Generac 004626-1, 004373-2, 004373-2, 004626-1 owner manual Electrical Hazards

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Important Safety Instructions

Guardian Liquid-cooled 40 kW Generator

Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts.

Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.

Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

ELECTRICAL HAZARDS

All generators covered by this manual produce dan- gerous 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- jected to.

Before installing or servicing this (and related) equip- ment, make sure that all power voltage supplies are positively turned off at their source. Failure to do so will result in hazardous and possibly fatal electrical shock.

Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the 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 conductor. If the victim is unconscious, apply first aid and get immediate medical help.

Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

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 FLAMMABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the unit’s fuel system frequently and correct any leaks imme- diately. Fuel supply lines must be properly installed, purged and leak tested according to applicable fuel- gas codes before placing this equipment into service.

Diesel fuels are highly FLAMMABLE. Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air; install leak detec- tors accordingly.

Generac® Power Systems, Inc. 3

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Contents Power SYSTEMS, INC Authorized Dealer Location IntroductionInstallation Safety Rules General InformationMaintenance Section Installation Drawings 56-57 Warranty Back CoverGeneral Hazards Electrical Hazards UNPACKING/INSPECTION Prepackaged Transfer SwitchGenerator Generator AC Connection SystemsEngine Protective Devices SpecificationsMain Circuit Breaker Generator and Load Compatibility Fuel Requirements RecommendationsEngine Conversion to LP GAS VaporAIR Fuel Ratio Controller CoolantEmissions Control System Basic Standby Electric System Standby Generator InstallationNfpa Standards Other Published StandardsPre-Packaged Type Switch Transfer Switch Start Signal ConnectionsGTS Type Engineered Switch Emergency Circuit Isolation MethodVented Batteries Battery InstallationPreparation Before START-UP Prior to Initial START-UP Using the AUTO/OFF/MANUAL Switch Manual Position OFF PositionAutomatic Transfer Operation Sequence of Automatic OperationChecking the Engine OIL Level Weekly Exercise CycleChanging the Engine AIR Cleaner Oil and Filter Change ProcedureChanging the Engine OIL and Filter Engine Oil RecommendationsSpark Plugs Battery MaintenanceCleaning the Generator Miscellaneous MaintenanceOverload Protection for Engine DC Electrical System DC FuseReturn To Service OUT of Service ProcedureRemoval From Service SYSTEM/COMPONENT Procedure Frequency Service ScheduleProblem Cause Correction Troubleshooting GuideElectrical Data Section Generac Generac Power Systems,Inc Electrical Data Electrical Data Electrical Data Wiring Diagram Customer Connection HRS Power Systems IncPart NO. QTY. Description Generators Part NO. QTY Description Part NO.QTY Description QTY Description 4640 31 33 Washer Flat 3/8-M10 Zinc Part NO.QTY. DescriptionExploded Views and Parts Lists Flywhl 4.3L GM SAE Stator Leads Scrolldetail To Engine Flywheel QTY Description Part NO. QTY Description QTY Assembly Cover AccessRadiator Copper Brass Gasket Carburetor Adaptor Gasket Carb Impco To Carburetor QTY. DescriptionSupport Solenoid NAT GAS QTY. Description To Starter Solenoid RED Black To Engine Block ALT Leads Sensing Wire Siemens FD 3 Pole QTY Description Exploded Views and Parts Lists Part NO. QTY. Description Muffler 2-1/2 INLET/OUTLET Guardian Liquid-cooled 40 kW Generators Installation Drawings 12V Battery see Note Lifting EYE Places This Warranty Shall not Apply to the Following Warranty Schedule