Generac 004373-1, 004626-0 Coolant, Emissions Control System, AIR Fuel Ratio Controller

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Section 1 — General Information

Guardian Liquid-cooled 40 kW Generator

1.9ENGINE 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 SF.” 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:

Temperature

Oil Grade(Recommended)

Above 80º F (27º C)

SAE 30W or 15W-40

32º to 80º F (-1º C to 27º C)

SAE 20W-20 or 15W-40

Below 32º F (0º C)

SAE 10W or 15W-40

 

 

 

 

 

 

Any attempt to crank or start the engine before it

!has been properly serviced with the recommended oil may result in an engine failure.

1.10 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 qual- ity rust inhibitor to the recommended coolant mixture. When adding coolant, always add the recommended 50- 50 mixture.

Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result.

Ethylene glycol base antifreeze is poisonous. Do not use mouth to siphon coolant from the radiator, recov- ery 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 poison- ous to them.

Do not use any chromate base rust inhibitor with eth- ylene glycol base antifreeze, or chromium 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 ethylene glycol base antifreeze. Using any high silicate antifreeze boosters or additives also will cause overheating. Generac also

recommends that any soluble oil inhibitor NOT be used for this equipment.

1.11 EMISSIONS CONTROL SYSTEM

(Model 004626-0)

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. These 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 specif- ic requirements.

Figure 1.3 - Emissions Control System

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 0D4221.

Principle of Operation: The oxygen sensor, installed on the exhaust pipe, between the engine and the catalytic muffler (closer to the engine), continuously monitors the exhaust gas composition. A feedback signal is sent from the oxygen sensor to the air fuel ratio controller, which controls the fuel system to maintain the optimal, stoichiometric air fuel ratio. The air fuel mixture to the engine is controlled by biasing the diaphragm in the fuel regulator using vacuum (from the carburetor). This vacuum signal is directed to the fuel regulator via the control valve. The air fuel ratio controller determines the amount of vacuum signal sent to the fuel regulator. The more vacuum sent to the regulator, the more restricted the fuel flow will be, therefore the leaner the air fuel mixture.

Generac® Power Systems, Inc. 7

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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 Generator UNPACKING/INSPECTION Generator AC Connection Systems Automatic System OperationSpecifications Main Circuit BreakerEngine Protective Devices Generator and Load Compatibility Fuel Requirements RecommendationsEngine Conversion to LP GAS VaporCoolant Emissions Control SystemAIR Fuel Ratio Controller Basic Standby Electric System Standby Generator InstallationNfpa Standards Other Published StandardsGTS Type Switch Transfer Switch Start Signal ConnectionsPre-Packaged Type Switch Emergency Circuit Isolation MethodBattery Installation Preparation Before START-UPVented Batteries 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 FuseOUT 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 Switch TOG Dpdt 15/10 SP Switch Rocker Dpst 125V SPDSwitch Selector 6A AMP/V Part of Control Panel Wire HarnessGenerators Screen CONTROLLER, B-C #DPG-2103Cover Plate AVR Cover Plate EgovConnector Interface Assembly Assembly Motor StepperHousing Governor Connect Cover Conn HousingAssembly Groundwire 10/3/8 BASE, Mounting ASSEMBLY, 4.3LPlug Button 3 DIA DIRECT-COUPLED4640 31 33 DC Alternator Assembly Switch OIL PressureEngine 4.3L GM Pulley TensionerExploded Views and Parts Lists Retainer Spark Plug Wires Retainer Plug WiresWires Spark Plug 4.3L Connector C/C VentAdd item #42 vinyl trim as shown Assembly Brush & Shunt FAN Assembly 390 SAE DDAssembly Scroll 390 SAE Carrier Rear BearingDuct Bottom Assembly Cover AccessShakeproof INT M6 SS Duct Front PanelBracket Coolant Recovery Tank Tank Coolant RecoveryRadiator 14 FIN/INCH Venturi 16 DIA 35KWPlate AIR Cleaner TOP Plate AIR Cleanr BottomGasket AIR Cleaner Gasket Carburetor AdaptorNPT X Mixer only Natural GASHose 1 in ID LP GAS Actuator Throttle 42MMNipple TOE 3/4 NPT X Support Solenoid NAT GASNipple Pipe 3/4NPTX4.5 BLK IRN Hose 1IN ID LP GASRegulator N/G R600S LUG Rngtng INSDECAL,INLET Pressure HEATER, Engine 1800W Hose Connection TEEHEATER, Engine 2000W HOSE, Preformed Block HeaterHold Down Battery Battery 12VDC 90-AH 27F OptionalCable Battery Black #1 X Cable Battery RED #1 X11 12 Bushing Snap SB-2.5-31 Cover Lower Connection BOXRelay Solenoid 12VDC PNL MNT Transformer 200A to 5A 5VAExploded Views and Parts Lists Muffler Catalyst 4.3L Tube Straight a GroupMounting Band A-GRP Catalyst Shield Heat Crossover 4.3LClamp 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