Generac 004373-1, 004626-0 owner manual General Hazards

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Important Safety Instructions

Guardian Liquid-cooled 40 kW Generator

 

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe

 

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operation be copied and posted in potential hazard areas. Safety should be stressed to all

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operators and potential operators of this equipment.

 

 

 

 

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SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be

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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.

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WARNING:

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This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The gen- erator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fun- damental rules or precautions.

Generac cannot possibly anticipate every possible circumstance that might involve a hazard. The warn- ings in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If 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.

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 equip- ment.

Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot

!during operation. Exercise care near running gen- erators.

! GENERAL HAZARDS !

• 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 hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

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.

2 Generac® Power Systems, Inc.

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Contents Power SYSTEMS, INC Introduction Authorized Dealer LocationSafety Rules General Information InstallationMaintenance Section Installation Drawings 56-57 Warranty Back CoverGeneral Hazards Electrical Hazards UNPACKING/INSPECTION GeneratorGenerator AC Connection Systems Automatic System OperationMain Circuit Breaker SpecificationsEngine Protective Devices Fuel Requirements Recommendations Generator and Load CompatibilityEngine Conversion to LP GAS VaporEmissions Control System CoolantAIR Fuel Ratio Controller Standby Generator Installation Basic Standby Electric SystemNfpa Standards Other Published StandardsTransfer Switch Start Signal Connections GTS Type SwitchPre-Packaged Type Switch Emergency Circuit Isolation MethodPreparation Before START-UP Battery InstallationVented Batteries Prior to Initial START-UP Using the AUTO/OFF/MANUAL Switch OFF Position Manual PositionAutomatic Transfer Operation Sequence of Automatic OperationWeekly Exercise Cycle Checking the Engine OIL LevelOil and Filter Change Procedure Changing the Engine AIR CleanerChanging the Engine OIL and Filter Engine Oil RecommendationsBattery Maintenance Spark PlugsMiscellaneous Maintenance Cleaning the GeneratorOverload Protection for Engine DC Electrical System DC FuseRemoval From Service OUT of Service ProcedureReturn To Service Service Schedule SYSTEM/COMPONENT Procedure FrequencyTroubleshooting Guide Problem Cause CorrectionElectrical Data Section Power Systems, Inc Generac Power Systems, Inc Electrical Data Electrical Data Electrical Data Wiring Diagram RED Brush Units DPEPanel Face Switch Rocker Dpst 125V SPD Switch TOG Dpdt 15/10 SPSwitch Selector 6A AMP/V Part of Control Panel Wire HarnessGenerators CONTROLLER, B-C #DPG-2103 ScreenCover Plate AVR Cover Plate EgovAssembly Motor Stepper Connector Interface AssemblyHousing Governor Connect Cover Conn HousingBASE, Mounting ASSEMBLY, 4.3L Assembly Groundwire 10/3/8Plug Button 3 DIA DIRECT-COUPLED4640 31 33 Switch OIL Pressure DC Alternator AssemblyEngine 4.3L GM Pulley TensionerExploded Views and Parts Lists Retainer Plug Wires Retainer Spark Plug WiresWires Spark Plug 4.3L Connector C/C VentAdd item #42 vinyl trim as shown FAN Assembly 390 SAE DD Assembly Brush & ShuntAssembly Scroll 390 SAE Carrier Rear BearingAssembly Cover Access Duct BottomShakeproof INT M6 SS Duct Front PanelTank Coolant Recovery Bracket Coolant Recovery TankRadiator 14 FIN/INCH Venturi 16 DIA 35KWPlate AIR Cleanr Bottom Plate AIR Cleaner TOPGasket AIR Cleaner Gasket Carburetor AdaptorMixer only Natural GAS NPT XHose 1 in ID LP GAS Actuator Throttle 42MMSupport Solenoid NAT GAS Nipple TOE 3/4 NPT XNipple Pipe 3/4NPTX4.5 BLK IRN Hose 1IN ID LP GASLUG Rngtng INS Regulator N/G R600SDECAL,INLET Pressure Hose Connection TEE HEATER, Engine 1800WHEATER, Engine 2000W HOSE, Preformed Block HeaterBattery 12VDC 90-AH 27F Optional Hold Down BatteryCable Battery Black #1 X Cable Battery RED #1 X11 12 Cover Lower Connection BOX Bushing Snap SB-2.5-31Relay Solenoid 12VDC PNL MNT Transformer 200A to 5A 5VAExploded Views and Parts Lists Tube Straight a Group Muffler Catalyst 4.3LMounting Band A-GRP Catalyst Shield Heat Crossover 4.3LMuffler 2-1/2 INLET/OUTLET Clamp Band MufflerGuardian Liquid-cooled 40 kW Generators Installation Drawings 12V Battery see Note Lifting EYE Places Warranty Schedule This Warranty Shall not Apply to the Following