Generac 004373-1, 004626-0 Introduction Inside Front Cover, Safety Rules General Information

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Table of Contents

Guardian Liquid-cooled 40 kW Generator

Introduction

Inside Front Cover

Read This Manual Thoroughly

IFC

Contents

IFC

Operation and Maintenance

IFC

How to Obtain Service

IFC

Authorized Dealer Locator Number

IFC

Safety Rules

2

Section 1 – General Information

4

1.1

Unpacking/Inspection

4

 

1.1.1

Lifting the Generator

4

1.2

The Generator

4

1.3

Generator AC Connection Systems

4

1.4

Automatic System Operation

4

1.5

Main Circuit Breaker

5

1.6

Engine Protective Devices

5

 

1.6.1 Low Oil Pressure Switch

5

 

1.6.2

High Coolant

 

 

 

Temperature Switch

5

 

1.6.3 Low Coolant Level Switch

5

 

1.6.4

Overspeed Shutdown

5

 

1.6.5

Overcrank Shutdown

5

 

1.6.6

DC Fuse

5

1.7

Specifications

5

 

1.7.1

Generator

5

 

1.7.1.1 Generator Load

 

 

 

and Compatibility

6

 

1.7.2

Engine

6

1.8Fuel Requirements

 

and Recommendations

6

 

1.8.1 Conversion to LP Gas Vapor

6

1.9

Engine Oil Recommendations

7

1.10

Coolant

7

1.11

Emission Control System

7

Section 2 – Installation

8

2.1

Basic Standby Electric System

8

2.2

Emergency Circuit Isolation Method

9

2.3

Total Circuit Isolation Method

9

2.4

Grounding the Generator

9

2.5

Generator AC Neutral Connections

9

2.6

Transfer Switch Start Signal Connections....

9

 

2.6.1

“GTS” Type Switch

9

 

2.6.2

Pre-Packaged Type Switch

9

2.7

Battery Installation

10

 

2.7.1

Vented Batteries

10

2.8

Preparation Before Start-up

10

 

2.8.1

Prior to Initial Start-up

11

 

2.8.2

Transfer Switch

11

 

2.8.3

Fuel System

11

 

2.8.4

Generator Set Lubrication

11

 

2.8.5

Engine Coolant

11

 

2.8.6

Belt Tension

11

 

2.8.7

Electrical System

11

 

2.8.8

Rodent Protection

11

Section 3 – Operation

12

3.1

Control Console Components

12

 

3.1.1

AC Voltmeter

12

 

3.1.2

AC Ammeter

12

 

3.1.3

AC Frequency Meter

12

 

3.1.4

DC Voltmeter

12

 

3.1.5

Hourmeter

12

 

3.1.6

Auto/Off/Manual Switch

12

 

3.1.7

Fault Indicator Lamp

12

 

3.1.8

15-amp Fuse

12

 

3.1.9

7.5 Amp Inline Fuse

12

 

3.1.10

Voltage-phase Selector Switch

12

 

3.1.11

Set Exercise Time Switch

12

3.2

Using the Auto/Off/Manual Switch

12

 

3.2.1

“Auto” Position

12

 

3.2.2

“Off” Position

13

 

3.2.3

“Manual” Position

13

3.3

Automatic Transfer Operation

13

3.4

Sequence of Automatic Operation

13

3.5

Engine Heater

13

3.6

Weekly Exercise Cycle

14

Section 4 – Maintenance

14

4.1

Checking the Engine Oil Level

14

4.2

Changing the Engine Oil and Filter

15

 

4.2.1

Engine Oil Recommendations

15

 

4.2.2

Oil and Filter Change Procedure

15

4.3

Changing the Engine Air Cleaner

15

4.4

Spark Plugs

16

4.5

Battery Maintenance

16

4.6

Cooling System

17

4.7Overload Protection for

 

Engine DC Electrical System

17

4.8

DC Fuse

17

4.9

Engine Coolant

17

4.10

Miscellaneous Maintenance

17

 

4.10.1 Cleaning the Generator

17

 

4.10.2 Rodent Protection

18

4.11 Out of Service Procedure

18

 

4.11.1 Removal From Service

18

 

4.11.2 Return to Service

18

4.12

Service Schedule

19

Section 5 – Troubleshooting

20

Section 6

– Electrical Data

21-29

Section 7

– Exploded Views and

 

 

 

Parts Lists

30-54

Section 8

– Notes

55

Section 9

– Installation Drawings

........56-57

Section 10 – Warranty

Back Cover

 

 

Generac® Power Systems, Inc. 1

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Contents Power SYSTEMS, INC Authorized Dealer Location IntroductionSection Installation Drawings 56-57 Warranty Back Cover Safety Rules General InformationInstallation MaintenanceGeneral Hazards Electrical Hazards Automatic System Operation UNPACKING/INSPECTIONGenerator Generator AC Connection SystemsSpecifications Main Circuit BreakerEngine Protective Devices Conversion to LP GAS Vapor Fuel Requirements RecommendationsGenerator and Load Compatibility EngineCoolant Emissions Control SystemAIR Fuel Ratio Controller Other Published Standards Standby Generator InstallationBasic Standby Electric System Nfpa StandardsEmergency Circuit Isolation Method Transfer Switch Start Signal ConnectionsGTS Type Switch Pre-Packaged Type SwitchBattery Installation Preparation Before START-UPVented Batteries Prior to Initial START-UP Using the AUTO/OFF/MANUAL Switch Sequence of Automatic Operation OFF PositionManual Position Automatic Transfer OperationChecking the Engine OIL Level Weekly Exercise CycleEngine Oil Recommendations Oil and Filter Change ProcedureChanging the Engine AIR Cleaner Changing the Engine OIL and FilterSpark Plugs Battery MaintenanceDC Fuse Miscellaneous MaintenanceCleaning the Generator Overload Protection for Engine DC Electrical SystemOUT of Service Procedure Removal From ServiceReturn To Service SYSTEM/COMPONENT Procedure Frequency Service ScheduleProblem Cause Correction Troubleshooting GuideElectrical Data Section Power Systems, Inc Generac Power Systems, Inc Electrical Data Electrical Data Electrical Data Wiring Diagram DPE RED Brush UnitsPanel Face Part of Control Panel Wire Harness Switch Rocker Dpst 125V SPDSwitch TOG Dpdt 15/10 SP Switch Selector 6A AMP/VGenerators Cover Plate Egov CONTROLLER, B-C #DPG-2103Screen Cover Plate AVRCover Conn Housing Assembly Motor StepperConnector Interface Assembly Housing Governor ConnectDIRECT-COUPLED BASE, Mounting ASSEMBLY, 4.3LAssembly Groundwire 10/3/8 Plug Button 3 DIA4640 31 33 Pulley Tensioner Switch OIL PressureDC Alternator Assembly Engine 4.3L GMExploded Views and Parts Lists Connector C/C Vent Retainer Plug WiresRetainer Spark Plug Wires Wires Spark Plug 4.3LAdd item #42 vinyl trim as shown Carrier Rear Bearing FAN Assembly 390 SAE DDAssembly Brush & Shunt Assembly Scroll 390 SAEDuct Front Panel Assembly Cover AccessDuct Bottom Shakeproof INT M6 SSVenturi 16 DIA 35KW Tank Coolant RecoveryBracket Coolant Recovery Tank Radiator 14 FIN/INCHGasket Carburetor Adaptor Plate AIR Cleanr BottomPlate AIR Cleaner TOP Gasket AIR CleanerActuator Throttle 42MM Mixer only Natural GASNPT X Hose 1 in ID LP GASHose 1IN ID LP GAS Support Solenoid NAT GASNipple TOE 3/4 NPT X Nipple Pipe 3/4NPTX4.5 BLK IRNRegulator N/G R600S LUG Rngtng INSDECAL,INLET Pressure HOSE, Preformed Block Heater Hose Connection TEEHEATER, Engine 1800W HEATER, Engine 2000WCable Battery RED #1 X Battery 12VDC 90-AH 27F OptionalHold Down Battery Cable Battery Black #1 X11 12 Transformer 200A to 5A 5VA Cover Lower Connection BOXBushing Snap SB-2.5-31 Relay Solenoid 12VDC PNL MNTExploded Views and Parts Lists Shield Heat Crossover 4.3L Tube Straight a GroupMuffler Catalyst 4.3L Mounting Band A-GRP CatalystClamp Band Muffler Muffler 2-1/2 INLET/OUTLETGuardian Liquid-cooled 40 kW Generators Installation Drawings 12V Battery see Note Lifting EYE Places This Warranty Shall not Apply to the Following Warranty Schedule