NHVH 3NION3 wil oO co 8 1 L Jovia o si YZL A009 JGOIG 1 59 D Wet 2 IN TANVd H3MO1 NOLLO3NNOO dO E 3 T Uses d S NOLLV LIOX3 LINOHIO 180 330 HOLIOVdVO dVO OI G WA Y 0 2i En 3OV L1OA AY3L1V8 YILIN WAS i LMS N ZSL HOLVINDSY SDVLIOA OILVWOLNY HAV c S A IVANVI LEV LS SHE INAYHND LNdLNO OV BLAN WY 9 ost osi AOA e i 9 La QN3931 S e NS EN m w 6c IS Y M a 19 00 s 0 95 P Ll ar S eilor e v H3 9 MSd s v ez 5 915 err e z ti 0 p O amp y B GIS IS v6L vi LY im 89 fo ama vl 291 O el 89 re 7 N N N O 9 LL vl UY v6L I Oc 19 SY SS 9 O P Oro ZH vl 0 230 58 189 Sg LN p vl 1 x S e 2 4 _ pa m 918 ES y 0 ZN gt a 0 291 O O X 00 PI 91S 915 915 8 E 91S SIS GIS SIS S 9 9 9 9 HAV 915 e s 0 H c ne J er o5
28. regulator These items are not sub ject to periodic maintenance or adjustment This model is of a size greater than 50 brakehorse power that may require a review by air permitting authorities prior to installation and operation Consult the local air management district for details and spe cific requirements Figure 1 4 Emissions Control System Regulator Carburetor A F Mixture Vacuum A F Ratio Controller Control Valve Q2 Sensor Throttie 3 Way Catalysi 1 12 1 AIR FUEL RATIO CONTROLLER The air fuel ratio controller is an advanced micro processor designed to work with a three way catalyst and a feedback rich bias carburetor to provide close loop fuel management Its digital adaptive control is able to compensate for variations in fuel mixtures and engine tunes It is time based activated For example it will activate after 45 seconds from receiving the power signal The part number for the air fuel ratio controller is 004221 Principle of Operation The oxygen sensor installed on the exhaust pipe between the engine and the cat alytic muffler closer to the engine continuously moni tors the exhaust gas composition A feedback signal is sent from the oxygen sensor to the air fuel ratio con troller which controls the fuel system to maintain the optimal stoichiometric air fuel ratio The air fuel mix ture to the engine is controlled by biasing the diaphragm
29. 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 ofa transfer switch so as to isolate the genrator electric system from the utility electric system while in oper ation 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 automatically 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 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
30. source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to per sonnel do not connect battery cables until the normal source voltage at the transfer switch is cor rect 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 bat tery 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 A 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 WARNING amp Do not dispose of the battery in a fire The battery is capable of exploding Do not open or mutilate the battery Released A electrolyte can be toxic and harmful to the skin and eyes A The battery represents a risk of high short circuit current When working on the battery always remove watches rings or other metal objects and only use tools th
31. water WARNING amp Do not dispose of the battery in a fire The bat tery is capable of exploding 1 Do not open or mutilate the battery Released electrolyte can be toxic and harmful to the skin and eyes A The battery represents a risk of high short circuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles 4 5 1 BATTERY REPLACEMENT Generac uses a Group 27F vented type battery that has 600 CCA 0 F Generac s part number is 058665 NOTE The BCI number should be located directly on the battery Guardian Liquid cooled 40 kW Generator 4 6 COOLING SYSTEM Air intake and outlet openings in the generator compart ment must be open and unobstructed for continued prop er operation This includes such obstructions 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 WARNING amp A The exhaust system of this product gets extremely hot and remains 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 7 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state engine controller circuit board Battery volt
32. 002775 028238 022145 022129 030795 025655 022132 051778 028641 057824 057422 043123 051779 007820 050279 026915 055934P 0A5737C 0D1509 061258 0C7650A 029745 022237 007059 033212 0A4120 064945 0A6344 0A4121 047290 0C7060 0D3485 022152 0C7908 0A6613 064090 022259 028237 QTY D A Po A Aa a A o c c c BR PO PO B PB PO PS 4 3L Nat Gas Fuel System Drawing No 0E1338 DESCRIPTION SUPPORT SOLENOID NAT GAS ELBOW 90D 3 4NPT NIPPLE PIPE 3 4 NPT X 4 5 BLK IRN ASSY NATURAL GAS SOLENOID NIPPLE PIPE 3 4 NPT X 2 BUSHING REDUCER 1 TO 3 4 REGULATOR N G R600S SUPPORT REGULATOR BRACKET REGULATOR 4 3L BOLT U 5 16 18 X 1 50 WASHER FLAT 5 16 ZINC WASHER LOCK 8 5 16 SCREW HHC 5 16 18 X 1 G5 PLUG STD PIPE 3 4 STEEL SQ HD WASHER FLAT 9 16 ZINC SCREW HHC M14 2 0 X 25 G8 8 NIPPLE TOE 3 4 NPT X 2 CLAMP HOSE 16 87 1 50 HOSE 1IN ID LP GAS 44 LG WASHER LOCK M14 NUT HEX 14 2 G8 YEL CHR MACHINING CARBURETOR ADAPTOR DECAL FUEL INLET LPG NIPPLE CLOSE 3 4 X 1 375 CLAMP VINYL 1 62 X 486 Z SPACER D C ALT 29MM LONG DECAL INLET PRESSURE GASKET AIR CLEANER MIXER EMISSIONS NATURAL GAS SCREW HHC 3 8 16 X 1 G5 WASHER LOCK 3 8 GASKET GOVERNOR THROTTLE BODY SCREW HHC 5 16 18 X 1 1 4 G5 ADAPTOR CARBURETOR W INLET GASKET CARBURETOR ADAPTOR BARBED ELBOW 90 DEG 1 8 NPT X 3 8 VALVE PCV
33. 022237 022241 022145 022129 045771 JJ T RRR RPP HP po mo no no G G K gt G co Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Connection Box Drawing No 0D8848 B DESCRIPTION LOWER PANEL 15 COVER LOWER CONNECTION BOX BUSHING SNAP SB 2 5 31 RELAY SOLENOID 12VDC PNL MNT DECAL REMOTE START CONNECTION TRANSFORMER 200A TO 5A 5VA HARNESS LOWER PANEL 4 3L GRDN BLOCK TERM 20A 2 X 6 X 1100V WASHER FLAT 6 ZINC COVER LOWER PANEL 15 DECAL CUSTOMER CONNECTN FOR TS WASHER LOCK M4 SCREW PHTT M4 0 7 X 16 ZYC SCREW HHC 5 16 18 X 3 4 G5 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR SCREW HHC 1 4 20 X 3 4 G5 WASHER FLAT 1 4 ZINC WASHER LOCK M6 1 4 NUT HEX 1 4 20 STEEL CB 0200A 3P 600V S FD6 LL PLATE CB MOUNT S FD 3905 COVER CB TERMINALS S FD 3P WASHER LOCK M6 1 4 SCREW HHC 1 4 20 X 3 4 G5 NUT HEX 1 4 20 STEEL WASHER FLAT 1 4 ZINC SCREW SHC 1 4 20 X 4 5 G8 8 NZ WASHER LOCK 3 8 SCREW SHC 3 8 16 X 3 4 G5 NEUTRAL BLOCK 390 200 400A JUNCTION BLOCK 3 8 16 WASHER LOCK 10 SCREW PHM 10 32 X 5 8 CAD WASHER LOCK 3 8 NUT HEX 3 8 16 STEEL WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR age LISTS Generac Power Systems Inc 39 Ge us Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generato
34. 046852 1 SCREW HHTT 10 32 X 1 4 CZ 26 022145 1 WASHER FLAT 5 16 ZINC 27 039287 4 SCREW 8 1 25 X 45 G8 8 FT 28 071641 1 BRUSH HOLDER ASSEMBLY 29 071639 1 HOLDER BRUSH SUPPORT 30 0A2110 2 SCREW SWAGE 1 4 20 X 1 2 Z YC 31 022473 8 WASHER FLAT 1 4 ZINC 32 022746 1 SCREW HHC 3 8 16 X 1 3 4 G5 33 031980 2 TIE WRAP UL 14 6 X 14 NATL 34 083549 1 SLEEVE RUBBER 35 0A4089 1 ASSEMBLY SCROLL 390 SAE KIT 044089 PARTS 36 0A2491 2 SHROUD ALTERNATOR SHEET METAL 37 0A2497 2 SCREEN SHROUD SAE 38 0A2496 2 BRACKET TENSIONER SAE SCROLL 39 056326 8 4 FT TRIM VINYL BLACK 1 8 GP 40 022097 6 WASHER LOCK M6 1 4 41 045757 2 SCREW HHC M6 1 0 X 25 G8 8 42 047411 4 SCREW HHC M6 1 0 X 16 G8 8 43 0A2110 12 SCREW SWAGE 1 4 20 X 1 2 Z YC ROTOR REPLACEMENT PARTS Generac Power Systems Inc 41 Ge us Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators 0 Engine Drawing No 0D6980 B 16 To Air Cleaner gt m 7 Coil O C 42 Generac Power Systems Inc PART NO 0A9046 0A9118A 070022 0A6021 0590564 0A9050 022237 045772 049226 051716 0A4244 0A4215 0A4231 059057 0A2440 026568 099729A 061012 069939 035606 0A4930B 0A4084 029745 044101 023152 022131 058030 0A4085 0A3928 0C7947 057794 0A4277 022241 057795 048191 032303 0A3852 098239 057522 0D2244M 075885 0D6979 0A4
35. 2 X 1 87 PWDR ZINC DAMPENER VIBRATION WASHER FLAT M12 NUT LOCKING M12 1 75 ASSEMBLY GROUNDWIRE 10 3 8 DAMPENER VIBRATION 50 WHITE BARBED STRAIGHT 1 2 NPT X 5 8 CLAMP HOSE 10 56 1 06 HOSE 5 8 ID TYPE 3 SINGLE 11 LG PLUG STD PIPE 1 2 STEEL SQ HD KIT VARMIT GUARD FOR N G L P VAPOR OR DUAL FUEL N G LP LIQUID UNITS KIT VARMIT GUARD FOR L P LIQUID UNITS KIT VARMIT GUARD FOR DUAL FUEL N G L P VAPOR UNITS CABLE BATT BLK 1 X 23 00 WASHER FLAT 3 8 M10 ZINC WASHER SHAKEPROOF EXT 7 16 STL HOLD DOWN BATTERY SCREW HHC 1 4 20 X 1 G5 WASHER FLAT 1 4 ZINC WASHER LOCK M6 1 4 NUT HEX 1 4 20 STEEL SCREW HHC 8 1 25 X 60 G8 8 FT NUT LOCK FL M8 1 25 BATT 12VDC 90 AH 27F HOLD DOWN BATTERY NUT LOCK HEX M8 1 25 NYL INSRT BOOT BATTERY CABLE PARTS ib ies O Generac Power Systems Inc 31 Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Compartment Drawing No 0D8992 PARTS 18 17 32 Generac Power Systems Inc PART NO 003594 0A3359 0A3360 002522 002527 002528 002535 002536 002547 002550 002555 002560 0D7904 002633 006749 060069 006748 080490 087233 25 22 22 25 25 55 55 55 25 25 022145 QTY 10 40 40 5 N NO Po WG OO
36. 3 1 8 15 amp FUSE 12 1 1 1 Lifting the Generator 4 3 1 9 7 5 Amp Inline Fuse 12 1 2 The Generato siii ia 4 3 1 10 Voltage phase Selector Switch 12 1 3 Generator AC Connection Systems 4 3 1 11 Set Exercise Time Switch 12 1 4 Prepackaged Transfer Switch 4 3 2 Using the Auto Off Manual Switch 12 ES On s b S 21 Aulo POSO seins 12 1 6 Main Circuit Breaker 5 3292 Position LLL 13 1 7 Engine Protective Devices 5 32 3 Manual Position LL 13 salen SOW s s 5 3 3 Automatic Transfer Operation 13 3 4 Sequence of Automatic Operation 13 MODO LM 5 dl 13 3 6 Weekly Exercise Cycle 14 1 7 4 Overspeed Shutdown 5 i l5 eee le SES dom eee oe 5 Section 4 Maintenance 14 WC Buses eee et died nu E UNE 5 4 1 Checking the Engine Oil Level 14 18 Specifications 5 4 2 Changing the Engine Oil and Filter 15 GOnEraloL sidad 5 4 2 1 Engine Oil Recommendations 15 1332 o ee eee 6 4 2 2 Oil and Filter Change Procedure 15 1 9 Fuel Requirements 4 3 Changing the Engine Air Cleaner
37. 308 QTY ND A A A O D BD nc Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Engine Drawing No 0D6980 B DESCRIPTION ENGINE 4 3L GM FLYWHL 4 3L GM SAE WASHER STAR M12 EXT SCREW HHC 7 16 20 X 1 G8 STARTER 5 7L 7 4L GM BOLT STARTER 4 3L WASHER LOCK 3 8 NUT HEX M10 1 5 G8 YEL CHR WASHER LOCK M5 NUT HEX M5 0 8 G8 YEL CHR CONNECTOR COIL TO DISTRIBUTOR DIP STICK 4 3L GM TUBE DIP STICK 4 3L HOSE 3 4 ID SAE 30R2 GASKET THERMOSET SCREW HHC 3 8 16 X 2 3 4 G5 HOUSING THERM IMPREX PLUG STD PIPE 1 8 SOCKET HEAD HOUSING THERMOSTAT WATER INLET SENSOR HI COOLANT SHUTDOWN HEAT SHIELD RIGHT MOUNT ENGINE SCREW HHC 3 8 16 X 1 G5 BRACKET SUPPORT SPARK PLUG WIRE SCREW HHC 3 8 16 X 3 4 G5 WASHER FLAT 3 8 M10 ZINC RETAINER PLUG WIRES GASKET EXHAUST MANIFOLD MANIFOLD RIGHT EXHAUST BOLT U 3 8 16 X 2 50 RETAINER SPARK PLUG WIRES WIRES SPARK PLUG 4 3L NUT HEX 3 8 16 STEEL CONNECTOR C C VENT PIN DOWEL M10 X 24 SCREW HHC 3 8 16 X 3 1 2 G5 PLATE FLEX GM CASTING ADAPTOR SENSOR COOLANT LEVEL ASSY MAGPICKUP 3 8 24 MALE MODEL 004626 ONLY THERMOSTAT 195 DEG 40KW GUARDIAN WIRE HARNESS NOT SHOWN FOR MOD 004626 0 HARNESS 4 3L STD WIRE NOT SHOWN FOR MOD 004373 1 LISTS age Generac Power Systems Inc 43 us Section
38. 4 Guardian Liquid cooled 40 kW Generators PART NO 059902A 009641 0D4208 0D5061 004126 0D5787 0A5215B 0E0699 0E0698 004170 004305 002454 003433A 022129 022145 045771 042907 080762 022237 022241 0E0701 0E0700 077879 0D4221 0D4512 043116 022471 022264 038150 036918 049811 022097 049813 0D8780 022131 QTY S S SS F ro Exhaust Drawing No 0E1347 A DESCRIPTION CAP RAIN 2 50 2 69 TUBE STRAIGHT A GROUP MUFFLER CATALYST 4 3L MOUNTING BAND A GRP CATALYST BRACKET MUFFLER MOUNTING TUBE ELBOW 90 DEG 2 5 PIPE FLEX 2 5 TUBE CROSS OVER TUBE 90 ELBOW BRACKET EXHAUST SHIELD SHIELD A GRP HEAT SCREW TH FRM M6 1 X 16 NWA Z JS CLAMP BAND 2 5 WASHER LOCK 8 5 16 WASHER FLAT 5 16 ZINC NUT HEX M8 1 25 G8 YEL CHR SCREW HHC M8 1 25 X 16 G8 8 BOLT U 3 8 16 X 2 62 WASHER LOCK 3 8 NUT HEX 3 8 16 STEEL SHIELD CROSSOVER HEAT SHIELD EXHAUST HEAT HOSE VACUUM 5 32 36 LG KIT AIR FUEL RATIO CONTROLLER BRACKET AIR FUEL CONTROLLER SCREW HHC M6 1 0 X 12 G8 8 NUT HEX 8 32 STEEL WASHER LOCK 8 4 WASHER FLAT 8 ZINC SCREW PPHM 8 32 X 1 2 WASHER FLAT M6 WASHER LOCK M6 1 4 NUT HEX M6 X 1 0 G8 YEL CHR DECAL IMPORTANT EXHAUST EMISSION INFO WASHER FLAT 3 8 M10 ZINC NOTE COMPONENT INSTALLED AT WAUKESHA FACILITY PARTS LISTS OG Generac Power S
39. Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 e AGRICULTURAL WIRING HANDBOOK obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 e 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 e 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 e NEC HANDBOOK available from the National Fire Protection Association 1 Batterymarch Park PO Box 9146 Quincy MA 02269 9959 2 1 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic diagram of a basic stand by electric system Both the UTILITY power supply and the STANDBY generator output are connected to an approved transfer switch The transfer switch is required by electrical code and serves the following functions Permits the LOAD circuits to be connected to only one power supply at a time Prevents electrical backfeed between STANDBY power 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 NOTE Generac recommends the use of a Generac Power Systems pre packaged type transfer swi
40. E 120VAC GREEN SUPPLY BLACK LEGEND ACTUATOR ELECTRONIC GOVERNOR DC ALTERNATOR BATTERY CONTROL CONTACTOR ENGINE CONNECTOR 1 BLACK ENGINE HEATER FUEL SOLENOID GROUND COOLANT HIGH TEMP SWITCH IGNITION COIL IGNITION DISTRIBUTOR LOW OIL PRESSURE SWITCH MAGNETIC PICKUP 1 STARTER WATER LEVEL SENSOR ONLY USED ON EMISSIONS MODELS 28 Generac Power Systems Inc Section 6 Electrical Data Guardian Liquid cooled 40 kW Generators Wiring Diagram Drawing No 0E2967 FREE gt ww ACT BET 161 161 lt 1 160 160 2 O lt 4 85 85 6 MM Pra O BLACK O 7 os MP1 NN O BARE 8 WLS LOS SS gt gt CLEAR 79 9 FS 14 10 12V BATTERY 18 mio ID i BLACK e RED IC Piel SC Sc 16 13 i CC LEGEND ACT ACTUATOR ELECTRONIC GOVERNOR ALT DC ALTERNATOR CC CONTROL CONTACTOR EC1 ENGINE CONNECTOR 1 BLACK BLACK 120VAC EH ENGINE HEATER EH WHITE UTILITY FS FUEL SOLENOID GREEN SUPPLY HCT COOLANT HIGH TEMP SWITCH IC IGNITION COIL ID IGNITION DISTRIBUTOR LOS LOW OIL PRESSURE SWITCH MP1 MAGNETIC PICKUP 1 SC STARTER
41. ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsi ble for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warrante
42. FLAT 3 8 M10 ZINC ADAPTOR M12 1 75 3 8 NPT BARBED STRAIGHT 3 8 NPT X 5 8 CLAMP HOSE 10 56 1 06 HOSE 5 8 ID TYPE 3 SINGLE 12 WASHER LOCK 8 5 16 SCREW HHC 5 16 18 X 3 4 G5 45KW SCREW HHC 5 16 24 X 3 4 G5 WASHER LOCK 3 8 SCREW HHC 3 8 16 X 1 G5 SCREW HHC 3 8 24 X 1 G5 SCREW HHC 3 8 16 X 4 G5 NUT HEX 3 8 16 STEEL WASHER FLAT HEAVY DUTY WASHER LOCK M10 SCREW HHC M10 1 5 X 25 G8 8 BOLT TENSIONER PULLEY NUT HEX M10 1 5 G8 YEL CHR SPARK PLUG 5 7L GM WASHER FLAT M12 CLAMP VINYL 1 06 X 406 Z FILTER OIL age LISTS Generac Power Systems Inc 45 LISTS Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators 4 3L Radiator Drawing No 0D7992 D 21 10 KIT PART NO 0D8121 N st O gt N Q O O Z lt ej O x O CN O gt 00 zo KIT PART NO 0D7948 46 Generac Power Systems Inc ITEM NOOB WP 36 k k 37 k k 38 k k 39 40 OPTIONAL WITH KIT 0D7948 OPTIONAL WITH KIT 0D7947 PART NO 0D7825 0D8251 0D8252 024655 022097 022473 0D7174 0D7174A 0D7870 035685 047290 040173 036865 029032 052250 058443 029745 022237 022131 0D7850 076749 0D7975 090388 048031C 0C4341 0A6984 0D7942 0D7943 022413 022097 022473 0D7924 024655 022097 022473
43. GINE HEATER This Generac standby generator comes equipped with a block heater Figure 3 2 page 14 that is similar to the block heaters used in automotive applications The block heater must be connected to a customer supplied 120V AC circuit Generac Power Systems Inc 13 MAINTENANCE LD Section 4 Maintenance Figure 3 2 Engine Block Heater Refer to applicable wiring diagram s and electrical schematic s at the back of this manual for wiring con nections 3 6 WEEKLY EXERCISE CYCLE The generator will start and exercise once every seven days During this weekly exercise the unit runs for approximately 20 minutes and shuts down Transfer of loads to generator output does not occur during the exercise unless power is lost during the exercise period To select the day of the week and time of day for exer cising proceed as follows Set the Auto Off Manual switch to OFF e Set generator s main circuit breaker to its OFF or open position e Locate the rocker switch on the control panel identi fied with the words Set Exercise Time Figure 3 3 e Push Set Exercise Time switch to the ON position for 20 to 30 seconds and then release The switch will spring back into its original position when released e Wait 30 seconds before setting the Auto Off Manual switch to the AUTO position NOTE The unit will exercise 20 minutes before it is set Example Set Noon Exercise 11 40 a m
44. GUARDIAN by Generac Power Systems Inc Owner s Manual Liquid cooled Prepackaged Standby Generators Models 0043733 0043734 amp 0043735 40 kW Single phase w 200 Amp Transfer Switch 0046262 0046263 amp 0046264 40 kW Single phase w 200 Amp Transfer Switch California Emissions 200005 000000 000000 10 000005 000000 1 000000 800000 000000 000 A Not intended for use in critical life support applications caution amp ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY This manual should remain with the unit INTRODUCTION Thank you for purchasing the Guardian product line by Generac Power Systems This model is a compact high performance liquid cooled engine driven gen erator designed to automatically supply electrical power to operate critical loads during a utility power failure This unit is factory installed in an all weather metal enclosure that is intended exclusively for outdoor installation READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact Generac or the nearest Generac Guardian Authorized 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 operation th
45. MABLE 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 Generac Power Systems Inc 3 Section 1 General Information 1 1 UNPACKING INSPECTION After unpacking carefully inspect the contents for dam age e This standby generator set has been factory installed in an all weather metal enclosure that is intended exclusively for outdoor installation WARNING amp If this generator is used to power electrical load circuits normally powered by a utility power source code requires to install a transfer switch The transfer switch must effectively isolate the electrical system from the utility distribution sys tem when the generator is operating NEC 701 Failure to isolate an electrical system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy If any loss or damage is noted at time of delivery have the person s making the delivery note all damage on the freight bill or affix his or her signature under the consignor s memo of loss or damage A If there is loss or damage after delivery separate the damaged materials and contact the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package that is not in evidence
46. MS HOLO3 3S 3SVHd sis m vk 3078 e 915 _ gis mM o f ania e 3m ZH e l d ji E a I SIS LE o e N F LL r M A cl I AMOO qat aay ZL l SIS 95 B d O A 81 IS aio ania 922 SL vl 9 V UY 8 1 Ld 6 ez ez 9 SIS del v6L v6L v 0 y lt 9 E oad 91 91 3 99 las a E eL i 0 91 091 291 21 HAV ola IH 5 N VSL 0 6 tt S Z amp 9 1 Am SL by pl s XA ezz bl Z SL 0 vaze 8 1 99 0 91 LMS M c Z ut B 6 v Sg I ON eel i Mees md NS 0 e wag 091 2 1 091 62 J N 98 lt Q O QA pe 5 0 VSI Q VN a _ n NOILISOd 440 0 INH YL vI rl i vl L Q el 622 622 t GI GL 91 pl ISL dvo ELECTRICAL DATA H3 HOLO3NNOO 3NION3 OL 24 Generac Power Systems Inc ELECTRICAL DATA gt 4 Section 6 Electrical Data Guardian Liquid cooled 40 kW Generator Wiring Diagram Schematic Lower Panel Drawing No 005997 NOLLO3NNOO 1HVIS SYIM 2 dlH1S TWNINYAL rS L NOLLO3NNOO HOLIMS YSSSNVYL Q39vMOVd 3Hd diHLS TVNIINH3L ESL 8319310Y4d TVINddH1 dl 39018 WHLAAN 8N ONIGNIM NOILV LIOX3 YAIWYOASNVYL LN3HHfO ZLO 8 119 TANVd H3MO HOLO3NNOO T3NVd TOHLNOO dO
47. 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 CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for Guardian models 0043733 0043734 0043735 0046262 0046263 amp 0046264 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 Guardian Authorized Dealer Normal maintenance service and replacement of maintenance 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 mainte nance service Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum See a Generac Guardian Authorized Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact a Generac Guardian Authorized Dealer for assistance Service technicians are factory trained and are capable of handling all
48. O 99 vol vol YOLVOIGNI LINY4 LHD 11 AONANOAYS YILIN ZH ez ez YILINENOH WH 3NITNI Sd S Z SN 23 SdNV SI ASN4 14 oN oN vz A009 3QOlG NOLLV LIOX3 43AV3Y9 LINOHIO 199 HOLIOVdVO dvO LN LN G LA 39V L10A AH3LLV8 YILIN old m YOLVINDAY ADVLIOA OLLVNOLNV HAV G 1N388N9 LNdLNO OV YILIN WY ZL ZL 841 vol A A aN3931 e81 ez LL LL I Y 091 um A sz n O 6 035010 S31VOIdNI X ES Hm cdi LL 2 xjojo vL 6l o_o i Sic o EE yy NEN E 0 o oox vL SL 2 9 L e o xjojo 1 gt o x o Z z o T au t 8 o ojo X 2l 0 m o gt x X X pz o Sl z X X O x Z z Ww A x X X o o o HdO Z Movi1a is 2 NOILISOd 9 LHL 3 3 m gt ES 1 z o e o i U 3 9 LL m P Pa 3LWINSNI NA lee o o to 00 u 3SVHd A802 HOS 38IM MOTT3A ISN cL SL 9 3SVHd AOve HOS SHIM ANTE ISN Odd o o IS 3 S 918 x A ee SE E t ls MSd 915 zo HOLIMS HO10313S SSVHd sis 5 O vi Q vi 1vg 915 GIS ZH U 5 S GLS 9 291 o o amp 0 0 A E H 2 Yuu Zl Il SIS 915 9 ll 81 915 8 2 39 vaze SL vl 91 Zk V 9 821 Ld ez e
49. OR 6A AMP V 62 0D5324 4 FUSE amp HOLDER LITTEL 7 5A 076037 1 VOLTMETER DC 8 18V 63 0A9611 1 FUSE 7 5AXBK AGC7 5NX W 22670 070081 1 HOURMETER 64 074908 4 SCREW HHTT M5 0 8 X 10 BP 070043 1 VOLTMETER AC 0 300 69 0E3783 1 DECAL WARNING REMOVE FUSE 070045 1 AMMETER AC 0 200 070042 1 FREQUENCY METER 240V 55 65HZ PART OF CONTROL PANEL WIRE HARNESS Generac Power Systems Inc 37 PARTS qp is OG we te ES LEADS amp PM SENSING WIRE Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Connection Box Drawing No 0D8848 B o SIEMENS A 7 ALT LEADS amp SENSING 12 29 30 FD 3 POLE ya Vy 600V WIRE 45 200A lt RECOMMENDED TERMINAL TIGHTENING TORQUES FOR CIRCUIT BREAKER AND NEUTRAL BLOCK ITEM RING TERMINALS FASTEN COMPRESSION STRIPPED END OF STRANDED DESCRIPTION FROM ALTERNATOR LUG TO CIRCUIT BREAKER CABLE TO COMPRESSION LUG 40 s 30 FT LB NA NA 40 ODE NA 12 5 FT LB 23 FT LB 52 NEUTRAL BLOCK 19 FT LB NA 23 FT LB 33 Generac Power Systems Inc PART NO QTY 068115 0D5489 023484N 056739 0D3388 058710 0D5492 048766 022985 068116 0D5840 022264 002212 022142 022145 022129 045771 022287 022473 022097 022127 0D5574 0D5689 0D5693 022097 022287 022127 022473 081320 022237 048527 0D5464B 057073 022152 033530
50. OVIDE ACCESS TO MUFFLER FOR SERVICING mn 158 6 22 CENTER OF ENGINE SERVICE CONNECTIONS GRAVITY a 981 38 62 INLET NATURAL GAS 3 4 NPT COUPLING OIL DRAIN 1 2 NPT COUPLING 1930 75 98 EXHAUST OUTLET 2 5 OD MUFFLER OUTLET RIGHT SIDE VIEW Generac Power Systems Inc 21 Section 6 Electrical Data EPECTBIDAT Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generator 4 DATA gt Electrical Schematic Stepper Motor Drawing No 045858 150 219 Sue CIS O O O exe GCB BLACK RED P N 98647 BLUE 6 BLUE 9 LEGEND S15 GCB GOVERNOR CONTROL BOARD HZ FREQUENCY METER TB1 TERMINAL BLOCKS 22 Generac Power Systems Inc gt ELECTRICAL DATA 38M GASNNN ALVINSNI 3SVHd A802 HOS 3HIM MOTT3A ASN 3SVHd AO0vz HOS SHIM 318 ISN
51. PART NO QTY DESCRIPTION 1 0C4905 1 BARBED EL 45 FITTING 2 057822 2 CLAMP HOSE 88 53 1 00 3 077043E 1 CONDUIT FLEX 1 BLACK 15 LG 4 050967 1 HOSE 5 8 ID RIA 250F 46 LG 5 0A6283 1 HOSE PREFORMED BLOCK HEATER 6 057822 2 CLAMP HOSE 8 53 1 00 7 053660 1 BARBED STR 1 4 NPT X 5 8 8 042568 4 SCREW HHC M6 1 0 X 20 G8 8 9 022473 4 WASHER FLAT 1 4 M6 ZINC 10 084918A 1 HEATER ENG 1000W 120V 084918B 1 HEATER BLOCK 1000W 240V 11 084427 1 BRACKET HEATER W WELDNUTS 12 022097 4 WASHER LOCK M6 1 4 13 049813 2 NUT HEX M6 X 1 0 G8 YEL CHR 14 055934D 1 CLAMP VINYL 1 06 X 406 Z NOT SHOWN 15 077043A 1 CONDUIT FLEX 38 ID 42 LG NOT SHOWN USED ON HEATER CORD USED ON 50HZ VOLTAGE GENERATORS ONLY USED ON NATURAL GAS amp L P VAPOR UNITS ONLY Generac Power Systems Inc 57 NOTES Section 8 Notes Guardian Liquid cooled 40 kW Generators 58 Generac Power Systems Inc Section 8 Notes NOTES Guardian Liquid cooled 40 kW Generators Generac Power Systems Inc 59 Section 9 Warranty WARRANTY Guardian Liquid cooled 40 kW Generators CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the state s stringent anti smog
52. PRE PACKAGED TYPE SWITCH Connect the six signal wires from the automatic trans fer switch to the engine generator control which is located on the upper right side and inside the lower control panel Match wires 23 194 N1 N2 T1 and T2 in the transfer switch to the corresponding wires on the terminal strip in the lower panel The conductors for these wires should be in a seperate conduit from the main AC output wires If the control wires are run in the same conduit the control wires must be a shielded cable 2 6 2 GTS Type Engineered Switch Connect the two wire start signal from the automatic transfer switch to the automatic start connection which is located in the right hand corner inside the lower 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 If the control wires are run in the same conduit the control wires must be a shielded cable Generac Power Systems Inc 9 INSTALLATION TED Section 2 Installation NOTE When using a GTS switch it is necessary to connect a 240V AC supply to N1 and N2 terminals of the generator to provide for battery charging Wires T1 T2 23 and 194 should not be connected 2 7 BATTERY INSTALLATION A Da A A Standby generators installed with automatic trans fer switches will crank and start automatically when normal utility
53. REW PHTT 6 32 X 1 2 ZYC 022676 1 FUSE 15A X AGC15 61 002323 4 SCREW PHTT 6 32 X 5 8 ZYC 064009 1 LIGHT 12VDC 02A LED RED PILOT 62 0D5324 REF FUSE amp HOLDER LITTEL 7 5A 061945 1 SWITCH SELECTOR 6A AMP V 63 0A9611 REF FUSE 7 5AXBK AGC7 5NX W 22670 076037 1 VOLTMETER DC 8 18V 64 074908 1 SCREW HHTT M5 0 8 X 10 BP 070081 1 HOURMETER 65 0E3783 1 DECAL WARNING REMOVE FUSE 070043 1 VOLTMETER AC 0 300 070045 1 AMMETER AC 0 200 PART OF CONTROL PANEL WIRE HARNESS Generac Power Systems Inc 35 Ge us Section 7 Exploded Views and Parts Lists Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generator Control Panel Drawing No 0D6978 C oO co 0 os Li z AZ lt LE O _ 5 a gt ZO z P gt ee P lt G a era 9 lt E gt BEE 0 0 om o N gt 89 0 VIEW A A IO Ol Ol Ol Ps
54. RONT W SILK 34 001229 1 DECAL CUST CONN BOX SCREEN 35 098647 REF ASSY L C ELECT GOV 0D1522 2 PANEL SIDE COVER CONTROL 36 0A3968 1 CAPACITOR FILTER ASY PANEL 37 048766 REF BLOCK TERM 20A 2 X 6 X 1100V 067680 1 ASSY VOLTAGE REGULATOR 60HZ 39 083264 1 TFMR ASM CMA 240 12V 0C8243 1 WASHER LOCK HDPDEUTSCH 41 057335 REF BLOCK TERM 20A 20 X 6 X 1100V 008244 1 NUT HDP DEUTSCH 42 076061 1 DECAL TERM STRIP 048467 1 CIRCT BRK 7 X 1 ETA 46 500 P 43 029333 6 TIE WRAP 7 4 X 19 NATL UL 057907 1 RES WW LUG 10R 10 25W 45 040479 4 VIB MNT 1 0 X 1 0 X 1 4 20 064008 1 COVER CON PNL TOP NOT SHOWN 46 022507 4 SCREW HHC 1 4 20 X 1 2 G5 055444 1 HEATSINK 47 022127 4 NUT HEX 1 4 20 STEEL 030468 1 WASHER STEP NYLON 20 48 022097 4 WASHER LOCK M6 1 4 049939 1 RECTIFIER MSC 12A 600V 1N1206R 49 033121 14 SCREW HHC 10 32 X 1 2 070370 1 WASHER MICA 203 50 022152 14 WASHER LOCK 10 022158 1 NUT HEX 10 32 STEEL 51 036902 4 SCREW 6 32 1 2 023762 1 WASHER SHAKEPROOF EXT 10 52 022155 6 WASHER LOCK 6 STL 53 022985 6 WASHER FLAT 6 ZINC 023897 15 WASHER FLAT 10 ZINC 54 036918 4 SCREW PPHM 8 32 X 1 2 076009A 1 PP LOGIC ASM 50 60HZ 55 022264 4 WASHER LOCK M4 040213 4 PCB SUPPORT SNAP IN 1 4 56 038150 4 WASHER FLAT 8 ZINC 027744 1 GROMMET 3 4 X 5 32 X 5 16 57 022471 4 NUT HEX 8 32 STEEL 082573 1 SWITCH ROCKER DPST 125V SPD 58 022188 6 NUT HEX 6 32 STEEL 076020 1 SWITCH TOG DPDT 15 10 SP 59 036908 2 SCREW PPHM 6 32 X 1 1 4 032300 1 HOLDER FUSE 60 002428 4 SC
55. SAE 15W 40 oil This oil should be changed after 30 hours of operation 2 8 5 ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Section 1 8 Specifications and Section 1 11 Coolant INSTALLATION Hh Section 2 Installation 2 8 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 approx imately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inch 10 to 16 mm 2 8 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 proper ly 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 2 8 8 RODENT PROTECTION Make sure the four 3 inch diameter cap plugs part 7 0A8785 are properly installed in the tie down holes in the side rails of the units base frame Figure 2 3 The cap plugs are shipped in a plastic bag located in the lower connection box These plugs are needed to pre vent rodents from accessing the interior of the genera tor set On acoustic units cap plugs also are needed to st
56. Y 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 or load test 16 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator A A Standby generators installed with automatic transfer switches will crank and start automatical ly when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to per sonnel do not connect battery cables until the normal source voltage at the transfer switch is correct and the system is ready to be placed into operation LA A 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 bat tery 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 A 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
57. a Do Not Operate tag on the generator panel and on the transfer switch 3 5 AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their Utility position i e loads connected to the utility power source 2 Be sure that normal utility power source voltage is available to transfer switch terminal lugs N1 and N2 3 Set the generator s Auto Off Manual switch to AUTO 4 Set the generator s main circuit breaker to its ON or closed position With the preceding steps complete the generator will start automatically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to Sequence of Automatic Operation 3 4 SEQUENCE OF AUTOMATIC OPERATION The generator s control panel houses a control logic cir cuit board This board constantly monitors utility power source voltage Should that voltage drop below a preset level circuit board action will signal the engine to crank and start After the engine starts the circuit board signals the transfer switch to activate and connect load circuits to the standby power supply load terminal lugs T1 T2 connect to terminal lugs E1 E2 OPERATION OD Upon restoration of utility source voltage above a preset level generator circuit board action signals the transfer switch to transfer loads back to that power
58. age is delivered to that circuit board via a 15 amp fuse These overcurrent protection devices will open if the circuit is overloaded caution amp A If a circuit breaker opens or a fuse element melts you should find the cause of the overload before resetting the circuit breaker or replacing the fuse 4 8 DC FUSE The generator panel s 15 amp AGC fuse Figure 4 4 pro tects the DC control circuit against overload The fuse is wired in series with the battery output lead to the panel If the fuse element has melted open cranking or starting the engine cannot occur Replace the fuse using only an identical 15 amp AGC replacement Figure 4 4 Location of 15 amp Fuse lt Senne TIME VOLTS HOURS AUTO INDICATOR 154 e MANUAL FAULT FUSE MAINTENANCE LD Section 4 Maintenance 4 9 ENGINE COOLANT Check the coolant level in the coolant recovery bottle e Add the recommended coolant mixture as necessary see Section 1 10 e Periodically remove the radiator pressure cap to make sure the coolant recovery system is functioning properly Coolant should be at the bottom of the radia tor filler neck If the coolant level is low inspect the gasket in the radiator pressure cap Replace the cap if necessary To have the pressure cap tested contact a Generac Guardian Authorized Dealer Inspect the cool ing system and coolant recovery system for leaks 4 10 MISCELLANEOUS MAINTENANCE
59. ase Remove the spark plug s and spray fogging agent into the spark plug s threaded openings Reinstall and tighten the spark plug s Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor Clean and wipe the entire generator 18 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator 4 11 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows l 8 9 Verify that utility power is turned off to the transfer switch and that the Auto Off Manual switch is set to OFF Check the tag on the engine for oil viscosity and classification Verify that the correct recommended oil is used in engine see Section 4 2 1 If necessary drain and refill with the proper oil Check the battery Fill all cells to the proper level with distilled water DO NOT USE TAP WATER IN THE BATTERY Remove the battery before charging Recharge the battery to 100 percent state of charge or if defective replace the battery with a 12 volt DC Group 27F battery rated for 90 amp hours part 058665 Clean and wipe the entire generator Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incor rectly Open the fuel shutoff valve Start the unit by moving the Auto Off Manual switch to MANUAL Allow the unit to warm up thoroughly Stop the unit and set the Auto Off Manual switch to AUTO
60. at have insulated handles 10 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator 2 7 1 VENTED BATTERIES caution amp A The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically con ductive and corrosive The following procedures are to be observed e Wear full eye protection and protective clothing e Where electrolyte contacts the skin wash it off immediately with water e Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical atten tion and e 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 bicarbonate 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 following proce dures are to be followed e DO NOT SMOKE when near batteries e DO NOT cause flame or spark in battery area and e Discharge static electricity from body before touching batteries by first touching a grounded metal surface Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries F
61. at may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows A DX A After this heading read instructions that if not strictly complied with will result in personal injury or property damage WARNING amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution Ak 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 A tion that if not followed could endanger personal safety and or property This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard Generac Power Systems Inc The operator is responsible for proper and safe use of the equipment Generac strongly recommends that the operator read this Owner s
62. at the time of delivery but is discovered later LIFTING THE GENERATOR WARNING amp A When lifting or hoisting equipment is used be careful not to touch overhead power lines 1 1 1 A The generator s weight of more than 2 000 pounds requires proper tools and equipment and qualified personnel to be used in all phases of handling and unpacking 1 2 THE GENERATOR This liquid cooled Guardian generator set is designed to supply electrical power to operate critical electrical loads during utility power failure Use this generator as a source of electrical power for the operation of 120 and or 240 volt single phase loads 1 3 GENERATOR AC CONNECTION SYSTEMS Figure 1 1 represents a single phase four wire genera tor AC connection system 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 a 120 volt 60 Hertz AC output 4 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator When the two windings are connected in series a 240 volt 60 Hertz AC output results Typically the two hot leads in the circuit are Wires 11 and 44 The neutral leads are the junction of Wires 22 and 33 Figure 1 1 Single phase Generator AC Connection System 120 VOLTS 120 VOLTS 00 Neutral Block 240 VOLTS 1 4 PREPACKAGED TRANSFER SWITCH The transfer switch shipped with this generato
63. ay within noise specification limits Figure 2 3 Base Frame Cap Plugs BASE FRAME 3 INCH DIA PLUG PART 0A8785 Generac Power Systems Inc 11 OPERATION OD 3 1 CONTROL CONSOLE COMPONENTS The components of a liquid cooled generator control console Figure 3 1 are as follows Section 3 Operation Figure 3 1 Control Console AC AC AC FREQUENCY VOLTMETER DC VOLTMETER HOURMETER SET EXERCISE TIME AUTO SWITCH Q7 VOLTAGE PHASE SELECTOR SWITCH FAULT INDICATOR URS FUSE 15A VOLTS HOI l OFF a 2 FUSE AUTO OFF MANUAL SWITCH FAULT INDICATOR LAMP 3 1 1 AC VOLTMETER The voltmeter displays generator AC output voltage dur ing operation Voltage is regulated by a solid state volt age regulator and is proportional to AC frequency Refer to the unit s DATA PLATE for rated AC voltage 3 1 2 AC AMMETER This indicates current draw of connected electrical loads during operation DO NOT EXCEED THE UNIT S RATED MAXIMUM CONTINUOUS CURRENT Refer to the unit DATA PLATE 3 1 3 AC FREQUENCY METER This indicates generator AC output frequency in Hertz cycles per second Frequency is proportional to engine speed Units with a four pole rotor supply 60 Hertz at 1 800 rpm The frequency reading with no electrical loads connected no load condition should be between 60 62 Hertz 3 1 4 DC VOLTMETER The generator
64. cy are not compatible NOTE This manual assumes that the standby generator has been properly selected installed and interconnected by a competent qualified electrician or installation contractor Once the installation is complete do nothing that may result in noncompatibility between the generator and connected electrical loads 1 8 3 ENGINE MAKE sra ea General Motors Displac meat seras 4 3 liters 262 cu in Cylinder ATPABSCPHODE V 6 Valve Arrangement dirias Overhead Valves lilii idole TR 1 6 5 4 3 2 Numi Der Of Main Bearings isis ica a obe Dr 4 Compression u u u y iique E BR TEMA dA 9 4 to 1 No Of Teeth on uuu L uu llas 168 Gon AAA Electronic Ignition Timing at 1 800 rpm 40 degrees BTDC Rated Horsepower at 1 800 rpm 67 Spark PUD GaP cnsacsansateteonatotoatiaueencaie 0 045 inch 1 1 mm Recommended Spark Plugs AC 41 932 or equivalent es 30 50 psi Crankcase Oil Capacity 4 5 U S quarts 4 25 L Recommended Engine Oil SAE 15W 40 Type of Cooling System Pressurized closed recovery OGL BAS T n eet Pusher Type Cooling System Capacity 4 5 U S gallons 17 L Recommended Coolant Use a 50 50 mixture of ethylene glycol and soft water Fuel Consumptio
65. d four lifting holes that are capped at the factory These caps are sometimes removed for transportation during installation but always should be replaced afterwards Check that they are secured in place The same applies for any access ports in the roof of the enclosure If any of these caps are missing contact a Generac Guardian Authorized Dealer Generac Power Systems Inc 17 MAINTENANCE Section 4 Maintenance 2 9 Inside the generator set the chance of rodent entry into the control panel is greatly reduced by the inclusion of adjustable wire connectors Check that the wire connector screws are tight thus closing off any gap between the access holes and the wires 4 11 OUT OF SERVICE PROCEDURE 4 11 1 REMOVAL FROM SERVICE If the generator cannot exercise every seven days and it is to be out of service longer than 90 days prepare the generator for storage as follows i 2 3 otart the engine and let it warm up Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down Once the unit has shut down it will signal a fault on the control panel Set the Auto Off Manual switch to OFF and turn off the utility power to the transfer switch While the engine is still warm from running drain the oil completely Refill the crankcase with SAE 15W 40 oil having API Service Class SG SH or Su Attach a tag to the engine indicating the viscosity and classification of the oil in the crankc
66. d parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including e LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 Generac Power Systems Inc 61 Section 9 Warranty WARRANTY Guardian Liquid cooled 40 kW Generators GENERAC POWER SYSTEMS STANDARD TWO YEAR LIMITED WARRANTY FOR GUARDIAN EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the date of original sale Generac Power Systems Inc Generac will at its option repair or replace any part which upon examination inspection and testing by Generac or a Generac Authorized Warranty Service Dealer is found to be d
67. dal rd AREA MODIFICATIONS REQUIRED FOR TYP APT A INSIDE STUB UPS uy ST at INR 4 IP Nil __ Y ALP PP 7 j 1 49 1 92 W S 140 5 50 WEIGHT DATA TYP X UNIT 729 7 kg 1609 Ibs MOUNTING HOLES BW id PW E STEEL COMPARTMENT 208 6 kg 460 Ibs 213 5 20 53 NOTES 2 7 d dis SA n279 UNITS mm INCHES 110 4 33 TYP p i J 37 1 44 570 22 44 a 665 26 19 TOP OR PLAN VIEW 965 87 99 2397 94 37 454 17 87 1160 45 67 NOTE 2 1117 43 98 NOTE 6 103 4 06 Y 53 2 09 E NATURAL GAS INLET 835 32 87 3 4 NPT FEMALE 877 34 51 936 36 85 OIL DRAIN 1 2 N P T FEMALE LEFT SIDE VIEW REAR VIEW NOTES 1 STANDARD BLOCK HEATER REQUIRES 120V AC CONNECTION 1 12V BATTERY 2 CONNECTION POINTS FOR AC LOAD LEADS TRANSFER SWITCH AND SEE NOTE 4 ENGINE AUTOMATIC START STOP CONTROL WIRES PROVIDED IN AC CONNECTION PANEL 3 EXHAUST MUFFLER SUPPORT BRACKETS SUPPLIED WITH OPTIONAL COMPARTMENT LIFTING EYE 4 12 VOLT NEGATIVE GROUND SYSTEM 4 PLACES BATTERY TRAY INSIDE DIMENSIONS 178 X 342 5 7 X 13 5 5 2 5 I D FLEX EXHAUST 6 MAIN LINE CIRCUIT BREAKER 7 DOORS MUST BE OPENED 90 DEG TO BE REMOVED 8 A1 MAY BE USED FOR CIRCUIT BREAKER STUB UP LOCATION 9 SEE DRAWING C3850 FOR DUCT REMOVAL REMOVAL OF FRONT DUCT WILL PR
68. ed fuels oils coolants or lack of proper fluid amounts e 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 infestation e Products that are modified or altered in a manner not authorized by Generac in writing e 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 e 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 Overnight freight costs for replacement part s Overtime labor Starting batteries fuses li
69. efective under normal use and service in accordance with the warranty schedule set forth below Any equip ment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and pre paid by the purchaser owner This warranty applies only to Generac 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 Generac generators that utilize non Generac replacement parts Generac Guardian generators utilizing non Generac Guardian automatic transfer switches Any Generac 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 contaminat
70. et to OFF but the engine 2 Defective control board 2 continues to run There is no AC output from 1 Generator main line circuit 1 Reset circuit breaker the generator breaker open to ON or closed 2 Generator internal failure Ze 1 There is no transfer to 1 Generator main line circuit 1 Reset circuit breaker standby after utility breaker open to ON or closed source failure 2 Defective transfer switch coil 2 3 Defective transfer relay s 4 Transfer relay circuit open 4 5 Defective control logic board Os Contact your nearest Generac Guardian Authorized Dealer for assistance eo Generac Power Systems Inc Section 6 Electrical Data Guardian Liquid cooled 40 kW Generator ELECTRICAL Mounting Dimensions Drawing No 0D5335 DATA lt lt NOTE 7 220 8 65 STUB UP AREA MEN po RECOMMENDED FUEL ELECTRICAL STUB UPS R677 R26 66 ra STUB UP AREA SEE TOP VIEW SEE NOTE 8 AND CHART DESCRIPTION INSIDE 247 9 73 E BASE A AC LOAD LEAD CONDUIT LEFT A1 aL eee i E A Sl INSIDE STUB UP FOR C 204 8 03 CH x aa FUEL CONNECTIONS E Bu NOTE L d JSS 794 81 28 FUEL SYSTEM SET UP WITH OUTSIDE STUB UPS PA STUB UP SEE LEFT SIDE VIEW SMALL FUEL SYSTEM 839 33 017 a
71. ght bulbs and engine fluids USE OF NON GENERAC GUARDIAN TRANSFER SWITCHES SHALL VOID THIS WARRANTY WITH RESPECT TO ALL GENERAC PRODUCT 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 conse quential 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 P O BOX 297 WHITEWATER WI 531 90 Part No OE1780 Revision D 05 09 03 Printed in U S A
72. ical voltages and can cause fatal electri cal shock Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in operation Avoid con tact with bare wires terminals connections etc while the unit is running Ensure all appropriate cov ers guards and barriers are in place before operating the generator If work must be done around an oper ating 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 requires the frame and external electrically conductive 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 condition 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 to Before installing or servicing this and
73. ighten the end cap 4 Invert the pressure reducer valve In other words turn it upside down end cap facing downward 5 Purge and leak test the entire fuel system according to gaseous fuel codes NO LEAKS can appear at any point in the system Figure 1 3 Conversion to LP Gas Vapor PRESSURE REDUCER VALVE INNER SPRING TENSION END CAP Guardian Liquid cooled 40 kW Generator 1 10 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 or SE Detergent oils keep the engine cleaner and reduce carbon deposits Use oil hav ing the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Temperature Above 80 F 27 C Oil Grade Recommended SAE 30W or 15W 40 SAE 20W 20 or 15W 40 SAE 10W or 15W 40 A caution amp Any attempt to crank or start the engine before it A has been properly serviced with the recommended oil may result in an engine failure 1 11 COOLANT Use a mixture of half low silicate ethylene glycol base antifreeze and half soft water Use only soft water and only low silicate antifreeze If desired add a high quali ty rust inhibitor to the recommended coolant mixture When adding coolant always add the recommended 50 50 mixture A DX A Do not remove the radiator pressure cap while the engine is hot or serious bu
74. in the fuel regulator using vacuum from the carburetor This vacuum signal is directed to the fuel regulator via the control valve The air fuel ratio con troller determines the amount of vacuum signal sent to the fuel regulator The more vacuum sent to the regula tor the more restricted the fuel flow will be therefore the leaner the air fuel mixture Generac Power Systems Inc 7 INSTALLATION TED Section 2 Installation Guardian Liquid cooled 40 kW Generator STANDBY GENERATOR INSTALLATION A A Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch such as the Generac GTS type transfer switch so as to isolate the electric system from the utility distribution system when the generator is operating Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy caution amp If an open bottom is used the engine generator is to be installed over non combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set 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 s
75. ipped from the factory The breaker for each unit is described as follows Model Number 0043733 0043734 0043735 0046262 0046263 0046264 1 7 ENGINE PROTECTIVE DEVICES The engine has several safety switches that cause it to automatically shut down under the following condi tions low oil pressure high coolant temperature low coolant level engine overspeed and overcrank Circuit Breaker Rating 200 amp breaker 200 amp breaker 1 71 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should oper ating oil pressure drop below approximately 10 psi 68 kPa the switch contacts close and the engine shuts down automatically Figure 1 2 Figure 1 2 Engine Protective Devices HIGH COOLANT TEMPERATURE SWITCH LOW COOLANT LEVEL SWITCH LOW OIL PRESSURE SWITCH LOCATED ON OPPOSITE SIDE OF GENERATOR 1 i i TRANSPARENT ENCLOSURE FOR CLARITY 1 7 2 HIGH COOLANT TEMPERATURE SWITCH This normally open N O thermostatic switch has a sensing tip that is immersed in captive coolant Should the coolant temperature exceed approximately 121 C 250 F the switch contac
76. is equipped with a belt driven DC alter nator which maintains battery state of charge when the engine operates The control module assembly CMA also incorporates a trickle charge circuit that maintains battery state of charge during nonoperating periods Battery voltage should read approximately12 5 to 14 5 volts DC A low battery voltage indicates the battery is discharging 3 1 5 HOURMETER This indicates the time the engine generator has operat ed in hours and tenths of hours Use the hourmeter along with the periodic maintenance schedule for your generator set 12 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator 3 1 6 AUTO OFF MANUAL SWITCH see Section 3 2 3 1 7 FAULT INDICATOR LAMP This lamp goes ON when one or more of the following engine faults occurs and when engine shuts down e Low oil pressure High coolant temperature e Low coolant level Overcrank Overspeed 3 1 8 15 AMP FUSE This fuse protects the control console s DC control cir cuit against electrical overload If the fuse has melted open because of an overload engine cranking and start up cannot occur Replace the fuse with an identical AGC 15 amp replacement fuse 3 1 9 7 5 AMP INLINE FUSE NOT SHOWN This inline fuse is connected in the 15 line that runs between the Auto Off Manual switch and position 10 of the 76009A PCB This fuse protects the start fuel field boost and transfer outputs fro
77. m the PCB and will open if there is excessive current draw on any one of these outputs 5 1 10 VOLTAGE PHASE SELECTOR SWITCH This switch permits selection between either line to line or line to neutral voltage and amperage readings on the console AC voltmeter and AC ammeter 5 1 11 SET EXERCISE TIME SWITCH This switch allows to program the generator to start and exercise automatically See Section 3 6 3 2 USING THE AUTO OFF MANUAL SWITCH 3 2 1 AUTO POSITION Selecting this switch position activates fully automatic system operation It also allows the unit to start and exercise the engine every seven days with the setting of the exercise timer Guardian Liquid cooled 40 kW Generator 3 2 2 OFF POSITION This switch position shuts down the engine This posi tion also prevents operation 3 2 3 MANUAL POSITION Set the switch to Manual to crank and start the engine Transfer to standby power will not automatically occur unless there is a utility failure WARNING With the switch set to AUTO the engine may crank and start at any time without warning Such automatic starting normally occurs when utility power source voltage drops below a preset level or during the normal exercise cycle To pre vent possible injury that might be caused by such sudden starts always set the switch to OFF and remove the fuse before working on or around the generator or transfer switch Then place
78. med only by a Generac Authorized Warranty Service Facility When requesting warranty serv ice evidence must be presented showing the date of the sale to the original purchaser owner If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the fol lowing address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part 1 60 Generac Power Systems Inc Section 9 Warranty Guardian Liquid cooled 40 kW Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and later model year engines a Applicability This warranty shall apply to 1995 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall con tinue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a war ranted emissions related part to fail to be identical in all material respects t
79. n Natural GaS TREE 720 cfh B ae eee re eer nner ee rere er rent rere ter yore 288 cfh 7 9gph 6 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator 1 9 FUEL REQUIREMENTS AND RECOMMENDATIONS With LP gas use only the vapor withdrawal system This type of system uses the vapors formed above the liquid fuel in the storage tank Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask your fuel supplier for the Btu content of your fuel Fuel pressure for both natural gas and liquid propane setups should be 11 inches to 14 inches of water column 0 6 psi at all load ranges WARNING amp Gaseous fuels such as natural gas and liquid propane LP 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 install leak detectors accord ingly 4 1 9 1 CONVERSION TO LP GAS VAPOR The generator is shipped from the factory configured for using natural gas as fuel To convert the fuel system to LP gas proceed as follows Figure 1 3 1 Remove end cap from the pressure reducer valve 2 Turn the tension screw counterclockwise until all ten sion is removed from the inner spring 3 Install and t
80. ng apply to the transfer switch in this type of system Ampere rating of the transfer switch must be equal to or greater than the ampere rating of the normal incoming utility service e The transfer switch must be installed between the utility service entrance and the building distribution panel 2 4 GROUNDING THE GENERATOR The National Electrical Code requires the frame and external electrically conductive parts of this equipment 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 generator mounting base Consult a qualified electrician for grounding requirements in your area Grounding procedures must meet local regulations INSTALLATION Hh Section 2 Installation A 19 A 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 electri cal shock in the event of a ground fault condition 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 BASE GROUNDING LUG 2 5 GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED AC neutral Grounding is recommended only at the main service entrance 2 6 TRANSFER SWITCH START SIGNAL CONNECTIONS 2 6 1
81. o the part as described in the engine man ufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the
82. oled 40 kW Generators 4 3L Exhaust Drawing No 0E0704 A 2 5 DIA CLAMP ASSEMBLY TO ENGINE QTY D po NN Po COMPARTMENT DESCRIPTION CAP RAIN 2 50 2 69 TUBE STRAIGHT A GROUP MUFFLER 2 1 2 INLET OUTLET CLAMP BAND MUFFLER 6 5 BRACKET MUFFLER MOUNTING TUBE ELBOW 90 DEG 2 5 PIPE FLEX 2 5 TUBE CROSS OVER TUBE 90 ELBOW BRACKET EXHAUST SHIELD SHIELD A GRP HEAT SCREW TH FRM M6 1 X 16 N WA Z JS 43 Generac Power Systems Inc FRONT p PART 4 022129 12 022145 12 009748 1 042907 12 080762 6 022237 12 022241 12 0E0701 1 0E0700 1 022131 8 11 DESCRIPTION CLAMP BAND 2 5 WASHER LOCK M8 5 16 WASHER FLAT 5 16 ZINC PLUG M18 1 5 SCREW HHC M8 1 25 X 16 G8 8 BOLT U 3 8 16 X 2 62 WASHER LOCK 3 8 NUT HEX 3 8 16 STEEL SHIELD CROSSOVER HEAT SHIELD EXHAUST HEAT WASHER FLAT 3 8 M10 ZINC ITEM CON OOF WP PART NO 037561 0A4632A 0A4637 0A4632B 062522 022127 057796 057795 QTY ee lA Section 7 Exploded Views and Parts Lists Cp us Guardian Liquid cooled 40 kW Generators 4 3L Air Cleaner Drawing No 0E0712 0 DESCRIPTION NUT WING 1 4 20 NYLK PLATE AIR CLEANER TOP FILTER AIR 11 5 CA326 PLATE AIR CLEANR BOT STUD TH 1 4 20 X 3 G2 ZNC FULL NUT HEX 1 4 20 STEEL GROMMET CONNECTOR C C VENT Generac Powe
83. or recommended batteries see Section 4 5 Battery Maintenance All batteries must be at 100 percent state of charge before they are installed on the generator When using maintenance free batteries it is not neces sary to check the specific gravity or electrolyte level Have these procedures performed at the intervals spec ified in Section 4 Maintenance A negative ground sys tem is used Battery connections are shown on the wiring diagrams Make sure all batteries 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 reversed 2 8 PREPARATION BEFORE START UP The instructions in this section assume that the standby 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 safe ty information in this manual before attempting to oper ate this and related equipment Guardian Liquid cooled 40 kW Generator 2 8 1 PRIOR TO INITIAL START UP caution amp A 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 quanti ties of engine fluids oil coolant fuel etc may result in an
84. r Systems Inc 49 us Section 7 Exploded Views and Parts Lists Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generators 4 3L Nat Gas Fuel System Drawing No 0E0714 Co Y re f e j p Z z le CC N LLI o ES a X u 5 X O E LO gt N A N O E NI D TO INTAKE MANIFOLD 50 Generac Power Systems Inc ITEM YO WP Section 7 Exploded Views and Parts Lists Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generators PART NO 065907 026812 076691 007598 026490 026577 055944 067018 002775 061910 022145 022129 030795 025655 022132 051778 028641 057824 057422 043123 051779 050279 026915 055934P 0A5737C 0D1509 061258 0A7631 029745 022237 052865 033212 0A4120 064945 0A6344 0A4121 047290 036409 022097 0A5763 082508 QTY N PN BN Pb PO PO PO PO YP gt oo fH HH 4 3L Nat Gas Fuel System Drawing No 0E0714 DESCRIPTION SUPPORT SOLENOID NAT GAS ELBOW 90D 3 4NPT NIPPLE PIPE 3 4 NPT X 4 5 BLK IRN ASSY NATURAL GAS SOLENOID NIPPLE PIPE 3 4 NPT X 2 BUSHING REDUCER 1 TO 3 4 REGULATOR NAT GAS LPG VAPOR SUPPORT REGULATOR BRACKET REGULATOR 4 3L SCREW HHTT 10 24 X 3 4 YC WASHER FLAT 5 16 ZINC WASHER LOCK 8
85. r a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a prob lem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe impor tant rights and obligations with respect to your new engine Warranty service can be perfor
86. r is rated 200 amps maximum at 120 240 volts AC single phase The enclosure of the transfer switch is NEMA 3R This type of enclosure is intended for indoor or outdoor use Follow these rules e Install the transfer switch on a firm sturdy support ing structure To prevent switch distortion level the switch if nec essary This can be done by placing washers between the switch enclosure and mounting surface Never install the switch where any corrosive sub stance might drop onto the enclosure Where practical protect the switch against excessive moisture dust dirt lint and construction grit Always prevent corrosive vapors from coming in con tact with enclosure 1 5 AUTOMATIC SYSTEM OPERATION When this generator along with its transfer switch has been installed and interconnected a circuit board in the generator panel continuously 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 gener ator starts the transfer switch transfers load circuits so the generator can power them When utility source voltage has been restored the switch transfers back to the utility source voltage and the generator then shuts down after a brief cool down time Guardian Liquid cooled 40 kW Generator 16 MAIN CIRCUIT BREAKER The generator s main circuit breaker is included with the unit as sh
87. r operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine Figure 4 1 Oil Dipstick and Fill OIL DIPSTICK OIL FILL CAP 4 2 CHANGING THE ENGINE OIL AND FILTER 4 2 1 ENGINE OIL RECOMMENDATIONS Use oil of API Service Class SG SH or SJ The recommended oil grade for the engine is SAE 15W 40 NOTE The unit is supplied with break in oil See the Service Schedule Section 4 12 Page 19 for the first required oil change A caution amp Any attempt to crank or start the engine before A it has been properly serviced with the recom mended oil may result in an engine failure 4 2 OIL AND FILTER CHANGE PROCEDURE To change the oil and filter proceed as follows Refer to the Service Schedule Section 4 12 Page 19 for engine oil and filter change frequencies Drain the oil while the engine is still warm from run ning This means warm up the engine shut it down and drain it immediately as follows 1 Remove the oil drain hose from its retaining clip located on the generator base frame 2 Loosen and remove the oil drain hose cap located on the base frame end of the hose Drain the oil completely into a suitable container 3 When all of the oil has drained install and tighten the oil drain hose cap 4 Turn the oil filter Generac part number 0A37970001 Figure 4 2 counterclockwise and remove it Properly dispose of
88. re near running gen erators 2 Generac Power Systems Inc A GENERAL HAZARDS e For safety reasons Generac recommends that the installation initial start up and maintenance of this equipment is carried out by a Generac Guardian Authorized Dealer e 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 not do anything that might render the unit unsafe or in noncompli ance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon monoxide 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
89. rns from boiling liquid or steam could result 32 to 80 F 1 C to 27 C Below 32 F 0 C A A Ethylene glycol base antifreeze is poisonous Do not use mouth to siphon coolant from the radia tor recovery bottle or any container Wash hands thoroughly after handling Never store used antifreeze in an open container because animals are atracted to the smell and taste of antifreeze even though it is poisonous to them Do not use any chromate base rust inhibitor with ethylene glycol base antifreeze or chromi um hydroxide green slime will form and cause overheating Engines that have been oper ated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base antifreeze Using any high silicate antifreeze boosters or additives also will cause overheating Generac also recommends that any soluble oil inhibitor NOT be used for this equip ment A Section 1 General Information GENERAL INFORMATION 1 12 EMISSIONS CONTROL SYSTEM MODELS 0046262 0046263 8 0046264 This model is equipped with an active exhaust emis sions control system to comply with certain California air district regulations for natural gas emergency gener ating sets including the South Coast Air Quality Management District Do not tamper with or disable any part of this system including the exhaust catalyst carburetor oxygen sensor air fuel ratio controller sole noid valve and gas
90. rs 0 Generator Drawing No 009490 STATOR LEADS SCROLL DETAIL 21 34 TO ENGINE FLYWHEEL 8 9 6 P y A TO ENGINE FILYWHEEL ADJUSTMENT 40 Generac Power Systems Inc NOTE THREAD IN SENSOR 6 UNTIL CONTACT IS MADE WITH RING GEAR THEN BACK OFF 1 2 TO 3 4 TURN AND TIGHTEN NUT CAUTION 27 DO NOT ROTATE ENGINE DURING THIS ADJUSTMENT Section 7 Exploded Views and Parts Lists Cp Ass Guardian Liquid cooled 40 kW Generators Generator Drawing No 009490 0 ITEM PART NO QTY DESCRIPTION 1 051768 SCREW HHC 12 1 75 X 25 08 8 2 051769 7 WASHER LOCK M12 3 0A8240 2 FLEX PLATE SAE10 4 039253 6 SCREW HHC M8 1 25 X 20 G8 8 9 022129 7 WASHER LOCK M8 5 16 6 082130D 1 ASSEMBLY MAG PICKUP 72 7 004286 1 ASSEMBLY FAN W PRESS DISC 10 75 X 3 8 0A2601 1 SCREW HHC M16 2 0 X 45 G8 8 g7 0A2602 1 WASHER FLAT 688 ID X 3 25 OD 10 0A1138 1 KEY SQ 3 8 X 2 1 2 STEEL 11 021941 1 COUPLER 390 SAE 12 020808A 1 ROTOR 390 40 1P DIRECT 13 052624 1 BEARING BALL 6212 SEALED 14 070892 1 SLIP RING MACHINED 15 0A5580 4 SCREW HHC M14 2 0 X 140 G8 8 16 041633 4 WASHER 390 SAE ALT 17 020729A 1 STATOR 390 40 AD2 SAE 18 022131 12 WASHER FLAT 3 8 M10 ZINC 19 022237 11 WASHER LOCK 3 8 20 022511 11 SCREW HHC 3 8 16 X 1 1 4 G5 21 068113 1 CARRIER REAR BEARING 15 22 068115 1 LOWER PANEL 15 23 043123 4 WASHER LOCK M14 24 051779 4 NUT HEX M14 2 0 G8 YEL CHR 25
91. service needs When contacting a Generac Guardian Authorized Dealer or the factory about parts and service always supply the complete model number and serial num ber of the unit as given on its data decal which is located on the generator Model No Serial No AUTHORIZED DEALER LOCATION To locate the nearest GENERAC GUARDIAN AUTHORIZED DEALER please call this number 1 800 333 1322 DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER Table of Contents a CONTENTS Guardian Liquid cooled 40 kW Generator Introduction Inside Front Cover Section 3 Operation 12 Read This Manual Thoroughly IFC 3 1 Control Console Components 12 S uu S au as IFC 3 1 1 AC 12 Operation and Maintenance IFC 31 2 AC Ammeter 12 How to Obtain Service IFC 3 1 3 AC Frequency Meter 12 Authorized Dealer Locator Number IFC 3 1 4 DC 12 Safety Bulu a 2 A 3 1 6 Auto Off Manual Switch 12 Section 1 General Information 4 3 1 7 Fault Indicator 12 1 1 Unpacking Inspection 4
92. standards Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modifi cation or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine o
93. supply After retransfer the engine is signalled to shut down Section 3 Operation The actual sequence of operation is controlled by sensors and timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility source voltage e If utility source voltage drops below about 60 per cent of the nominal supply voltage the sensor ener gizes a 15 second timer Once the timer has expired the engine will crank and start B Engine Warm up Time Delay This mechanism lets the engine warm up for about 10 seconds before the load is transferred to a stand by source C Standby Voltage Sensor This sensor monitors generator AC output voltage When the voltage has reached 50 percent of the nominal rated voltage transfer to standby can occur D Utility Voltage Pickup Sensor This sensor monitors utility power supply voltage When that voltage is restored above 80 percent of the nominal source voltage a retransfer time delay starts timing E Retransfer Time Delay e This timer runs for about 15 seconds e Atend of a 15 second delay circuit board action de energizes transfer relay in the transfer switch Retransfer to utility power source then occurs F Engine Cool down Timer When the load is transferred back to utility power source the engine cool down timer starts timing The timer will run for about one minute and the generator will then shut down 3 5 EN
94. t ES 1X 7 z89 X 61 J S H GIS 4 9 915 a Zlo de O 89 lt N 29 XH m o es N 00 vr co LL O i Uuuu ER d m IS Bra 5 SSVdAd HOLOALOYd TVINH3H L 3 9 SINN Hsnua 9 y v uv N q 1 L 25 Generac Power Systems Inc 3HIM GASNNN ALVINSNI 3SVHd A802 HOS 3HIM MOTIAA ISN 3SVHd HOS 38M 318 ISN 6Z 091 LOL
95. tch Part No 0D4406 in conjunction with this generator Guardian Liquid cooled 40 kW Generator Figure 2 1 Basic Standby Electric System MAIN LINE CIRCUIT BREAKER UTILITY POWER SUPPLY TO LOAD CIRCUITS MAI CIRCUIT BREAKER 2 2 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping elec trical loads below the wattage amperage capacity of the generator If the generator is powering only critical loads within its wattage amperage capacity during util ity power outages consider using the emergency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are within the wattage amperage capacity of the generator set When this method is used it is difficult to overload the gener ator The transfer switch must meet the following requirements e It must have an ampere rating equal to or greater than the total amperage rating of the emergency dis tribution panel circuit It must be installed between the building s main distri bution panel and the emergency distribution panel 2 3 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 genera tor to be overloaded when this isolation method is employed The followi
96. the old filter Guardian Liquid cooled 40 kW Generator MAINTENANCE 2D Section 4 Maintenance Figure 4 2 Oil Filter OIL FILTER OIL DRAIN HOSE TO BASE e Apply a light coating of engine oil to the seal of new oil filter Install the filter and tighten by hand only DO NOT OVERTIGHTEN 6 Remove the oil fill cap Figure 4 1 Add the recom mended oil see Section 4 2 1 DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 5 U S quarts 4 25 L caution amp A After refilling the crankcase with oil always check the oil level on the dipstick Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 7 Start the engine and check for oil leaks 8 Check the oil level after checking for leaks to ensure that the oil is filled to the proper level 4 3 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner Generac part num ber 0A4637 simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover See Figure 4 3 page 16 Generac Power Systems Inc 15 MAINTENANCE Section 4 Maintenance Figure 4 3 Engine Air Cleaner
97. trictly with all codes standards and regulations per taining to the installation This genset must be installed on a level surface The base frame must be level within two 2 inches all around caution amp After the system has been installed you must not do anything that might render the installation in noncom pliance with such codes standards and regulations NOTE For more information about the installation of a stand by system you can order Engine Generator Standby Electric Power Systems Installer s Guide and Reference Manual part 046622 from a Generac Authorized Service Dealer NFPA STANDARDS The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection Association NFPA Batterymarch Park Quincy MA 02269 e NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES e NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES e 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 8 Generac Power Systems Inc OTHER PUBLISHED STANDARDS In addition to NFPA standards the following informa tion pertaining to the installation and use of standby electric systems is available e
98. ts close which causes the engine to shut down automatically Figure 1 2 Section 1 General Information GENERAL INFORMATION 1 72 5 LOW COOLANT LEVEL SWITCH Should the engine coolant level drop below the level of the high coolant temperature switch it is possible for the engine to overheat without automatic shut down To pre vent such overheating without automatic shut down the engine has a low coolant level sensor If the engine coolant drops too low the engine automatically shuts down Figure 1 2 1 74 OVERSPEED SHUTDOWN The control module assembly CMA circuit board on liquid cooled units receives AC frequency rpm signals directly from the stator AC power windings Should AC frequency exceed approximately 72 Hertz circuit board action will automatically shut down the engine 1 75 OVERCRANK SHUTDOWN After 90 seconds of crank rest cycles about seven sec onds cranking seven seconds at rest this function ends cranking if the engine fails to start in that 90 second span 1 76 DCFUSE This fuse is located on the front panel of the control sys tem It protects the panel wiring and components from damaging overload Always remove this fuse before commencing work on the generator The unit will not start or crank if the fuse is blown Replace the fuse with one of the same size type and rating Generac uses an AGC fuse rated at 15 amps 1 8 SPECIFICATIONS 1 8 1 GENERATOR Models
99. uct 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 Generac cannot possibly anticipate every possible circumstance that might involve a hazard The warn ings 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 Generac does not specifically recommend satisfy your self that it is safe for others Also make sure the proce dure work method or operating technique chosen does not render the generator unsafe A DX A A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possi ble injury or death Permit only responsible and capable persons to operate or maintain this equipment A 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 1 Parts of the generator are rotating and or hot during operation Exercise ca
100. ystems Inc 55 Ge Section 7 Exploded Views and Parts Lists Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generators OG Electronic Governor Drawing No 0A2615 F ITEM 18 NEOPRENE COATING WIRE HARNESS SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN 16 EXISTING ENGINE id HARDWARE CARB ARM REF nA ITEM PART NO QTY DESCRIPTION 1 098290 1 ASSEMBLY MOTOR STEPPER 2 0A3439 1 BRACKET GOVERNOR MOUNTING 3 098958A 1 CONNECTOR INTERFACE ASSEMBLY 4 021888 1 LEVER STEPPER MOTOR 5 082508 2 BALL JOINT 1 4 28 9 036409 2 NUT HEX 1 4 28 STEEL 11 043146 3 SCREW HHC M6 1 0 X 10 G8 8 12 098941A 2 HOUSING GOVERNOR CONNECT 13 098942A 2 COVER CONN HOUSING 14 098225 4 SCREW FHM 2 X 5 8 SELF TAP 15 022097 4 WASHER LOCK M6 1 4 16 064526 1 SCREW TAP HWH 6 25 X 3 8 ZINC 17 029333A 1 TIE WRAP 7 4 X 19 BLACK UL 18 074031 NEOPRENE LIQUID COATING NOT SHOWN 19 051716 2 NUT HEX M5 0 8 G8 YEL CHR 20 049226 2 WASHER LOCK M5 21 076040 2 SCREW PPHM M5 0 8 X 16 22 098647 1 ASSEMBLY L C ELECTRONIC GOVERNOR 23 036409 2 NUT HEX 1 4 28 STEEL 24 002184 1 STUD THR 1 4 28 X 3 1 2 G2 ZINC 56 Generac Power Systems Inc 22 21 Section 7 Exploded Views and Parts Lists Cp Ass Guardian Liquid cooled 40 kW Generators Engine Coolant Heater Drawing No 0E2352 0 TO THERMOSTAT HOUSING a S 4 TO ENGINE BLOCK ITEM
101. z e 6 v6l v 0 S 915 lt t L3 9 1 921 3 god 2 2g d mo ELO LO sh 091 2891 4 21 HAV l9 IH 5 S Z vs Vio 391 0b 6 H G Z S Z se i wo 9 1 m SL E ae ids vL 841 99 0 ki de 9 0 D vst EMS 1 S D 6ez vi Sg e ON Os n i 4 PS mg Jv N 0 WAS 091 091 6ec 58 38 gt x ka M ou j BS 58 gt VSL 99 a _ NOILISOd 440 93 NI NMOHS v a 0 vi c est os v L el Q L 2 ezz 622 GL SL 91 dvo LSL 0 0 6l 6l LOL LOL Section 6 Electrical Data Guardian Liquid cooled 40 kW Generators oe Wiring Diagram Drawing No 0E2966 DATA 2 ACT m LOS 1 OBLACK 1 79 CLEAR ALT BAT CC 1 FS GND HCT IC ID LOS MP1 SM WLS EH Ll UTILITY WHIT

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