Generac 004373-3 , 004626-2, 004373-3, 004626-2 owner manual

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)

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

DANGER

*This manual should remain with the unit.

Contents

Main Owners Manual Liquid-cooled, Prepackaged Standby Generators DANGER INTRODUCTION READ THIS MANUAL THOROUGHLY CONTENTS OPERATION AND MAINTENANCE HOW TO OBTAIN SERVICE Introduction ......................Inside Front Cover Section 2 Installation ..................................8 Section 3 Operation ..................................12 Section 4 Maintenance ............................14 GENERAL HAZARDS WARNING: !! WARNING: ELECTRICAL HAZARDS FIRE HAZARDS EXPLOSION HAZARDS 1.1 UNPACKING/INSPECTION 1.1.1 LIFTING THE GENERATOR 1.2 THE GENERATOR 1.3 GENERATOR AC CONNECTION SYSTEMS Figure 1.1 Single-phase Generator AC Connection System 1.6 MAIN CIRCUIT BREAKER 1.7 ENGINE PROTECTIVE DEVICES 1.7.1 LOW OIL PRESSURE SWITCH Figure 1.2 Engine Protective Devices 1.7.2 HIGH COOLANT TEMPERATURE SWITCH 1.9 FUEL REQUIREMENTS AND RECOMMENDATIONS 1.9.1 CONVERSION TO LP GAS VAPOR Section 1 General Information 1.10 ENGINE OIL RECOMMENDATIONS 1.11 COOLANT DANGER 1.12 EMISSIONS CONTROL SYSTEM Figure 1.4 - Emissions Control System 2.1 BASIC STANDBY ELECTRIC SYSTEM STANDBY GENERATOR INSTALLATION Figure 2.1 Basic Standby Electric System 2.2 EMERGENCY CIRCUIT ISOLATION METHOD 2.3 TOTAL CIRCUIT ISOLATION METHOD 2.4 GROUNDING THE GENERATOR Figure 2.2 Generator Grounding Lug (typical) 2.5 GENERATOR AC NEUTRAL CONNECTIO NS 2.7 BATTERY INSTALLATION 2.7.1 VENTED BATTERIES 2.8 PREPARATION BEFORE START-UP 2.8.1 PRIOR TO INITIAL START-UP 2.8.2 Transfer Switch Figure 2.3 - Base Frame Cap Plugs 2.8.3 Fuel System 2.8.4 Generator Set Lubrication 3.1 CONTROL CONSOLE COMPONENTS Figure 3.1 Control Console 3.1.1 AC VOLTMETER 3.1.2 AC AMMETER 3.1.3 AC FREQUENCY METER 3.3 AUTOMATIC TRANSFER OPERATION 3.4 SEQUENCE OF AUTOMATIC OPERATION 3.5 ENGINE HEATER Figure 3.2 Engine Block Heater OUTLET 3.6 WEEKLY EXERCISE CYCLE T Figure 3.3 Set Exercise Switch on Control Panel 4.1 CHECKING THE ENGINE OIL LEVEL INLE 4.2 CHANGING THE ENGINE OIL AND FILTER 4.2.1 ENGINE OIL RECOMMENDATIONS 4.2.2 OIL AND FILTER CHANGE PROCEDURE Figure 4.2 Oil Filter 4.3 CHANGING THE ENGINE AIR CLEANER 4.4 SPARK PLUGS Figure 4.4 Setting the Spark Plug Gap 4.5 BATTERY MAINTENANCE 4.5.1 BATTERY REPLACEMENT 4.6 COOLING SYSTEM 4.7 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Figure 4.4 Location of 15-amp Fuse 4.8 DC FUSE 4.9 ENGINE COOLANT 4.11 OUT OF SERVICE PROCEDURE 4.11.1 REMOVAL FROM SERVICE 4.11.2 RETUR N TO SERVICE 4.12 SERVICE SCHEDULE 5.1 TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION GeneracPower Systems, Inc. 21 IN REARVIEW Guardian Liquid-cooled 40 kW Generator Mounting Dimensions - Drawing No. 0D5335 S A B = 6 IMILAR T Page S 1 CK UE T S1 G HZ LE Wiring Diagram Pre-pack Panel (4.3L) Drawing No. 0D4992-A GeneracPower Systems, Inc. 25 AC 15C 15 Electrical Schematic Pre-pack Panel (4.3L) Drawing No. 0D4993-A AM VM L TO F2 GeneracPower Systems, Inc. 27 S SC 183 RED Wiring Diagram - Control Panel - Drawing No. 0D6974 EH P HM 183 Electrical Schematic - Control Panel - Drawing No. 0D6975 GeneracPower Systems, Inc. 29 L PC E Page Page Page Page 34 GeneracPower Systems, Inc. V Control Panel 4.3L Drawing No. 0D4995-C PANEL FA CE Hz S Page 36 GeneracPower Systems, Inc. A VDC PANEL FA CE Hz V Page 38 GeneracPower Systems, Inc. ( OF O E CONTROL PANEL ( E O 3 G Page SC R O LL DETAIL Page Page Page Page Page Page Page Page Page Page Page Page Page 4.3L Nat. Gas Fuel System Drawing No. 0E1338 Page Page Page Page Page CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS MANUFACTURERS EMISSION CONTROL SYSTEM WARRANTY COVERAGE: PURCHASERS/OWNERS WARRANTY RESPONSIBILITIES: 1-800-333-1322 EMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWING: WARRANTY SCHEDULE THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING: GENERACPOWER SYSTEMS, INC. P.O. BOX 297 WHITEWATER, WI 53190