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Generac Power Systems 004373-6 User's Manual

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1. TWANVW 44O0 0 LNV HO LIMS LMS 8 1 84 15009 01315 HOLSISSH YHOLOATAS 3SVHd HOLIMS MSd 581 581 H3TIOHLNOO H3MOd 239 H3TIOHINOO GHVOE LINDHIO dod 76 761 HOLVOIGNI Ln vd 11 AONANDAYS H313N ZH HSLSWHNOH WH ANIT NI Sd S 7 3505 24 SdNV SI ISNA 14 YZL A009 aqOIdq 199 HOLIOVdVO dvO LN LN 39V L10A AH3LLV8 HALA WAG HOLVINDAY 39Vv L10A OLLVWOLNY HAV LAdLNO Ov YILIN 21 21 841 761 QN3931 581 LL 0 9 0 09 19 o 4 6 038010 SALVOIGNI X m a Lk 61 0 oot x xt sem 0 vl 91 WY 9 9 i 5 85 x O O 21 a 5 o ZL 0 i 25 gt x X x 1 2 ot 251 ji 2 X x Oo x 2 2 x x
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4. gt 4 N Ni D T dr 5 L Oo Lo en oo 9 p Oo 0 i e o o o Q ca gt c o 0 lel _ _ d 5 Br f 5 0 gt 5 a A Fe In 36 Generac Power Systems Inc Section 8 Exploded Views and Parts Lists Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generator PARTS 9 LISTS Control Panel Drawing No 0D6978 C O ITEM PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 0D7397 1 PNL BTM amp BACK CNTL PNL 04626 33 081988 1 DECAL EXERCISE INFO 2 001521 1 CONTROL PANEL FRONT W SILK 34 001229 1 DECAL CUST CONN BOX SCREEN 35 0D3440 1 CONTROLLER B C DPG 2103 3 0D1522 1 PANEL SIDE COVER CONTROL 36 0A3968 1 CAPACITOR FILTER ASY PANEL 37 048766 REF BLOCK TERM 20A 2 X 6 X 1100V 4 067680 1 ASSY VOLTAGE REGULATOR 60HZ 38 0A1441B 1 COVER PLATE AVR 5 068243 1 WASHER LOCK HDP DEUTSCH 39 083264 1 TFMR ASM CMA 240 12V 6 0C8244 1 NUT DEUTSCH 40 0 1441 1 COVER PLATE EGOV 7 0 6321 1 PANEL LEFT SIDE E 41 057335 BLOCK TER
5. dO HOLO3NNOO 13NVd H3MO1 OL 581 84 t6L t6L im LAdLNO Ov HALA WA ec 9 diH LS TVNIINH3LL 2612151 ONISNAS ALNILN H3SINHOJSNVHL HHL ZN ZN T 3SIOH3X3 13S HOLIMS ZMS c TWANVW 44O 0 LNV HOLIMS LMS IN IN 15008 HOLSISSH LH est tHO10313S 3SVHd HOLIMS MSd 21 21 H3TIOHLNOO QHVO8 2 HOLVOIGQNI Ln v LHOM 17 841 61 LL LL AONANO SYS YILIN ZH S H313AHROH WH lt LINN H3T1OHLNOO HONH3AO 129 i mM 3NIT NI Sd S 3805 24 HOLYNLOY wn SI ISN H HONH3AOO OL 19 oeo o A009 aqOId 035010 SALVOIGNI X Ka 17 er NOLLV LIOX3 H3MV3H8 LINDUIO 190 ih 7 wines o o ea HOLIOVdVO dvO aN O X X O ersi NV _ 1 1 g 39V L10A AH3 LLV8 H313N WAS 4 o ae re H3TIOHINOO HL ret 1 1 OLLVWOLNY HAV 261 ra
6. ECT 0 rOBLACK 0 0 BARE gt 79 79 0 10 14 11 gt 14 L5 5 459 120VAC UTILITY O m LEGEND ACT ACTUATOR ELECTRONIC GOVERNOR BAT ALT DC ALTERNATOR BAT BATTERY CC CONTROL CONTACTOR EC1 ENGINE CONNECTOR 1 BLACK EH ENGINE HEATER FS FUEL SOLENOID GND GROUND HCT COOLANT HIGH TEMP SWITCH IC IGNITION COIL ID IGNITION DISTRIBUTOR LOS LOW OIL PRESSURE SWITCH MP1 MAGNETIC PICKUP 1 SM STARTER WLS WATER LEVEL SENSOR ONLY USED ON EMISSIONS MODELS ee Generac Power Systems Inc mu 2 GREEN WHITE BLACK Section 7 Electrical Data Guardian Liquid cooled 40 kW Generators Wiring Diagram Drawing No 0E2967 4 CAL ww ACT 161 161 lt 4
7. gt OO PO PM PP A a Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Connection Box Drawing No 0E6892 A DESCRIPTION LOWER PANEL 15 COVER LOWER CONNECTION BOX PLATE GLAND BUSHING SNAP SB 2 5 31 BRACKET NEUTRAL RELAY SOLENOID 12VDC PNL MNT SCREW THF M6 1X16 N WA Z JS NUT HEX M4 0 7 G8 YEL CHR 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 WASHER LOCK M4 SCREW HHC 4 0 7 X 20 G8 8 SCREW HHC 8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC DECAL CUSTOMER CONNECTN FOR TS WASHER LOCK 8 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 240V 2P S QJ22B200HL PLATE CB MOUNT S QJ 2P 3905 COVER TERMINALS S QJ 2P WASHER LOCK 3 8 NUT HEX 3 8 16 STEEL SCREW SHC 1 4 20 X 4 5 G8 8 NZ SCREW SHC 3 8 16 X 3 4 G5 NEUTRAL BLOCK 390 200 400A JUNCTION BLOCK 3 8 16 SCREW PHTT M5 0 8 X 16 ZYC PARTS LISTS OG Generac Power Systems Inc 39 Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Generator Drawing No 0E6891 PARTS Or OG 0 sqval 301915 LNAWLSAPOV ONIHNG 3NIDN3 ALVLOY LON OQ NOLLOVO LAN NALHDIL ANY NYNL v OL 2 1 440 MOVE N3HL YV39 ONIY SQVW SI 56 LOWLNOO TIL
8. Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators 4 5L Radiator Drawing No 0D7992 E 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 10 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 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 7 LISTS 0 Generac Power Systems Inc 47 PARTS Ce LISTS 0 21 77 CONDOR WD 059902A 009641 0C9650 0C4114A 0C4126 0D5787 0A5215B 0 0699 0 0698 004170 004305 002454 PART NO Section 8 Exploded Views and Parts Lists Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generators 4 3L Exhaust Drawing No 0E0704 A 2 5 DIA CLAMP ASSEMBLY Q
9. 999 PS 0 9999 U UU UJ EE ob fee OP s a G 5 amp 5 M B 34 Generac Power Systems Inc Section 8 Exploded Views and Parts Lists Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generator PARTS 9 LISTS Control Panel 4 3L Drawing No 0D4995 F O ITEM_ PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 0D5488 1 PANEL BTM amp BACK CONTROL 32 070042 1 FREQUENCY METER 240V 55 65HZ PANEL 33 081988 1 DECAL EXERCISE INFO 2 001521 1 CONTROL PANEL FRONT W SILK 34 001229 1 DECAL CUST CONN BOX SCREEN 35 098647 REF ASSY L C ELECT GOV 3 0D1522 2 PANEL SIDE COVER CONTROL 36 0A3968 1 CAPACITOR FILTER ASY PANEL 37 048766 REF BLOCK TERM 20A 2 X 6 X 1100V 4 067680 1 ASSY VOLTAGE REGULATOR 60HZ 39 083264 1 TFMR ASM CMA 240 12V 5 0C8243 1 W
10. Use a 50 50 mixture of ethylene glycol and deionized water Fuel Consumption N Ir LU 720 cfh LPOG 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 the fuel supplier for the Btu content of the 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 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
11. BLUE 6 BLUE 9 LEGEND S15 GCB GOVERNOR CONTROL BOARD HZ FREQUENCY METER TB1 TERMINAL BLOCKS ee Generac Power Systems Inc ELECTRICAL DATA 3HIM GASNNN ALVINSNI ASVHd A802 HOS 3HIM MOTT3A ASN 3SVHd 072 HOS an18 ASN 23 Generac Power Systems Inc
12. 8 2 1 Basic Standby Electric System 8 2 2 Emergency Circuit Isolation Method 9 2 3 Total Circuit Isolation Method 9 2 4 Grounding the Generator 9 2 5 Generator AC Neutral Connections 9 2 6 Transfer Switch Start Signal Connections 9 2 7 Battery Installation 10 2 8 Preparation Before Start up 11 Guardian Liquid cooled 40 kW Generator TABLE OF CONTENTS Table of Contents Section 3 Operation 12 3 1 Control Console Components 12 3 2 Using the Auto Off Manual Switch 12 3 9 Automatic Transfer Operation 13 3 4 Sequence of Automatic Operation 13 Deo Eome CAGE TERT S 13 9 0 Weekly Exercise Cycle 14 Section 4 Maintenance 14 4 1 Checking the Engine Oil Level 14 4 2 Changing the Engine Oil and Filter 15 4 3 Changing the Engine Air Cleaner 15 4 4 Spark Plugs 16 4 5 Battery Maintenance 16 4 6 Cooling System 16 4 7 Overload Protection for Engine DC Electrical System 17 FSC
13. HAV c e a AWANVW LYVLS r INSYYND LAdLNO OV YALIN WV 091 091 9 GNd3931 Gu I a iud S 2 3 2 b N o 19 00 es 5 0 a 99 0 QF gs v H3 0 MSd v9 ez 5 as erler e zr is 0 9 O 75 amp 9 zat vL LH G anid vL c9L 84 21 U y L 7 OS Orr vi 9 29 9 BO geo 01 vi amp 2H 98 v Lao P Ib de uw pv 2 s lt a 91 55 0 ZN gt 0 291 O lt 00 Lj 91 91 91 anid 0 e E 91 515 SIS SIS 5 9 9 9 9 HAV 6 916 gg 0 H 90 2 bt M g 8 v b P a m 95 1 vari a LJ a 95 gs lt 90 is S an b es m se O s es S 00 LL ZL SL 86 Mm SLS IN HN yovid M 841 ez m oN ZN 0 LS gz 96 at IN yovig 2 8 1 00 581 Nid el dVO 2 e SIS e 99 ZN a 0 98 915 9 LN vi el vi 58 for ZN 8 88 aa alsls a se a o 99 vl 4 el 0 gt H vi 39NVHO v p ei e e MOTI3A ez 21 94 rL m 2 E eb wi NOD e yovia 3 81 X3 t 0 96 o o 98 r r QJ nig ama ama ana 821 821
14. Ti N N aa pn Tl 4 3L Nat Gas Fuel System Drawing No 0E7013 B DESCRIPTION SUPPORT SOLENOID NAT GAS ELBOW 90D 3 4NPT NUT HEX 5 16 18 STEEL ASSY NATURAL GAS SOLENOID NIPPLE PIPE 3 4 NPT X 2 BUSHING REDUCER 1 TO 3 4 REGULATOR N G R600S SUPPORT REGULATOR SADDLE 1 3 8 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 M14 2 G8 YEL CHR MACHINING CARBURETOR ADAPTOR DECAL FUEL INLET LPG NIPPLE CLOSE 3 4 X 1 375 CLAMP VINYL 1 62 X 486 7 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 STR 1 8NPT X 3 8 VALVE PCV 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 PARTS LISTS OG Generac Power Systems Inc 53 INSAWLSNPAOV HO 39NVN3ANIVIN OIdOldAd OL LOALENS LON SWALI ASSHL HO1v1n93u8 SVD ANY SATIVA GION310S H3TIOHLINOO D OILVY 1 HOSN3S N39AXO
15. O LNdLNO OV HALA WV ww gt x o 2 0 a ZS x x o x 2 2 6 INa3931l x x 5 2 e o o AON la LL z Le 4 V 1 SLOVLNOO 21 v9 9 9 e 55 LHL gt gk 5 9 pa 2 9 2 9 O 3HIM GASNNN 1 106 Wa M 00 S ASVHd A80Z SHIM ASN T GL 3SVHd 0 2 HOS SHIM ASN noo a 15 mM Q wov18 e ovig MSd nu l 915 915 E er x L HOLIMS HOLO3 13S 3SVHd Sis m vt 69 dau qat 3n18 e ania 91 s Mg c ania e ang ZH gt a n 915 291 o o 2 0 5 0 A eL lt aay ZL SIS 95 3 81 915 ajo ania 22 vk 9 V p 2 ez ez i v6l 61 v 0 9 915 ers 4 m 9 921 921 3 z 291 ania gi LO 41 981 HAV LIH VSL S vst o 6 Wazs Z L 2 11 4 2 bis vi 9 vl AA s vszz 8 1 ezz 95 0 MS 58 z ON 251 li ice Ton 0 0 us 0 WAg 281 291 58 amp 98 UIO YV EU 24070 Mess Sg 5 si VSL 95 VN 24 _ z NOILISOd 440 NI NMOHS 0 vk vL vi i vL
16. 17 JEHPIDC Coolant uuu aaa 17 4 10 Miscellaneous 17 4 11 Out of Service Procedure 18 4 12 Service Schedule 19 Section 5 Troubleshooting 20 5 1 Troubleshooting Guide 20 Section 6 Installation Diagram 21 Section 7 Electrical Data 22 Section 8 Exploded Views and Parts Lists 30 Section 9 Notes 58 Section 10 Warranty 60 Generac Power Systems Inc M 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 product contains or emits chemicals known to the state of California to cause cancer birth defects or other repr
17. 6 2 Lo o o 440 Z L E i S10VINOO Movida ts M 1504 LHL 39 3 4 we ul es LL oy anata m 6L 3HIM GASNNN ALVINSNI 5 Wa e e o oi 00 ASVHd A80 SHIM MOTIAA ISN el E 9L ASVHd 072 HOS SHIM aria ASN Odd o A IS BP PL j 91 E 0 ivg MSd 91 HOLIMS 1 145 3SVHd SIS vl 69 vL e ivd 918 SIS 0 4 ZH L gig ___4 91 o 0 0 LL cL qaq 9 gt qaq cL 11 95 916 E 915 2 anid SL vl 9L ZL g ra v6L 761 Y 0 9 915 2 lt 2 Ve ama 9 1 941 3 99 Z 29L d Osh 291 ZL HAV 6 0 N Z VSL cip OL 6 IL Z S El 92 m ES vaze d 8 9S 0 ST rh get J E 9 VSL LMS s b ON 291 Aa ve CN ZMS 0 0 0 291 291 655 Gg Sg 5 VSL 9S x NOILISOd 440 i vig NI NMOHS vi 0 vi vl vl os vL 51 L 69 6cc SL SL SL rL dvo LSL 6 91 62 091 191 P dO HOLO3NNOO 13NVd H3MO1 OL HOLO3NNOO 3NION3 OL 27 Generac Power Systems Inc ELECTRICAL DATA gt Section 7 Electrical Data Guardian Liquid cooled 40 kW Generators Wiring Diagram Drawing No 0E2966
18. 91 8S1 sdf Subs 3 ISALng H SdN 4NLS SCTSNI 3 03911934 SNDILIVOIJIGUMW MALA JUIS 1441 3483 13 15 5 1303 JLON 9 SNOTILOSNNOO 1313 03 dN ENLS 3m DsNI ASVd ACISNI S32V ld v 1331 LINCNOO NV T Ovo 3v 1 21 y 33S 411 D CMSIA SdN dNLS d1w3lI8123 13 1313 C3CEN3ANWLDIO 3el L31100 SJ 143304 13 110 SDIVHXA DNI Id LdN 2 1 NIVAd ID DNI Id L LdN 7 6 SVO WaNLlLVYN L3 INI SNOTLOSANNOO 323IAS3S M3IA AVA L IG v 448 L9 Sv 090 JSNIJSIAS 3S S3 d3lass0WN UL 55300 TIIM L NA 14043 30 1VADW3M IWAOQWSY 1900 03 05862 ONIMVAC 335 6 NUILIVOU dN dNlS 325398 1103313 sl 38 AVW IV 8 3dAUW34 38 OL 7140 06 3N3dU 38 1 55008 7Z LINDAID d3NI 9 ISnvHX3 313 M I 6 S S X 4 G eve X BLT SCISNI AVAL 11 9 8 N3LSAS GNAUSD SATLVOSN LIA cI v LNSWLAVGWOD IVNDIIdU 13114408 514342948 LaOddAS 3313308 ISQVHX3 TANVd NDIIO3NND3 9 NI 31IADe d SSSIM TOSLNOD dOLS LAVLS 3NIDN3 211 5 345 941 50931 SD 29v 904 SLNIOd NO
19. a 29 os 9 00 655 o z ja Lei H3 S v9 MSd a lt 0 9 id id erler 4 2 GIS 0 vi WAG LS 761 vi 99 ZN 4 5 er 90 0 vi 291 5 0 hka 8S c N N z Odor N S 18 O gs gO POF ZH SIS pe 48 vr T 9 SIS ral 58 WH 2 y 2 98 900 O e e ds 4 29 0 __ 5 L yp 916 5 916 gis e O 916 SLS SIS SIS 9 5 i 9 9 HAV amp eg 0 Te ow 0 Lh e 291 5 8 S LN a 8 1 i N 61 oN Sg 5 U 21 LN yovig 0 gz 95 oz z e vL 0 2 e ae gz 588 5 D 1 99 vl ra a un S 5 8 o d 2 vl 2 581 L Y Y L gt gt w go mos 3o 5 4 4 zo qu m go ac m Odd ELECTRICAL DATA ee Generac Power Systems Inc Section 7 Electrical Data Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generators ELECTRICAL DATA lt 39V L1OA LAdLNO YILIN WA lt 16 1 2517161 ONISNAS ALITLLO H3INHOJSNVHL LHL 3SIOH3X3 LAS HOLIMS ZMS 09 Electrical Schematic Control Panel Drawing 006975
20. e Steel enclosures that are rusting due to the improper installation location a harsh or saltwater environment or scratched where integrity of paint applied is compromised Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine e Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing 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 t
21. 160 160 lt 9 I 0 lt 4 F3 HCT 85 85 lt 6 MM Pra O 7 os 0 VV MP1 NN O BARE 8 WLS LOS SS SS 79 CLEAR 79 lt 9 O FS 14 10 12V BATTERY 14 i AA ID ALT BLACK e RED 4 IC s m 8 Sc 16 13 CC LEGEND ACT ACTUATOR ELECTRONIC GOVERNOR ALT DC ALTERNATOR CC CONTROL CONTACTOR EC1 ENGINE CONNECTOR 1 BLACK BLACK 120VAC EH ENGINE HEATER 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 CONTACTOR SM STARTER MOTOR WLS WATER LEVEL SENSOR USED ON EMISSIONS MODELS Generac Power Systems Inc 29 LISTS an Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Mounting Base Drawing No 0E6976 A 27 28 lt gt N Q TO STARTER SOLENOID To Oil Drain On Oil Pan Generac Power Systems Inc ERRA n ITEM CONDOR WD PART NO 0 6900 038804 055414 044084 022129 045771 022237 029745 023152 043107 022145 027482 055597 052251 052257 052252 052259 052860 0536210098 052251 044118 057823 057448 024310 0042390 038805 022131 025507 061902 022413 022473 022097 022127 0 4010 052858 058665 059473 049820
22. 8 Check the oil level after checking for leaks to ensure that the oil is filled to the proper level 4 5 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner Generac part num ber 0A4637 remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover See Figure 4 3 Figure 4 3 Engine Air Cleaner Air Cleaner TRANSPARENT ENCLOSURE FOR CLARITY See the Service Schedule Section 4 12 for recom mended air cleaner maintenance Generac Power Systems Inc 15 MAINTENANCE 4 4 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary See Section 4 12 Section 4 Maintenance 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 F
23. Refer to the Service Schedule Section 4 12 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 7970001 Figure 4 2 counterclockwise and remove it Properly dispose of the old filter Figure 4 2 Oil Filter OIL FILTER 4 TO BASE Guardian Liquid cooled 40 kW Generator MAINTENANCE 5 Section 4 Maintenance 5 Apply a light coating of clean 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 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
24. 5AXBK AGC7 5NX W 22670 28 076037 1 VOLTMETER DC 8 18V 64 074908 1 SCREW HHTT M5 0 8 X 10 BP 29 070081 1 HOURMETER 65 0E3783 1 DECAL WARNING REMOVE FUSE 30 070043 1 VOLTMETER AC 0 300 31 070045 1 AMMETER 0 200 PART OF CONTROL PANEL WIRE HARNESS Generac Power Systems Inc 35 Q us Section 8 Exploded Views and Parts Lists Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generator Control Panel Drawing No 0D6978 C ce N co 0 z lt Li O 5 l gt z P gt ee P lt e G A era lt gt BEE 0 0 om N oS 89 59 VIEW S D E a Y o 9 5 P bbbbb 5 D Te 2 Te 10 x 2
25. 8 vL Q 51 622 62 622 1 GI SL SL rL LSL dvo ELECTRICAL DATA H3 HOLO3NNO2 3NIBN3 OL 24 Generac Power Systems Inc Section 7 Electrical Data Guardian Liquid cooled 40 kW Generator Wiring Diagram Schematic Lower Panel Drawing 005997 ELECTRICAL DATA lt NOLLO3NNOO LYVLS 2 dIHLS TVNIIWH3L YSL NOLLO3NNOO HOLIMS H34SNVH L Q39vVMOVd 3Hd diHLS TWNINYAL S L ualoaloHd IVINH3HI dL 39018 WHLNAN ONIGNIM NOLLV LIOX3 Add H3lINHOJSNVH L LNSYYND 219 8 LLO TANVd H3MO T1HOLO3NNOO TANVd TOH LNOO dO NIYIN H35 1V3H8 LINDYID qO YOLVLS HOLVNYSLTV SV HOLOH HOLVNHALTIV HV INVH9VIG 1 A0vc Ocl NOILO3NNOO YAWOLSND 00 0153 000113 AOve AOL LA 3937 212 us O H a SIO 4 818 85 22 9 9 2 2 9 2 S19 OVH3N3O QHVONVISWOH4 2005 841 NOLLO3NNOO 1915 SHIM Z OO C e 2 L1Oo3ula ONIMVA OL
26. BIRBO PF rS p 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 8 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 Systems Inc 55 Ge us Section 8 Exploded Views and Parts Lists Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generators KO Electronic Governor Drawing No 0A2615 F ITEM 18 NEOPRENE COATING WIRE HARNESS SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN 16 Lene ENGINE HARDWARE 12 ITEM PART NO QTY DESCRIPTION 1 098290 1 ASSEMBLY MOTOR STEPPER 2 0A343
27. HOLAYNEYVO LSATVLVO LSnVHX3 JHL ONIGNIONI W3LSAS SIHL dO LYVd d 18VSIGO HO H3dlNV L LON LOIWLSIG INAWADVNVW LSVOO HLNOS JHL 513 ONILVYSANSD AON39HU3IA3 9 5 1Jole nB u OL SNOASVD SNOILVINGAY HIV VINHOSIIVO NIV LH3O A TdIlNOO OL WALSAS SNOISSIWA LSNVHX 3ALLOV NV QaddInO3 SI LINN SIHL NOILVINHOJNI SNOISSIIN3 15 LNV LHOdMI Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generators A Section 8 Exploded Views and Parts Lists Exhaust Drawing No 0E1347 LISTS PARTS 0 OL JNION3 OL LL 81 E 81 62 Oc amp 54 Generac Power Systems Inc ITEM CONDOR WD Section 8 Exploded Views and Parts Lists Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generators PART NO 059902A 009641 0D4208 0D5061 004126 0D5787 0A5215B 0 0699 0 0698 004170 004305 002454 0C3433A 022129 022145 045771 042907 080762 022237 022241 0E0701 0E0700 077879 004221 004512 043116 022471 022264 038150 036918 049811 022097 049813 008780 022131 QTY
28. Section 10 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 to 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 accord
29. 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 5 ENGINE MARG eT N General Motors Displacemerit 4 3 liters 262 cu in Cylinder ATPABSCPHODE V 6 Valve Overhead Valves tre ee 1 6 5 4 3 2 Numi Der Of Main 6 u u uu 4 Compression u u u y das iique 9 4 to 1 Noof Teeth on Ply Whee 168 Gon Sy STOLE Electronic Ignition Timing at 1 800 rpm 40 degrees BTDC Rated Horsepower at 1 800 rpm 67 Spark PUD 0 045 inch 1 1 mm Recommended Spark Plugs AC 41 932 or equivalent m 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 ees Pusher Type Cooling System Capacity 4 5 U S gallons 17 L Recommended Coolant
30. 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 WASHER FLAT M12 CLAMP VINYL 1 06 X 406 Z FILTER OIL WASHER FLAT M16 RELAY SOLENOID 12VDC PNL MNT NOT SHOWN SADDLE 2 1 2 age LISTS Generac Power Systems Inc 45 Se us Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators 0 4 3L Radiator Drawing No 0D7992 E 21 10 KIT PART NO 0D8121 UM NNNNNNNN MMMM WY at Tt Pu KIT PART NO 0D7947 37 38 39 co lt OD Mm Cc lt 46 Generac Power Systems Inc ITEM NOOB WD 31 32 33 34 35 36 377 387 39 40 OPTIONAL WITH KIT 0D7948 OPTIONAL WITH 007947 PART NO 0D7825A 0D8251 0D8252 024655 022097 022473 0D7174 0D7174A 0D7870 035685 047290 040173 036865 029032 052250 058443 029745 022237 022131 0D7850 076749 0D7975 090388 048031C 004341 0A6984 0D7942 0D7943 022413 022097 022473 0D7924 024655 022097 022473 090283 QTY po hA a A P so
31. 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 240VAC single phase loads 1 5 GENERATOR 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 120VAC 60 Hertz output When 4 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator the two windings are connected in series a 240VAC 60 Hertz 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 generator is rated 200 amps maximum at 120 240VAC single phase The enclosure of the transfer switch is NEMA 3R This type
32. 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 Guardian Liquid cooled 40 kW Generator 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 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 engine failure Before starting the generator for the first time the installer must
33. 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 base frame of the unit contains an optional fuel inlet location and 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 2 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 closing off any gap between the access holes and the wires Generac Power Systems Inc 17 MAINTENANCE Section 4 Maintenance 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 1 2 3 Start the engine and let it warm up Close the fuel shutoff valve in the fuel supply line
34. 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 1 800 555 1522 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 performed 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
35. complete the following procedures For follow up maintenance information and or service inter vals please refer to Section 4 Maintenance 2 8 2 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 3 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 SAE 15W 40 oil This oil should be changed after 30 hours of operation 2 8 4 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 Section 2 Installation 2 8 5 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
36. 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 10 Warranty WARRANTY Guardian Liquid cooled 40 kW Generators GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the date of original sale Generac Power Systems Inc Generac warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below Generac will at its option repair or replace any part which upon examination inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer is found to be defective Any equipment that the purchaser owner claims to be defective must be examined by the nearest Guardian Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Guardi
37. 0 9611 1 FUSE 7 5AXBK AGC7 5NX W 22670 29 070081 1 HOURMETER 64 074908 4 SCREW HHTT M5 0 8 X 10 BP 30 070043 1 VOLTMETER AC 0 300 65 0E3783 1 DECAL WARNING REMOVE FUSE 31 070045 1 AMMETER AC 0 200 32 070042 1 FREQUENCY METER 240V 55 65HZ PART OF CONTROL PANEL WIRE HARNESS Generac Power Systems Inc 37 PARTS Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Connection Box Drawing No 0E6892 A 3415 avon 3415 3 NOISS3NdWOD 01 31492 B3 V388 11 2412 OL 903 19 179 KT NR IBINV3IS JO AN3 AaddINLS NOISS3NdWOI N3LSV Jj SVNIWAH3LI ONIS WALI MOO 18 UNS aus yo ONINJIHDIL 66 A ez K AG lt 1 LC BARB 4 2 2 2 7002 SS BAR 22 2 AOvd 2 Z p 310d ZrO 0 2 e SN3W3IS 22 i i l E 3uIM ONISN3S 3 sava1 S ONISN3S SQvii Z S LL 3NVd IOHLNOO JO WOLLOd 38 Generac Power Systems Inc ITEM N QTY 0E6353 0D5489 0E6427 023484N 0 6454 056739 0 2454 051715 003388 058710 005492 048766 022985 0 6689 022264 052813 039253 022145 005840 022129 045771 022287 022473 022097 022127 0 4458 0 5586 0 5587 022237 022241 081320 048527 005464 057073 0 2266 20 O Tl
38. 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generators 4 3L Nat Gas Fuel System Drawing No 0E7011 B OG a IO3INVIN JAV LNI OL HOLON d3dd3l OL 50 Generac Power Systems Inc ITEM CONDOR WD NOT SHOWN Section 8 Exploded Views and Parts Lists Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generators PART NO 065907 026812 028238 007598 026490 026577 055944 028237 0 0521 022259 022145 022129 030795 025655 022132 051778 028641 057824 057422 043123 051779 082508 050279 026915 055934P 0A5737C 0D1509 061258 0A7631 029745 022237 052865 033212 0A4120 064945 044074 0A4121 047290 036409 022097 0A5763 QTY JJ H JJ N Ti Ti N gt N M Tl 4 3L Nat Gas Fuel System Drawing No 0E7011 B DESCRIPTION SUPPORT SOLENOID NAT GAS ELBOW 90D 3 4 NPT BOLT U 5 16 18 X 1 50 ASSY NATURAL GAS SOLENOID NIPPLE PIPE 3 4 NPT X 2 BUSHING REDUCER 1 TO 3 4 REGULATOR NAT GAS LPG VAPOR SADDLE 1 3 8 SUPPORT REGULATOR NUT HEX 5 16 18 STEEL 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 42 LG WASHER LOCK M14 NUT HEX M14 2 G8 Y
39. 075763 QTY JJ TI PP S SS S S Po Pe B HB PO GW P YP N MO Section 7 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Mounting Base Drawing No 0E6976 A DESCRIPTION MTG BASE 4 3L D D PRE PACK 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 8 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 62 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 4 3L PRE PACK CABLE BATT BLK 1 X 23 00 WASHER FLAT 3 8 10 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 LISTS OG Generac Power Systems Inc 31 us Section 8 Exploded Views and Parts Lists 0 Guardian Liquid cooled 40 kW Generat
40. 1538010 e81 aval x 4 Nu 2 19 8 HOLIMS 1 1 149 XH H34SNvuL cL 659 69 39vxOVvdaud oe 9 Q ez HO 8 O O L 76 M3HOS DL uaaioHHsnua C9 L L v dO HOLO3NNOO 13NVd 1OHINOO OL r 81 OILVIN3HOS g lt 581 J s lt IN 1 N SVHd L 7 0 2 061 N lt H Q Seg HaWOISnO iN I X 61 95 M SIS 9 913 249 ob 89 lt LLO N 29 XH 55 N 00 br 55 44 LL 9 VA AAA 27 IS 5 Ks 718 SSVdAd HOIO3LOHd TVINH3H L 4 9 SLINN Hsnug 9 v v HV V q lt L L 25 Generac Power Systems Inc 3HIM GASNNN ALVINSNI 3SVHd A802 HOS 3HIM MOTT3A ISN 3SVHd 072 HOS SHIM 30118 ASN
41. 2 8 6 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 7 RODENT PROTECTION Make sure the four 3 inch diameter cap plugs part 7 OA8785 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 stay within noise specification limits Figure 2 3 Base Frame Cap Plugs INN 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 AMMETER AC FREQUENCY VOLTMETER METER DC C c VOLTMETER HOURMETER SET EXERCISE TIME SWITCH VOLTAGE PHASE SELECTOR SWITCH AUTO OFF MANUAL FUSE SWITCH FAULT INDICATOR LAMP 3 1 1 AC VOLTMETER The voltmeter displays generator AC outp
42. 5 0A3927 0 7947 0 1232 0A7801B 021928 0C6239 0A4241 0C2885 0A5737C 022131 077456 044117 057823 057448 022129 022142 048614 022237 029745 042633 033819 022241 0A5768 046526 049814 003756 045772 0A37970172 052259 055934D 0A37970001 0A1646 056739 0C7947B QTY Aa CO CO S po N N Q c Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Engine Drawing No 0A4304 N 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 U BOLT 3 8 16 2 5 I D 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 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
43. 7 0C4905 1 BARBED EL 45 3 8NPT X 5 800 CORD 8 042568 4 SCREW HHC M6 1 0 X 20 G8 8 16 062303 1 ADAPTOR 1 4 NPT TO 3 8 NPT 9 022473 4 WASHER FLAT 1 4 M6 ZINC 10 084918A 1 HEATER ENG 1000W 120V USED ON 50HZ VOLTAGE GENERATORS ONLY 084918B 1 HEATER BLOCK 1000W 240V USED ON NATURAL GAS amp L P VAPOR UNITS ONLY Generac Power Systems Inc 57 NOTES Section 9 Notes Guardian Liquid cooled 40 kW Generators 58 Generac Power Systems Inc Section 9 Notes NOTES Guardian Liquid cooled 40 kW Generators Generac Power Systems Inc 59 Section 10 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 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 conditio
44. 9 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 21 Section 8 Exploded Views and Parts Lists CG Guardian Liquid cooled 40 kW Generators Engine Coolant Heater Drawing No 0E2352 A O TO THERMOSTAT HOUSING TO ENGINE BLOCK ITEM A PART QTY DESCRIPTION ITEM APART NO QTY DESCRIPTION 1 0C4905 1 BARBED EL 45 FITTING 11 084427 1 BRACKET HEATER W WELDNUTS 2 057822 2 CLAMP HOSE 8 53 1 00 12 022097 4 WASHER LOCK M6 1 4 3 077043E 1 CONDUIT FLEX 1 BLACK 15 LG 13 049813 2 NUT HEX M6 X 1 0 G8 YEL CHR 4 050967 1 HOSE 5 8 ID RIA 250F 46 LG 14 055934D 1 CLAMP VINYL 1 06 X 406 Z NOT 5 0A6283 1 HOSE PREFORMED BLOCK SHOWN HEATER 15 077043A 1 CONDUIT FLEX 38 ID 42 LG NOT 6 057822 2 CLAMP HOSE 8 53 1 00 SHOWN USED ON HEATER
45. AMP This lamp goes ON when one or more of the following engine faults occurs and when engine shuts down Low oil pressure High coolant temperature Low coolant leve 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 75 AMP INLINE FUSE NOT SHOWN This inline fuse is connected in the 15A line that runs between the AUTO OFF MANUAL switch and position 10 of the 076009A PCB This fuse protects the start fuel field boost and transfer outputs from 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 POSI
46. ASHER LOCK HDPDEUTSCH 41 057335 REF BLOCK TERM 20A 20 X 6 X 1100V 6 0C8244 1 NUT HDP DEUTSCH 42 076061 1 DECAL TERM STRIP 8 048467 1 CIRCT BRK 7 X 1 ETA 46 500 P 43 029333 6 TIE WRAP 7 4 X 19 NATL UL 9 057907 1 RES WW LUG 10R 10 25W 45 040479 4 VIB MNT 1 0 X 1 0 X 1 4 20 10 064008 1 COVER CON PNL TOP NOT SHOWN 46 022507 4 SCREW HHC 1 4 20 X 1 2 G5 12 055444 1 HEATSINK 47 022127 4 NUT HEX 1 4 20 STEEL 13 030468 1 WASHER STEP NYLON 20 48 022097 4 WASHER LOCK M6 1 4 14 049939 1 RECTIFIER MSC 12A 600V 1N1206R 49 033121 14 SCREW HHC 10 32 X 1 2 15 070370 1 WASHER MICA 203 50 022152 14 WASHER LOCK 10 16 022158 1 NUT HEX 10 32 STEEL 51 036902 4 SCREW PPHM 6 32 X 1 2 17 023762 1 WASHER SHAKEPROOF EXT 10 52 022155 6 WASHER LOCK 6 STL 53 022985 6 WASHER FLAT 6 ZINC 18 023897 15 WASHER FLAT 10 ZINC 54 036918 4 SCREW PPHM 8 32 X 1 2 19 076009A 1 PP LOGIC ASM 50 60HZ 55 022264 4 WASHER LOCK M4 20 040213 4 PCB SUPPORT SNAP IN 1 4 56 038150 4 WASHER FLAT 8 ZINC 21 027744 1 GROMMET 3 4 X 5 32 X 5 16 57 022471 4 NUT HEX 8 32 STEEL 22 082573 1 SWITCH ROCKER DPST 125V SPD 58 022188 6 NUT HEX 6 32 STEEL 23 076020 1 SWITCH TOG DPDT 15 10 SP 59 036908 2 SCREW PPHM 6 32 X 1 1 4 24 032300 1 HOLDER FUSE 60 002428 4 SCREW PHTT 6 32 X 1 2 ZYC 25 022676 1 FUSE 15A X AGC15 61 0C2323 4 SCREW PHTT 46 32 X 5 8 ZYC 26 064009 1 LIGHT 12VDC 02A LED RED PILOT 62 005324 REF FUSE amp HOLDER LITTEL 7 5A 27 061945 1 SWITCH SELECTOR 6A AMP V 63 0 9611 REF FUSE 7
47. EL CHR BALL JOINT PLA 25 28 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 STR 1 8NPT 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 age LISTS Generac Power Systems Inc 51 LISTS an Section 8 Exploded Views and Parts Lists Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generators KO 4 3L Nat Gas Fuel System Drawing No 0E7013 B ATTACH TO AN SCROLL 29 ASSEMBLY P N 0D3509 TO INTAKE MANIFOLD 52 Generac Power Systems Inc ITEM CONDOR WD NOT SHOWN Section 8 Exploded Views and Parts Lists Model No 0046262 0046263 amp 0046264 Guardian Liquid cooled 40 kW Generators PART NO 065907 026812 022259 0C7598 026490 026577 0D2758 0 0521 028237 028238 022145 022129 030795 025655 022132 051778 028641 057824 057422 043123 051779 0C7820 050279 026915 055934P 0A5737C 0D1509 061258 0C7650A 029745 022237 0C7059 033212 0A4120 064945 044074 0A4121 047290 0C7060 0D3485 022152 0C7908 0A6613 064090 QTY JJ p Ae
48. 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 generator 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 automat ic start up and possible injury to personnel disable the generator s automatic start circuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and on the transfer switch In case of accident caused by electric shock immedi ately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct
49. GUARDIAN by Generac Power Systems Inc Owner s Manual Liquid cooled Prepackaged Standby Generators Models 004373 6 40 kW Single phase w 200 Amp Transfer Switch 004626 5 40 kW Single phase w 200 Amp Transfer Switch California Emissions JJ J 1 J A Not intended for use in critical life support applications caution ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMIPT 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 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 that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as fol
50. ILOSNNOD NOITLOSNNOO 2 AOZT 391 934 ASLVSH NOO1d CaVaNvlS 71 S SLEUIN 1 66461 696 MJIA ELS 1441 jJlVWN34 Ld N 42 1 Nivad Wo 2319434 LdN 7 6 69 6 v6 c 9310 LYTI LE 6 41 14 des 0S S amp 1 C 8cl 764 l8VHO ANY 8 33S dfl 8fllS l3 NI 99 IVaflLVN 58961 956 Z8 cE SEB 602 86 v 6 28741 vSv LE vel Z6 amp c NV Id dol L 6T 9c G99 L vv22 015 LEE 00 WOLLO amp NO S3IDH 8 1 8500 GED S3 10H DBNILNLUN 15 L STET vee ES d 1 26 1 6v 4 4 p LICEE 658 5 0 8 voz Lng IV 6 61 Lye 1719 dAL L 99 Jed 298 L 3LON 21 Generac Power Systems Inc Section 7 Electrical Data EPECTBIDAT Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generator 4 DATA 5 Electrical Schematic Stepper Motor Drawing No 045858 lt a cook kTT HLL L NSBSREBEE TS1 acg BLACK RED P N 98647
51. LH DUCT FRONT RH DUCT BOTTOM DUCT FRONT PANEL DUCT FRONT TOP RH ALUMINUM NUT HEX LOCK M6 1 0 SS NY INS ASSEMBLY COVER ACCESS SCREW TH FRM M6 1 X 16 N WA Z JS WASHER LOCK M8 5 16 SCREW HHC 8 1 25 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 age LISTS ALUMINUM ENCLOSURE NOTE ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 2 amp 29 THREAD FORMING FASTENER AND ITEM 27 LOCK NUT LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER Generac Power Systems Inc 33 us Section 8 Exploded Views and Parts Lists gt Model No 0043733 0043734 amp 0043735 Guardian Liquid cooled 40 kW Generator q KO Control Panel 4 3L Drawing No 0D4995 F 22722772777772 Hz D So TI PANEL FACE
52. M 20A 20 X 6 X 1100V 8 048467 1 CIRCT BRK 7 X 1 ETA 46 500 P 42 076061 1 DECAL TERM STRIP 9 057907 1 RES WW LUG 10R 10 25W 43 029333 6 TIE WRAP 7 4 X 19 NATL UL 10 064008 1 COVER CON PNL TOP NOT SHOWN 44 040479 4 VIB MNT 1 0 X 1 0 X 1 4 20 11 0E3550 1 CHASSIS UNIVERSAL 45 022507 4 SCREW HHC 1 4 20 X 1 2 G5 12 055444 1 HEATSINK 46 022127 4 NUT HEX 1 4 20 STEEL 13 030468 1 WASHER STEP NYLON 20 47 022097 4 WASHER LOCK M6 1 4 14 049939 1 RECTIFIER MSC 12A 600V 1N1206R 48 033121 14 SCREW HHC 10 32 X 1 2 15 070370 1 WASHER MICA 203 49 022152 14 WASHER LOCK 10 16 022158 1 NUT HEX 10 32 STEEL 50 036902 4 SCREW PPHM 6 32 X 1 2 17 023762 1 WASHER SHAKEPROOF EXT 10 51 022155 6 WASHER LOCK 6 STL 52 022985 8 WASHER FLAT 6 ZINC 18 023897 15 WASHER FLAT 10 ZINC 53 036918 8 SCREW PPHM 8 32 X 1 2 19 076009A 1 PP LOGIC ASM 50 60HZ 54 022264 8 WASHER LOCK M4 20 040213 4 PCB SUPPORT SNAP IN 1 4 55 038150 8 WASHER FLAT 8 ZINC 21 0A3394 1 GROMMET 3 4 X 5 32 X 5 16 56 022471 8 NUT HEX 8 32 STEEL 22 082573 1 SWITCH ROCKER DPST 125V SPD 57 022188 6 NUT HEX 6 32 STEEL 23 076020 1 SWITCH TOG DPDT 15 10 SP 58 002428 8 SCREW PHTT 6 32 X 1 2 ZYC 24 032300 1 HOLDER FUSE 59 002323 4 SCREW PHTT 6 32 X 5 8 ZYC 25 022676 1 FUSE 15A AGC15 60 0A2284 4 SCREW SWAGE 8 32 X 1 2 Z YC 26 064009 1 LIGHT 12VDC 02A LED RED PILOT 61 001127 1 DECAL AVR COVER 27 061945 1 SWITCH SELECTOR 6A AMP V 62 005324 4 FUSE amp HOLDER LITTEL 7 5 28 076037 1 VOLTMETER DC 8 18V 63
53. NN 9 HOSN3S NI QV3HHL ALON INANLSAPAV TASHMA Tl3 D JNION3 OL 133HMA 13 3NION3 OL Generac Power Systems Inc ITEM O1 why O N ROTOR REPLACEMENT PARTS PART NO 051768 051769 0A8240 039253 022129 082130D 0C4286 0A2601 0A2602 0A1138 021941 020808A 052624 070892 0A5580 0A1633 020729A 022131 022237 022511 068113 0E6353 043123 051779 046852 022145 039287 071641 071639 0A2110 022473 022746 031980 083549 0A4089 0A2491 0A2497 0A2496 056326 022097 045757 047411 0A2110 QTY 8 4 FT O gt N Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Generator Drawing No 0E6891 DESCRIPTION SCREW HHC M12 1 75 X 25 G8 8 WASHER LOCK M12 FLEX PLATE SAE10 SCREW HHC 8 1 25 X 20 G8 8 WASHER LOCK M8 5 16 ASSEMBLY MAG PICKUP 72 ASSEMBLY FAN W PRESS DISC 10 75 X 3 SCREW HHC M16 2 0 X 45 G8 8 WASHER FLAT 688 ID X 3 25 OD KEY SQ 3 8 X 2 1 2 STEEL COUPLER 390 SAE ROTOR 390 40 1P DIRECT BEARING BALL 6212 SEALED SLIP RING MACHINED SCREW HHC M14 2 0 X 140 G8 8 WASHER 390 SAE ALT STATOR 390 40 AD2 SAE WASHER FLAT 3 8 M10 ZINC WASHER LOCK 3 8 SCREW HHC 3 8 16 X 1 1 4 G5 CARRIER REAR BEARING 15 LOWER PANEL 15 WASHER LOCK M14 NUT HEX M14 2 0 G8 YEL CHR SCREW 10 32 X 1 4 CZ WASHER FLAT 5 16 ZINC SCREW HHC 8 1 25 X 45 G8 8 FT BRU
54. O 0043736 0046265 Rated Maximum Continuous AC Power Output IW 40 Rated Voltage 120 240 Rated Maximum Continuous Current at 240 Volts Single phase amrps 167 Number or Rotor 4 Driven Speed of Rotor rpm 1 800 AVG Ol 5 DO MT Four wire Rotor Excitation System Direct Excited Brush type System Class Rotor Insulation Class 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 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 frequency are not compatible NOTE
55. SH HOLDER ASSEMBLY HOLDER BRUSH SUPPORT SCREW SWAGE 1 4 20 X 1 2 Z YC WASHER FLAT 1 4 ZINC SCREW HHC 3 8 16 X 1 3 4 G5 TIE WRAP UL 14 6 X 14 NATL SLEEVE RUBBER ASSEMBLY SCROLL 390 SAE KIT 0A4089 PARTS SHROUD ALTERNATOR SHEET METAL SCREEN SHROUD SAE BRACKET TENSIONER SAE SCROLL TRIM VINYL BLACK 1 8 GP WASHER LOCK M6 1 4 SCREW HHC M6 1 0 X 25 G8 8 SCREW HHC M6 1 0 X 16 G8 8 SCREW SWAGE 1 4 20 X 1 2 Z YC age LISTS Generac Power Systems Inc 41 Q us Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators KO Engine Drawing No 0D6980 D TO AIR CLEANER N O DISTRIBUTOR 13 42 Generac Power Systems Inc PART NO 0A9046 0A9118A 070022 0 6021 059056 0 9050 022237 045772 049226 051716 0 4244 0 4215 0 4231 059057 0 2440 026568 099729 061012 069939 035606 0A4930B 0A4084 029745 044101 023152 022131 058030 0 4085 0 3928 0 7947 057794 0A4277 022241 057795A 048191 032303 0A3852 098239 0 0561 002244 075885 0C7947B 0D6979 0A4308 QTY N lt NN N G RS Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Engine Drawing No 0D6980 D DESCRIPTION ENGINE 4 3L GM FLYWHL 4 3L GM SAE WASHER
56. 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 5 NUT 5 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 U BOLT 3 8 16 2 5 I D RETAINER SPARK PLUG WIRES WIRES SPARK PLUG 4 3L NUT HEX 3 8 16 STEEL BARBED EL 90 3 4 PLASTIC PIN DOWEL M10 X 24 SCREW HHC 3 8 16 X 3 1 2 G5 PLATE FLEX GM CASTING ADAPTOR ASSY WATER LEVEL SENSOR ASSY MAGPICKUP 3 8 24 MALE MODEL 004626 ONLY THERMOSTAT 195 DEG SADDLE 2 1 2 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 Se us Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators q KO Engine Drawing No 0A4304 N 44 Generac Power Systems Inc ITEM or O N PART NO 0A9046 0A4084 0A4239 0A4240 0A5640 0A5640A 0A5639 0D3293A 077996 057823 035579 037065 022302 0A8584 052644 0A4278A 0A4930A 0A408
57. TION This switch position shuts down the engine This posi tion also prevents operation 3 2 5 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 wanNiNG amp A 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 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 generators 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 s
58. TY 1 1 1 2 2 1 2 1 1 2 1 2 COMPARTMENT FRONT p 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 2 45 48 Generac Power Systems Inc PART NO QTY 0C3433A 4 022129 12 022145 12 0C9748 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 8 1 25 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 CONDO WD PART NO 037561 0A4632A 0A4637 0A4632B 062522 022127 057796 057795A QTY _ L Section 8 Exploded Views and Parts Lists Qi Guardian Liquid cooled 40 kW Generators 4 3L Air Cleaner Drawing No 0E0712 A 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 BARBED EL 90 3 4 PLASTIC Generac Power Systems Inc 49 Section 8 Exploded Views and Parts Lists LISTS PARTS 0 Model 0043733
59. afety reasons Generac recommends that the installation initial start up and maintenance of this equipment is carried out by a Generac Guardian Authorized Dealer 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 and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating A
60. all ten sion is removed from the inner spring 3 Install and tighten 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 23 7 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 Oil Grade Recommended SAE 30W or 15W 40 SAE 20W 20 or 15W 40 SAE 10W or 15W 40 Temperature Above 80 F 27 C 32 to 80 F 1 C to 27 C Below 32 F 0 C caution 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 deionized water Use only deionized water and only low silicate antifreeze If desired add a high quality rust inhibitor to the recommended coolant mixture When adding coolant
61. always add the recom mended 50 50 mixture DX A Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result 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 attracted to the smell and taste of antifreeze even though it is poisonous to them A A 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 MODEL 0046265 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
62. an prepackaged emergency automatic standby generators sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS ONE and TWO 100 one hundred percent transferable coverage on Labor and Part s listed proof of purchase and main tenance is required Engine All Components Alternator All Components Transfer System All Components Steel enclosures are warranted against rusting for the first year of ownership only Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty Nicks scrapes dents or scratches to the painted enclosure should be repaired promptly by the owner All warranty expense allowances are subject to the conditions defined in Guardian s Warranty Policies Procedures and Flat Rate M l un THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Guardian generators that utilize non Guardian Generac replacement parts Guardian generators utilizing non Guardian Generac automatic transfer switches e Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems e Any Guardian 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
63. 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 crankcase 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 trans fer 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
64. ator 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 Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical atten tion and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams 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 DO NOT SMOKE when near batteries DO NOT cause flame or spark in battery area and 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 For recommended batteries see Section 4 5 Battery Maintenance All batteries must be
65. ched 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 This timer runs for about 15 seconds At end of a 15 second delay circuit board action de energizes transfer relay in the transfer switch Retransfer to utility power source then occurs 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 ENGINE 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 2D 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 exe
66. d use of standby electric systems is available Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John otreet New York N Y 10038 AGRICULTURAL WIRING HANDBOOR obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 364 2 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 A52 1 AMERICAN NATIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYS TEMS available from the American National Standard Institute 1430 Broadway New York N Y 10018 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 EMERGENCY 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 Gene
67. dequate 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 N ELECTRICAL HAZARDS All generators covered by this manual produce dan gerous electrical voltages and can cause fatal electri cal shock Utility power delivers extremely high and dangerous vo
68. e 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 Introduction Inside Front Cover Read This Manual Thoroughly IFC Bo sie 1 Operation and Maintenance IFC How to Obtain Service IFC Authorized Dealer Locator Number IFC Safety Rules 2 Section 1 General Information 4 1 1 Unpacking Inspection 1 4 12 u uu eee 4 1 3 Generator AC Connection Systems 4 1 4 Prepackaged Transfer Switch 4 1 5 Automatic System Operation 4 1 6 Main Circuit Breaker 5 1 7 Engine Protective Devices 5 LS Specifications 5 1 9 Fuel Requirements Recommendations uuu rasan nested 6 1 10 Engine Oil Recommendations 7 L TD COOL 7 1 12 Emission Control System 7 Section 2 Installation
69. electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times DO NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris Generac generator sets may operate using one of sev eral types of fuels All fuel types are potentially FLAM MABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks immediately Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural
70. en this isolation method is employed The following 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 The transfer switch must be installed between the utility service disconnect circuit breaker 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 the area Grounding procedures must meet local regulations INSTALLATION Section 2 Installation 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 serv
71. es 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 amp Do not dispose of the battery a fire The bat tery is capable of exploding Do not open or mutilate the battery Released electrolyte can be toxic and harmful to the skin and eyes 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 Generac s part number is 058665 NOTE The BCI number should be located directly on the battery 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 dow
72. 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 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 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 at the time of delivery but is discovered later LIFTING THE GENERATOR wanNiNG amp
73. he air fuel mix ture to the engine is controlled by biasing the diaphragm 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 Section 2 Installation Guardian Liquid cooled 40 kW Generator STANDBY GENERATOR INSTALLATION A DING 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 Pre packaged 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 cauroN 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 regulation
74. ible injury to personnel 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 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 warninc amp Do not dispose of the battery in a fire The battery is capable of exploding 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 10 Generac Power Systems Inc Guardian Liquid cooled 40 kW Gener
75. ice entrance 2 6 TRANSFER SWITCH START SIGNAL CONNECTIONS 2 6 1 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 1 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 separate conduit from the main AC output wires 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 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 Generac Power Systems Inc s INSTALLATION Section 2 Installation 2 1 BATTERY INSTALLATION Dita A A Standby generators installed with automatic trans fer switches will crank and start automatically when NORMAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and poss
76. if defective replace the battery with a 12 volt DC Group 27F battery rated for 90 amp hours part 7 0586695 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 thor oughly Stop the unit and set the AUTO OFF MANUAL switch to AUTO 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 2 0 ATTENTION It is recommended that all service work be performed by the 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 30 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 condi
77. igure 4 4 Setting the Spark Plug Gap lt 0 045 inch 1 1 mm gt Cam 7 52 NN 4 5 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 4 12 The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fil with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer or load test DX 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 personnel 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 16 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator 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 hous
78. imer needs to be reset for automatic exercise operation Figure 3 3 Set Exercise Switch on Control Panel EXERCISE TIME VOLTS 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 Figure 4 1 Oil Dipstick and Fill OIL DIPSTICK OIL FILL CAP caution amp Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 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 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 2 OIL AND FILTER CHANGE PROCEDURE To change the oil and filter proceed as follows
79. ing 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 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 respon
80. is included with the unit as shipped from the factory The breaker for each unit is described as follows Model Number 0043736 0046265 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 LEVEL SWITCH SWITCH LOCATED ON LOW COOLANT LOW OIL PRESSURE SWITCH OF GENERATOR Li i Li j i O i i TRANSPARENT ENCLOSURE FOR CLARITY 1 72 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 contacts cl
81. lows A After this heading read instructions that if not strictly complied with will result in personal injury or property damage wanNiNG amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution amp 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 Manual and thor oughly understand all instructions before using this equipment Generac also strongly recommend
82. ltages 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 related equip ment make sure that all power voltage supplies are positively turned off at their source
83. n waRNING amp The exhaust system of this product gets extremely f 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 Guardian Liquid cooled 40 kW Generator 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 voltage is delivered to that circuit board via a 15 amp fuse These overcurrent protection devices will open if the circuit is overloaded caution If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse 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 1 6 EXERCISE KLA FUSE VOLTS AUTO INDICATOR 15A Qe MANUAL 49 ENGINE COOLANT Check the coolant level in the coolant recovery bottle Add the recommended coolant mixture as necessary see Section 1 10 Periodically remove the radiator pressure cap to make sure the co
84. n 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 or 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
85. oductive 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 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 Parts of the generator are rotating and or hot during operation Exercise care near running gen erators 2 Generac Power Systems Inc A GENERAL HAZARDS For s
86. of enclosure is intended for outdoor use but it can be mounted indoors It also protects enclosed parts from windblown dust and water The enclosure is sealed for dust rain or sleet and is ice resistant Follow these rules 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
87. olant 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 MAINTENANCE Section 4 Maintenance 4 10 MISCELLANEOUS MAINTENANCE 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
88. ors 0 Compartment Drawing No 0D8992 A UENCE ASAE SSNS m nom mere ERN x 32 Generac Power Systems Inc ONE PER SIDE PART NO 003594 0E3257 0A3359 022769 0D7904 A 002633 0C6749 060069 0C6748 080490 087233 0 4065 A 0C4064 A A A 002454 022129 042907 022473 022097 022127 0A9881 003393 0C3400 A 003397 066760 022145 QTY 4 CO komt a pp 39 3 8 OPTIONAL COMPARTMENT MATERIALS ALL P N S WITH AN A SUFFIX INDICATE ALUMINUM MATERIAL OPTION ONE PER PADDLE HANDLE Section 8 Exploded Views and Parts Lists Guardian Liquid cooled 40 kW Generators Compartment Drawing No 0D8992 A DESCRIPTION ASSEMBLY M6 HINGE SCREW TH FRM M6 W CAP SHKPRF W SCREW BHSC M6 1 0 X 16 SS WASHER SHAKEPROOF INT 10 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 BRACE SIDE TOP AND BOTTOM SIDE SUPPORT ROOF ONE PC WELD ALUMINUM 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
89. ose 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 DC FUSE 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 555956 TENER
90. ource 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 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 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 the engine generator output C Standby Voltage Sensor This sensor monitors generator AC output voltage When the voltage has rea
91. oxygen sensor air fuel ratio controller sole noid valve and gas regulator These items are not sub ject to periodic maintenance or adjustment This model is of a size greater than 50 brake horse 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 AIF Ratio Controller Control Valve Sensor Throttle 3 Way Catalyst 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 T
92. rac Power Systems pre packaged type transfer switch Part No OE5782 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 method prevents overloading the generator by keeping electrical loads below the wattage amperage capacity of the generator If the generator is powering only critical loads within its wattage amperage capacity during utility power outages consider using the emer gency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are 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 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 5 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 wh
93. rcise 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 Set generator s main circuit breaker to its OFF or open position Locate the rocker switch on the control panel identi fied with the words Set Exercise Time Figure 3 3 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 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 caution amp A 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 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 14 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator NOTE If the battery terminals are disconnected or the con trol panel fuse is removed the exercise t
94. roubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Revision 02 01 05 Part No 7018 Revision D 06 02 05 Printed in U S A
95. s 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 0043736 and 0046265 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 contact a Generac Guardian Authorized Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting a Generac Guardian Authorized Dealer about parts and service always supply the complete model number and serial number of th
96. s should install this standby electric power system The installation must comply strictly 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 1 2 inch all around caution amp After the system has been installed do nothing that might render the installation in noncompliance with such codes standards and regulations NOTE For more information about the installation of a stand by system 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 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES NFPA No 220 STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No 68 GUIDE FOR EXPLOSION VENTING NFPA No 70 NATIONAL ELECTRICAL CODE NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 8 Generac Power Systems Inc OTHER PUBLISHED STANDARDS In addition to NFPA standards the following informa tion pertaining to the installation an
97. si 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 warranted 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
98. 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 255 pressure switch 3 Defective high temperature De 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 i 5 is set 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 2 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 Contact the nearest Generac Guardian Authorized Dealer for assistance eo Generac Power Systems Inc INSTALLATION Section 6 Installation Diagram Guardian Liquid cooled 40 kW Generator Drawing No 0E7015 0971 8 4 9802 SIHONI J ww SLINA 591 INSWLAVdWOO 13315 60911 84 7 62 Viva LINN 541 SUIS 86 87 0561 29861 186 ALIAVAD 30 331N32 N31SAS 1303 TIVWS
99. tion 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 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 7 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 3 Open 14 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
100. ut voltage dur ing operation Voltage is regulated by a solid state volt age regulator and is proportional to AC frequency Refer to the units 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 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 12 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator 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 the generator set 3 1 6 AUTO OFF MANUAL SWITCH see Section 3 2 5 1 7 FAULT INDICATOR L

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