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Generac 004373-3 , 004626-2 Portable Generator User Manual

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6. 52 58 58 59 5 00D El NO JY 0 _ A A SI 9 2 TEE 0009 ON Y 0 SET EXERCISE TIME ONS V A Hz FAULT INDHZKTORM FUBE Q PANEL FACE 34 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Cp Model No 004373 3 Guardian Liquid cooled 40 kW Generator Control Panel 4 3L Drawing No 0D4995 C 0 ITEM PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 0D1523 1 PANEL BTM amp BACK CONTROL 31 070045 1 AMMETER AC 0 200 PANEL 32 070042 1 FREQUENCY METER 240V 55 65HZ 2 0D1521A 1 CONTROL PANEL FRONT W SILK 33 081988 1 DECAL EXERCISE INFO SCREEN 94 0C1229 1 DECAL CUST CONN BOX 3 0D1522 2 PANEL SIDE COVER CONTROL 35 098647 1 ASSY L C ELECT GOV PANEL 36 043968 1 CAPACITOR FILTER ASY 4 067680 1 ASSY VOLTAGE REGULATOR 60HZ 37 048766 REF BLOCK TERM 20A 2 X 6 X 1100V 5 0C8243 1 WASHER LOCK HDPDEUTSCH 39 083264 1 TFMR ASM CMA 240 12V 6 0C8244 1 NUT HDP DEUTSCH 41 057335 REF BLOCK TERM 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 45 040479 4 VIB MNT 1 0 X 1 0 X 1 4 20 12 055444 1 H
7. B S ro ro ro Section 7 Exploded Views and Parts Lists Model No 004626 2 Guardian Liquid cooled 40 kW Generators Exhaust Drawing No 0E1347 DESCRIPTION CAP RAIN 2 50 2 69 TUBE STRAIGHT A GROUP MUFFLER CATALYST 4 3L MOUNTING BAND A GRP CATALYST BRACKET MUFFLER MOUNTING TUBE ELBOW 90 DEG 2 5 PIPE FLEX 2 5 TUBE CROSS OVER TUBE 90 ELBOW BRACKET EXHAUST SHIELD SHIELD A GRP HEAT SCREW TH FRM M6 1 X 16 NWA Z JS CLAMP BAND 2 5 WASHER LOCK 8 5 16 WASHER FLAT 5 16 ZINC NUT HEX M8 1 25 G8 YEL CHR SCREW HHC M8 1 25 X 16 G8 8 BOLT U 3 8 16 X 2 62 WASHER LOCK 3 8 NUT HEX 3 8 16 STEEL SHIELD CROSSOVER HEAT SHIELD EXHAUST HEAT HOSE VACUUM 5 32 36 LG KIT AIR FUEL RATIO CONTROLLER BRACKET AIR FUEL CONTROLLER SCREW HHC M6 1 0 X 12 G8 8 NUT HEX 8 32 STEEL WASHER LOCK 8 4 WASHER FLAT 8 ZINC SCREW PPHM 8 32 X 1 2 WASHER FLAT M6 WASHER LOCK M6 1 4 NUT HEX M6 X 1 0 G8 YEL CHR DECAL IMPORTANT EXHAUST EMISSION INFO WASHER FLAT 3 8 M10 ZINC NOTE COMPONENT INSTALLED AT WAUKESHA FACILITY PARTS LISTS OG Generac Power Systems Inc 57 Section 7 Exploded Views and Parts Lists PARTS Ce LISTS UP Model No 004373 3 Guardian Liquid cooled 40 kW Generators 0 Electronic Governor Drawing No 0A2615 F ITEM 18 NEOPRENE COATING WIRE HARNESS
8. 158 6 22 CENTER OF ENGINE SERVICE CONNECTIONS GRAVITY a 981 38 62 INLET NATURAL GAS 3 4 NPT COUPLING OIL DRAIN 1 2 NPT COUPLING 1930 75 98 EXHAUST OUTLET 2 5 OD MUFFLER OUTLET RIGHT SIDE VIEW Generac Power Systems Inc 21 indi e Y iud Y LLJ c Y un Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generator Wiring Diagram 4 3L Drawing No 0A4591 B ELECTRICAL DATA 85 WIRE USED ON A amp B OPTION PANELS ONLY 86 WIRE USED ON C OPTION PANELS ONLY HOLIMS SYNLVYSdWSLYSLVM SIM HOSN3S 3A31H31VM SIM YOLVNYSLIV 90 dA3Ld31VWH3QN3S LMS x HOLNEIELSIC NOLLINOI dl QION310S 4401MHS 13603 3905939 NIO YIONIS dOS 109 C HOLOVINOD YOLOW H3 1HVI1S INS dina 1304 di 1VISONH3HI LLVd HOIOVINOO H3IHVIS 95 QION3OS 44OLNHS 1904 93 HALWSH AMALIE XINO NOILdO NO GASN HOSN3S 03345 Wd AYSLLVE HOLIMS 10 5901 E is e o o 1 5 9 O lt m Es an O 2 o 2 2 OnO Bg n El 2 o B 2 Q O 0 Y 9
9. 720 cfh LP Gas 004373 3 amp 004626 2 288 cfh 7 9gph 6 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator 1 9 FUEL REQUIREMENTS AND RECOMMENDATIONS With LP gas use only the vapor withdrawal system This type of system uses the vapors formed above the liquid fuel in the storage tank Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask your fuel supplier for the Btu content of your fuel Fuel pressure for both natural gas and liquid propane setups should be 11 inches to 14 inches of water column 0 6 psi at all load ranges WARNING amp Gaseous fuels such as natural gas and liquid propane LP gas are highly explosive Even the slightest spark can ignite such fuels and cause an explosion No leakage of fuel is permitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas install leak detectors accord ingly 1 9 1 CONVERSION TO LP GAS VAPOR The generator is shipped from the factory configured for using natural gas as fuel To convert the fuel system to LP gas proceed as follows Figure 1 3 1 Remove end cap from the pressure reducer valve 2 Turn the tension screw counterclockwise until all ten sion is removed from the inner spring 3 Install and tig
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11. SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN 16 enc ENGINE HARDWARE PART NO 098290 0A3439 098958A 021888 082508 036409 043146 098941A 098942A 098225 022097 064526 029333A 074031 051716 049226 076040 098647 036409 0C2184 QTY APN CARB ARM REF 22 21 A m DESCRIPTION ASSEMBLY MOTOR STEPPER BRACKET GOVERNOR MOUNTING CONNECTOR INTERFACE ASSEMBLY LEVER STEPPER MOTOR BALL JOINT 1 4 28 NUT HEX 1 4 28 STEEL SCREW HHC M6 1 0 X 10 G8 8 HOUSING GOVERNOR CONNECT COVER CONN HOUSING SCREW FHM 2 X 5 8 SELF TAP WASHER LOCK M6 1 4 SCREW TAP HWH 6 25 X 3 8 ZINC TIE WRAP 7 4 X 19 BLACK UL NEOPRENE LIQUID COATING NOT SHOWN NUT HEX M5 0 8 G8 YEL CHR WASHER LOCK M5 SCREW PPHM 5 0 8 X 16 ASSEMBLY L C ELECTRONIC GOVERNOR NUT HEX 1 4 28 STEEL STUD THR 1 4 28 X 3 1 2 G2 ZINC 58 Generac Power Systems Inc Section 8 Notes NOTES Guardian Liquid cooled 40 kW Generators Generac Power Systems Inc 59 Section 9 Warranty WARRANTY Guardian Liquid cooled 40 kW Generators CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine In California new utility and lawn and
12. PO PO B PO PS Section 7 Exploded Views and Parts Lists Model No 004626 2 Guardian Liquid cooled 40 kW Generators 4 3L Nat Gas Fuel System Drawing No 0E1338 DESCRIPTION SUPPORT SOLENOID NAT GAS ELBOW 90D 3 4NPT NIPPLE PIPE 3 4 NPT X 4 5 BLK IRN ASSY NATURAL GAS SOLENOID NIPPLE PIPE 3 4 NPT X 2 BUSHING REDUCER 1 TO 3 4 REGULATOR N G R600S SUPPORT REGULATOR BRACKET REGULATOR 4 3L BOLT U 5 16 18 X 1 50 WASHER FLAT 5 16 ZINC WASHER LOCK 8 5 16 SCREW HHC 5 16 18 X 1 G5 PLUG STD PIPE 3 4 STEEL SQ HD WASHER FLAT 9 16 ZINC SCREW HHC M14 2 0 X 25 G8 8 NIPPLE TOE 3 4 NPT X 2 CLAMP HOSE 16 87 1 50 HOSE 1IN ID LP GAS 44 LG WASHER LOCK M14 NUT HEX 14 2 G8 YEL CHR MACHINING CARBURETOR ADAPTOR DECAL FUEL INLET LPG NIPPLE CLOSE 3 4 X 1 375 CLAMP VINYL 1 62 X 486 Z SPACER D C ALT 29MM LONG DECAL INLET PRESSURE GASKET AIR CLEANER MIXER EMISSIONS NATURAL GAS SCREW HHC 3 8 16 X 1 G5 WASHER LOCK 3 8 GASKET GOVERNOR THROTTLE BODY SCREW HHC 5 16 18 X 1 1 4 G5 ADAPTOR CARBURETOR W INLET GASKET CARBURETOR ADAPTOR BARBED ELBOW 90 DEG 1 8 NPT X 3 8 VALVE PCV HOSE 3 8 ID SINGLE BRAID 10 GASKET CARBURETOR ADAPTOR ASSY THROTTLE PF42 WIRE CONN WASHER LOCK 10 SCREW SHC 10 32 X 5 8 G8 8 NZ GASKET CARB IMPCO 225 SCREW PHM SEMS 12 24 X 5 8 EX NUT HEX 5 16 18 STEEL SADDLE 1 3 8 LISTS Generac Power Systems Inc 55 Mod
13. MAIN LINE CIRCUIT BREAKER UTILITY POWER SUPPLY TO LOAD CIRCUITS MAI CIRCUIT BREAKER 2 2 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping elec trical loads below the wattage amperage capacity of the generator If the generator is powering only critical loads within its wattage amperage capacity during util ity power outages consider using the emergency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are within the wattage amperage capacity of the generator set When this method is used it is difficult to overload the gener ator The transfer switch must meet the following requirements e It must have an ampere rating equal to or greater than the total amperage rating of the emergency dis tribution panel circuit It must be installed between the building s main distri bution panel and the emergency distribution panel 2 3 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed use the Total Circuit Isolation Method It is possible for the genera tor to be overloaded when this isolation method is employed The 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 rati
14. 077043A 077043A USED ON R VOLTAGE GENERATORS ONLY NOT SHOWN QTY 1 1 4 1 1 1 1 1 1 4 4 2 4 1 1 Section 7 Exploded Views and Parts Lists Model Nos 004373 3 004626 2 Guardian Liquid cooled 40 kW Generators Engine Coolant Heater Drawing No 0E0539 TO THERMOSTAT HOUSING TO ENGINE DESCRIPTION BARBED ELBOW 90 3 8 NPT X 5 8 CLAMP VINYL 1 06 X 406 Z MOUNTED TO ALTERNATOR TO HOLD 5 IN PLACE CLAMP HOSE 8 53 1 00 HEATER ENGINE 1800W 120V HEATER ENGINE 2000W 240V HOSE 5 8 ID RIA 250F 36 HOSE 5 8 ID RIA 250F 16 BARBED STRAIGHT 1 4 NPT X 5 8 BRACKET HEATER W WELDNUTS WASHER LOCK M6 1 4 WASHER FLAT 1 4 ZINC NUT HEX M6 X 1 0 G8 YEL CHR SCREW HHC M6 1 0 X 20 G8 8 FLEXIBLE CONDUIT 1 BLACK 15 CONDUIT FLEX 38 ID 42 USED ON HEATER WIRE HARNESS CONDUIT FLEX 38 ID 18 GUARDIAN 46 Generac Power Systems Inc lt TO ENGINE BLOCK PART NO 058665 061902 059473 038805H 038804T 0A4010 052858 049820 023152 022131 025507 022237 QTY A VAD ND PO KS Section 7 Exploded Views and Parts Lists Cp Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators Battery Drawing No 0A6708 G 0 STARTER SOLEN 6 DESCRIPTION BATTERY 12VDC 90 AH 27F OPTIONAL HOLD DOWN BATTERY HOLD DOWN BATTERY CABLE BATTERY BLACK 1 X 23
15. m O 98 ww ZH SIS _ E m cg vl T 145 0 y OO 5 a 0 98 o NH 4 A es l r 0 ZN 0 291 O p 00 vl 915 7 915 915 IN Q 91S SIS SIS SIS S uuum 515 29 nuw de 0 ll v 0 g A Li e 3 291 98 G O 96 E 821 IN e qa ro v6l 98 O U qau A 1 0 E ZN e G ez 99 Ox el 60 esl PL 0 Zu so ez Sg 5 ly 5 gg 1 gio s LE N 58 o 3 z e A vi B Y Y gt gt vs vs 1 5 3 3 8 8 8 4 I m Odd ELECTRICAL DATA 28 Generac Power Systems Inc Section 6 Electrical Data Model No 004626 2 Guardian Liquid cooled 40 kW Generators ELECTRICAL DATA tf Electrical Schematic Control Panel Drawing No 0D6975 3SV11OA LNdLNO OV YILIN WA dle 1S WNINYAL 251151 9NISN3S ALMILA H3INHOJSNVHL 3SIOU3X3 13S HOLIMS ZMS 091
16. Generac Power Systems Inc 31 Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators Section 7 Exploded Views and Parts Lists Compartment Drawing No 0D8992 LISTS OG PARTS Qe 18 17 22 Pas 36 32 Generac Power Systems Inc PART NO 003594 0A3359 0A3360 002522 002527 002528 002535 002536 002547 002550 002555 002560 0D7904 002633 006749 060069 006748 080490 087233 25 22 22 25 25 55 55 55 25 25 022145 QTY 10 40 40 5 N Po MO Or FS 39 3 8 2 Section 7 Exploded Views and Parts Lists Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators Compartment Drawing No 0D8992 DESCRIPTION ASSEMBLY M6 HINGE SCREW BHSC M6 1 0 X 16 SS SHAKEPROOF INT M6 SS DOOR SMALL STD WELD CORNER POST LH REAR CORNER POST RH REAR CORNER POST LH FRONT CORNER POST RH FRONT REAR BRACE TOP amp BOTTOM SIDE BRACE TOP amp BOTTOM SIDE SUPPORT ROOF ONE PIECE WLDMT FRONT BRACE TOP PLATE STRIKER SCREW PPHM M4 0 7 X 12 SS PADDLE HANDLE LOCK NUT LOCK HEX M4 0 7 SS NYL INS WASHER FLAT 8 SS RIVET POP 3 16 X 1 4 DUCT FRONT LH DUCT FRONT RH DUCT BOTTOM DUCT FRONT PANEL DUCT FRONT TOP RH AS
17. NIPPLE CLOSE 3 4 X 1 375 CLAMP VINYL 1 62 X 486 Z SPACER D C ALT 29MM LONG NOT SHOWN DECAL INLET PRESSURE GASKET AIR CLEANER CARB REWORK 4 3L SCREW HHC 3 8 16 X 1 G5 WASHER LOCK 3 8 GASKET CARBURETOR SCREW HHC 5 16 18 X 1 1 4 G5 ADAPTOR CARBURETOR W INLET GASKET CARBURETOR ADAPTOR BARBED ELBOW 90 DEG 1 8 NPT X 3 8 VALVE PCV HOSE 3 8 ID SINGLE BRAID 10 NUT HEX 1 4 28 STEEL WASHER LOCK M6 1 4 ARM THROTTLE REWORK BALL JOINT PLA 25 28 LISTS Generac Power Systems Inc 53 Ge Section 7 Exploded Views and Parts Lists Model No 004626 2 Guardian Liquid cooled 40 kW Generators 0 4 3L Nat Gas Fuel System Drawing No 0E1338 ATTACH TO Cy FAN SCROLL T d 29 e 18 NO SZ DE 2 EN A P S 25 gt L 7 ASSEMBLY P N 0D3509 36 TO INTAKE MANIFOLD 54 Generac Power Systems Inc ITEM YO WP NOT SHOWN PART NO 065907 026812 076691 007598 026490 026577 0D2758 0E0521 002775 028238 022145 022129 030795 025655 022132 051778 028641 057824 057422 043123 051779 007820 050279 026915 055934P 0A5737C 0D1509 061258 0C7650A 029745 022237 007059 033212 0A4120 064945 0A6344 0A4121 047290 0C7060 0D3485 022152 0C7908 0A6613 064090 022259 028237 QTY D A Po A Aa a A o c c c BR
18. S BE KO m oO m LO e e O Lj E 5 a a I O rT C A O N 8 8 8 x A o l ON lt U x du X o x lt HE J ec m lt k Se ee E E y K Bd Y CUSTOMER TO CONTROL PANEL TO AMMETER TO CONTROL PANEL 120V UTILITY TERMINAL STRIP TERMINAL STRIP PONE TION 69 SOP 68 SWT 13 amp 13A TO AMMETER 79 0 RPM B AND BC NOT USED ON GUARDIAN UNIT N3911 MOX 59 QU Hg x I m I m J m 0 N O t e co O I m l ms 0 NUR E CUSTOMER 120V UTILITY E CONNECTION O SIMILAR TO 87086 ee Generac Power Systems Inc Section 6 Electrical Data Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generator gt ELECTRICAL DATA m N 180 8 Ol LINN NVIONVhO NO 5 LON 28 c O 6Z YILINAVY OL VEL LMS 89 dOS 69 E 31IH o N33a39 N33aD gt 2v18 DAMES us lis dO NOLLI3NND9I ALIMLO 02l ASWOLSND I ug El vel OL 418415 69 IVNINY31 J3NVd 9g OL Schematic 4 3L Drawing AYSLLVE 6 0 AINO SIINVA NOILdO 82 NO Q3Sn S8 AINO SI3N
19. SCREW HHC 1 4 20 X 3 4 G5 NUT HEX 1 4 20 STEEL WASHER FLAT 1 4 ZINC SCREW SHC 1 4 20 X 4 5 G8 8 NZ WASHER LOCK 3 8 SCREW SHC 3 8 16 X 3 4 G5 KIT NEUTRAL BLOCK 390 200 400A NEUTRAL BLOCK 390 200 400A JUNCTION BLOCK 3 8 16 WASHER LOCK 10 SCREW PHM 10 32 X 5 8 CAD WASHER LOCK 3 8 NUT HEX 3 8 16 STEEL WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR LISTS Generac Power Systems Inc 39 Ge us Section 7 Exploded Views and Parts Lists Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators 0 Generator Drawing No 009490 STATOR LEADS 34 SCROLL DETAIL 21 TO ENGINE FLYWHEEL IS MADE WITH RING GEAR THEN BACK OFF 1 2 TO 3 4 TURN AND TIGHTEN NUT THREAD IN SENSOR 6 UNTIL CONTACT CAUTION NOTE TO ENGINE FILYWHEEL ADJUSTMENT 40 Generac Power Systems Inc 27 DO NOT ROTATE ENGINE DURING THIS ADJUSTMENT Section 7 Exploded Views and Parts Lists Cp Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators Generator Drawing No 0D9490 0 ITEM PART NO QTY DESCRIPTION 1 051768 SCREW HHC 12 1 75 X 25 08 8 2 051769 7 WASHER LOCK M12 3 0A8240 2 FLEX PLATE SAE10 4 039253 6 SCREW HHC M8 1 25 X 20 G8 8 022129 7 WASHER LOCK M8 5 16 6 082130D 1 ASSEMBLY MAG PICKUP 72 7 004286 1 ASSEMBLY FAN W PRESS DISC 10 75 X 3 8 0A2601 1 SCREW HHC M16 2 0 X
20. 1 8 SPECIFICATIONS 4 1 8 1 GENERATOR 8 e 004373 3 amp 004626 2 Rated Maximum Continuous AC Power Output kW 40 Rated Voltage VOS ns 120 240 Rated Maximum Continuous Current at 240 Volts Single phase amrps 167 Number or Rotor PolesS uuu Qua asasseqasawskaqakaskanqasqaqkawahaaa 4 Driven Speed of Rotor rpm 1 800 AVG Ol OLALOL MT Four wire Rotor Excitation System Direct Excited Brush type System THSUEIEIOI semis Class H Rotor Insulation Class F Rated power of generator is subject to and limited by such factors as ambient tempera ture altitude engine condition and other factors Engine power will decrease about 3 5 percent for each 1 000 feet above sea level and also will decrease an additional 1 percent for each 6 C 10 F above 15 5 C 60 F ambient Maximum output power of the gener ator is limited by maximum engine power Generac Power Systems Inc 5 Section 1 General Information GENERAL INFORMATION 4 1 8 1 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
21. 3L GM MOUNT ENGINE R amp L PULLEY CRANKSHAFT PULLEY WATER PUMP SPACER FAN 50MM 4 3L 35KW UNITS ONLY SPACER FAN 62MM 45KW UNITS ONLY FAN 17 REVRS ROT 35KW UNITS ONLY FAN COOLING 22 DIA REVRS ROT 45KW UNITS ONLY CAP HOSE CLAMP HOSE 10 56 1 06 BUSHING REDUCER 1 4 TO 1 8 SCREW HHC 7 16 20 X 2 1 4 G5 WASHER LOCK 7 16 SWITCH OIL PRESSURE SPACER 5 X 1 5 X 25 STL ZINC BELT SERPENTNE 72 5 HEAT SHIELD LEFT GASKET EXHAUST MANIFOLD MANIFOLD LEFT EXHAUST BOLT U 3 8 16 X 2 50 DC ALTERNATOR ASSEMBLY PULLEY PLOY V 82 OD BRACKET ALT SUPPORT BRACKET MOUNTING WELD ASSEMBLY PULLEY GROOVED IDLER PULLEY TENSIONER SPACER DC ALTERNATOR 34MM WASHER FLAT 3 8 M10 ZINC ADAPTOR M12 1 75 3 8 NPT BARBED STRAIGHT 3 8 NPT X 5 8 CLAMP HOSE 10 56 1 06 HOSE 5 8 ID TYPE 3 SINGLE 12 WASHER LOCK 8 5 16 SCREW HHC 5 16 18 X 3 4 G5 45KW SCREW HHC 5 16 24 X 3 4 G5 WASHER LOCK 3 8 SCREW HHC 3 8 16 X 1 G5 SCREW HHC 3 8 24 X 1 G5 SCREW HHC 3 8 16 X 4 G5 NUT HEX 3 8 16 STEEL WASHER FLAT HEAVY DUTY WASHER LOCK M10 SCREW HHC M10 1 5 X 25 G8 8 BOLT TENSIONER PULLEY NUT HEX M10 1 5 G8 YEL CHR SPARK PLUG 5 7L GM WASHER FLAT M12 CLAMP VINYL 1 06 X 406 Z FILTER OIL LISTS Generac Power Systems Inc 45 PARTS a O ITEM PART NO 1 034339 2 055934D 3 057822 4 084918C 084918D 050967 050967 7 053660 8 084427 10 022097 11 022473 12 049813 13 042568 14 077043E 15
22. 45 G8 8 g7 0A2602 1 WASHER FLAT 688 ID X 3 25 OD 10 0A1138 1 KEY SQ 3 8 X 2 1 2 STEEL 11 021941 1 COUPLER 390 SAE 12 020808A 1 ROTOR 390 40 1P DIRECT 13 052624 1 BEARING BALL 6212 SEALED 14 070892 1 SLIP RING MACHINED 15 0A5580 4 SCREW HHC M14 2 0 X 140 G8 8 16 041633 4 WASHER 390 SAE ALT 17 020729A 1 STATOR 390 40 AD2 SAE 18 022131 12 WASHER FLAT 3 8 M10 ZINC 19 022237 11 WASHER LOCK 3 8 20 022511 11 SCREW HHC 3 8 16 X 1 1 4 G5 21 068113 1 CARRIER REAR BEARING 15 22 068115 1 LOWER PANEL 15 23 043123 4 WASHER LOCK M14 24 051779 4 NUT HEX M14 2 0 G8 YEL CHR 25 046852 1 SCREW HHTT 10 32 X 1 4 CZ 26 022145 1 WASHER FLAT 5 16 ZINC 27 039287 4 SCREW HHC 8 1 25 X 45 G8 8 FT 28 071641 1 BRUSH HOLDER ASSEMBLY 29 071639 1 HOLDER BRUSH SUPPORT 30 0A2110 2 SCREW SWAGE 1 4 20 X 1 2 Z YC 31 022473 8 WASHER FLAT 1 4 ZINC 32 022746 1 SCREW HHC 3 8 16 X 1 3 4 G5 33 031980 2 TIE WRAP UL 14 6 X 14 NATL 34 083549 1 SLEEVE RUBBER 35 0A4089 1 ASSEMBLY SCROLL 390 SAE KIT 044089 PARTS 36 0A2491 2 SHROUD ALTERNATOR SHEET METAL 37 0A2497 2 SCREEN SHROUD SAE 38 0A2496 2 BRACKET TENSIONER SAE SCROLL 39 056326 8 4 FT TRIM VINYL BLACK 1 8 GP 40 022097 6 WASHER LOCK M6 1 4 41 045757 2 SCREW HHC M6 1 0 X 25 G8 8 42 047411 4 SCREW HHC M6 1 0 X 16 G8 8 43 0A2110 12 SCREW SWAGE 1 4 20 X 1 2 Z YC ROTOR REPLACEMENT PARTS Generac Power Systems Inc 41 Section 7 Exploded Views and Parts Lists LISTS Model Nos 004373 3 amp 004626 2 G
23. 6 NUT HEX 6 32 STEEL 24 032300 1 HOLDER FUSE 58 002428 8 SCREW PHTT 6 32 X 1 2 ZYC 20 022676 1 FUSE 15A X AGC15 99 002323 4 SCREW PHTT 6 32 X 5 8 ZYC 26 064009 1 LIGHT 12VDC 02A LED RED PILOT 60 042284 4 SCREW SWAGE 8 32 X 1 2 Z YC 27 061945 1 SWITCH SELECTOR 6A AMP V 61 0C1127 1 DECAL AVR COVER 28 076037 1 VOLTMETER DC 8 18V 005324 4 FUSE amp HOLDER LITTEL 7 5A 29 070081 1 HOURMETER 63 0A9611 1 FUSE 7 5AXBK AGC7 5NX W 22670 30 070043 1 VOLTMETER AC 0 300 31 070045 1 AMMETER AC 0 200 PART OF CONTROL PANEL WIRE HARNESS Generac Power Systems Inc 37 PARTS qp is O LEADS amp SENSING WIRE Section 7 Exploded Views and Parts Lists Model Nos 004373 3 004626 2 Guardian Liquid cooled 40 kW Generators Connection Box Drawing No 0D8848 A BOTTOM OF CONTROL PANE 12 29 30 50 2 AUN 8 y 42 SIEMENS a 3 E 47 600 43 i544 2004 lt 222222 2222 2327 AA p 36 3 RECOMMENDED TERMINAL TIGHTENING TORQUES FOR CIRCUIT BREAKER AND NEUTRAL BLOCK ITEM RING TERMINALS FASTEN COMPRESSION STRIPPED END OF STRANDED DESCRIPTION FROM ALTERNATOR LUG TO CIRCUIT BREAKER CABLE TO COMPRESSION LUG CIRCUIT BREAKER 40 TINE SIDE 30 FT LB NA NA CIRCUIT BREAKER 40 Sabe NA 12 5 FT LB 23 FT LB 52 NEUTRAL BLOCK 19 FT LB NA 23 FT LB 38 Generac Power Systems Inc S
24. ELBOW 10 0C4170 2 BRACKET EXHAUST SHIELD 11 004305 1 SHIELD A GRP HEAT 12 0 2454 2 SCREW TH FRM M6 1 X 16 N WA LISTS OG Section 7 Exploded Views and Parts Lists Model No 004373 3 Guardian Liquid cooled 40 kW Generators 4 3L Exhaust Drawing No 0E0704 2 2 5 DIA CLAMP ASSEMBLY Z JS 50 Generac Power Systems Inc 21 PART NO QTY 0C3433A 022129 022145 0C9748 042907 080762 022237 022241 0E0701 0E0700 022131 4 12 12 1 12 8 16 16 1 1 8 di 18 14 a 15 DESCRIPTION CLAMP BAND 2 5 WASHER LOCK M8 5 16 WASHER FLAT 5 16 ZINC PLUG M18 1 5 SCREW HHC M8 1 25 X 16 G8 8 BOLT U 3 8 16 X 2 62 WASHER LOCK 3 8 NUT HEX 3 8 16 STEEL SHIELD CROSSOVER HEAT SHIELD EXHAUST HEAT WASHER FLAT 3 8 M10 ZINC ITEM CON O WP PART NO 037561 0A4632A 0A4637 0A4632B 062522 022127 057796 057795 LK lA QTY Section 7 Exploded Views and Parts Lists Cp Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators 4 3L Air Cleaner Drawing No 0E0712 0 DESCRIPTION NUT WING 1 4 20 NYLK PLATE AIR CLEANER TOP FILTER AIR 11 5 CA326 PLATE AIR CLEANR BOT STUD TH 1 4 20 X 3 G2 ZNC FULL NUT HEX 1 4 20 STEEL GROMMET CONNECTOR C C VENT Generac Power Systems Inc 51 us Section 7 Exploded Views and Parts Lists 0 M
25. GASNNN SLVINSNI NA Loy o_o 00 3SVHd A80Z 3HIM MOTT3A ISN gl QL ASVHd HOS ISN noo 15 mM 5 Q wov18 e MOVI8 MSd A i 915 915 Y F L HOLIMS HOLO313S 3SVHd 515 vL 69 dau 30718 e m8 MS AG O ana ame ZH a O i SIS o 0 0 Sx 5 LL U 1 5 ZL L SIS 915 9 J A IS ama SL vL V 821 Ya ww M c ec v6l v6L y S 915 Y LJ 941 941 3 zg Yims eL 091 291 21 HAV ola IH 5 N 0 6 S Z amp 9 1 Am SL by pl 2 vl AA s y pn vece 841 99 0 9 UN vsi y c Z B 6 v Sg olv A O N zug 99 v 5 9 0 091 OS cg e S8 J j INN DNA gg 0 8 i 9 96 VN lt E _ n NOILISOd 440 NI 0 NH vi rl vL L el 622 Q 622 t SL SL SL pl ISL dvo ELECTRICAL DATA 4 H3 HOLO3NNOO 3NION3 OL ee Generac Power Systems Inc Section 6 Electrical Data Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generator ELECTRICAL DATA 4 Wiring Diagram Schematic Lower Panel Drawing No 0D5997 NOLLO3NNOO
26. GENERAC Y GUARDIAN AUTHORIZED DEALER Generac Power Systems Inc 19 TROUBLESHOOTING Section 5 Troubleshooting Guardian Liquid cooled 40 kW Generator 5 1 TROUBLESHOOTING GUIDE PROBLEM The engine will not crank CAUSE 1 Fuse blown CORRECTION Replace fuse 2 Loose corroded or defective 2 Tighten clean or replace battery cables as necessary 3 Defective starter contactor oe 4 4 Defective starter motor 4 5 Dead Battery 5 Charge or replace battery The engine cranks but 1 Out of fuel 1 Replenish fuel will not start 2 Defective fuel solenoid FS 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 spark plug s 2 Clean re gap or replace plug s 3 Dirty Blocked air filter 3 Clean or replace as required The engine starts but then 1 Engine oil level low 1 Check oil and add oil as needed shuts down 2 Defective low oil 2 pressure switch 3 Defective high temperature 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 1 is set to OFF but the engine 2 Defective control board 2 continues to run T
27. H E 1 A mm 9 9 MN o O O TRANSPARENT ENCLOSURE FOR CLARITY See the Service Schedule Section 4 12 Page 19 for rec ommended air cleaner maintenance 4 4 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary See Section 4 12 Page 19 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 Page 19 for recommended inspection 3 Check the spark plug gap using a feeler gauge Adjust the gap to 0 045 inch 1 1 mm by carefully bending the ground electrode Figure 4 4 Figure 4 4 Setting the Spark Plug Gap 0 045 inch 1 1 mm DLE y SA 4 5 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 4 12 Page 19 The following proce dure should be followed for inspection G lt 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be do
28. IS 99 LT x AS d 0 MSd 915 S HOLIMS 1934135 3SVHd SIS vl vl 1 915 SIS ZH Ls c9L o o 0 e LAA LL qaq l SIS 9 5 9 gt 881 915 2 8 1 and vaze St vL 9 21 V g ez ez ta 61 v6L v 0 S 915 v E on 941 941 3 dod 2 2g s ei c Ve s 081 Osh zi HAV glo al S Z VSL cip 391 o 6 d Z Z El 9 1 17 SL ed Yr p e vL NA 9 S22 821 ezz 99 0 9 VSL LMS p L 0 98 NE ze mE 8 1 Se p SEE y nd O N ams 909 b i A B 9 0 WAd OSI OSI Sg gt ee VSL 96 e NOILISOd 430 93 e ma NI NMOHS 0 vl vl bl vI el EL Q L 633 amp 622 SL SL SL rL dvo ISL 62 62 191 01 d dO HOLO3NNOO TANVd H3MO1 OL H3 HOLO3NNOO 3NION3 OL Generac Power Systems Inc Section 7 Exploded Views and Parts Lists LISTS Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators 0 Base Drawing No 0C4399 D N 0 09 P 18 0 15 uf Va To Oil Drain On Oil Pan 28 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators Base Drawing No 0C4399 D ITEM PARTNO QTY DESCRIPTION 1 003250 1 ASSEMBLY B
29. If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times DO NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris Generac generator sets may operate using one of sev eral types of fuels All fuel types are potentially FLAM MABLE and orEXPLOSIVE and should be handled with care Comply with all laws regulating the stor age and handling of fuels Inspect the unit s fuel sys tem frequently and correct any leaks immediately uel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equip
30. No 0D6978 A o 354555 Loo MN 0912 I TA 49 VIEW A A PANEL FACE 36 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Model No 004626 2 Guardian Liquid cooled 40 kW Generator PARTS Ce LISTS Control Panel Drawing No 0D6978 A 0 ITEM PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 0D7397 1 PNL BTM amp BACK CNTL PNL 04626 32 070042 1 FREQUENCY METER 240V 55 65HZ 2 0D1521A 1 CONTROL PANEL FRONT W SILK 33 081988 1 DECAL EXERCISE INFO SCREEN 34 001229 1 DECAL CUST CONN BOX 3 0D1522 1 PANEL SIDE COV
31. a trickle charge circuit that maintains battery state of charge during nonoperating periods Battery voltage should read approximately12 5 to 14 5 volts DC A low battery voltage indicates the battery is discharging 3 1 5 HOURMETER This indicates the time the engine generator has operat ed in hours and tenths of hours Use the hourmeter along with the periodic maintenance schedule for your generator set Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator 3 1 6 AUTO OFF MANUAL SWITCH see Section 3 2 3 1 7 FAULT INDICATOR LAMP This lamp goes ON when one or more of the following engine faults occurs and when engine shuts down e Low oil pressure High coolant temperature e Low coolant level Overcrank Overspeed 3 1 8 15 AMP FUSE This fuse protects the control console s DC control cir cuit against electrical overload If the fuse has melted open because of an overload engine cranking and start up cannot occur Replace the fuse with an identical AGC 15 amp replacement fuse 3 1 9 7 5 AMP INLINE FUSE NOT SHOWN This inline fuse is connected in the 15A line that runs between the Auto Off Manual switch and position 10 of the 76009A PCB This fuse protects the start fuel field boost and transfer outputs 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
32. 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 condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should how
33. recommended coolant mixture Check the system for leaks and other problems See Specifications Page 5 and Coolant Page 7 INSTALLATION Hh Section 2 Installation 2 8 6 Belt Tension Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approx imately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inch 10 to 16 mm 2 8 7 Electrical System Make sure the generator is properly connected to an approved earth ground and or ground rod Make sure the generator battery is fully charged proper ly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components 2 8 8 Rodent Protection Make sure the four 3 inch diameter cap plugs part 0A8785 are properly installed in the tie down holes in the side rails of the unit s 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 BASE FRAME 3 INCH DIA PLUG PART 0A8785 Generac Power Syst
34. the upper right side and inside the lower control panel Match wires 23 194 N1 N2 T1 and T2 in the transfer switch to the corresponding wires on the terminal strip in the lower panel The conductors for these wires should be in a seperate conduit from the main AC output wires If the control wires are run in the same conduit the control wires must be a shielded cable 2 6 2 GTS Type Engineered Switch Connect the two wire start signal from the automatic transfer switch to the automatic start connection which is located in the right hand corner inside the lower panel Match wires 178 and 183 in the transfer switch to 178 and 183 on the terminal strip in the control panel The conductors for the two wire start circuit must be in their own conduit If the control wires are run in the same conduit the control wires must be a shielded cable Generac Power Systems Inc 9 INSTALLATION Section 2 Installation NOTE When using a GTS switch it is necessary to connect a 240V AC supply to N1 and N2 terminals of the generator to provide for battery charging Wires T1 T2 23 and 194 should not be connected 27 BATTERY INSTALLATION A Da 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 possible injury to per sonnel do not co
35. 00 CABLE BATTERY RED 1 X 31 00 SCREW HHC 8 1 25 X 60 NUT LOCK M8 NUT LOCK HEX M8 1 25 NYLON INSERT SCREW HHC 3 8 16 X 3 4 G5 WASHER FLAT M10 3 8 ZINC WASHER SHAKEPROOF EXT 7 16 STL WASHER LOCK 3 8 Generac Power Systems Inc 47 Section 7 Exploded Views and Parts Lists LISTS 0 Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators 0 4 3L Radiator Drawing No 0D7992 C 21 10 KIT PART NO 0D8121 TO A LOM UMM UU UMMM N NS KIT PART NO 0D7947 37 38 39 0 Le gt 2 X B s s LO PART NO 007948 48 Generac Power Systems Inc ITEM WP 36 k k 37 k k 38 k k 39 40 OPTIONAL WITH KIT 0D7948 OPTIONAL WITH KIT 0D7947 PART NO 0D7825 0D8251 0D8252 024655 022097 022473 0D7174 0D7174A 0D7870 035685 047290 040173 049340 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 O po Aa B geo o Section 7 Exploded Views and Parts Lists Model No
36. 1HVIS 15 rS L NOLLO3NNOO HOLIMS Q39vMOVd 3Hd diHLS TVNIINH3L ESL 8319310Y4d TVINddH1 dl 39018 WHLAAN ONIGNIM NOILV LIOX3 5 LN3HHfO ZLO 8 119 TANVd H3MO HOLO3NNOO T3NVd 49 NIVIN H35 1V3H8 LINDYID 89 YOLVLS SV YOLOY HOLVNHALTV WVYSVIC NOZ L 3SVHd L AOrc OcL NOILOANNOO 00 OL 00 OL 3 OL aNa3931 219 vy i O H i3 oe ED 1918 s 5 zz 9 Ji 519 OVH3N3O QHVONVISWOH4 2005 841 5 Q QO SSL C 2 193810 cme ONIHV38 OL 1838010 page a x Nu N 19 Y HOLIMS LL 18 XH H34SNVH1 21 199 S Y ez Te O O 1 61969 MIYOS DLN Hsnug Q 1 L Y v 49 HOLO3NNOO TANVd 1OHINOO OL
37. ASE MOUNTING DIRECT COUPLED 3 055414 1 LUG SLDLSS 2 8 X 17 64 CU 4 0A4084 2 MOUNT ENGINE R amp L 5 022129 2 WASHER LOCK 8 5 16 6 045771 2 NUT HEX M8 1 25 G8 YEL CHR 7 022237 6 WASHER LOCK 3 8 8 029745 6 SCREW HHC 3 8 16 X 1 G5 10 043107 2 SCREW HHC M8 1 25 X 25 G8 8 11 022145 2 WASHER FLAT 5 16 ZINC 12 027482 3 WASHER SHAKEPROOF EXT 5 16 STL 13 055597 4 SCREW HHC M12 1 75 X 85 G8 8 14 052251 2 DAMPENER VIBRATION 40 BLUE 15 052257 4 SPACER 49 X 62 X 1 87 PWDR ZINC 16 052252 4 DAMPENER VIBRATION 17 052259 4 WASHER FLAT M12 18 052860 4 NUT LOCKING M12 1 75 19 0536210098 1 ASSEMBLY GROUNDWIRE 10 3 8 20 052251A 2 DAMPENER VIBRATION 50 WHITE 21 044118 1 BARBED STRAIGHT 1 2 NPT X 5 8 22 057823 2 CLAMP HOSE 10 56 1 06 23 057448 11 HOSE 5 8 ID TYPE 3 SINGLE 24 024310 1 PLUG STD PIPE 1 2 STEEL SQ HD 25 0A8785 4 PLUG BUTTON 3 DIA 26 0C4360 8 PLATE VARMINT 27 071693 16 WASHER FLAT 281 ID X 1 0 OD 28 0C2454 16 SCREW TH FRM M6 1 X 16 N WA Z JS 29 0C4753 1 PLUG 3 4 BUTTON 30 022413 1 SCREW HHC 1 4 20 X 1 G5 31 022473 1 WASHER FLAT 1 4 ZINC 32 022097 1 WASHER LOCK M6 1 4 33 022127 1 NUT HEX 1 4 20 STEEL PARTS LISTS OG NOTES 1 ITEMS 25 26 27 28 amp 29 ARE INCLUDED FOR UNITS WITH ENCLOSURES ONLY NOT INCLUDED WITH OPEN SETS 2 ITEM 25 PLUG BUTTON 3 DIA IS USED AFTER SHIPPING HOLES ARE TO REMAIN UNCOVERED FOR SHIPPING PURPOSES PLUGS CAN BE FOUND IN THE MANUAL BAG LOCATED INSIDE THE LOWER CONNECTION BOX
38. CH The transfer switch shipped with this generator is rated 200 amps maximum at 120 240 volts AC single phase The enclosure of the transfer switch is NEMA 3R This type of enclosure is intended for indoor or outdoor use Follow these rules e Install the transfer switch on a firm sturdy support ing structure To prevent switch distortion level the switch if nec essary This can be done by placing washers between the switch enclosure and mounting surface Never install the switch where any corrosive sub stance might drop onto the enclosure Where practical protect the switch against excessive moisture dust dirt lint and construction grit Always prevent corrosive vapors from coming in con tact with enclosure 1 5 AUTOMATIC SYSTEM OPERATION When this generator along with its transfer switch has been installed and interconnected a circuit board in the generator panel continuously monitors utility power source voltage Should that voltage drop below a preset value and remain at such a low state for a preset amount of time the generator cranks and starts After the gener ator starts the transfer switch transfers load circuits so the generator can power them When utility source voltage has been restored the switch transfers back to the utility source voltage and the generator then shuts down after a brief cool down time Guardian Liquid cooled 40 kW Generator 1 6 MAIN CIRCUIT BREAKER The generator s
39. DRAIN HOSE o BASE 5 Apply a light coating of engine oil to the seal of new oil filter Install the filter and tighten by hand only DO NOT OVERTIGHTEN 6 Remove the oil fill cap Figure 4 1 Add the recom mended oil see Section 4 2 1 DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 5 U S quarts 4 25 L caution amp A After refilling the crankcase with oil always check the oil level on the dipstick Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 7 Start the engine and check for oil leaks 8 Check the oil level after checking for leaks to ensure that the oil is filled to the proper level 4 3 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner Generac part num ber 0A4637 simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover See Figure 4 3 page 16 Generac Power Systems Inc 15 MAINTENANCE Section 4 Maintenance Figure 4 3 Engine Air Cleaner Air Cleaner L pa SSS a 7 Van NTF Of Wasa N
40. EATSINK 46 022507 4 SCREW HHC 1 4 20 X 1 2 G5 13 030468 1 WASHER STEP NYLON 20 47 022127 4 NUT HEX 1 4 20 STEEL 14 049939 1 RECTIFIER MSC 12A 600V 1N1206R 48 022097 4 WASHER LOCK M6 1 4 15 070370 1 WASHER MICA 203 49 033121 14 SCREW 10 32 X 1 2 16 022158 1 NUT HEX 10 32 STEEL 50 022152 14 WASHER LOCK 10 17 023762 1 WASHER SHAKEPROOF EXT 10 51 036902 4 SCREW PPHM 46 32 X 1 2 STL 52 022155 6 WASHER LOCK 6 18 023897 15 WASHER FLAT 10 ZINC 53 022985 8 WASHER FLAT 6 ZINC 19 076009A 1 PP LOGIC ASM 50 60HZ 54 036918 8 SCREW PPHM 8 32 X 1 2 20 040213 4 PCB SUPPORT SNAP IN 1 4 55 022264 8 WASHER LOCK M4 21 027744 1 GROMMET 3 4 X 5 32 X 5 16 56 038150 8 WASHER FLAT 8 ZINC 22 0825 3 1 SWITCH ROCKER DPST 125V SPD 97 022471 8 NUT HEX 48 32 STEEL 23 076020 1 SWITCH TOG DPDT 15 10 SP 58 022188 6 NUT HEX 6 32 STEEL 24 032300 1 HOLDER FUSE 59 036908 2 SCREW PPHM 6 32 X 1 1 4 25 022676 1 FUSE 15A X AGC15 60 002428 4 SCREW PHTT 6 32 X 1 2 ZYC 26 064009 1 LIGHT 12VDC 02A LED RED PILOT 61 0C2323 4 SCREW PHTT 46 32 X 5 8 ZYC 27 061945 1 SWITCH SELECTOR 6A AMP V 62 0D5324 1 FUSE amp HOLDER LITTEL 7 5A 28 076037 1 VOLTMETER DC 8 18V 63 0A9611 REF FUSE 7 5AXBK AGC7 5NX W 22670 29 070081 1 HOURMETER 30 070043 1 VOLTMETER AC 0 300 PART OF CONTROL PANEL WIRE HARNESS Generac Power Systems Inc 35 Section 7 Exploded Views and Parts Lists LISTS 0 Model No 004626 2 Guardian Liquid cooled 40 kW Generator 0 Control Panel Drawing
41. ER CONTROL 35 0D3440 1 CONTROLLER B C DPG 2103 PANEL 36 0A3968 1 CAPACITOR FILTER ASY 4 067680 1 ASSY VOLTAGE REGULATOR 60HZ 37 048766 REF BLOCK TERM 20A 2 X 6 X 1100V 5 0C8243 1 WASHER LOCK HDP DEUTSCH 38 0A1441B 1 COVER PLATE AVR 6 008244 1 NUT HDP DEUTSCH 39 083264 1 TFMR ASM CMA 240 12V 7 0A6321 1 PANEL LEFT SIDE E 40 0A1441C 1 COVER PLATE EGOV 8 048467 1 CIRCT BRK 7 X 1 ETA 46 500 P 41 057335 REF BLOCK TERM 20A 20 X 6 X 1100V 9 057907 1 RES WW LUG 10R 10 25W 42 076061 1 DECAL TERM STRIP 10 064008 1 COVER CON PNL TOP NOT SHOWN 43 029333 6 TIE WRAP 7 4 X 19 NATL UL 11 0A6323 1 CHASSIS AVR amp E GOV 44 040479 4 VIB MNT 1 0 X 1 0 X 1 4 20 12 055444 1 HEATSINK 45 022507 4 SCREW HHC 1 4 20 X 1 2 G5 13 030468 1 WASHER STEP NYLON 20 46 022127 4 NUT HEX 1 4 20 STEEL 14 049939 1 RECTIFIER MSC 12A 600V 1N1206R 47 022097 4 WASHER LOCK M6 1 4 15 070370 1 WASHER MICA 203 48 033121 14 SCREW HHC 10 32 X 1 2 16 022158 1 NUT HEX 10 32 STEEL 49 022152 14 WASHER LOCK 10 17 023762 1 WASHER SHAKEPROOF EXT 10 50 036902 4 SCREW PPHM 46 32 X 1 2 STL 91 022155 6 WASHER LOCK 6 18 023897 15 WASHER FLAT 10 ZINC 52 022985 8 WASHER FLAT 6 ZINC 19 076009A 1 PP LOGIC ASM 50 60HZ 53 036918 8 SCREW PPHM 8 32 X 1 2 20 040213 4 PCB SUPPORT SNAP IN 1 4 54 022264 8 WASHER LOCK M4 21 0A3394 1 GROMMET 3 4 X 5 32 X 5 16 55 038150 8 WASHER FLAT 8 ZINC 22 082573 1 SWITCH ROCKER DPST 125V SPD 56 022471 8 NUT HEX 8 32 STEEL 23 076020 1 SWITCH TOG DPDT 15 10 SP 57 022188
42. G HANDBOOK obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 e ASAE EP 364 2 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 e A52 1 AMERICAN NATIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYS TEMS available from the American National Standard Institute 1430 Broadway New York 10018 e NEC HANDBOOK available from the National Fire Protection Association 1 Batterymarch Park PO Box 9146 Quincy MA 02269 9959 2 1 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic diagram of a basic stand by electric system Both the UTILITY power supply and the STANDBY generator output are connected to an approved transfer switch The transfer switch is required by electrical code and serves the following functions Permits the LOAD circuits to be connected to only one power supply at a time Prevents electrical backfeed between STANDBY power and the UTILITY power circuits Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker NOTE Generac recommends the use of a Generac Power Systems pre packaged type transfer switch Part No 0D4406 in conjunction with this generator Guardian Liquid cooled 40 kW Generator Figure 2 1 Basic Standby Electric System
43. GUARDIAN by Generac Power Systems Inc Owner s Manual Liquid cooled Prepackaged Standby Generators Models 004373 3 40 kW Single phase w 200 Amp Transfer Switch 004626 2 40 kW Single phase w 200 Amp Transfer Switch California Emissions 00000 000000 00000 000000 0000 100000 000000 000000 500000 000000 000000 c SS gt lt lt gt lt lt lt olg c plg 109 99 R0 0 0000 000000 nl 20000 000 000000 000000 000000 0000 This manual should remain with the unit A DIG A ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION 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 you do not understand any portion of this manual contact Generac or the nearest Generac Guardian Authorized Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert you to special instruction about a par
44. IFOLD 0A3928 1 MANIFOLD RIGHT EXHAUST 0C7947 2 BOLT U 3 8 16 X 2 50 057794 2 RETAINER SPARK PLUG WIRES 0 4277 1 WIRES SPARK PLUG 4 3L 022241 4 NUT HEX 3 8 16 STEEL 057795 1 CONNECTOR C C VENT 048191 2 PIN DOWEL M10 X 24 032303 6 SCREW HHC 3 8 16 X 3 1 2 G5 0A3852 3 PLATE FLEX GM 098239 1 CASTING ADAPTOR 057522 1 SENSOR COOLANT LEVEL 0D2244M 1 ASSY MAGPICKUP 3 8 24 MALE MODEL 004626 ONLY 075885 1 THERMOSTAT 195 DEG 140KW GUARDIAN WIRE HARNESS NOT SHOWN FOR MOD 004626 0 1HARNESS 4 3L STD WIRE NOT SHOWN FOR MOD 004373 1 LISTS age Generac Power Systems Inc 43 us Section 7 Exploded Views and Parts Lists Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators 0 Engine Drawing No 0A4304 L 44 Generac Power Systems Inc ITEM con PART NO 0A9046 0A4084 0A4239 0A4240 0A5640 0A5640A 0A5639 0D3293A 077996 05 823 035579 037065 022302 0A8584 052644 0A4278A 0A4930A 0A4085 0A3927 007947 0A1232 0A7801B 021928 006239 0A4241 002885 0A5737C 022131 077456 044117 057823 057448 022129 022142 048614 022237 029745 042633 033819 022241 0A5768 046526 049814 003756 045772 0D2514 052259 055934D 0A37970001 Section 7 Exploded Views and Parts Lists Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators Engine Drawing No 0A4304 L DESCRIPTION ENGINE 4
45. 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 according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by G
46. SEMBLY COVER ACCESS SCREW TH FRM M6 1X16 N WA Z JS WASHER LOCK M8 5 16 SCREW 8 1 25 X 16 G8 8 WASHER FLAT M6 1 4 ZINC WASHER LOCK M6 1 4 NUT HEX 1 4 20 STEEL GASKET DOOR RUBBER SCREW SHOULDER COVER EXHAUST HOLE FASTENER RATCHET STRIP SEALANT 1 8 X 1 WASHER FLAT 5 16 ZINC OPTIONAL COMPARTMENT MATERIALS ALL P N S WITH AN A SUFFIX INDICATEALUMINUM MATERIAL OPTION LISTS Generac Power Systems Inc 33 Section 7 Exploded Views and Parts Lists Model No 004373 3 Guardian Liquid cooled 40 kW Generator Control Panel 4 3L Drawing No 0D4995 C 05 0 e
47. TUB UPS uy ST at INR 4 IP __ Y ALP j 1 49 1 92 W S 140 5 50 WEIGHT DATA TYP X TYP UNIT 729 7 kg 1609 Ibs MOUNTING HOLES BW id PW E STEEL COMPARTMENT 208 6 kg 460 Ibs 213 5 20 53 NOTES 2 7 d dis SA n279 UNITS mm INCHES 110 4 33 TYP p 37 1 44 570 22 44 665 26 19 TOP OR PLAN VIEW 965 87 99 2397 94 37 454 17 87 1160 45 67 NOTE 2 1117 43 98 NOTE 6 103 4 06 Y 53 2 09 E NATURAL GAS INLET 835 32 87 3 4 NPT FEMALE 877 34 51 936 36 85 OIL DRAIN 1 2 N P T FEMALE LEFT SIDE VIEW REAR VIEW NOTES 1 STANDARD BLOCK HEATER REQUIRES 120V AC CONNECTION 1 12V BATTERY 2 CONNECTION POINTS FOR AC LOAD LEADS TRANSFER SWITCH AND SEE NOTE 4 ENGINE AUTOMATIC START STOP CONTROL WIRES PROVIDED IN AC CONNECTION PANEL 3 EXHAUST MUFFLER SUPPORT BRACKETS SUPPLIED WITH OPTIONAL COMPARTMENT LIFTING EYE 4 12 VOLT NEGATIVE GROUND SYSTEM 4 PLACES BATTERY TRAY INSIDE DIMENSIONS 178 X 342 5 7 X 13 5 5 2 5 1 0 FLEX EXHAUST 6 MAIN LINE CIRCUIT BREAKER 7 DOORS MUST BE OPENED 90 DEG TO BE REMOVED 8 A1 MAY BE USED FOR CIRCUIT BREAKER STUB UP LOCATION 9 SEE DRAWING C3850 FOR DUCT REMOVAL REMOVAL OF FRONT DUCT WILL PROVIDE ACCESS TO MUFFLER FOR SERVICING mn
48. Us ZH 0 x 50 98 yl 199 Sg LO B e I 2 91S eS N a eli S P 0 291 O O 00 S Load 915 7 918 915 iN E 915 SIS SIS GIS g e 9 9 9 9 HAV X 915 e s 0 H c ne 4 Lt 15 291 2 p vk bl lo A S S H 99 tjo 7 99 98 S v IN vL 9 LS ZS 8 1 el An ZH gs m elm S8 gS ZS 00 LL SL qaq m 99 SLS IN L HN yovid ZN ZN 0 is ez 99 2 00 LN eal ISL Bi 8 1 Ni 5 L vl sis e do Ivo ys 0 UU UU 98 91S IN ez v vl el pl 98 9 ZN 4 L e NL NI 5 gt gt 9 vl 0 I e vi l a e H e 3ONVEO H pl el o e MOTIA C ez eL 9G bl c vi o d d 99 9 9 81 98 v v so Ny ama ama ana anid OL 821 821 dO HOLO3NNOO TANVd H3MO1 OL
49. Vd NOILdO NO JYIM 98 VEI A INO SVO AINVdOdd AINON 3NVd OL vi HOLIMS JYNLVYSdWAL YOSN3S 13 31 JINIVIIIN L S3JLVM 330N3S JYNSSAYd 1IO 383Q0N3S YOLOW 5314715 HOLOVINOO 33l3NVlS 0 AINO NOILdO GSSA SOSN3S 03395 HOLIMS MOT YOLNEIYLSIG NOILINSI NOILINOI GNNOYD QION31OS 1314 dWAd 1303 g31V3H ANIONS JOLWNY331 IV 90 GION31OS JJOLNHS 13n3 88VO2 YOLOVINOD IOYLNOOD IVISONWS3HI N31V3H AS311V8 AS3LIV8 YSDYVHO AYFLLVE XX 23 Generac Power Systems Inc Section 6 Electrical Data EPECTBIDAT Model No 004373 3 Guardian Liquid cooled 40 kW Generator 4 DATA gt Electrical Schematic Stepper Motor Drawing No 045858 150 219 Sue CIS O O O exe GCB BLACK RED P N 98647 BLUE BLUE LEGEND S15 GCB GOVERNOR CONTROL BOARD HZ FREQUENCY METER TB1 TERMINAL BLOCKS 24 Generac Power Systems Inc GASNNN ALVINSNI 3SVHd A802 HOS 3HIM MOTT3A ASN 3SVHd HOS SHIM 318 ISN ELECTRICAL DATA
50. When contacting a Generac Guardian Authorized Dealer or the factory about parts and service always supply the complete model number and serial num ber of the unit as given on its data decal which is located on the generator Model No Serial No AUTHORIZED DEALER LOCATION To locate the GENERAC GUARDIAN AUTHORIZED DEALER nearest you please call this number 1 800 333 1322 DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER Table of Contents a CONTENTS Guardian Liquid cooled 40 kW Generator Introduction Inside Front Cover Section 3 Operation 12 Read This Manual Thoroughly IFC 3 1 Control Console Components 12 S uu S au as IFC 3 1 1 12 Operation and Maintenance IFC 31 2 Ammeter 12 How to Obtain Service IFC 3 1 3 AC Frequency Meter 12 Authorized Dealer Locator Number IFC 3 1 4 DC 12 Safety Bulu a 2 A 3 1 6 Auto Off Manual Switch 12 Section 1 General Information 4 3 1 7 Fault Indicator 12 1 1 Unpacking Inspection 4 3 1 8 15
51. ally in about two 2 minutes Set the generator s main circuit breaker to its ON or closed position The generator is now programmed to start and exer cise every seven days thereafter on the day and at the time of day the switch was activated 14 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator Place a sign on the generator s control panel and on the transfer switch that indicates the day and time the generator will be exercising NOTE If the battery terminals are disconnected or the con trol panel fuse is removed the exercise timer needs to be reset for automatic exercise operation Figure 3 3 Set Exercise Switch on Control Panel VOLTS SET EXERCISE TIME FAULT AUTO INDICATOR MANUAL 4 1 CHECKING THE ENGINE OIL LEVEL For oil capacities see Specifications Section 1 7 2 Page 6 For engine oil recommendations see Section 4 2 1 To check the engine oil level proceed as follows Figure 4 1 1 Remove the dipstick and wipe it dry with a clean cloth 2 Install the dipstick cap then remove it again The oil level should be at the dipstick Full mark If nec essary add oil to the Full mark only DO NOT FILL ABOVE THE FULL MARK 3 Install the dipstick caution amp Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine Figure 4 1 Oil Dipstick an
52. amp FUSE 12 1 1 1 Lifting the Generator 4 3 1 9 7 5 Amp Inline Fuse 12 1 2 The Generato siii ia 4 3 1 10 Voltage phase Selector Switch 12 1 3 Generator AC Connection Systems 4 3 1 11 Set Exercise Time Switch 12 1 4 Prepackaged Transfer Switch 4 3 2 Using the Auto Off Manual Switch 12 ES On s b S 21 Aulo POSO seins 12 1 6 Main Circuit Breaker 5 3292 Position LLL 13 1 7 Engine Protective Devices 5 393 Manual Position LL 13 salen SOW 5 3 3 Automatic Transfer Operation 13 3 4 Sequence of Automatic Operation 13 MODO LM 209 13 OA 3 6 Weekly Exercise Cycle 14 1 7 4 Overspeed Shutdown 5 SES 5 Section 4 Maintenance 14 WC Buses eee et died nu E UNE 5 4 1 Checking the Engine Oil Level 14 18 Specifications 5 4 2 Changing the Engine Oil and Filter 15 GOnEraloL sidad 5 4 2 1 Engine Recommendations 15 1332 6 4 2 2 Oil and Filter Change Procedure 15 1 9 Fuel Requirements 4 3 Changing the E
53. are rotating and or hot during operation Exercise care near running gen erators A 2 Generac Power Systems Inc A GENERAL HAZARDS e For safety reasons Generac recommends that the installation initial start up and maintenance of this equipment is carried out by a Generac Guardian Authorized Dealer 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 han
54. ation during installation but always should be replaced afterwards Check that they are secured in place The same applies for any access ports in the roof of the enclosure If any of these caps are missing contact a Generac Guardian Authorized Dealer Generac Power Systems Inc 17 MAINTENANCE Section 4 Maintenance 2 9 Inside the generator set the chance of rodent entry into the control panel is greatly reduced by the inclusion of adjustable wire connectors Check that the wire connector screws are tight thus closing off any gap between the access holes and the wires 4 11 OUT OF SERVICE PROCEDURE 4 11 1 REMOVAL FROM SERVICE If the generator cannot exercise every seven days and it is to be out of service longer than 90 days prepare the generator for storage as follows i 2 3 otart the engine and let it warm up Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down Once the unit has shut down it will signal a fault on the control panel Set the Auto Off Manual switch to OFF and turn off the utility power to the transfer switch While the engine is still warm from running drain the oil completely Refill the crankcase with SAE 15W 40 oil having API Service Class SG SH or Su Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase Remove the spark plug s and spray fogging agent into the spark plug s threaded openings Re
55. 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 page 14 3 2 USING THE AUTO OFF MANUAL SWITCH 3 2 1 AUTO POSITION Selecting this switch position activates fully automatic system operation It also allows the unit to start and exercise the engine every seven days with the setting of the exercise timer Guardian Liquid cooled 40 kW Generator 3 2 2 OFF POSITION This switch position shuts down the engine This posi tion also prevents operation 3 2 3 MANUAL POSITION Set the switch to Manual to crank and start the engine Transfer to standby power will not automatically occur unless there is a utility failure WARNING With the switch set to AUTO the engine may crank and start at any time without warning Such automatic starting normally occurs when utility power source voltage drops below a preset level or during the normal exercise cycle To pre vent possible injury that might be caused by such sudden starts always set the switch to OFF and remove the fuse before working on or around the generator or transfer switch Then place 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 f
56. can be damaged if voltage num ber of phases and frequency are not compatible NOTE This manual assumes that the standby generator has been properly selected installed and interconnected by a competent qualified electrician or installation contractor Once the installation is complete do nothing that may result in noncompatibility between the generator and connected electrical loads 1 8 2 ENGINE MARKO apparel General Motors Displacement 4 3 liters 262 cu in Cyimder Arrangement sustancias V 6 Valve Arrangement arica Overhead Valves birms oe a dai 1 6 5 4 3 2 Number Of Main Bearings u uu 4 Compression RAO rra 9 4 to 1 No of Teeth on 168 A AA Electronic Ignition Timing at 1 800 rpm 40 degrees BTDC Rated Horsepower at 1 800 67 Spark Gap erat nanus 0 045 inch 1 1 mm Recommended Spark Plugs AC 41 932 or equivalent OTS ii proses ee se eee cee 30 50 psi Crankcase Oil Capacity 4 5 U S quarts 4 25 L Recommended Engine SAE 15W 40 Type of Cooling System Pressurized closed recovery Pal M Pm Pusher Type Cooling System Capacity 4 5 U S gallons 17 L Recommended Coolant Use a 50 50 mixture of ethylene glycol and soft water Fuel Consumption Natural Gas 004373 3 amp 004626 2
57. d Fill OIL DIPSTICK OIL FILL CAP 4 2 CHANGING THE ENGINE OIL AND FILTER 4 2 1 ENGINE OIL RECOMMENDATIONS Use oil of API Service Class SG SH or SJ The recommended oil grade for the engine is SAE 15W 40 NOTE The unit is supplied with break in oil See the Service Schedule Section 4 12 Page 19 for the first required oil change 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 Refer to the Service Schedule Section 4 12 Page 19 for engine oil and filter change frequencies Drain the oil while the engine is still warm from run ning This means warm up the engine shut it down and drain it immediately as follows 1 Remove the oil drain hose from its retaining clip located on the generator base frame 2 Loosen and remove the oil drain hose cap located on the base frame end of the hose Drain the oil completely into a suitable container 3 When all of the oil has drained install and tighten the oil drain hose cap 4 Turn the oil filter Generac part number 0A37970001 Figure 4 2 counterclockwise and remove it Properly dispose of the old filter Guardian Liquid cooled 40 kW Generator MAINTENANCE 5 Section 4 Maintenance Figure 4 2 Oil Filter OIL FILTER OIL
58. ds feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and 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 you are physically or mentally fatigued Important Safety Instructions SAFETY RULES Guardian Liquid cooled 40 kW Generator Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts Before performing any maintenance on the generator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS All generators c
59. ds and regulations per taining to the installation caution amp After the system has been installed you must not do anything that might render the installation in noncom pliance with such codes standards and regulations NOTE For more information about the installation of a stand by system you can order Engine Generator Standby Electric Power Systems Installer s Guide and Reference Manual part 046622 from a Generac Authorized Service Dealer NFPA STANDARDS The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection Association NFPA Batterymarch Park Quincy MA 02269 e NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES e NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES e NFPA No 220 STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No 68 GUIDE FOR EXPLOSION VENTING NFPA No 70 NATIONAL ELECTRICAL CODE NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 8 Generac Power Systems Inc OTHER PUBLISHED STANDARDS In addition to NFPA standards the following informa tion pertaining to the installation and use of standby electric systems is available e Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 e AGRICULTURAL WIRIN
60. e applications The block heater must be connected to a customer supplied 120V AC circuit Generac Power Systems Inc 13 MAINTENANCE LD Section 4 Maintenance Figure 3 2 Engine Block Heater Refer to applicable wiring diagram s and electrical schematic s at the back of this manual for wiring con nections 3 6 WEEKLY EXERCISE CYCLE The generator will start and exercise once every seven days During this weekly exercise the unit runs for approximately 20 minutes and shuts down Transfer of loads to generator output does not occur during the exercise unless power is lost during the exercise period To select the day of the week and time of day for exer cising proceed as follows Set the Auto Off Manual switch to OFF e Set generator s main circuit breaker to its OFF or open position e Locate the rocker switch on the control panel identi fied with the words Set Exercise Time Figure 3 3 e Push Set Exercise Time switch to the ON position for 20 to 30 seconds and then release The switch will spring back into its original position when released e Wait 30 seconds before setting the Auto Off Manual switch to the AUTO position NOTE The unit will exercise 20 minutes before it is set Example Set Noon Exercise 11 40 a m cauroN If you switch the Auto Off Manual switch is switched too soon the engine may start If engine does start it will shut down automatic
61. e exceed approximately 121 C 250 F the switch contacts close which causes the engine to shut down automatically Figure 1 2 Section 1 General Information GENERAL INFORMATION 1 73 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
62. e information and or service inter vals please refer to Section 4 Maintenance 2 8 2 Transfer Switch If this generator is used to supply power to any electri cal system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents electrical backfeed between two different electrical systems For additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compli ance with applicable codes standards and regulations 2 8 3 Fuel System Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and b is properly purged and leak tested according to code No fuel leakage is permitted See Specifications Page 6 for more information 2 8 4 Generator Set Lubrication Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULL mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications Page 5 and Engine Oil Recommendations Page 7 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 5 Engine Coolant Have the engine cooling system properly filled with the
63. ead this Owner s Manual and thor oughly understand all instructions before using this equipment Generac also strongly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for Guardian models 004373 1 amp 004626 0 OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Guardian Authorized Dealer Normal maintenance service and replacement of maintenance parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for mainte nance service Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum See a Generac Guardian Authorized Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact a Generac Guardian Authorized Dealer for assistance Service technicians are factory trained and are capable of handling all service needs
64. ection 7 Exploded Views and Parts Lists Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators ITEM PART NO QTY 1 068115 1 2 0D5489 1 4 023484N 2 6 056739 1 9 0D3388 1 10 058710 2 11 0D5492 1 048766 REF 12 022985 2 13 068116 1 18 0D5840 1 29 022264 2 30 002212 2 31 022142 4 32 022145 4 33 022129 4 34 045771 4 35 022287 19 36 022473 23 37 022097 23 38 022127 4 40 0D5574 1 41 0D5595A 1 PARTS SHOWN BELOW I N S 42 50 42 0D5689 1 43 0D5693 1 44 022097 12 45 022287 8 46 022127 12 47 022473 4 48 081320 4 49 022237 3 50 048527 3 51 0D5463B PARTS SHOWN BELOW I N S 52 60 52 0D5464B 1 53 057073 2 54 022152 4 55 033530 4 56 022237 2 57 022241 2 58 022145 2 59 022129 1 60 045771 1 Connection Box Drawing No 0D8848 A DESCRIPTION LOWER PANEL 15 COVER LOWER CONNECTION BOX BUSHING SNAP SB 2 5 31 RELAY SOLENOID 12VDC PNL MNT DECAL REMOTE START CONNECTION TRANSFORMER 200A TO 5A 5VA HARNESS LOWER PANEL 4 3L GRDN BLOCK TERM 20A 2 X 6 X 1100V WASHER FLAT 6 ZINC COVER LOWER PANEL 15 DECAL CUSTOMER CONNECTN FOR TS WASHER LOCK M4 SCREW PHTT M4 0 7 X 16 ZYC SCREW HHC 5 16 18 X 3 4 G5 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR SCREW HHC 1 4 20 X 3 4 G5 WASHER FLAT 1 4 ZINC WASHER LOCK M6 1 4 NUT HEX 1 4 20 STEEL CB 0200A 3P 600V S FD6 LL KIT CB MOUNT S FD 390S PLATE CB MOUNT S FD 390S COVER CB TERMINALS S FD 3P WASHER LOCK M6 1 4
65. ed to Before installing or servicing this and related equip ment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in hazardous and possibly fatal electrical shock Connecting this unit to an electrical system normally supplied by an electric utility shall be by means ofa transfer switch so as to isolate the genrator electric system from the utility electric system while in oper ation Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatically transfer switch will crank and start automatically when nor mal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel disable the generator s automatic start circuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and on the transfer switch In case of accident caused by electric shock immedi ately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a rope or board to free the victim from the live con ductor
66. el No 004626 2 Guardian Liquid cooled 40 kW Generators Section 7 Exploded Views and Parts Lists Exhaust Drawing No 0E1347 LISTS PARTS der LNAWLSANPAV YO JONVNILNIVIA LOAPANS LON SWALI 3S3H L SVD ANY JAVA GION31OS H3TIOHLNOO OLLVH 13N3 HIV HOSN3S N39AXO 1SATVIVO 1SNVHX3 JHL ONIGNIONI IW31SAS SIHL JO 3 18VSIO HO HLIM H3dlAV L LON OQ L9lH LSIQ INAWASVNVW ALI TVOYO 1SVO9 HLNOS AHL ONIGNTONI 5145 ONILVH3N3O AON3DH3I3 GSLINDI MYVdS SNOASVSD LOIHLISIO HIV VINHOJITVO NIV LH3O HLIM Ad WOO OL WALSAS SNOISSIW3 1SnVHX3 3ALLOV NV SI LINN SIHL NOLLVINHOJNI SNOISSIIN3 5 LNV LHOdaMWI OG S 2 pl 8l 1uOJ4 juauyeduloo Ol JNION3 OL C JNION3 OL b 1 es e 9 Oc A quassy duelo SZ 56 Generac Power Systems Inc ITEM O WP PART 059902 0 9641 0D4208 0D5061 004126 0D5787 0A5215B 0E0699 0E0698 004170 004305 002454 003433A 022129 022145 045771 042907 080762 022237 022241 0E0701 0E0700 077879 0D4221 0D4512 043116 022471 022264 038150 036918 049811 022097 049813 0D8780 022131 QTY
67. ems Inc 11 OPERATION OD 3 1 CONTROL CONSOLE COMPONENTS The components of a liquid cooled generator control console Figure 3 1 are as follows Section 3 Operation Figure 3 1 Control Console AC AC AC FREQUENCY VOLTMETER VOLTMETER HOURMETER SET EXERCISE TIME AUTO SWITCH 9 VOLTAGE PHASE SELECTOR SWITCH FAULT INDICATOR URS FUSE 15A VOLTS HOI l OFF a 2 FUSE AUTO OFF MANUAL SWITCH FAULT INDICATOR LAMP 3 1 1 AC VOLTMETER The voltmeter displays generator AC output voltage dur ing operation Voltage is regulated by a solid state volt age regulator and is proportional to AC frequency Refer to the unit s DATA PLATE for rated AC voltage 3 1 2 AC AMMETER This indicates current draw of connected electrical loads during operation DO NOT EXCEED THE UNIT S RATED MAXIMUM CONTINUOUS CURRENT Refer to the unit DATA PLATE 3 1 3 AC FREQUENCY METER This indicates generator AC output frequency in Hertz cycles per second Frequency is proportional to engine speed Units with a four pole rotor supply 60 Hertz at 1 800 rpm The frequency reading with no electrical loads connected no load condition should be between 60 62 Hertz 3 1 4 DC VOLTMETER The generator 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
68. enerac 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 responsi ble for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for d
69. es 10 Section 5 Troubleshooting MENORES 20 PI MAN UA ais ad Section 6 Electrical Data 21 2 8 1 Prior to Initial Start up 11 2 8 2 Transfer Switch 11 Section 7 Exploded Views and 2 8 3 Fuel 11 Parts Lists 30 2 8 4 Generator Set Lubrication 11 Section 8 Notes 59 2 0 0 Engine Coolant 11 _ D o qar O O O Section 9 Warranty 60 2 8 7 Electrical System 11 2 8 8 Rodent Protection 11 Generac Power Systems Inc 1 SAFETY RULES Important Safety Instructions Guardian Liquid cooled 40 kW Generator SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas Safety should be stressed to all operators and potential operators of this equipment SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries WARNING 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 Th
70. esting by Generac or a Generac Authorized Warranty Service Dealer is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer All trans portation 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 Guardian prepackaged emergency automatic standby generators sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS ONE and TWO 100 one hundred percent transferable coverage on Labor and Part s listed proof of purchase and maintenance is required Engine All Components e Alternator All Components Transfer System All Components All warranty expense allowances are subject to the conditions defined in Generac s Warranty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac Guardian generators that utilize non Generac replacement parts Generac Guardian generators utilizing non Generac Guardian automatic transfer switches Any Generac 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 norma
71. ever 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 can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty descr
72. g performed 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 conse quential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part No OE1780 Revision O 08 06 02 Printed in U S A
73. he contents of a package that is not in evidence at the time of delivery but is discovered later LIFTING THE GENERATOR WARNING amp A When lifting or hoisting equipment is used be careful not to touch overhead power lines 1 1 1 A The generator s weight of more than 2 000 pounds requires proper tools and equipment and qualified personnel to be used in all phases of handling and unpacking 1 2 THE GENERATOR This liquid cooled Guardian generator set is designed to supply electrical power to operate critical electrical loads during utility power failure Use this generator as a source of electrical power for the operation of 120 and or 240 volt single phase loads 1 3 GENERATOR AC CONNECTION SYSTEMS Figure 1 1 represents a single phase four wire genera tor AC connection system The stator assembly in this system consists of a pair of stationary windings with two leads brought out of each winding Each single winding can supply a 120 volt 60 Hertz AC output Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator When the two windings are connected in series a 240 volt 60 Hertz AC output results Typically the two hot leads in the circuit are Wires 11 and 44 The neutral leads are the junction of Wires 22 and 33 Figure 1 1 Single phase Generator AC Connection System 120 VOLTS 120 VOLTS 00 Neutral Block 240 VOLTS 1 4 PREPACKAGED TRANSFER SWIT
74. here is no AC output from 1 Generator main line circuit 1 Reset circuit breaker the generator breaker open to ON or closed 2 Generator internal failure Ze 1 There is no transfer to 1 Generator main line circuit 1 Reset circuit breaker standby after utility breaker open to ON or closed source failure 2 Defective transfer switch coil 2 3 Defective transfer relay 4 Transfer relay circuit open 4 5 Defective control logic board Os Contact your nearest Generac Guardian Authorized Dealer for assistance eo Generac Power Systems Inc Section 6 Electrical Data Guardian Liquid cooled 40 kW Generator ELECTRICAL Mounting Dimensions Drawing No 0D5335 DATA lt lt NOTE 7 220 8 65 STUB UP AREA MEN po RECOMMENDED FUEL ELECTRICAL STUB UPS R677 R26 66 ra STUB UP AREA SEE TOP VIEW SEE NOTE 8 AND CHART DESCRIPTION INSIDE 247 9 73 E BASE A AC LOAD LEAD CONDUIT LEFT A1 aL eee i E A Sl INSIDE STUB UP FOR C 204 8 03 CH aa FUEL CONNECTIONS E Bu NOTE L d K 794 81 28 FUEL SYSTEM SET UP WITH OUTSIDE STUB UPS PA STUB UP SEE LEFT SIDE VIEW SMALL FUEL SYSTEM 839 33 017 a dal rd AREA MODIFICATIONS REQUIRED FOR TYP E 5 APT A INSIDE S
75. hten the end cap 4 Invert the pressure reducer valve In other words turn it upside down end cap facing downward 5 Purge and leak test the entire fuel system according to gaseous fuel codes NO LEAKS can appear at any point in the system Figure 1 3 Conversion to LP Gas Vapor PRESSURE REDUCER VALVE INNER SPRING TENSION END CAP Guardian Liquid cooled 40 kW Generator 1 10 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE or SE Detergent oils keep the engine cleaner and reduce carbon deposits Use oil hav ing the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Oil Grade Recommended SAE 30W or 15W 40 SAE 20W 20 or 15W 40 SAE 10W or 15W 40 A caution amp Any attempt to crank or start the engine before it A has been properly serviced with the recommended oil may result in an engine failure 1 11 COOLANT Use a mixture of half low silicate ethylene glycol base antifreeze and half soft water Use only soft water and only low silicate antifreeze If desired add a high quali ty rust inhibitor to the recommended coolant mixture When adding coolant always add the recommended 50 50 mixture A DX A Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or stea
76. ibe 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 Section 9 Warranty Guardian Liquid cooled 40 kW Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and later model year engines a Applicability This warranty shall apply to 1995 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall con tinue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty
77. ing Do not open or mutilate the battery Released electrolyte can be toxic and harmful to the skin and eyes LA A The battery represents a risk of high short circuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles 4 5 1 BATTERY REPLACEMENT Generac uses a Group 27F vented type battery that has 600 CCA 0 F Generac s part number is 058665 NOTE The BCI number should be located directly on the battery Guardian Liquid cooled 40 kW Generator 4 6 COOLING SYSTEM Air intake and outlet openings in the generator compart ment must be open and unobstructed for continued prop er operation This includes such obstructions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down WARNING amp A The exhaust system of this product gets extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system 4 7 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state engine controller circuit board Battery voltage is delivered to that circuit board via a 15 amp fuse These overcurrent protection devices will open if
78. install 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 1 8 9 Verify that utility power is turned off to the transfer switch and that the Auto Off Manual switch is set to OFF Check the tag on the engine for oil viscosity and classification Verify that the correct recommended oil is used in engine See Section 4 2 1 Page 14 If necessary drain and refill with the proper oil Check the battery Fill all cells to the proper level with distilled water DO NOT USE TAP WATER IN THE BATTERY Remove the battery before charging Recharge the battery to 100 percent state of charge or if defective replace the battery with a 12 volt DC Group 27F battery rated for 90 amp hours part 058665 Clean and wipe the entire generator Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incor rectly Open the fuel shutoff valve Start the unit by moving the Auto Off Manual switch to MANUAL Allow the unit to warm up thoroughly Stop the unit and set the Auto Off Manual switch to AUTO Turn on the utility power to the transfer switch 10 The generator is now ready for
79. is product contains or emits chemicals A A known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The gen erator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fun damental rules or precautions Generac cannot possibly anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If you use a procedure work method or operating technique Generac does not specifically recommend you must satisfy yourself that it is safe for you and others You also must make sure the procedure work method or operating technique that is chosen does not render the generator unsafe DINE A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator A A Parts of the generator
80. isallowing 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 so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including e LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 Generac Power Systems Inc 61 Section 9 Warranty WARRANTY Guardian Liquid cooled 40 kW Generators GENERAC POWER SYSTEMS STANDARD TWO YEAR LIMITED WARRANTY FOR GUARDIAN PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years Generac Power Systems Inc Generac will at its option repair or replace any part which upon examination inspection and t
81. lly exist Costs of normal maintenance adjustments installation and start up Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts e Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent infestation e Products that are modified or altered in a manner not authorized by Generac in writing e Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses e Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are bein
82. m could result Temperature Above 80 F 27 C 32 to 80 F 1 C to 27 C Below 32 F 0 C A A Ethylene glycol base antifreeze is poisonous Do not use mouth to siphon coolant from the radia tor recovery bottle or any container Wash hands thoroughly after handling Never store used antifreeze in an open container because animals are atracted to the smell and taste of antifreeze even though it is poisonous to them Do not use any chromate base rust inhibitor with ethylene glycol base antifreeze or chromi um hydroxide green slime will form and cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethyl ene glycol base antifreeze Using any high sili cate antifreeze boosters or additives also will cause overheating Generac also recommends that any soluble oil inhibitor NOT be used for this equipment Section 1 General Information GENERAL INFORMATION 1 12 EMISSIONS CONTROL SYSTEM MODEL 004626 2 This model is equipped with an active exhaust emis sions control system to comply with certain California air district regulations for natural gas emergency gener ating sets including the South Coast Air Quality Management District Do not tamper with or disable any part of this system including the exhaust catalyst carburetor oxygen sensor air fuel ratio controller sole noid valve and gas regulator The
83. main circuit breaker is included with the unit as shipped from the factory The breaker for each unit is described as follows Model Number 004373 3 004626 2 Circuit Breaker Rating 200 amp breaker 200 amp breaker 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 4 1 7 1 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should oper ating oil pressure drop below approximately 10 psi 68 kPa the switch contacts close and the engine shuts down automatically Figure 1 2 Figure 1 2 Engine Protective Devices HIGH COOLANT TEMPERATURE SWITCH LOW COOLANT LEVEL SWITCH LOW OIL PRESSURE SWITCH N LOCATED ON OPPOSITE SIDE OF GENERATOR ze O O 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 temperatur
84. ment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detectors accordingly Generac Power Systems Inc 3 Section 1 General Information 1 1 UNPACKING INSPECTION After unpacking carefully inspect the contents for dam age e This standby generator set has been factory installed in an all weather metal enclosure that is intended exclusively for outdoor installation WARNING amp If this generator is used to power electrical load circuits normally powered by a utility power source code requires to install a transfer switch The transfer switch must effectively isolate the electrical system from the utility distribution sys tem when the generator is operating NEC 701 Failure to isolate an electrical system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy If any loss or damage is noted at time of delivery have the person s making the delivery note all damage on the freight bill or affix his or her signature under the consignor s memo of loss or damage A If there is loss or damage after delivery separate the damaged materials and contact the carrier for claim procedures Concealed damage is understood to mean damage to t
85. n the generator When using maintenance free batteries it is not neces sary to check the specific gravity or electrolyte level Have these procedures performed at the intervals spec ified in Section 4 Maintenance A negative ground sys tem is used Battery connections are shown on the wiring diagrams Make sure all batteries are correctly connected and terminals are tight Observe battery polarity when connecting batteries to the generator set NOTE Damage will result if the battery connections are reversed 2 8 PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed serviced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules on Pages 2 and 3 as well as all other safe ty information in this manual before attempting to oper ate this and related equipment Guardian Liquid cooled 40 kW Generator 2 8 1 PRIOR TO INITIAL START UP caution amp A Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quanti ties of engine fluids oil coolant fuel etc may result in an engine failure Before starting the generator for the first time the installer must complete the following procedures For follow up maintenanc
86. ne with an automotive type bat tery hydrometer or load test 16 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator A A Standby generators installed with automatic transfer switches will crank and start automatical ly when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to per sonnel do not connect battery cables until the normal source voltage at the transfer switch is correct and the system is ready to be placed into operation A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the bat tery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery A Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water WARNING amp Do not dispose of the battery in a fire The bat tery is capable of explod
87. ng of the normal incoming utility service e The transfer switch must be installed between the utility service entrance and the building distribution panel 2 4 GROUNDING THE GENERATOR The National Electrical Code requires the frame and external electrically conductive parts of this equipment to be properly connected to an approved earth ground and or grounding rods For that purpose a GROUND LUG Figure 2 2 is provided on the generator mounting base Consult a qualified electrician for grounding requirements in your area Grounding procedures must meet local regulations INSTALLATION Hh Section 2 Installation A 19 A Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against electri cal shock in the event of a ground fault condition in the generator or in connected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded devices Figure 2 2 Generator Grounding Lug typical BASE GROUNDING LUG 2 5 GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED AC neutral Grounding is recommended only at the main service entrance 2 6 TRANSFER SWITCH START SIGNAL CONNECTIONS 2 6 1 PRE PACKAGED TYPE SWITCH Connect the six signal wires from the automatic trans fer switch to the engine generator control which is located on
88. ng vacuum from the carburetor This vacuum signal is directed to the fuel regulator via the control valve The air fuel ratio con troller determines the amount of vacuum signal sent to the fuel regulator The more vacuum sent to the regula tor the more restricted the fuel flow will be therefore the leaner the air fuel mixture Generac Power Systems Inc 7 INSTALLATION TED Section 2 Installation Guardian Liquid cooled 40 kW Generator STANDBY GENERATOR INSTALLATION Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch such as the Generac GTS type transfer switch so as to isolate the electric system from the utility distribution system when the generator is operating Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy caution amp If an open bottom is used the engine generator is to be installed over non combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set Only qualified competent installation contractors or electricians thoroughly familiar with applicable codes standards and regulations should install this standby electric power system The installation must comply strictly with all codes standar
89. ngine Air Cleaner 15 and Recommendations 6 posco 16 1 9 1 Conversion to LP Gas Vapor 6 4 5 Battery Maintenance 16 1 10 Engine Oil Recommendations 7 4 5 1 Battery Replacement 16 oleo A o A 7 ALO Cooling DUE sacacasa 17 1 12 Emission Control System 7 4 7 Overload Protection for Section 2 Installation 8 E 2 1 Basic Standby Electric System 8 48 DC Puse ds 17 2 2 Emergency Circuit Isolation Method 9 4 9 Engine Coolant 17 2 3 Total Circuit Isolation Method 9 4 10 Miscellaneous Maintenance 17 2 4 Grounding the Generator 9 4 10 1 Cleaning the Generator d 25 Generator AC Neutral Connection oos 9 4 10 2 Rodent Protection u a 17 26 Transfer Switch Start Signal Connections 9 4 11 Out of Service Procedure 18 2 6 1 Pre Packaged Type Switch 9 4 11 1 Removal From Service os 18 2 6 2 GTS Type Switch 9 4 1 1 2 Return to 18 2 7 Battery Installation 10 4 12 Service Schedule career ads 19 2 7 1 Vented Batteri
90. nnect battery cables until the normal source voltage at the transfer switch is cor rect and the system is ready to be placed into operation Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the bat tery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame Sparks or any spark producing tools or equipment near the battery A Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water WARNING amp Do not dispose of the battery in a fire The battery is capable of exploding Do not open or mutilate the battery Released A electrolyte can be toxic and harmful to the skin and eyes A The battery represents a risk of high short circuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles 10 Generac Power Systems Inc Guardian Liquid cooled 40 kW Generator 2 7 1 VENTED BATTERIES cauti
91. odel No 004373 3 Guardian Liquid cooled 40 kW Generators 0 4 3L Nat Gas Fuel System Drawing No 0E0714 TO STEPPER 42 TO INTAKE MANIFOLD 52 Generac Power Systems Inc ITEM YO WP PART NO 065907 026812 076691 007598 026490 026577 055944 067018 002775 061910 022145 022129 030795 025655 022132 051778 028641 057824 057422 043123 051779 050279 026915 055934P 0A5737C 0D1509 061258 0A7631 029745 022237 052865 033212 0A4120 064945 0A6344 0A4121 047290 036409 022097 0A5763 082508 QTY N PN BN Pb FPO PO PO PO PO YP fH HH Section 7 Exploded Views and Parts Lists Model No 004373 3 Guardian Liquid cooled 40 kW Generators 4 3L Nat Gas Fuel System Drawing No 0E0714 DESCRIPTION SUPPORT SOLENOID NAT GAS ELBOW 90D 3 4NPT NIPPLE PIPE 3 4 NPT X 4 5 BLK IRN ASSY NATURAL GAS SOLENOID NIPPLE PIPE 3 4 NPT X 2 BUSHING REDUCER 1 TO 3 4 REGULATOR NAT GAS LPG VAPOR SUPPORT REGULATOR BRACKET REGULATOR 4 3L SCREW HHTT 10 24 X 3 4 YC WASHER FLAT 5 16 ZINC WASHER LOCK 8 5 16 SCREW HHC 5 16 18 X 1 G5 PLUG STD PIPE 3 4 STEEL SQ HD WASHER FLAT 9 16 ZINC SCREW HHC M14 2 0 X 25 G8 8 NIPPLE TOE 3 4 NPT X 2 CLAMP HOSE 16 87 1 50 HOSE 1IN ID LP GAS 42 LG WASHER LOCK M14 NUT HEX M14 2 G8 YEL CHR DECAL FUEL INLET NG
92. ollowing 1 Make sure the transfer switch main contacts are set to their Utility position i e loads connected to the utility power source 2 Be sure that normal utility power source voltage is available to transfer switch terminal lugs N1 and N2 3 Set the generator s Auto Off Manual switch to AUTO 4 Set the generator s main circuit breaker to its ON or closed position With the preceding steps complete the generator will start automatically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to Sequence of Automatic Operation 3 4 SEQUENCE OF AUTOMATIC OPERATION The generator s control panel houses a control logic cir cuit board This board constantly monitors utility power source voltage Should that voltage drop below a preset level circuit board action will signal the engine to crank and start After the engine starts the circuit board signals the transfer switch to activate and connect load circuits to the standby power supply load terminal lugs T1 T2 connect to terminal lugs E1 E2 OPERATION OD Upon restoration of utility source voltage above a preset level generator circuit board action signals the transfer switch to transfer loads back to that power supply After retransfer the engine is signalled to shut down Section 3 Operation The actual sequence of operation is controlled by sensors and
93. on amp A The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically con ductive and corrosive The following procedures are to be observed e Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water e Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical atten tion and e Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbonate of soda to one gallon 4 liters of water The bicarbonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The following proce dures are to be followed e DO NOT SMOKE when near batteries e DO NOT cause flame or spark in battery area and e Discharge static electricity from body before touching batteries by first touching a grounded metal surface Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries For recommended batteries see Battery Maintenance page 16 All batteries must be at 100 percent state of charge before they are installed o
94. overed by this manual produce dan gerous electrical voltages and can cause fatal electri cal shock Utility power delivers extremely high and dangerous voltages to the transfer switch as 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 ject
95. s 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators 4 5L Radiator Drawing No 0D7992 C 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 BARBED EL 90 1 4 NPT X 3 8 DRAINCOCK HOSE 9 32 ID 64 LG TAPE FOAM 1 X 1 29 LG SCREW CRIMPTITE 1 4 20 X 5 8 SCREW HHC 3 8 16 X 1 G5 WASHER LOCK 3 8 WASHER FLAT 3 8 M10 ZINC RADIATOR HOSE UPPER BOTTLE COOLANT RECOVERY WATER BOTTLE BRACKET SCREW HHTT M6 1 0 X 12 YC CLAMP HOSE BAND 1 4 SUPPORT RADIATOR A GRP BRACKET AIR DUCT TOP BOT SUPPORT AIR DUCT RH SIDE SUPPORT AIR DUCT LH SIDE SCREW HHC 1 4 20 X 1 G5 WASHER LOCK M6 1 4 WASHER FLAT 1 4 ZINC SCREEN FRONT SCREW HHTT 1 4 20 X 1 CZ WASHER LOCK M6 1 4 WASHER FLAT 1 4 ZINC CAP RADIATOR 13 PSI FOR SERVICE ONLY LISTS Generac Power Systems Inc 49 PARTS 5 E2 TO S COMPARTMENT TO ENGINE OD FRONT ENGINE 15 14 18 ITEM PART NO QTY DESCRIPTION 1 059902A 1 CAP RAIN 2 50 2 69 2 009641 1 TUBE STRAIGHT A GROUP 0C9650 1 MUFFLER 2 1 2 INLET OUTLET 4 0C4114A 2 CLAMP BAND MUFFLER 6 5 5 0C4126 2 BRACKET MUFFLER MOUNTING 6 005787 1 TUBE ELBOW 90 DEG 2 5 7 0A5215B 2 PIPE FLEX 2 5 8 0 0699 1 TUBE CROSS OVER 9 0 0698 1 TUBE 90
96. se items are not sub ject to periodic maintenance or adjustment This model is of a size greater than 50 brakehorse power that may require a review by air permitting authorities prior to installation and operation Consult the local air management district for details and spe cific requirements Figure 1 4 Emissions Control System Regulator Carburetor Vacuum A F Ratio Controller Control Valve Q2 Sensor Throttie A F Mixture 3 Way Catalysi 1 12 1 AIR FUEL RATIO CONTROLLER The air fuel ratio controller is an advanced micro processor designed to work with a three way catalyst and a feedback rich bias carburetor to provide close loop fuel management Its digital adaptive control is able to compensate for variations in fuel mixtures and engine tunes It is time based activated For example it will activate after 45 seconds from receiving the power signal The part number for the air fuel ratio controller is 004221 Principle of Operation The oxygen sensor installed on the exhaust pipe between the engine and the cat alytic muffler closer to the engine continuously moni tors the exhaust gas composition A feedback signal is sent from the oxygen sensor to the air fuel ratio con troller which controls the fuel system to maintain the optimal stoichiometric air fuel ratio The air fuel mix ture to the engine is controlled by biasing the diaphragm in the fuel regulator usi
97. service 4 12 SERVICE SCHEDULE Section 4 Maintenance Guardian Liquid cooled 40 kW Generator MAINTENANCE LD ATTENTION It is recommended that all service work be performed by your nearest Generac Guardian Authorized Dealer SYSTEM COMPONENT PROCEDURE FREQUENCY X Action Inspect Change Clean W Weekly R Replace Adjust as Needed M Monthly Notify Dealer Y Yearly if Repair is Needed H Hours FUEL Fuel lines and connections X EVERY LUBRICATION Oil level X M Oil X FIRST 9 H EVERY 150H 6M Oil filter X FIRST 9 H EVERY 150H 6M Oil line leakage X 100 H COOLING Engine cooling system X M Coolant X Y Enclosure louvers X X W EXHAUST Exhaust system X EVERY Retorque Exhaust Manifold X FIRST 100 H AND EVERY 800 H BATTERY Charge and condition X R X EVERY3M FAN BELT Tension and condition X R EVERY 3M ENGINE Retorque cylinder head X FIRST 100 H AND EVERY 800 H Retorque intake manifold X FIRST 100 H AND EVERY 800 H Starter motor X R EVERY 500 H DC alternator X R EVERY 500 H AND Y Air cleaner X R EVERY 500 H Compression X EVERY 800 H Valve clearance X R EVERY 800 H Governor X R Y Safety devices X R EVERY 6M Spark plugs X R 500 H AND Y Ignition system X R EVERY M GENERAL Overall condition X X M Exercise system W COMPLETE TUNE UP TO BE COMPLETED BY A
98. sture that accumulate on internal generator windings have an adverse effect on insulation resist ance Periodically clean the generator s exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspect ed by a Generac Guardian Authorized Dealer Service technicians will use dry low pressure air to clean inter nal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying 4 10 2 RODENT PROTECTION The intrusion of rodents into the generator set can cause a wide range of problems from failure of the unit to start to personal injury and in extreme circum stances short circuit or fire Although the unit was designed to limit this problem further precautions can be taken by the owner to help minimize both the chance of rodent entry and the extent of any damage The fol lowing inspection should be performed 1 The base frame of the unit contains an optional fuel inlet location and four lifting holes that are capped at the factory These caps are sometimes removed for transport
99. the circuit is overloaded caution amp A If a circuit breaker opens or a fuse element melts you should find the cause of the overload before resetting the circuit breaker or replacing the fuse 4 8 DC FUSE The generator panel s 15 amp AGC fuse Figure 4 4 pro tects the DC control circuit against overload The fuse is wired in series with the battery output lead to the panel If the fuse element has melted open cranking or starting the engine cannot occur Replace the fuse using only an identical 15 amp AGC replacement Figure 4 4 Location of 15 amp Fuse lt Senne TIME VOLTS HOURS AUTO INDICATOR 154 e MANUAL FAULT FUSE MAINTENANCE LO Section 4 Maintenance 4 9 ENGINE COOLANT Check the coolant level in the coolant recovery bottle e Add the recommended coolant mixture as necessary See Section 1 10 on Page 7 e Periodically remove the radiator pressure cap to make sure the coolant recovery system is functioning properly Coolant should be at the bottom of the radia tor filler neck If the coolant level is low inspect the gasket in the radiator pressure cap Replace the cap if necessary To have the pressure cap tested contact a Generac Guardian Authorized Dealer Inspect the cool ing system and coolant recovery system for leaks 4 10 MISCELLANEOUS MAINTENANCE 4 10 1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moi
100. ticular operation that may be hazardous if performed incorrectly or care lessly Observe them carefully Their definitions are as A DX A After this heading read instructions that if not strictly complied with will result in personal injury or property damage WARNING amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution 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 A 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 r
101. timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility source voltage e If utility source voltage drops below about 60 per cent of the nominal supply voltage the sensor ener gizes a 15 second timer Once the timer has expired the engine will crank and start B Engine Warm up Time Delay This mechanism lets the engine warm up for about 10 seconds before the load is transferred to a stand by source C Standby Voltage Sensor This sensor monitors generator AC output voltage When the voltage has reached 50 percent of the nominal rated voltage transfer to standby can occur D Utility Voltage Pickup Sensor This sensor monitors utility power supply voltage When that voltage is restored above 80 percent of the nominal source voltage a retransfer time delay starts timing E Retransfer Time Delay e This timer runs for about 15 seconds e Atend of a 15 second delay circuit board action de energizes transfer relay in the transfer switch Retransfer to utility power source then occurs F Engine Cool down Timer When the load is transferred back to utility power source the engine cool down timer starts timing The timer will run for about one minute and the generator will then shut down 3 5 ENGINE HEATER This Generac standby generator comes equipped witha block heater Figure 3 2 page 14 that is similar to the block heaters used in automotiv
102. uardian Liquid cooled 40 kW Generators 0 Engine Drawing No 006980 16 To Air Cleaner 7 43 18 MAP v Distributor 34 A z AAN WU A ve A Ey 42 Generac Power Systems Inc 0D6979 0A4308 Section 7 Exploded Views and Parts Lists Model Nos 004373 3 amp 004626 2 Guardian Liquid cooled 40 kW Generators Engine Drawing No 0D6980 A PART DESCRIPTION 0A9046 1 ENGINE 4 3L GM 0A9118A 1 FLYWHL 4 3L GM SAE 070022 1 WASHER STAR M12 EXT 0A6021 6 SCREW HHC 7 16 20 X 1 G8 059056A 1 STARTER 5 7L 7 4L GM 0A9050 2 BOLT STARTER 4 3L 022237 17 WASHER LOCK 3 8 045772 1 NUT HEX M10 1 5 G8 YEL CHR 049226 1 WASHER LOCK M5 051716 1 NUT HEX M5 0 8 G8 YEL CHR 0M244 1 CONNECTOR COIL TO DISTRIBUTOR 0A4215 1 DIP STICK 4 3L GM 0A4231 1 TUBE DIP STICK 4 3L 059057 10 HOSE 3 4 ID SAE 30R2 0A2440 2 GASKET THERMOSET 026568 2 SCREW HHC 3 8 16 X 2 3 4 G5 099729A 1 HOUSING THERM IMPREX 061012 1 PLUG STD PIPE 1 8 SOCKET HEAD 069939 1 HOUSING THERMOSTAT WATER INLET 035606 1 SENSOR HI COOLANT SHUTDOWN 0A4930B 1 HEAT SHIELD RIGHT 0A4084 1 MOUNT ENGINE 029745 3 SCREW HHC 3 8 16 X 1 G5 044101 2 BRACKET SUPPORT SPARK PLUG WIRE 023152 2 SCREW HHC 3 8 16 X 3 4 G5 022131 2 WASHER FLAT 3 8 M10 ZINC 058030 2 RETAINER PLUG WIRES 0A4085 I GASKET EXHAUST MAN

Generac 004373-3 , 004626-2 Portable Generator User Manual

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