Generac Power Systems 004373-1, 004626-0 Owner's Manual

POWER SYSTEMS, INC.

®

Owner’s Manual

Liquid-cooled, Prepackaged

Standby Generators

Models:

004373-1 (40 kW/Single-phase

w/ 200 Amp
Transfer Switch)

004626-0 (40 kW/Single-phase

w/ 200 Amp
Transfer Switch
California Emissions)

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

*This Manual Should

Remain With The Unit*

POWER SYSTEMS, INC.

®

®

Generac®Power Systems, Inc.

INTRODUCTION

Thank you for purchasing the Guardian product line
by Generac Power Systems. This model is a compact,
high performance, liquid-cooled, engine-driven gen­erator designed to automatically supply electrical
power to operate critical loads during a utility power
failure.

This unit is factory installed in an all-weather, metal
enclosure that is intended exclusively for outdoor
installation.

READ THIS MAN UAL THOROUGHLY

If you do not understand any portion of this manual,
contact Generac or the nearest Generac/Guardian
Authorized Dealer for starting, operating and servicing
procedures.

Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert you to
special instruction about a particular operation that
may be hazardous if performed incorrectly or care­lessly. Observe them carefully. Their definitions are as
follows:

After this heading, read instructions that, if not
strictly complied with, will result in personal injury
or property damage.

After this heading, read instructions that, if not
strictly complied with, may result in personal injury
or property damage.

After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.

NOTE:

After this heading, read explanatory state­ments that require special emphasis.

These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compli­ance with the special instructions while performing
the service are essential to preventing accidents.

Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:

This symbol points out important safety informa­tion that, if not followed, could endanger personal
safety and/or property.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock
hazard.

The operator is responsible for proper and safe use
of the equipment. Generac strongly recommends that
the operator read this Owner's Manual and thor­oughly understand all instructions before using this
equipment. Generac also strongly recommends
instructing other users to properly start and operate
the unit. This prepares them if they need to operate
the equipment in an emergency.

CONTENTS

This manual contains pertinent owner’s information,
including warranty, electrical diagrams, exploded
views and lists of repair parts, for Guardian models:

004373-1 & 004626-0.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by a Generac/
Guardian Authorized Dealer. Normal maintenance
service and replacement of maintenance parts are the
responsibility of the owner/operator and, as such, are
not considered defects in materials or workmanship
within the terms of the warranty. Individual operating
habits and usage contribute to the need for mainte­nance service.

Proper maintenance and care of the generator ensure a
minimum number of problems and keep operating
expenses at a minimum. See a Generac/Guardian
Authorized Dealer for service aids and accessories.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs,
simply contact a Generac/Guardian Authorized
Dealer for assistance. Service technicians are factory­trained and are capable of handling all service needs.

When contacting a Generac/Guardian Authorized
Dealer or the factory about parts and service, always
supply the complete model number and serial num­ber of the unit as given on its data decal, which is
located on the generator.

Model No. ____________ Serial No. ______________

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AUTHORIZED

DEALER LOCATION

To locate the GENERAC/GUARDIAN AUTHORIZED

DEALER nearest you, please call this number:

1-800-747-1530

DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

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Table of Contents

Guardian Liquid-cooled 40 kW Generator

Generac®Power Systems, Inc. 1

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

1.8 Fuel 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

4.7 Overload 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

2 Generac®Power Systems, Inc.

Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar
with this Owner’s Manual and with the unit. The gen­erator 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 fun­damental rules or precautions.

Generac cannot possibly anticipate every possible
circumstance that might involve a hazard. The warn­ings 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 equip­ment.

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 gen­erators.

GENERAL HA

ZARDS

• 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 gener­ator is installed, operated and serviced in accordance
with the manufacturer’s instructions and recommen­dations. Following installation, do not do anything
that might render the unit unsafe or in noncompli­ance 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, ade­quate 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 gen­erator to prevent buildup of explosive gases and to
ensure correct generator operation. Do not alter the
installation or permit even partial blockage of ventila­tion provisions, as this can seriously affect safe oper­ation of the generator.

• Keep the area around the generator clean and unclut­tered. Remove any materials that could become haz­ardous.

• When working on this equipment, remain alert at all
times. Never work on the equipment when you are
physically or mentally fatigued.

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Important Safety Instructions

Guardian Liquid-cooled 40 kW Generator

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas. Safety should be stressed to all
operators and potential operators of this equipment.

!

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be
followed during installation and maintenance of the generator and batteries.

!

!

This product contains or emits chemicals
known to the state of California to cause

cancer, birth defects or other reproductive harm.

WARNING:

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Generac®Power Systems, Inc. 3

• 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.

ELECTR

ICAL HAZARDS

• All generators covered by this manual produce dan­gerous electrical voltages and can cause fatal electri­cal shock. Utility power delivers extremely high and
dangerous voltages to the transfer switch as does the
standby generator when it is in operation. Avoid con­tact with bare wires, terminals, connections, etc.,
while the unit is running. Ensure all appropriate cov­ers, guards and barriers are in place before operating
the generator. If work must be done around an oper­ating 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 elec­trical current (ampacity) to which they will be sub­jected to.

• Before installing or servicing this (and related) equip­ment, 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 oper­ation. 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 nor­mal (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, immedi­ately 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.

F

IRE HA Z

ARDS

• 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 sev­eral 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 imme­diately. Fuel supply lines must be properly installed,
purged and leak tested according to applicable fuel­gas 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 detec­tors accordingly.

Important Safety Instructions

Guardian Liquid-cooled 40 kW Generator

4 Generac®Power Systems, Inc.

1.1 UNPACKING/INSPECTION

After unpacking, carefully inspect the contents
for damage.

• This standby generator set has been factory installed
in an all-weather, metal enclosure that is intended
exclusively for outdoor installation.

If this generator is used to power electrical load
circuits normally powered by a utility power
source, code requires to install a transfer switch.
The transfer switch must effectively isolate the
electrical system from the utility distribution sys­tem when the generator is operating (NEC 701).
Failure to isolate an electrical system by such
means will result in damage to the generator and
also may result in injury or death to utility power
workers due to backfeed of electrical energy.

If any loss or damage is noted at time of delivery, have
the person(s) making the delivery note all damage on
the freight bill or affix his or her signature under the
consignor's memo of loss or damage.

If there is loss or damage after delivery, separate the
damaged materials and contact the carrier for claim
procedures.

“Concealed damage” is understood to mean damage to
the contents of a package that is not in evidence at the
time of delivery, but is discovered later.

1.1.1 LIFTI NG THE GEN ER ATOR

When lifting or hoisting equipment is used, be
careful not to touch overhead power lines.

The generator’s weight of more than 2,000
pounds requires proper tools and equipment, and
qualified personnel to be used in all phases of
handling and unpacking.

1.2 THE GENERATOR

This liquid-cooled, Guardian generator set is designed
to supply electrical power to operate critical electrical
loads during utility power failure. Use this generator as
a source of electrical power for the operation of 120
and/or 240-volt, single-phase loads.

1.3 GENERATOR AC
CONNECTION SYSTEMS

Figure 1.1 represents a single-phase, four-wire genera­tor AC connection system. The stator assembly in this
system consists of a pair of stationary windings with
two leads brought out of each winding. Each single
winding can supply a 120-volt, 60-Hertz AC output.
When the two windings are connected in series, a 240­volt, 60-Hertz AC output results. Typically, the two “hot”
leads in the circuit are Wires 11 and 44. The neutral
leads are the junction of Wires 22 and 33.

Figure 1.1 – Single-phase

Generator AC Connection System

1.4 AUTOMATIC SYSTEM OPERATION

When this generator, along with its transfer switch, has
been installed and interconnected, a circuit board in the
generator panel continuously monitors utility power
source voltage. Should that voltage drop below a preset
value, and remain at such a low state for a preset amount
of time, the generator cranks and starts. After the gener­ator starts, the transfer switch transfers load circuits so
the generator can power them.

When utility source voltage has been restored, the
switch transfers back to the utility source voltage, and
the generator then shuts down after a brief cool-down
time.

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Section 1 — General Information

Guardian Liquid-cooled 40 kW Generator

Neutral Block

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1.5 MAIN CIRCUIT BREAKER

The generator’s main circuit breaker is included with the
unit as shipped from the factory. The breaker for each
unit is described as follows:

1.6 ENGINE PROTECTIVE DEVICES

The engine has several safety switches that cause
it to automatically shut down under the following condi­tions: low oil pressure, high coolant temperature, low
coolant level, engine overspeed and overcrank.

1.6.1 LOW OIL PR ESSURE SWITCH

This switch is normally closed (N.C.) but is held open by
engine oil pressure during engine running. Should oper­ating oil pressure drop below approximately 10 psi (68
kPa), the switch contacts close, and the engine shuts down
automatically (Figure 1.2).

Figure 1.2 – Engine Protective Devices

1.6.2 HIGH COOLANT TEMP ER ATURE SWITCH

This normally open (N.O.) thermostatic switch has a
sensing tip that is immersed in captive coolant. Should
the coolant temperature exceed approximately 121° C
(250° F), the switch contacts close, which causes the
engine to shut down automatically ( Figure 1.2).

1.6.3 LOW COOLANT LEVEL SWITCH

Should the engine coolant level drop below the level of the
high coolant temperature switch, it is possible for the
engine to overheat without automatic shut down. To pre­vent such overheating without automatic shut down, the
engine has a low coolant level sensor. If the engine coolant
drops too low, the engine automatically shuts down
(Figure 1.2).

1.6.4 OVERSPEED SHUTDOWN

The control module assembly (CMA) circuit board on
liquid-cooled units receives AC frequency (rpm) signals
directly from the stator AC power windings. Should AC
frequency exceed approximately 72 Hertz, circuit board
action will automatically shut down the engine.

1.6.5 OVERCRANK SHUTDOWN

After 90 seconds of crank-rest cycles (about seven sec­onds cranking/seven seconds at rest), this function ends
cranking if the engine fails to start in that 90-second
span.

1.6.6 DC FUSE

This fuse is located on the front panel of the control sys­tem. It protects the panel wiring and components from
damaging overload. Always remove this fuse before
commencing work on the generator. The unit will not
start or crank if the fuse is blown. Replace the fuse with
one of the same size, type, and rating. Generac uses an
AGC fuse rated at 15 amps.

1.7 SPECIFICATIONS

1.7.1 GEN ER ATOR

Models 004373-1 & 004626-0

Rated Maximum Continuous
AC Power Output (kW)* 40

Rated Voltage (volts) 120/240
Rated Maximum Continuous

Current at 240 Volts, 167
Single-phase (amps)

Number of Rotor Poles 4
Driven Speed of Rotor (rpm) 1,800
Type of Stator Four-wire
Rotor Excitation System Direct Excited

Brush-type System

Rotor and Stator Insulation Class “H”

*Rated power of generator is subject to and limited by such factors as ambient tempera­ture, altitude, engine condition and other factors. Engine power will decrease about 3.5
percent for each 1,000 feet above sea level; and also will decrease an additional 1 percent
for each 6° C (10° F) above 15.5° C (60° F) ambient. Maximum output power of the gener­ator is limited by maximum engine power.

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Section 1 — General Information

Guardian Liquid-cooled 40 kW Generator

Generac®Power Systems, Inc. 5

Model Number Circuit Breaker Rating

004373-1 200-amp breaker
004626-0 200-amp breaker

6 Generac®Power Systems, Inc.

1.7.1.1 Generator and Load Compatibility

The generator must be fully compatible with the rated
voltage, number of phases and frequency of the con­nected electrical loads. The generator, connected elec­trical devices, or both, can be damaged if voltage, num­ber of phases and frequency are not compatible.

Note:

This manual assumes that the standby generator
has been properly selected, installed and intercon­nected by a competent, qualified electrician or
installation contractor. Once the installation is
complete, do nothing that may result in noncom­patibility between the generator and connected
electrical loads.

1.7.2 ENGI N E

Make........................................................General Motors

Displacement ................................4.3 liters (262 cu. in.)

Cylinder Arrangement ................................................V-6

Valve Arrangement..................................Overhead Valves

Firing Order ..................................................1-6-5-4-3-2

Number of Main Bearings..............................................4

Compression Ratio..............................................9.4-to-1

No. of Teeth on Flywheel............................................168

Ignition System ................................................Electronic

Ignition Timing at 1,800 rpm ..............40 degrees BTDC

Rated Horsepower at 1,800 rpm..................................67

Spark Plug Gap ..............................0.045 inch (1.1 mm)

Recommended Spark Plugs ......AC 41-932 or equivalent

Oil Pressure......................................................30-50 psi

Crankcase Oil Capacity ..............4.5 U.S. quarts (4.25 L)

Recommended Engine Oil............................SAE 15W-40

Type of Cooling System ......Pressurized, closed recovery

Cooling Fan ..................................................Pusher Type

Cooling System Capacity ..............4.5 U.S. gallons (17 L)

Recommended Coolant..................Use a 50-50 mixture of

ethylene glycol and soft water.

Fuel Consumption

Natural Gas

004373-1 & 004626-0 ........................................720 cfh

LP Gas

004373-1 & 004626-0..............................288 cfh/7.9gph

1.8 FUEL REQUIREMENTS
AND RECOMM ENDATIONS

With LP gas, use only the vapor withdrawal system.

This type of system uses the vapors formed above the
liquid fuel in the storage tank.

Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at
least 2,520 Btus per cubic foot for LP gas. Ask your fuel
supplier for the Btu content of your fuel.

Fuel pressure for both natural gas and liquid propane
setups should be 11 inches to 14 inches of water column
(0.6 psi) at all load ranges.

Gaseous fuels such as natural gas and liquid
propane (LP) gas are highly explosive. Even the
slightest spark can ignite such fuels and cause an
explosion. No leakage of fuel is permitted. Natural
gas, which is lighter than air, tends to collect in
high areas; LP gas is heavier than air and tends to
settle in low areas – install leak detectors accord­ingly.

1.8.1 CONVERSION TO LP GAS VAPOR

The generator is shipped from the factory configured for
using natural gas as fuel. To convert the fuel system to LP
gas, proceed as follows (Figure 1.5).

1. Remove end cap from the pressure reducer valve.

2. Turn the tension screw counterclockwise until all ten-

sion is removed from the inner spring.

3. Install and tighten the end cap.

4. Invert the pressure reducer valve. In other words, turn

it upside down (end cap facing downward).

5. Purge and leak test the entire fuel system according to

gaseous fuel codes. NO LEAKS can appear at any point
in the system.

Figure 1.5 – Conversion to LP Gas Vapor

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Section 1 — General Information

Guardian Liquid-cooled 40 kW Generator

1.9 ENGINE 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 hav­ing the following SAE viscosity rating, based on the
ambient temperature range anticipated before the next
oil change:

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 qual­ity rust inhibitor to the recommended coolant mixture.
When adding coolant, always add the recommended 50­50 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, recov­ery 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 poison­ous to them.

Do not use any chromate base rust inhibitor with eth­ylene 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 emis­sions control system to comply with certain California
air district regulations for natural gas emergency gener­ating 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, sole­noid valve and gas regulator. These items are not sub­ject to periodic maintenance or adjustment.

This model is of a size (greater than 50 brakehorse­power) that may require a review by air permitting
authorities prior to installation and operation. Consult
the local air management district for details and specif­ic requirements.

Figure 1.3 - Emissions Control System

AIR FU EL RATIO CONTROLLER

The air fuel ratio controller is an advanced micro­processor designed to work with a three-way catalyst
and a feedback (rich bias) carburetor to provide close­loop 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.

Section 1 — General Information

Guardian Liquid-cooled 40 kW Generator

Generac®Power Systems, Inc. 7

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

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8 Generac®Power Systems, Inc.

If an open bottom is used, the engine-generator is
to be installed over non-combustible materials
and should be located such that combustible
materials are not capable of accumulating under
the generator set.

Only qualified, competent installation contractors or
electricians thoroughly familiar with applicable codes,
standards and regulations should install this standby
electric power system. The installation must comply
strictly with all codes, standards and regulations per­taining to the installation.

After the system has been installed, you must not do
anything that might render the installation in noncom­pliance with such codes, standards and regulations.

NOTE:

For more information about the installation of a stand­by system, you can order Engine- Generator Standby

Electric Power Systems Installer’s Guide and
Reference Manual (part #046622) from a Generac

Authorized Service Dealer.

NFPA STANDARDS

The following published standards booklets pertaining
to standby electric systems are available form the
National Fire Protection Association (NFPA),
Batterymarch Park, Quincy, MA 02269:

• NFPA No. 37, ST ATIONARY COMBUSTION ENGINES
AND GAS TURBINES.

• NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS
FOR HEALTH CARE FACILITIES.

• NFPA No. 220, STANDARD TYPES OF BUILDING
CONSTRUCTION

• NFPA No. 68, GUIDE FOR EXPLOSION VENTING

• NFPA No. 70, NATIONAL ELECTRICAL CODE.

• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE.

• NFPA No. 10, INSTALLATION, MAINTENANCE AND
USE OF PORTABLE FIRE EXTINGUISHERS.

OTHER PUBLISHED STANDARDS

In addition to NFPA standards, the following informa­tion pertaining to the installation and use of standby
electric systems is available:

• Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85 John
Street, New York, N.Y. 10038.

• AGRICULTURAL WIRING HANDBOOK, obtainable
from the Food and Energy Council, 909 University
Avenue, Columbia, MO, 65201.

• ASAE EP-364.2, INSTALLATION AND MAINTE­NANCE OF FARM STANDBY ELECTRIC POWER,
available from the American Society of Agricultural
Engineers, 2950 Niles Road, St. Joseph, MI 49085.

• A52.1, AMERICAN NATIONAL STANDARD FOR
CHIMNEYS, FIREPLACES AND VENTING SYS­TEMS, available from the American National
Standard Institute, 1430 Broadway, New York, N.Y.

10018.

• NEC HANDBOOK available from the National Fire
Protection Association, 1 Batterymarch Park,
PO Box 9146, Quincy, MA 02269-9959.

2.1 BASIC STANDBY ELECTRIC SYSTEM

Figure 2.1 shows a schematic diagram of a basic stand­by electric system. Both the UTILITY power supply and
the STANDBY (generator) output are connected to an
approved transfer switch. The transfer switch is
required by electrical code and serves the following
functions:

• Permits the LOAD circuits to be connected to only one
power supply at a time.

• Prevents electrical backfeed between STANDBY
power and the UTILITY power circuits.

Notice that both the STANDBY and the UTILITY power
supplies to the transfer switch are protected against
overload by a main line circuit breaker.

NOTE:

Generac recommends the use of a Generac Power
Systems “pre-packaged” type transfer switch (Part
No. 0D4406) in conjunction with this generator.

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Section 2 — Installation

Guardian Liquid-cooled 40 kW Generator

STAN DBY GENER ATOR INSTALLATION

Connecting this generator to an electrical system normally supplied by an electric utility shall be by
means of a transfer switch (such as the Generac “GTS” type transfer switch), so as to isolate the electric
system from the utility distribution system when the generator is operating. Failure to isolate the
electric system by these means will result in damage to the generator and may also result in injury
or death to utility workers due to backfeed of electrical energy.

Generac®Power Systems, Inc. 9

Figure 2.1 – Basic Standby Electric System

2.2 EMERGENCY CIRCU IT ISOLATION
METHOD

This prevents overloading the generator by keeping elec­trical loads below the wattage/amperage capacity of the
generator. If the generator is powering only critical
loads, within its wattage/amperage capacity, during util­ity power outages, consider using the emergency circuit
isolation method.

Critical electrical loads are grouped together and wired
into a separate “Emergency Distribution Panel.” Load
circuits powered by that panel are within the
wattage/amperage capacity of the generator set. When
this method is used, it is difficult to overload the gener­ator. The transfer switch must meet the following
requirements:

• It must have an ampere rating equal to or greater

than the total amperage rating of the emergency dis­tribution panel circuit.

• It must be installed between the building’s main distri-

bution panel and the emergency distribution panel.

2.3 TOTAL CIRCU IT ISOLATION METHOD

When a generator capable of powering all electrical
loads in the circuit is to be installed, use the “Total
Circuit Isolation Method.” It is possible for the genera­tor to be overloaded when this isolation method is
employed. The following apply to the transfer switch in
this type of system.

• Ampere rating of the transfer switch must be equal to

or greater than the ampere rating of the normal
incoming utility service.

• The transfer switch must be installed between the

utility service entrance and the building distribution
panel.

2.4 GROUNDI NG TH E GEN ERATOR

The National Electrical Code requires the frame and
external electrically conductive parts of this equipment
to be properly connected to an approved earth ground
and/or grounding rods. For that purpose, a GROUND
LUG (Figure 2.2) is provided on the generator mounting
base. Consult a qualified electrician for grounding
requirements in your area. Grounding procedures must
meet local regulations.

Do not connect the ground wire to any pipe that
carries a flammable or explosive substance – FIRE
or an EXPLOSION may result.

Proper grounding helps protect personnel against electri­cal shock in the event of a ground fault condition in the
generator or in connected electrical devices. In addition,
grounding helps dissipate static electricity that often
builds up in ungrounded devices.

Figure 2.2 – Generator Grounding Lug (typical)

2.5 GENERATOR AC NEUTRAL
CONNECTIONS

Generac uses an UNGROUNDED AC neutral. Grounding
is recommended only at the main service entrance.

2.6 TR ANSFER SWITCH START SIGNAL
CONNECTIONS

2.6.1 “GTS” Type Switch

Connect the two-wire start signal from the automatic
transfer switch to the automatic start connection, which is
located in the right hand corner inside the lower panel.
Match wires 178 and 183 in the transfer switch to 178
and 183 on the terminal strip in the control panel. The
conductors for the two-wire start circuit must be in their
own conduit.

2.6.2 Pre-Packaged Type Switch

Connect the six signal wires from the automatic trans­fer switch to the engine generator control, which is
located on the upper right side and inside the lower
control panel. Match wires 23, 194, N1, N2, T1 and T2
in the transfer switch to the corresponding wires on the
terminal strip in the lower panel. The conductors for
these wires must be in seperate conduit from the main
AC output wires.

Section 2 — Installation

Guardian Liquid-cooled 40 kW Generator

10 Generac®Power Systems, Inc.

2.7 BAT TERY INSTALLATION

Standby generators installed with automatic trans­fer switches will crank and start automatically
when normal (utility) source voltage is removed or
is below an acceptable preset level. To prevent
such automatic start-up and possible injury to per­sonnel, do not connect battery cables until the
normal source voltage at the transfer switch is cor­rect and the system is ready to be placed into
operation.

Storage batteries give off explosive hydrogen gas.
This gas can form an explosive mixture around
the battery for several hours after charging. The
slightest spark can ignite the gas and cause an
explosion. Such an explosion can shatter the bat­tery and cause blindness or other injury. Any area
that houses a storage battery must be properly
ventilated. Do not allow smoking, open flame,
sparks or any spark producing tools or equipment
near the battery.

Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe burns.
Do not permit fluid to contact eyes, skin, clothing,
painted surfaces, etc. Wear protective goggles,
protective clothing and gloves when handling a
battery. If fluid is spilled, flush the affected area
immediately with clear water.

Do not dispose of the battery in a fire. The
battery is capable of exploding.

Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
and eyes.

The battery represents a risk of high short circuit
current. When working on the battery, always
remove watches, rings or other metal objects, and
only use tools that have insulated handles.

2.7.1 VENTED BATTERIES

The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically con­ductive and corrosive. The following procedures
are to be observed:

• Wear full eye protection and protective clothing,

• Where electrolyte contacts the skin, wash it off
immediately with water,

• Where electrolyte contacts the eyes, flush thoroughly
and immediately with water and seek medical atten­tion, and

• Spilled electrolyte is to be washed down with an acid­neutralizing agent. A common practice is to use a
solution of one pound (500 grams) bicarbonate of
soda to one gallon (4 liters) of water. The bicarbonate
of soda solution is to be added until the evidence of
reaction (foaming) has ceased. The resulting liquid is
to be flushed with water and the area dried.

Lead acid batteries present a risk of fire because
they generate hydrogen gas. The following proce­dures are to be followed:

• DO NOT SMOKE when near batteries,

• DO NOT cause flame or spark in battery area, and

• Discharge static electricity from body before touching
batteries by first touching a grounded metal surface.

Servicing of batteries is to be performed or supervised
by personnel knowledgeable of batteries and the
required precautions. Keep unauthorized personnel
away from batteries.

For recommended batteries, see “Battery Maintenance”
page 16. All batteries must be at 100 percent state- of­charge before they are installed on the generator.

When using maintenance-free batteries, it is not neces­sary to check the specific gravity or electrolyte level.
Have these procedures performed at the intervals spec­ified in Section 4, “Maintenance.” A negative ground sys­tem is used. Battery connections are shown on the
wiring diagrams. Make sure all batteries are correctly
connected and terminals are tight. Observe battery
polarity when connecting batteries to the generator set.

Note:

Damage will result if the battery connections are
reversed.

2.8 PREPARATION BEFORE START-UP

The instructions in this section assume that the standby
generator has been properly installed, serviced, tested,
adjusted and otherwise prepared for use by a competent,
qualified installation contractor. Be sure to read the
“Safety Rules” on Pages 2 and 3, as well as all other safe­ty information in this manual, before attempting to oper­ate this (and related) equipment.

Section 2 — Installation

Guardian Liquid-cooled 40 kW Generator

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2.8.1 PRIOR TO INITIAL START-UP

Prior to initially starting the generator, it must be
properly prepared for use. Any attempt to crank
or start the engine before it has been properly
serviced with the recommended types and quanti­ties of engine fluids (oil, coolant, fuel, etc.) may
result in an engine failure.

Before starting the generator for the first time, the
installer must complete the following procedures. For
follow-up maintenance information and/or service inter­vals, please refer to Section 4, “Maintenance.”

2.8.2 Transfer Switch

If this generator is used to supply power to any electri­cal system normally powered by an electric utility, the
National Electrical Code requires that a transfer switch
be installed. The transfer switch prevents electrical
backfeed between two different electrical systems. (For
additional information, see the applicable transfer
switch manual for this unit.) The transfer switch, as
well as the generator and other standby components,
must be properly located and mounted in strict compli­ance with applicable codes, standards and regulations.

2.8.3 Fuel System

Make sure the fuel supply system to the generator (a)
delivers the correct fuel at the correct pressure and (b)
is properly purged and leak tested according
to code. No fuel leakage is permitted. See
“Specifications” (Page 6) for more information.

2.8.4 Generator Set Lubrication

Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level below
the dipstick “ADD” mark. See “Specifications” (Page 5)
and “Engine Oil Recommendations” (Page 7).

NOTE:

This engine is shipped from the manufacturer with
SAE 15W-40 oil. This oil should be changed after
30 hours of operation.

2.8.5 Engine Coolant

Have the engine cooling system properly filled with the
recommended coolant mixture. Check the system for
leaks and other problems. See “Specifications” (Page 5)
and “Coolant” (Page 7).

2.8.6 Belt Tension

Check the engine fan belt tension and condition prior to
placing the unit into service and at recommended
intervals. Belt tension is correct when a force of approx­imately 22 pounds (10 kg), applied midway between
pulleys, deflects the belt about 3/8- to 5/8-inch (10 to 16
mm).

2.8.7 Electrical System

Make sure the generator is properly connected to an
approved earth ground and/or ground rod.

Make sure the generator battery is fully charged, proper­ly installed and interconnected, and ready for use.

Check to ensure that there are no loose electrical con­nections. Restrain any loose wires to keep them clear of
any moving generator set components.

2.8.8 Rodent Protection

Make sure the four 3-inch diameter cap plugs (part #
0A8785) are properly installed in the tie- down holes in
the side rails of the unit’s base frame (Figure 2.3). The
cap plugs are shipped in a plastic bag located in the
lower connection box. These plugs are needed to pre­vent rodents from accessing the interior of the genera­tor set. On acoustic units, cap plugs also are needed to
stay within noise specification limits.

Figure 2.3 - Base Frame Cap Plugs

Section 2 — Installation

Guardian Liquid-cooled 40 kW Generator

Generac®Power Systems, Inc. 11

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12 Generac®Power Systems, Inc.

3.1 CONTROL CONSOLE COMPONENTS

The components of a liquid-cooled generator control
console (Figure 3.1) are as follows:

Figure 3.1 – Control Console

3.1.1 AC VOLTM ETER

The voltmeter displays generator AC output voltage dur­ing operation. Voltage is regulated by a solid-state volt­age regulator and is proportional to AC frequency. Refer
to the unit’s DATA PLATE for rated AC voltage.

3.1.2 AC AMMETER

This indicates current draw of connected electrical
loads during operation. DO NOT EXCEED THE UNIT’S
RATED MAXIMUM CONTINUOUS CURRENT. Refer to
the unit DATA PLATE.

3.1.3 AC FREQUENCY METER

This indicates generator AC output frequency in Hertz
(cycles per second). F requency is proportional to engine
speed. Units with a four-pole rotor, supply 60 Hertz at
1,800 rpm. The frequency reading with no electrical
loads connected (no-load condition) should be between
60-62 Hertz.

3.1.4 DC VOLTMETER

The generator is equipped with a belt-driven DC alter­nator, which maintains battery state of charge when the
engine operates. The control module assembly (CMA)
also incorporates a trickle charge circuit that maintains
battery state of charge during nonoperating periods.
Battery voltage should read approximately12.5 to 14.5
volts DC. A low battery voltage indicates the battery is
discharging.

3.1.5 HOURMETER

This indicates the time the engine-generator has operat­ed, in hours and tenths of hours. Use the hourmeter
along with the periodic maintenance schedule for your
generator set.

3.1.6 AUTO/OFF/MANUAL SWITCH

See Section 3.2.

3.1.7 FAULT INDICATOR LAMP

This lamp goes ON when one or more of the following
engine faults occurs and when engine shuts down.

• Low oil pressure • High coolant temperature

• Low coolant level • Overcrank

• Overspeed

3.1.8 15-AMP FUSE

This fuse protects the control console’s DC control cir­cuit against electrical overload. If the fuse has melted
open because of an overload, engine cranking and start­up cannot occur. Replace the fuse with an identical AGC
15-amp replacement fuse.

3.1.9 7.5 AM P I N LIN E F USE (NOT SHOWN)

This inline fuse is connected in the 15A line that runs
between the Auto/Off/Manual switch and position 10 of
the 76009A PCB. This fuse protects the start, fuel, field
boost, and transfer outputs from the PCB and will open
if there is excessive current draw on any one of these
outputs.

3.1.10 VOLTAGE-PHASE SELECTOR SWITCH

This switch permits selection between either line-to-line
or line-to -neutral voltage and amperage readings on the
console AC voltmeter and AC ammeter.

3.1.11 SET EXERCISE TIME SWITCH

This switch allows to program the generator to start and
exercise automatically. (See Section 3.6, page 14)

3.2 USING THE AUTO/OFF/MANUAL

SWITCH

3.2.1 “AUTO” POSITION

Selecting this switch position activates fully automatic
system operation. It also allows the unit to start and
exercise the engine every seven days with the setting of
the exercise timer.

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Section 3 — Operation

Guardian Liquid-cooled 40 kW Generator

15

3.2.2 “OFF” POSITION

This switch position shuts down the engine. This posi­tion also prevents operation.

3.2.3 “MANUAL” POSITION

Set the switch to Manual to crank and start the engine.
Transfer to standby power will not automatically occur
unless there is a utility failure.

With the switch set to AUTO, the engine may
crank and start at any time without warning.
Such automatic starting normally occurs when
utility power source voltage drops below a preset
level or during the normal exercise cycle. To pre­vent possible injury that might be caused by such
sudden starts, always set the switch to OFF and
remove the fuse before working on or around the
generator or transfer switch. Then, place a “Do
Not Operate” tag on the generator panel and on
the transfer switch.

3.3 AUTOMATIC TRANSFER OP ER ATION

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts are set
to their “Utility” position, i.e., loads connected to the
utility power source.

2. Be sure that normal utility power source voltage is
available to transfer switch terminal lugs N1 and N2.

3. Set the generator’s Auto/Off/Manual switch to A UTO.

4. Set the generator’s main circuit breaker to its ON
(or closed) position.

With the preceding steps complete, the generator will
start automatically when utility source voltage drops
below a preset level. After the unit starts, loads are
transferred to the standby power source. Refer to
“Sequence of Automatic Operation.”

3.4 SEQUENCE OF AUTOMATIC OPERATION

The generator’s control panel houses a control logic cir­cuit board. This board constantly monitors utility
power source voltage. Should that voltage drop below a
preset level, circuit board action will signal the engine to
crank and start. After the engine starts, the circuit
board signals the transfer switch to activate and connect
load circuits to the standby power supply (load terminal
lugs T1/T2 connect to terminal lugs E1/E2).

Upon restoration of utility source voltage above a preset
level, generator circuit board action signals the transfer
switch to transfer loads back to that power supply. After
retransfer, the engine is signalled to shut down.

The actual sequence of operation is controlled by
sensors and timers on a control logic circuit board, as
follows:

A.Utility Voltage Dropout Sensor

• This sensor monitors utility source voltage.

• If utility source voltage drops below about 60 per­cent of the nominal supply voltage, the sensor ener­gizes a 15-second timer.

• Once the timer has expired, the engine will crank
and start.

B. Engine Warm-up Time Delay

• This mechanism lets the engine warm up for about
10 seconds before the load is transferred to a stand­by source.

C. Standby Voltage Sensor

• This sensor monitors generator AC output voltage.
When the voltage has reached 50 percent of the
nominal rated voltage, transfer to standby can
occur.

D.Utility Voltage Pickup Sensor

• This sensor monitors utility power supply voltage.
When that voltage is restored above 80 percent of
the nominal source voltage, a retransfer time delay
starts timing.

E. Retransfer Time Delay

• This timer runs for about 15 seconds.

• At end of a 15-second delay , circuit board action de­energizes transfer relay in the transfer switch.

• Retransfer to utility power source then occurs.

F. Engine Cool-down Timer

• When the load is transferred back to utility power
source, the engine cool-down timer starts timing.

• The timer will run for about one minute, and the
generator will then shut down.

3.5 ENGINE H EATER

This Generac standby generator comes equipped with a
block heater (Figure 3.2, page 14) that is similar to the
block heaters used in automotive applications.

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Generac®Power Systems, Inc. 13

Section 3 — Operation

Guardian Liquid-cooled 40 kW Generator

Figure 3.2 – Engine Block Heater

Refer to applicable wiring diagram(s) and electrical
schematic(s) at the back of this manual for wiring con­nections.

3.6 WEEKLY EXERCISE CYCLE

The generator will start and exercise once every seven
days. During this weekly exercise, the unit runs for
approximately 20 minutes and shuts down. Transfer of
loads to generator output does not occur during the
exercise unless power is lost during the exercise period.

To select the day of the week and time of day for exer­cising, proceed as follows:

• Set the Auto/Off/Manual switch to OFF.

• Set generator’s main circuit breaker to its OFF (or
open) position.

• Locate the rocker switch on the control panel identi­fied with the words “Set Exercise Time” (Figure 3.3).

• Push “Set Exercise Time” switch to the ON position
for 20 to 30 seconds and then release. The switch will
spring back into its original position when released.

• Wait 30 seconds before setting the Auto/Off/
Manual switch to the AUTO position.

NOTE:

The unit will exercise 20 minutes before it is set.
Example: Set – Noon; Exercise – 11:40 a.m.

If you switch the Auto/Off/Manual switch is
switched too soon, the engine may start. If
engine does start, it will shut down automatically
in about two (2) minutes.

• Set the generator’s main circuit breaker to its ON (or
closed) position.

• The generator is now programmed to start and exer­cise every seven days thereafter, on the day and at the
time of day the switch was activated.

• Place a sign on the generator’s control panel and on

the transfer switch that indicates the day and time
the generator will be exercising.

NOTE:

If the battery terminals are disconnected or the
control panel fuse is removed, the exercise timer
needs to be reset for automatic exercise operation.

Figure 3.3 – “Set Exercise” Switch on Control Panel

4.1 CHECKING THE ENGI N E OIL LEVEL

For oil capacities, see “Specifications,” Section 1.7.2,
Page 6. For engine oil recommendations, see Section

4.2.1. To check the engine oil level, proceed as follows
(Figure 4.1):

1. Remove the dipstick and wipe it dry with a
clean cloth.

2. Install the dipstick cap; then, remove it again. The
oil level should be at the dipstick “F ull” mark. If nec­essary, add oil to the “Full” mark only. DO NOT FILL
ABOVE THE “FULL” MARK.

3. Install the dipstick.

Never operate the engine with the oil level below
the “Add” mark on the dipstick. Doing this could
damage the engine.

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Section 4 — Maintenance

Guardian Liquid-cooled 40 kW Generator

14 Generac®Power Systems, Inc.

OUTLET

INLE

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Figure 4.1 – Oil Dipstick and Fill

4.2 CHANGING THE ENGI NE OIL AN D F ILTER

4.2.1 Engine Oil Recommendations

Use oil of API Service Class SG, SH or SJ. The
recommended oil grade for the engine is
SAE 15W-40.

NOTE:

The unit is supplied with “break-in” oil. See the
“Service Schedule,” Section 4.12 (Page 19), for
the first required oil change.

Any attempt to crank or start the engine before
it has been properly serviced with the recom­mended oil may result in an engine failure.

4.2.2 Oil and Filter Change Procedure

To change the oil and filter, proceed as follows:
Refer to the “Service Schedule,” (Section 4.12, Page 19)

for engine oil and filter change frequencies.
Drain the oil while the engine is still warm from run-

ning. This means, warm up the engine, shut it down
and drain it immediately as follows:

1. Remove the oil drain hose from its retaining clip,
located on the generator base frame.

2. Loosen and remove the oil drain hose cap, located
on the base frame end of the hose. Drain the oil
completely into a suitable container.

3. When all of the oil has drained, install and tighten
the oil drain hose cap.

4. Turn the oil filter (Generac part number
0A37970001, Figure 4.2) counterclockwise and
remove it. Properly dispose of the old filter.

Figure 4.2 – Oil Filter

5. Apply a light coating of engine oil to the seal of
new oil filter. Install the filter and tighten by hand
only. DO NOT OVERTIGHTEN.

6. Remove the oil fill cap (Figure 4.1). Add the recom­mended oil (see Section 4.2.1). DO NOT FILL
ABOVE THE DIPSTICK “FULL” MARK. Crankcase
oil capacity is 4.5 U.S. quarts (4.25 L).

After refilling the crankcase with oil, always
check the oil level on the dipstick. Never
operate the engine with the oil level below the
“Add” mark on the dipstick. Doing this could
damage the engine.

7. Start the engine and check for oil leaks.

8. Check the oil level after checking for leaks to
ensure that the oil is filled to the proper level.

4.3 CHANGING THE ENGI NE AIR CLEAN ER

To replace the engine air cleaner, (Generac part num­ber 0A4637, simply remove the air cleaner cover and
replace the air filter making sure it is positioned
properly before reattaching the cover. (See Figure

4.3, page 16)

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Section 4 — Maintenance

Guardian Liquid-cooled 40 kW Generator

Generac®Power Systems, Inc. 15

OIL FILL CAP

OIL DIPSTICK

OIL FILTER

OIL DRAIN HOSE

TO BASE

16 Generac®Power Systems, Inc.

Figure 4.3 – Engine Air Cleaner

See the “Service Schedule,” Section 4.12, Page 19, for rec­ommended air cleaner m aintenance.

4.4 SPARK PLUGS

Reset the spark plug gap or replace the spark plugs as
necessary. See Section 4.12, Page 19.

1. Clean the area around the base of the spark plugs to
keep dirt and debris out of the engine. Clean the
plugs by scraping using a wire brush. Do not “blast”
the spark plugs to clean.

2. Remove the spark plugs and check the condition.
Replace the spark plugs if worn or if reuse is ques­tionable. See the “Service Schedule,” Section 4.12,
Page 19, for recommended inspection.

3. Check the spark plug gap using a feeler gauge.
Adjust the gap to 0.045 inch (1.1 mm) by carefully
bending the ground electrode (Figure 4.4).

Figure 4.4 – Setting the Spark Plug Gap

4.5 BATTERY MAINTENANCE

The battery should be inspected per the “Service
Schedule,” Section 4.12, Page 19. The following proce­dure should be followed for inspection:

1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with DISTILLED WATER
ONLY. DO NOT USE TAP WATER IN BATTERIES.

3. Have the state of charge and condition checked.
This should be done with an automotive-type bat­tery hydrometer or load test.

Standby generators installed with automatic
transfer switches will crank and start automatical­ly when normal (utility) source voltage is removed
or is below an acceptable preset level. To prevent
such automatic start-up and possible injury to per­sonnel, do not connect battery cables until the
normal source voltage at the transfer switch is
correct and the system is ready to be placed into
operation.

Storage batteries give off explosive hydrogen gas.
This gas can form an explosive mixture around
the battery for several hours after charging. The
slightest spark can ignite the gas and cause an
explosion. Such an explosion can shatter the bat­tery and cause blindness or other injury. Any area
that houses a storage battery must be properly
ventilated. Do not allow smoking, open flame,
sparks or any spark producing tools or equipment
near the battery.

Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe burns.
Do not permit fluid to contact eyes, skin, clothing,
painted surfaces, etc. Wear protective goggles,
protective clothing and gloves when handling a
battery. If fluid is spilled, flush the affected area
immediately with clear water.

Do not dispose of the battery in a fire. The bat­tery is capable of exploding.

Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
and eyes.

The battery represents a risk of high short circuit
current. When working on the battery, always
remove watches, rings or other metal objects, and
only use tools that have insulated handles.

Battery replacement

Generac uses a Group 27F vented type battery that has
600 CCA @ 0º F. Generac’s part number is 058665.

Note:

The BCI number should be located directly on the
battery.

▼

Section 4 — Maintenance

Guardian Liquid-cooled 40 kW Generator

Air Cleaner

!

!

!

Generac®Power Systems, Inc. 17

4.6 COOLING SYSTEM

Air intake and outlet openings in the generator compart­ment must be open and unobstructed for continued prop­er operation. This includes such obstructions as high
grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it to
shut down.

The exhaust system of this product gets extremely
hot and remains hot after shutdown. High grass,
weeds, brush, leaves, etc. must remain clear of the
exhaust. Such materials may ignite and burn from
the heat of the exhaust system.

4.7 OVERLOAD PROTECTION FOR ENGINE DC
ELECTRICAL SYSTEM

Engine cranking, start-up and running are controlled by
a solid-state engine controller circuit board. Battery
voltage is delivered to that circuit board via a 15-amp
fuse. These overcurrent protection devices will open if
the circuit is overloaded.

If a circuit breaker opens or a fuse element melts,
you should find the cause of the overload before
resetting the circuit breaker or replacing the fuse.

4.8 DC FUSE

The generator panel’s 15-amp AGC fuse (Figure 4.4) pro­tects the DC control circuit against overload. The fuse is
wired in series with the battery output lead to the panel.
If the fuse element has melted open, cranking or starting
the engine cannot occur. Replace the fuse using only an
identical 15-amp AGC replacement.

Figure 4.4 – Location of 15-amp Fuse

4.9 ENGINE COOLANT

Check the coolant level in the coolant recovery bottle.

• Add the recommended coolant mixture as
necessary. See Section 1.10 on Page 7.

• Periodically remove the radiator pressure cap to make
sure the coolant recovery system is functioning
properly. Coolant should be at the bottom of the radia­tor filler neck. If the coolant level is low, inspect the
gasket in the radiator pressure cap. Replace the cap, if
necessary. To have the pressure cap tested, contact a
Generac/Guardian Authorized Dealer. Inspect the cool­ing system and coolant recovery system for leaks.

4.10 MISCELLANEOUS MAINTENANCE

4.10.1 Cleaning the Generator

Keep the generator as clean and as dry as possible. Dirt
and moisture that accumulate on internal generator
windings have an adverse effect on insulation resist­ance.

Periodically, clean the generator’s exterior surfaces. A
soft brush may be used to loosen caked on dirt. Use a
vacuum system or dry, low pressure air to remove any
accumulations of dirt. The generator is housed inside
an all-weather enclosure; clean the enclosure with a
soft, damp cloth or sponge and water.

Once each year, have the generator cleaned and inspect­ed by a Generac/Guardian Authorized Dealer. Service
technicians will use dry, low pressure air to clean inter­nal windings. Parts inside the control console should be
cleaned and inspected at this time as well.

Finally, have the insulation resistance of stator and rotor
windings checked. If insulation resistances are excessive­ly low, the generator may require drying.



Section 4 — Maintenance

Guardian Liquid-cooled 40 kW Generator

15

18 Generac®Power Systems, Inc.

4.10.2 Rodent Protection

The intrusion of rodents into the generator set can
cause a wide range of problems, from failure of the unit
to start, to personal injury and, in extreme circum­stances, short circuit or fire. Although the unit was
designed to limit this problem, further precautions can
be taken by the owner to help minimize both the chance
of rodent entry and the extent of any damage. The fol­lowing inspection should be performed.

1. The base frame of the unit contains an optional fuel
inlet location and four lifting holes that are capped at
the factory. These caps are sometimes removed for
transportation during installation but always should
be replaced afterwards. Check that they are secured in
place. The same applies for any access ports in the
roof of the enclosure. If any of these caps are missing,
contact a Generac/Guardian Authorized Dealer.

2. Inside the generator set, the chance of rodent entry
into the control panel is greatly reduced by the inclu­sion of adjustable wire connectors. Check that the
wire connector screws are tight, thus closing off any
gap between the access holes and the wires.

4.11 OUT OF SERVICE PROCEDURE

4.11.1 Removal From Service

If the generator cannot exercise every seven days, and it
is to be out of service longer than 90 days, prepare the
generator for storage as follows:

1. Start the engine and let it warm up.

2. Close the fuel shutoff valve in the fuel supply line
and allow the unit to shut down.

3. Once the unit has shut down, it will signal a fault on
the control panel.

4. Set the Auto/Off/Manual switch to OFF and turn off
the utility power to the transfer switch.

5. While the engine is still warm from running, drain
the oil completely. Refill the crankcase with SAE
15W-40 oil having API Service Class SG, SH or SJ.

6. Attach a tag to the engine indicating the viscosity
and classification of the oil in the crankcase.

7. Remove the spark plug(s) and spray fogging agent
into the spark plug(s) threaded openings. Reinstall
and tighten the spark plug(s).

8. Remove the battery and store it in a cool, dry room
on a wooden board. Never store the battery on any
concrete or earthen floor.

9. Clean and wipe the entire generator.

4.11.2 Return To Service

To return the unit to service after storage, proceed
as follows:

1. Verify that utility power is turned off to the transfer
switch and that the Auto/Off/Manual switch is set to
OFF.

2. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recommended
oil is used in engine. See Section 4.2.1 (Page 14). If
necessary, drain and refill with the proper oil.

3. Check the battery. Fill all cells to the proper level
with distilled water. DO NOT USE TAP WATER IN
THE BATTERY. Remove the battery before charging.
Recharge the battery to 100 percent state of charge,
or, if defective, replace the battery with a 12-volt DC
Group 27F battery rated for 90 amp hours (part #

058665).

4. Clean and wipe the entire generator.

5. Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected incor­rectly.

6. Open the fuel shutoff valve.

7. Start the unit by moving the Auto/Off/Manual switch
to MANUAL. Allow the unit to warm up thoroughly.

8. Stop the unit and set the Auto/Off/Manual switch to
AUTO.

9. Turn on the utility power to the transfer switch.

10. The generator is now ready for service.







Section 4 — Maintenance

Guardian Liquid-cooled 40 kW Generator

Generac®Power Systems, Inc. 19

Section 4 — Maintenance

Guardian Liquid-cooled 40 kW Generator

4.12 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work

be performed by your nearest Generac/Guardian Authorized Dealer.

SYSTEM/COMPONENT PROCEDURE FREQUENCY

X = Action Inspect Change Clean W = Weekly
R = Replace/Adjust as Needed M = Monthly
* = Notify Dealer Y = Yearly

if Repair is Needed. H = Hours

FUEL

Fuel lines and connections* X EVERY 3 M

LUBRICATION

Oil level X M
Oil X FIRST 9 H,

EVERY 150 H / 6 M

Oil filter X FIRST 9 H,

EVERY 150 H / 6 M

Oil line leakage* X 100 H

COOLING

Engine cooling system* X M
Coolant X Y
Enclosure louvers X X W

EXHAUST

Exhaust system X EVERY 3 M
Retorque Exhaust Manifold* X FIRST 100 H AND

EVERY 800 H

BATTERY

Charge and condition X R X EVERY 3 M

FAN BELT

Tension and condition* X R EVERY 3 M

ENGINE

Retorque cylinder head* X FIRST 100 H AND

EVERY 800 H

Retorque intake manifold* X FIRST 100 H AND

EVERY 800 H
Starter motor* X R EVERY 500 H
DC alternator* X R EVERY 500 H AND Y
Air cleaner* X R EVERY 500 H
Compression* X EVERY 800 H
Valve clearance* X R EVERY 800 H
Governor* X R Y
Safety devices* X R EVERY 6 M
Spark plugs X R 500 H AND Y
Ignition system* X R EVERY 3 M

GENERAL

Overall condition X X M
Exercise system W

COMPLETE TUNE-UP* TO BE COMPLETED BY A GENERAC/ Y

GUARDIAN AUTHORIZED DEALER

20 Generac®Power Systems, Inc.

Section 5 — Troubleshooting

Guardian Liquid-cooled 40 kW Generator

5.1 TROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

The engine will not crank. 1. Fuse blown 1. Replace fuse.

2. Loose, corroded or defective 2. Tighten, clean or replace
battery cables as necessary.

3. Defective starter contactor 3. *

4. Defective starter motor 4. *

5. Dead Battery 5. Charge or replace battery.

The engine cranks but 1. Out of fuel 1. Replenish fuel.
will not start. 2. Defective fuel solenoid (FS) 2. *

3. Open #14 wire from 3. *
engine control board

4. Defective spark plug(s) 4. Clean, re -gap or replace plug(s).

5. Dirty/Blocked air filter 5. Clean or replace as required.

The engine starts hard 1. Air cleaner 1. Check, clean or replace air cleaner.
and runs rough. plugged or damaged

2. Defective spark plug(s) 2. Clean, re -gap or replace plug(s).

3. Dirty/Blocked air filter 3. Clean or replace as required.

The engine starts, but then 1. Engine oil level low 1. Check oil and add oil as needed.
shuts down. 2. Defective low oil 2. *

pressure switch

3. Defective high temperature 3. *
switch

4. Defective control board 4. *

5. Low coolant level 5. Check coolant level, repair leaks

and refill.

The Auto/Off/Manual switch 1. Defective switch 1. *
is set to OFF, but the engine 2. Defective control board 2. *

continues to run.

There is no AC output from 1. Generator main line circuit 1. Reset circuit breaker
the generator. breaker open to ON (or closed).

2. Generator internal failure 2. *

There is no transfer to 1. Generator main line circuit 1. Reset circuit breaker
standby after utility breaker open to ON (or closed).

source failure. 2. Defective transfer switch coil 2. *

3. Defective transfer relay 3. *

4. Transfer relay circuit open 4. *

5. Defective control logic board 5. *

*Contact your nearest Generac/Guardian Authorized Dealer for assistance.

Generac®Power Systems, Inc. 21

INSULATE UNUSED WIRE END

USE YELLOW WIRE FOR 208V, 3 PHASE

USE BLUE WIRE FOR 240V, 1 PHASE

Section 6 — Electrical Data

(Model No. 004373-1) Guardian Liquid-cooled 40 kW Generator

Electrical Schematic (Control Panel) – Drawing No. 0D4993-A

A

CAP

LEGEND

CAP - CAPACITOR

CB1 - CIRCUIT BREAKER - EXCITATION

D1 - DIODE- 600V, 12A

F1 - FUSE 15 AMPS

BVM - METER, BATTERY VOLTAGE

AM - METER, AC OUTPUT CURRENT

INSULATE UNUSED WIRE END

USE YELLOW WIRE FOR 208V, 3 PHASE

14

USE BLUE WIRE FOR 240V, 1 PHASE

AVR - AUTOMATIC VOLTAGE REGULATOR

F2 - FUSE 7.5 AMPS IN-LINE

178

F1

BLUE

176

176

E

194

194

4

PCB

183

14

0

YELLOW

23

BLUE

RED

T2

T1

RED

BLACK

RED

BLACK

225A

BLUE

BLUE

GCU

TR1

ORANGE
YELLOW
BROWN
BLACK

T2

BLACK

TS2

BLACK

T1

N2

N1

23

ACTUATOR

TO GOVERNOR

23

CONNECTOR

1 2 3 OFF

CONTACTS

2

CONTROLLER

X

O

OOO

OXX

O

O

X

X

O

X

X

O

X

O

X

O

X

O

O

O

X

X

OOX

O

XO

O

O

O

O

X

X

X

X

2 - 3

2 - 7

2 - 11

X INDICATES CLOSED

12 - 3

12 - 7

12 - 11

15 - 14

15 - 18

19 - 16

19 - 14

+

-

0

AM

67

1211

BLUE

BLUE

T2 RED

S16 S15 T1

0

HZ

S15

65

PSW

PHASE SELECTOR SWITCH

POSITION

VM

64

19

15

3

15

14

16

17

A

B

13

0

0

BVM

-

HM

+

+

15C

15

-

OFF POSITION

15A

N.C.

SW2

15C

14

14

SHOWN IN

15C

15A

15

225A

13

176

L1

15

15

15C

15A

F2

0

183

14

13

SW1

239

15A

178

14

15C

10

12

9

178

11

239

D

229

7
5

560

2

85

13
1

4

PSW - SWITCH, PHASE SELECTOR

TR1 - TRANSFORMER, UTILITY SENSING 24VA

SW2 - SWITCH, SET EXERCISE

SW1 - SWITCH, AUTO/OFF/MANUAL

R1 - RESISTOR, FIELD BOOST

TS1,TS2 - TERMINAL STRIP

PCB - CIRCUIT BOARD CONTROLLER

L1 - LIGHT, FAULT INDICATOR

HZ - METER, FREQUENCY

HM - HOURMETER

GCU - GOVERNOR CONTROLLER UNIT

VM - METER, AC OUTPUT VOLTAGE

178

183

194

T1

N1

T2

23

N2

0

183

194

0

229

13

14

4

56

85

0

AVR

3

2

5

6

1

4

4

6

S15

S16

162

1

S15

S16

S16

14

16

3

18

7

TS1

15 15 15

229

13

14

14

56

85

85

14

0

1

11

4

D

5

10123

6

TO ENGINE (CONNECTOR EH)

S3

00

S15

S1

S16

4

6

D1

R1

4

2 162

57

58

0

T1

N1

T2

23

N2

194

183

178 178

29

C

F

E

G

Q

H

K

N

M

O

A

V

U

TSW

X

J

B

TO LOWER PANEL (CONNECTOR CP)

22 Generac®Power Systems, Inc.

Section 6 — Electrical Data

(Model No. 004373-1) Guardian Liquid-cooled 40 kW Generator
Wiring Diagram (Control Panel) – Drawing No. 0D4992-A

BLUE

BLUE

1

44

2

1

4

E

D

V

C

183

B

W

J

0

A

X

K

X

L

194

W

V

23

T2

T1

23

0

T1

T2

194

183

1

4
1

85

85

56

14

14

13

56

13

85

85

BLUE

BLUE

0

14

14

56

14

85

85

GCU

BLACK

BROWN

YELLOW

ORANGE

ACTUATOR

TO GOVERNOR

2

6

S16

S15

178

H

G

F

U

G

H

A

B

C

M

U

T

N2

S1

J

T

K

S

L

R

F

M

E

PIN

Q

N

D

P

O

O

P

N

Q

S

R

00

N1

CP

6

S15

2

S1

00

S3

57

58

S1

2

S16

00

S3

57

N1

N2

T2

23

58

178

T1

N1

N2

T2

194

23

183

219
218

4

150
86
85
69
68
56
229
4
15

1

15A
15A
14
14
13
79
0

RED

0
0

0

14

13

14

85

85

23

TS1

13

GRD

CAP

14

0

14

14

13

BLACK

56

15

N1

N2

N2

0

BLACK

RED

85

2

58

T1

0

T1

T2

178

85

15

56

229

4

4

14
14
14

1

0

00

13

F1

15

4

162

1

2

N1

AVR

56

0

85

14

14

13

00

S16

BLUE

S16

HZ

S15

BLUE

AM

S16

6

S15

0

S15

0

0

67

64

VM

S16

S15

65

64

14

HM

4

14

2

CB1

85

85

6

5

6

5

DEUTSCH

7

8

-

85

14

0

4

3

3

421

10911

10

0

67

+

-

00

BVM

0

0

64

65

12

19
15

16

PSW

73

57

57

14 18

2

11

58

S1

194

183

15

15C

0

15C

65

67

00

S3

S1

0

S3

178

15C

0

15C

OFF

START/MANUAL

15A

239

SW1

183

T1

T2

229

15C

AUTO

178

178

15C

23

194

4

56

229

4

0

14

0

14

14

4

D1

162

R1

4

29

4

BLACK

BLACK

TS2

N1

N2

56

EH

12

11

12

14

14

13

A

14

+

S15

S3

S16

2

6

4

0

0

S15

0

S16

162

S16

S15

6

53641

N1

N2

65

14

15C

15

N.C.

SW2

F2

14

BLUE

225A

15

15A

4

85
23

194

56

14

178
15A
239

BLUE

RED

0

BLACK

15C

RED

225A

T2

T1

BLACK

T1 T1

T2 T2

LEGEND

CP - CONNECTION, LOWER PANEL

CAP - CAPACITOR

BVM - METER, BATTERY VOLTAGE

AM - METER, AC OUTPUT CURRENT

D1 - DIODE- 600V, 12A

CB1 - CIRCUIT BREAKER- EXCITATION

AVR - AUTOMATIC VOLTAGE REGULATOR

EH - ENGINE HARNESS CONNECTION

F2 - FUSE 7.5A IN-LINE

GCU - GOVERNOR CONTROLLER UNIT

F1 - FUSE 15A

S16

15

+

L1

-

15

176

S15

S16

229

D

E

A

B

BLUE

PCB

1417 16 15 13 12 11 5810 9 7 6 43 21

TR1

BLUE

LPC - LOWER PANEL CONNECTION

HZ - METER, FREQUENCY

HM - HOURMETER

USE BLUE WIRE FOR 240V, 1 PHASE

USE YELLOW WIRE FOR 208V, 3 PHASE

TS1, TS2 - TERMINAL STRIPS

R1 - RESISTOR, FIELD BOOST

SW2 - SWITCH- SET EXERCISE

PSW - SWITCH- PHASE SELECTOR

TR1 - TRANSFORMER UTILITY SENSING 24 VA

PCB - CIRCUIT BOARD CONTROLLER

L1 - LIGHT - FAULT INDICATOR

SW1 - SWITCH- AUTO/MANUAL/OFF

INSULATE UNUSED WIRE END

VM - METER, AC OUTPUT VOLTAGE

Generac®Power Systems, Inc. 23

Section 6 — Electrical Data

(Model No. 004626-0) Guardian Liquid-cooled 40 kW Generator

Schematic (Control Panel) – Drawing No. 0D6975

160

161

79

0

0

0

161

00

79

160

LEGEND

CAP - CAPACITOR

CB1 - CIRCUIT BREAKER - EXCITATION

D1 - DIODE- 600V, 12A

F1 - FUSE 15 AMPS

BVM - METER, BATTERY VOLTAGE

AM - METER, AC OUTPUT CURRENT

AVR - AUTOMATIC VOLTAGE REGULATOR

F2 - FUSE 7.5 AMPS IN-LINE

HZ - METER, FREQUENCY

HM - HOURMETER

14

TR1 - TRANSFORMER, UTILITY SENSING 24VA

TS1,TS2 - TERMINAL STRIP

PCB - CIRCUIT BOARD CONTROLLER

L1 - LIGHT, FAULT INDICATOR

PFC - POWER FLOW CONTROLLER

VM - METER, AC OUTPUT VOLTAGE

SW2 - SWITCH, SET EXERCISE

SW1 - SWITCH, AUTO/OFF/MANUAL

R1 - RESISTOR, FIELD BOOST

PSW - SWITCH, PHASE SELECTOR

USE YELLOW WIRE FOR 208V, 3 PHASE

INSULATE UNUSED WIRE END

USE BLUE WIRE FOR 240V, 1 PHASE

178

13

15

BLUE

176

176

AVR

2

162

F1

PCB

0

183

14

0

0

14

BAT-

BAT+

HZ

PSW

PHASE SELECTOR SWITCH

S16

S16

S15

YELLOW

TR1

BLACK

T2

T1

MPU SHIELD

MPU-

MPU+

PFC

ACT-

ACT+

POSITION

1 2 3 OFF

CONTACTS

VM

64

65

2

19

15

14

18

16

194

23

BLUE

RED

T2

T1

225A

23

194

3E4

15

14

16

RED

T2

0

S15

T1

A17

S15

B

S16

3

5

S15

S16

13

0

0

BVM

-

HM

+

15C

15

14

0

­176

+

L1

15

15

N.C.

15

14

SHOWN IN

OFF POSITION

15A

SW2

225A

15C

15C

15C

15A

15A

F2

183

14

13

CAP

0

161

79

160

15

229

13

14

56

SW1

239

85

15E

15C

178

10

12

9

178

11

239

D

229

7

14

5

56

2

85

0

13
1

4

4

6

1

4

0

4

6

1

X

X
X
O

X

2 - 3

TS2

0

161

X

O

X

X

O

O

O

X

O

X

X

12 - 3

2 - 11

2 - 7

0

3117

0

161

0

79

160

178

183

194

23

T1

N1

T2

0

79

160

O

O

O

O

O

O

X

O

O

X

O

X
O

X

O

X

X INDICATES CLOSED

19 - 14

19 - 16

+

67

12

0

X

O

O

X

O

X

O

O

15 - 18

15 - 14

12 - 11

12 - 7

­AM

23

N2

183

178

194

TS1

15

229

13

14

14

891

2

7

101112

0

56

85

85

436

5

4

14

D1

R1

1

D

4

29

C

TO ENGINE (CONNECTOR EH)

162

S3

00

S1

6

F

S15

2

E

S16

G

Q

H

K

57

58

N

M

O

0

T1

N1

T2

A

V

U

23

N2

178

183

194

BJX

WST

TO LOWER PANEL (CONNECTOR CP)

24 Generac®Power Systems, Inc.

Section 6 — Electrical Data

(Model No. 004626-0) Guardian Liquid-cooled 40 kW Generator
Wiring Diagram (Control Panel) – Drawing No. 0D6974

Generac®Power Systems, Inc. 25

Section 6 — Electrical Data

(Model Nos. 004373-1 & 004262-0) Guardian Liquid-cooled 40 kW Generator

Electrical Schematic — Engine (4.3L) – Drawing No. 0A4592-B

26 Generac®Power Systems, Inc.

Section 6 — Electrical Data

(Model Nos. 004373-1 & 004262-0) Guardian Liquid-cooled 40 kW Generator
Wiring Diagram — Engine (4.3L) – Drawing No. 0A4591-B

Generac®Power Systems, Inc. 27

Section 6 — Electrical Data

(Model No. 004373-1) Guardian Liquid-cooled 40 kW Generator

Electrical Schematic – Stepper Motor – Drawing No. 0A5858

J

S15

Q

N

00

O

P

178

K

M

L

S1

23

N2

N1

T1

S

R

T

V

U

T2

W

X

194

G

H

F

C

B

A

D

E

6

S16

2

1

57

58

S3

N1

N2

T1

T2

23

194

CUSTOMER CONNECTION
120/240V. 1-PHASE

E1 TO E3 240V.

E3 TO 00

E1 TO 00

120V.

DPE = EXCITATION WINDING

TP = THERMAL PROTECTER

TS3 = TERMINAL STRIP, PRE-PACKAGED TRANSFER SWITCH CONNECTION

LEGEND

AR = ALTERNATOR ROTOR

CT1 & CT2 = CURRENT TRANSFORMER

CB2 = CIRCUIT BREAKER - MAIN

AS = ALTERNATOR STATOR

TS4 = TERMINAL STRIP, 2-WIRE START CONNECTION

CP = CONTROL PANEL CONNECTOR LOWER PANEL

NB = NEUTRAL BLOCK

E3

E1

CB2

00

DIRECT

(390mm)

A S

CP

TS3

TS4

A R

NB

57

S3

S15

S1

S16

58

S3

1

0

S15

4

0

57

57

58

0

11

44

33

5

22

58

6

2

FROM STANDARD GENERAC GTS

178

183

2-WIRE START CONNECTION

1

4

RED

CLOSEST TO BEARING.

BRUSH WITH RED(4) LEAD

BRUSH HOLDER
MTG. SCREW.

1

183

0

4

183

183

0

0

2

2

2

6

6

6

00

S15

S16

PREPACKAGE

TRANSFER

SWITCH

CONNECTION

CT1

CT2

Q

PIN

X

M

N

D

O

P

C

K

L

B

U

F

R

S

G

T

H

W

J

V

E

A

28 Generac

®

Power Systems, Inc.

Section 6 — Electrical Data

(Model Nos. 004373-1 & 004262-0) Guardian Liquid-cooled 40 kW Generators

Wiring Diagram - Lower Panel - Drawing No. 0D5997

Generac®Power Systems, Inc. 29

TS3

TS4

NB

Section 6 — Electrical Data

(Model Nos. 004373-1 & 004262-0) Guardian Liquid-cooled 40 kW Generators

Electrical Schematic - Lower Panel - Drawing No. 0D5997

6

THERMAL PROTECTOR BYPASS

6

DPE

S1

AS

11

CT1

0

3322

57

1

4

5

5

TP

44

1

AR

RED

4

BRUSH UNITS

2

00

S3

58

CT2

D

C

F

E

K

Q

M

N

O

0

S15

CB2

E1

NB

CUSTOMER CONNECTION

120/240-V. 1-PHASE

E3

S16

TS3

TS4

194
23
T2
T1
N2
N1
183
178

A

G

H

X

W

V

U

T

S

B

J

TO CONTROL PANEL (CONNECTOR CP)

30 Generac®Power Systems, Inc.

RISK OF ELECTRICAL SHOCK.

DO NOT REMOVE COVER.

NO USER SERVICEABLE PARTS INSIDE.

REFER SERVICING TO QUALIFIED

MAY CAUSE ENGINE TO START. IF

POSITION. FAILURE TO WAIT 30 SEC.

OFF/MANUAL SWITCH TO THE "AUTO"

20 SECONDS AND THEN RELEASE.

TIME" SWITCH TO "ON" POSITION FOR

PUSH AND HOLD "SET EXERCISE

TO "OFF" POSITION.

PLACE AUTO/OFF/MANUAL SWITCH

OFF AUTOMATICALLY WITHIN 2 MIN.

ENGINE DOES START, IT WILL SHUT

EVERY 7 DAYS, AT TIME SET.

GENERATOR WILL NOW EXERCISE

PLACE AUTO/

81988

CAUTION

Section 7 — Exploded Views and Parts Lists

(Model No. 004373-1) Guardian Liquid-cooled 40 kW Generators
Control Panel - Drawing No. 0D4995-C

34

DO NOT REMOVE COVER.

RISK OF ELECTRICAL SHOCK.

CAUTION

VDC

REFER SERVICING TO QUALIFIED

NO USER SERVICEABLE PARTS INSIDE.

1

0

3

2

31

32

30

A

HRS

PANEL FACE

22

VHz

33

E

SOITCU N

ESICR MIT

R

E

NI TS

ES XET

.
S
D

OCES N3TIAW 0

MAY CAUSE ENGINE TO START. IF

POSITION. FAILURE TO WAIT 30 SEC.

OFF/MANUAL SWITCH TO THE "AUTO"

20 SECONDS AND THEN RELEASE.

TIME" SWITCH TO "ON" POSITION FOR

PUSH AND HOLD "SET EXERCISE

TO "OFF" POSITION.

PLACE AUTO/OFF/MANUAL SWITCH

ENGINE DOES START, IT WILL SHUT

PLACE AUTO/

81988

OFF AUTOMATICALLY WITHIN 2 MIN.

EVERY 7 DAYS, AT TIME SET.

GENERATOR WILL NOW EXERCISE

48

3

45 46 47

+ -

62 63

5049

18

28

27

2524

29

26

23

43

53 58

51 52

3

53 58

39

51 52

61

41

42

36

0
0
0

18 49 50

1

61

60

8

9

A

A

60

37

12

56 57
55
54

14

12

2

3

10 11

9

5

8

DEUTSCH

6

7

20

PIN

Q

P

R

O

S

E

F

D

T

N

G

C

A

U

M

H

B

J

V

L

W

K

X

21

19

18 49 50

5 6

35

4

16

17

18

59

13

52 53 58

15

VIEW A-A

14

12

54 55 56 57

Generac®Power Systems, Inc. 31

ITEM PART NO. QTY. DESCRIPTION

1 0D1523 1 PANEL BTM & BACK CONTROL PANEL
2 0D1521A 1 CONTROL PANEL, FRONT W/ SILK SCREEN
3 0D1522 2 PANEL,SIDE COVER CONTROL PANEL
4 067680 1 ASSY VOLTA GE REGULATOR 60HZ
5 0C8243 1 WASHER LOCK HDP DEUTSCH
6 0C8244 1 NUT, HDP DEUTSCH
8 048467 1 CIRCT BRK 7 X 1 ETA 46-500-P

9 057907 1 RES WW LUG 10R 10% 25W
10 064008 1 COVER CON PNL TOP (NOT SHOWN)
12 055444 1 HEATSINK
13 030468 1 WASHER STEP NYLON .20
14 049939 1 RECTIFIER MSC 12A 600V 1N1206R
15 070370 1 WASHER MICA .203
16 022158 1 NUT HEX #10-32 STEEL
17 023762 1 WASHER SHAKEPROOF EXT #10 STL
18 023897 15 WASHER FLAT #10 ZINC
19 076009A 1 PP LOGIC ASM 50/60HZ
20 040213 4 PCB SUPPORT SNAP-IN 1/4"
21 027744 1 GROMMET 3/4 X 5/32 X 5/16
22 082573 1 SWITCH ROCKER DPST 125V SPD
23 076020 1 SWITCH TOG DPDT 15/10 SP
24 032300 1 HOLDER FUSE
25 022676 1 FUSE 15A X AGC15
26 064009 1 LIGHT 12VDC .02A LED RED PILOT
27 061945 1 SWITCH SELECTOR 6A AMP/V
28 076037 1 VOLTMETER DC 8-18V
29 070081 1 HOURMETER
30 070043 1 VOLTMETER AC 0-300
31 070045 1 AMMETER AC 0-200

ITEM PART NO. QTY. DESCRIPTION

32 070042 1 FREQUENCY METER 240V 55-65HZ
33 081988 1 DECAL EXERCISE INFO
34 0C1229 1 DECAL CUST CONN BOX
35 098647 1 ASSY L.C. ELECT GOV
36 0A3968 1 CAPACITOR FILTER ASY
37 048766 REF BLOCK TERM 20A 2 X 6 X 1100V
39 083264 1 TFMR ASM,CMA 240/12V
41 057335 REF BLOCK TERM 20A 20 X 6 X 1100V
42 076061 1 DECAL, TERM. STRIP
43 029333 6 TIE WRAP 7.4" X .19" NATL UL
45 040479 4 VIB MNT 1.0 X 1.0 X 1/4-20
46 022507 4 SCREW HHC 1/4-20 X 1/2 G5
47 022127 4 NUT HEX 1/4-20 STEEL
48 022097 4 WASHER LOCK M6-1/4
49 033121 14 SCREW HHC #10-32 X 1/2
50 022152 14 WASHER LOCK #10
51 036902 4 SCREW PPHM #6-32 X 1/2
52 022155 6 WASHER LOCK #6
53 022985 8 WASHER FLAT #6 ZINC
54 036918 8 SCREW PPHM #8-32 X 1/2
55 022264 8 WASHER LOCK #8-M4
56 038150 8 WASHER FLAT #8 ZINC
57 022471 8 NUT HEX #8-32 STEEL
58 022188 6 NUT HEX #6-32 STEEL
59 036908 2 SCREW PPHM #6-32 X 1-1/4
60 0C2428 4 SCREW PHTT #6-32 X 1/2 ZYC

61 0C2323 4 SCREW PHTT #6-32 X 5/8 ZYC
62* 0D5324 1 FUSE & HOLDER LITTEL 7.5A
63* 0A9611 REF. FUSE 7.5AXBK/AGC7.5NX

* PART OF CONTROL PANEL WIRE HARNESS

Section 7 — Exploded Views and Parts Lists

(Model No. 004373-1) Guardian Liquid-cooled 40 kW Generators

Control Panel - Drawing No. 0D4995-C

32 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

(Model No. 004626-0) Guardian Liquid-cooled 40 kW Generators
Control Panel - Drawing No. 0D6978-A

60

2

AVR BEHIND COVER

34

INSIDE.

CAUTION

DO NOT REMOVE COVER.

RISK OF ELECTRICAL SHOCK.

NO USER SERVICEABLE PARTS

1

Hz

0

3

VDC

AV

HRS

51 5158 58

2

32

31

BEHIND COVER

(IF SO EQUIPPED)

21 38 61

GOVERNOR CONTROL

40

-+

7

25

30

27

28

7

11

53 54 55 56

44 45 46 47

41

24

8

59

23

29

26

58

59

43

33

81988

ETEX

NUCTIO S

SNSECO D

R

E

STIN

0

E
STIMRCISE

PLACE AUTO/

GENERATOR WILL NOW EXERCISE

EVERY 7 DAYS, AT TIME SET.

ENGINE DOES START, IT WILL SHUT

OFF AUTOMATICALLY WITHIN 2 MIN.

PUSH AND HOLD "SET EXERCISE

TIME" SWITCH TO "ON" POSITION FOR

20 SECONDS AND THEN RELEASE.

OFF/MANUAL SWITCH TO THE "AUTO"

POSITION. FAILURE TO WAIT 30 SEC.

MAY CAUSE ENGINE TO START. IF

PLACE AUTO/OFF/MANUAL SWITCH

TO "OFF" POSITION.

WAIT 3 .

6362

18 48 49 22

51 52 57

3

50

50 51 52 57

39

9

PANEL FACE

35

A

A

581253 54 55 56

37

42

36

0
0
0

12

23

1110

41

9

5

8

DEUTSCH

6

7

53545556

PIN

Q

P

S

O

E

FRD

T

N

C

G

A

U

M

H

B

J

V

L

W

K

X

20

19

4

18
4849

65

494818

1

16

17

18

VIEW A-A

13

14

15

12

Generac®Power Systems, Inc. 33

ITEM PART NO. QTY. DESCRIPTION

1 0D7397 1 PNL BTM & BACK CNTL PNL 04626
2 0D1521A 1 CONTROL PANEL FRONT W/ SILK

SCREEN
3 0D1522 1 PANEL SIDE COVER CONTROL PANEL
4 067680 1 ASSY VOLTA GE REGULAT OR 60HZ
5 0C8243 1 WASHER LOCK HDP DEUTSCH
6 0C8244 1 NUT, HDP DEUTSCH
7 0A6321 1 PANEL LEFT SIDE E
8 048467 1 CIRCT BRK 7 X 1 ETA 46-500-P
9 057907 1 RES WW LUG 10R 10% 25W

10 064008 1 COVER CON PNL TOP (NOT SHOWN)
11 0A6323 1 CHASSIS AVR & E-GOV
12 055444 1 HEATSINK
13 030468 1 WASHER STEP NYLON .20
14 049939 1 RECTIFIER MSC 12A 600V 1N1206R
15 070370 1 WASHER MICA .203
16 022158 1 NUT HEX #10-32 STEEL
17 023762 1 WASHER SHAKEPROOF EXT #10 STL
18 023897 15 WASHER FLAT #10 ZINC
19 076009A 1 PP LOGIC ASM 50/60HZ
20 040213 4 PCB SUPPORT SNAP-IN 1/4"
21 0A3394 1 DECAL, ELEC GOVERNOR
22 082573 1 SWITCH ROCKER DPST 125V SPD
23 076020 1 SWITCH TOG DPDT 15/10 SP
24 032300 1 HOLDER FUSE
25 022676 1 FUSE 15A X AGC15
26 064009 1 LIGHT 12VDC .02A LED RED PILOT
27 061945 1 SWITCH SELECTOR 6A AMP/V
28 076037 1 VOLTMETER DC 8-18V
29 070081 1 HOURMETER
30 070043 1 VOLTMETER AC 0-300
31 070045 1 AMMETER AC 0-200
32 070042 1 FREQUENCY METER 240V 55-65HZ
33 081988 1 DECAL EXERCISE INFO

ITEM PART NO. QTY. DESCRIPTION

34 0C1229 1 DECAL CUST CONN BOX
35 0D3440 1 CONTROLLER, B-C #DPG-2103
36 0A3968 1 CAPACITOR FILTER ASY
37 048766 REF BLOCK TERM 20A 2 X 6 X 1100V
38 0A1441B 1 COVER PLATE AVR
39 083264 1 TFMR ASM,CMA 240/12V
40 0A1441C 1 COVER PLATE EGOV
41 057335 REF BLOCK TERM 20A 20 X 6 X 1100V
42 076061 1 DECAL TERM. STRIP
43 029333 6 TIE WRAP 7.4" X .19" NATL UL
44 040479 4 VIB MNT 1.0 X 1.0 X 1/4-20
45 022507 4 SCREW HHC 1/4-20 X 1/2 G5
46 022127 4 NUT HEX 1/4-20 STEEL
47 022097 4 WASHER LOCK M6-1/4
48 033121 14 SCREW HHC #10-32 X 1/2
49 022152 14 WASHER LOCK #10
50 036902 4 SCREW PPHM #6-32 X 1/2
51 022155 6 WASHER LOCK #6
52 022985 8 WASHER FLAT #6 ZINC
53 036918 8 SCREW PPHM #8-32 X 1/2
54 022264 8 WASHER LOCK #8-M4
55 038150 8 WASHER FLAT #8 ZINC
56 022471 8 NUT HEX #8-32 STEEL
57 022188 6 NUT HEX #6-32 STEEL
58 0C2428 8 SCREW PHTT #6-32 X 1/2 ZYC
59 0C2323 4 SCREW PHTT #6-32 X 5/8 ZYC
60 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC

61 0C1127 1 DECAL AVR COVER
62* 0D5324 4 FUSE & HOLDER LITTEL 7.5A
63* 0A9611 1 FUSE 7.5AXBK/AGC7.5NX

* PART OF CONTROL PANEL WIRE HARNESS

Section 7 — Exploded Views and Parts Lists

(Model No. 004626-0) Guardian Liquid-cooled 40 kW Generators

Control Panel - Drawing No. 0D6978-A

11

34 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

(Model No. 004373-1) Guardian Liquid-cooled 40 kW Generator
Electronic Governor – Drawing No. 0A2615-F

ITEM PART NO.QTY. DESCRIPTION

1 098290 1 ASSEMBLY MOTOR STEPPER
2 0A3439 1 BRACKET GOVERNOR MOUNTING
3 098958A 1 CONNECTOR INTERFACE ASSEMBLY
4 021888 1 LEVER STEPPER MOTOR
5 082508 2 BALL JOINT PLA .25-.28

9 036409 2 NUT HEX 1/4-28 STEEL
11 043146 3 SCREW HHC M6-1.0 X 10 G8.8
12 098941A 2 HOUSING GOVERNOR CONNECT
13 098942A 2 COVER CONN HOUSING
14 098225 4 SCREW FHM #2 X 5/8 SELF TAP
15 022097 4 WASHER LOCK M6-1/4
16 064526 1 SCREW TAP HWH #6-25 X 3/8 ZINC
17 029333A 1 TIE WRAP 7.4" X .19" BLACK UL
18 074031 - LIQUID NEOPRENE (NOT SHOWN)
19 051716 2 NUT HEX M5-0.8 G8 YEL CHR
20 049226 2 WASHER LOCK M5
21 076040 2 SCREW PPHM M5-0.8 X 16
22 098647 1 ASSEMBLY L.C. ELECTRONIC GOVERNOR
23 036409 2 NUT HEX 1/4-28 STEEL
24 0C2184 1 STUD THR 1/4-28 X 3-1/2 G2 ZINC

15

16

ITEM (18) NEOPRENE

14

13

COATING

3

12

1

"A"

9

15

4

SECURE WIRE HARNESS
WITH TIE WRAP AS SHOWN.

17

WIRE HARNESS

9

23

EXISTING
ENGINE
HARDWARE

CARB. ARM
(REF.)

24

5

2

19

20

22

21
15
11

"A"

14

13

3

12

ITEM PART NO. QTY. DESCRIPTION

1 0C3250 1 BASE, MOUNTING ASSEMBLY, 4.3L

(DIRECT-COUPLED)
3 055414 1 LUG SLDLSS #2-#8 X 17/64 CU
5 022129 2 WASHER LOCK M8-5/16
6 045771 2 NUT HEX M8-1.25 G8 YEL CHR

10 043107 2 SCREW HHC M8-1.25 X 25 G8.8
11 022145 2 WASHER FLAT 5/16 ZINC
12 027482 3 WASHER SHAKEPROOF EXT 5/16 STL
13 055597 4 SCREW HHC M12-1.75 X 85 G8.8
14 052251 2 DAMPENER VIBRATION 40 BLUE
15 052257 4 SPACER .49 X .62 X 1.87 PWDR/ZINC
16 052252 4 DAMPENER VIBRATION
17 052259 4 WASHER FLAT M12
18 052860 4 NUT LOCKING M12-1.75
19 0536210098 1 ASSEMBLY GROUNDWIRE 10"/3/8
20 052251A 2 DAMPENER VIBRATION 50 WHITE
21 044118 1 BARBED STRAIGHT 1/2 NPT X 5/8
22 057823 2 CLAMP HOSE #10 .56 - 1.06
23 057448 11" HOSE 5/8 ID TYPE 3 SINGLE
24 024310 1 PLUG STD PIPE 1/2 STEEL SQ HD

ITEM PART NO. QTY. DESCRIPTION

* 25 0A8785 4 PLUG BUTTON 3" DIA.
* 26 0C4360 8 PLATE VARMINT
* 27 071693 16 WASHER FLAT .281 ID X 1.0 OD
* 28 0C2454 16 SCREW TH-FRM M6-1 X 16 N WA Z/JS
* 29 0C4753 1 PLUG 3/4 BUTTON

30 022413 1 SCREW HHC 1/4-20 X 1 G5
31 022473 1 WASHER FLAT 1/4 ZINC
32 022097 1 WASHER LOCK M6-1/4
33 022127 1 NUT HEX 1/4-20 STEEL

NOTES: 1) * ITEMS 25, 26, 27, 28 & 29 ARE INCLUDED FOR UNITS

WITH ENCLOSURES ONLY. NOT INCLUDED WITH
OPEN SETS.

2) ITEM 25 (PLUG BUTTON 3" DIA.) IS USED AFTER
SHIPPING. HOLES ARE TO REMAIN UNCOVERED
FOR SHIPPING PURPOSES. PLUGS CAN BE FOUND
IN THE MANUAL BAG LOCATED INSIDE THE LOWER
CONNECTION BOX.

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generator

Mounting Base – Drawing No. 0C4399-C

Generac®Power Systems, Inc. 35

*26

*28

*27

*27

29

24

*27

*28

12

19

18

5

1

6

16

17

13

3

*27

31

30

11

14
15

23

*26

12

10

21

22

6

5

12

To Oil Drain
On Oil Pan.

*26

33

32

16

19

11

10

18
20

15

*27

*28

*25

17
13

36 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generator
Engine Common Parts – Drawing No. 0A4304-J

15

17

38

34

26

16

12

1

9

47

18

30

29

28

27

44

8

7

43

43

40

22

40

39

45

41

25

23

40

21

46

40

34

26

35

34

42

20

34

24

35

19

37

14

3

34

4

13

36

11

31

33

10

5

6

31

32

Generac®Power Systems, Inc. 37

ITEM PART NO.QTY. DESCRIPTION

1 0A9046 1 ENGINE 4.3L GM
3 0A4239 1 PULLEY CRANKSHAFT
4 0A4240 1 PULLEY WATER PUMP
5 0A5640 1 SPACER FAN 50MM (35 kW UNITS ONLY)

0A5640A 1 SPACER FAN 62MM (45KW UNITS ONLY)

6 0A5639 1 FAN 17" REVRS ROT (35KW UNITS ONLY)

0D3293A 1 FAN COOLING 22" DIA REVRS ROT

(45KW UNITS ONLY)
7 077996 1 CAP HOSE
8 057823 1 CLAMP HOSE #10 .56 - 1.06
9 035579 1 BUSHING REDUCER 1/4 TO 1/8

10 037065 1 SCREW HHC 7/16-20 X 2-1/4 G5
11 022302 1 WASHER LOCK 7/16
12 0A8584 1 SWITCH OIL PRESSURE
13 052644 1 SPACER .5 X 1.5 X .25 STL/ZINC
14 0A4278A 1 BELT SERPENTNE 72.5"
15 0A4930A 1 HEAT SHIELD LEFT
16 0A4085 1 GASKET EXHAUST MANIFOLD
17 0A3927 1 MANIFOLD LEFT EXHAUST
18 0C7947 2 BOLT U 3/8-16 X 2.50
19 0A1232 1 DC ALTERNATOR ASSEMBLY
20 0A7801B 1 PULLEY PLOY-V 82 OD.
21 021928 1 BRACKET ALT.SUPPORT
22 0C6239 1 ASSEMBLY BRACKET MOUNTING WELD
23 0A4241 1 PULLEY GROOVED IDLER

ITEM PART NO.QTY. DESCRIPTION

24 0C2885 1 PULLEY TENSIONER
25 0A4100G 1 SPACER DC ALTERNATOR 32MM
26 022131 8 WASHER FLAT 3/8-M10 ZINC
27 077456 1 ADAPTOR M12-1.75 3/8 NPT
28 044117 1 BARBED STRAIGHT 3/8 NPT X 5/8
29 057823 1 CLAMP HOSE #10 .56 - 1.06
30 057448 1 HOSE 5/8 ID TYPE 3 SINGLE (12")
31 022129 8 WASHER LOCK M8-5/16
32 022142 4 SCREW HHC 5/16-18 X 3/4 G5 (45KW)
33 048614 4 SCREW HHC 5/16-24 X 3/4 G5
34 022237 12 WASHER LOCK 3/8
35 029745 4 SCREW HHC 3/8-16 X 1 G5
36 042633 3 SCREW HHC 3/8-24 X 1 G5
37 033819 1 SCREW HHC 3/8-16 X 4 G5
38 022241 4 NUT HEX 3/8-16 STEEL
39 0A5768 1 WASHER FLAT HEAVY DUTY
40 046526 5 WASHER LOCK M10
41 049814 2 SCREW HHC M10-1.5 X 25 G8.8
42 0C3756 1 BOL T TENSIONER PULLEY
43 045772 2 NUT HEX M10-1.5 G8 YEL CHR
44 0D2514 8 SPARK PLUG 5.7L GM
45 052259 1 WASHER FLAT M12
46 055934D 1 CLAMP VINYL 1.06 X .406 Z
47 0A37970001 1 FILTER OIL

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generator

Engine Common Parts – Drawing No. 0A4304-J

38 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generators
Engine Parts – Drawing No. 0D6980

Generac®Power Systems, Inc. 39

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generators

Engine Parts – Drawing No. 0D6980

ITEM PART NO. QTY. DESCRIPTION

1 0A9046 1 ENGINE 4.3L GM
2 0A9118A 1 FLYWHL 4.3L GM SAE
3 070022 1 WASHER STAR M12 EXT
4 0A6021 6 SCREW HHC 7/16-20 X 1 G8
6 059056A 1 STARTER 5.7L/7.4L GM
8 0A9050 2 BOLT STARTER 4.3L

9 022237 17 WASHER LOCK 3/8
10 045772 1 NUT HEX M10-1.5 G8 YEL CHR
11 049226 1 WASHER LOCK M5
12 051716 1 NUT HEX M5-0.8 G8 YEL CHR
13 0A4244 1 CONNECTOR COIL TO DISTRIBUTOR
14 0A4215 1 DIP STICK 4.3L GM
15 0A4231 1 TUBE DIP STICK 4.3L
16 059057 10" HOSE 3/4 ID SAE-30R2
17 0A2440 2 GASKET THERMOST AT
18 026568 2 SCREW HHC 3/8-16 X 2-3/4 G5
19 099729A 1 HOUSING THERM IMPREX
20 061012 1 PLUG STD PIPE 1/8 SOCKET HEAD
21 069939 1 HOUSING THERMOSTAT/WATER INLET
22 035606 1 SENSOR HI COOLANT SHUTDOWN
23 0A4930B 1 HEAT SHIELD RIGHT
24 0A4084 1 MOUNT ENGINE R & L
25 029745 3 SCREW HHC 3/8-16 X 1 G5
26 044101 2 SPARK PLUG WIRE SUPPORT BRACKET

ITEM PART NO. QTY. DESCRIPTION

27 023152 2 SCREW HHC 3/8-16 X 3/4 G5
28 022131 2 WASHER FLAT 3/8-M10 ZINC
29 058030 2 RETAINER PLUG WIRES
30 0A4085 1 GASKET EXHAUST MANIFOLD
31 0A3928 1 MANIFOLD RIGHT EXHAUST
32 0C7947 2 BOLT U 3/8-16 X 2.50
33 057794 2 RETAINER SPARK PLUG WIRES
34 0A4277 1 WIRES SPARK PLUG 4.3L
35 022241 4 NUT HEX 3/8-16 STEEL
36 057795 1 CONNECTOR C/C VENT
37 048191 2 PIN DOWEL M10 X 24
38 032303 6 SCREW HHC 3/8-16 X 3-1/2 G5
39 0A3852 3 PLATE FLEX GM
40 098239 1 CASTING ADAPTOR
41 057522 1 SENSOR COOLANT LEVEL
42 0D2244M 1 ASSY MAGPICKUP (3/8-24 MALE)

(MODEL 004626 0NLY)

43 075885 1 THERMOSTAT 195 DEG

* 0D6979 1 40KW GUARDIAN WIRE HARNESS

(NOT SHOWN FOR MOD.004626-0)

* 0A4308 1 HARNESS 4.3L STD WIRE

(NOT SHOWN FOR MOD.004373-1)

40 Generac

®

Power Systems, Inc.

TORQUE ITEM #6 TO 24 FT/LB AND USE

NOTE:

THREAD LOCKING COMPOUND (T-13717).

To Engine Flywheel

22

adjustment.

Do not rotate engine during this

Caution:

1/2 to 3/4 turn and tighten nut.

is made with Ring Gear, then back off

Thread in Sensor (8) until contact

Note:

39

36

37

35

38

To Engine

4

3

21

39

20

11

6

5

18

23

41

7

40

17

9

13

10

1

2

32

33

34

31

28

29

30

25

24

26

14

15

16

12

Add item #42
vinyl trim as
shown.

27

Flywheel Housing

19

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generators

Generator – Drawing No. 0D5333-A

Generac®Power Systems, Inc. 41

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-0 & 004626-0) Guardian Liquid-cooled 40 kW Generators

Generator – Drawing No. 0D5333-A

ITEM PART NO. QTY. DESCRIPTION

1 051768 6 SCREW HHC M12-1.75 X 25 G8.8

2 051769 6 WASHER LOCK M12

3 022237 8 WASHER LOCK 3/8

4 043097 8 SCREW SHC 3/8-16 X 1 G8.8 NZ

5 0A3852 3 PLATE FLEX GM

6 055173 6 SCREW HHC M8-1.25 X 20 G10.9

7 022129 6 WASHER LOCK M8-5/16

9 0A5526 1 FAN ASSEMBLY 390 SAE DD
10 0A2601 1 SCREW HHC M16-2.0 X 45 G8.8
11 0A2602 1 WASHER FLAT .688 ID X 3.25 OD
12 0A1138 1 KEY SQ 3/8 X 2-1/2 STEEL
13 021941 1 COUPLER 390 SAE
14 020808A 1 ROTOR 390 40 1P DIRECT
15 052624 1 BEARING BALL 6212 SEALED
16 070892 1 SLIP RING -MACHINED­17 065477 4 SCREW HHC M14-2.0 X 150 G8.8
18 0A1633 4 WASHER 390 SAE ALT
19 020729A 1 STATOR 390 40AD2 SAE
20 022131 12 WASHER FLAT 3/8-M10 ZINC
21 046526 12 WASHER LOCK M10
22 057642 12 SCREW HHC M10-1.5 X 40 G8.8

ITEM PART NO. QTY. DESCRIPTION

23 068113 1 CARRIER REAR BEARING 15"
24 068115 1 LOWER PANEL 15
25 043123 4 WASHER LOCK M14
26 051779 4 NUT HEX M14-2.0 G8 YEL CHR
27 046852 1 SCREW HHTT #10-32 X 1/4 BP
28 022250 1 WASHER FLAT 7/16
29 051769 1 WASHER LOCK M12
30 057821 1 SCREW HHC M8-1.25 X 40 G8.8
31 022145 1 WASHER FLAT 5/16 ZINC
32 022129 1 WASHER LOCK M8-5/16
33 057821 4 SCREW HHC M8-1.25 X 40 G8.8
34 024044A 2 ASSEMBLY BRUSH & SHUNT
35 023877D 4 BRUSH HOLDER-UNIV
36 022155 4 WASHER LOCK #6
37 025105 4 SCREW RHM 6-32 X 1/4 SIMS
38 071639 1 HOLDER BRUSH SUPPORT
39 0A4089 1 ASSEMBLY SCROLL 390 SAE
40 0A2437 2 SCREW SWAGE 1/4-20 X 5/8 Z/YC
41 022473 2 WASHER FLAT 1/4 ZINC
42 056326 8.4' TRIM VINYL BLACK 1/8 GP

ITEM PART NO. QTY. DESCRIPTION

1 0C3594 10 ASSEMBLY M6 HINGE
3 0A3359 40 SCREW BHSC M6-1.0 X 16 SS
4 0A3360 40 SHAKEPROOF INT M6 SS
5 0C2522 (A) 5 DOOR SMALL STD.WELD
6 0C2527 (A) 1 CORNER POST LH REAR
7 0C2528 (A) 1 CORNER POST RH REAR
8 0C2535 (A) 1 CORNER POST LH FRONT

9 0C2536 (A) 1 CORNER POST RH FRONT
10 0C2547 (A) 2 REAR BRACE TOP & BOTTOM
11 0C2550 (A) 4 SIDE BRACE TOP & BOTTOM
12 0C2555 (A) 2 SIDE SUPPORT
13 0C2560 (A) 1 ROOF ONE-PIECE WLDMT
14 0C2642 (A) 1 FRONT BRACE BOTTOM (2.4L & 4.3L)

0C4567 (A) 1 FRONT BRACE BOTTOM (3.0L D ONLY)

15 0C2641 (A) 1 FRONT BRACE TOP (2.4L & 4.3L)

0C4566 (A) 1 FRONT BRACE TOP (3.0L D ONLY)
16 0C2633 5 PLATE STRIKER GEN 2000
17 0C6749 20 SCREW PPHM M4-0.7 X 12 SS
18 060069 5 PADDLE HANDLE LOCK
19 0C6748 20 NUT LOCK HEX M4-0.7 SS NYL INS
20 080490 20 WASHER FLAT #8 SS
21 087233 5 RIVET POP 3/16 X 1/4
22 0C4065 (A) 1 DUCT FRONT LH

ITEM PART NO. QTY. DESCRIPTION

23 0C4064 (A) 1 DUCT FRONT RH
24 0C4066 (A) 1 DUCT BOTTOM
25 0C4067 (A) 1 DUCT FRONT PANEL
26 0C4117 (A) 1 DUCT FRONT TOP RH
28 0C2634A 1 ASSEMBLY COVER ACCESS
29 0C2454 76 SCREW TH-FRM M6-1X16 N WA Z/JS
30 022129 2 WASHER LOCK M8-5/16
31 042907 2 SCREW HHC M8-1.25 X 16 G8.8
32 022473 15 WASHER FLAT 1/4 ZINC
33 022097 1 WASHER LOCK M6-1/4
34 022127 1 NUT HEX 1/4-20 STEEL
35 0A9881 49.1 FT. GASKET DOOR RUBBER
36 0C3393 2 SCREW SHOULDER
39 0C3400 (A) 1 COVER EXHAUST HOLE
42 0C3397 4 FASTENER RATCHET
43 066760 39-3/8" STRIP SEALANT 1/8 X 1
44 022145 2 WASHER FLAT 5/16 ZINC

OPTIONAL COMPARTMENT MATERIALS:
ALL P/N'S WITH AN "A" SUFFIX INDICATE
ALUMINUM MATERIAL OPTION.

42 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generators
Compartment – Drawing No. 0C4401-F

28

26

13

23

29

25

31

30

44

22

43

24

36

1

4

3

15

39

29

8

1

4

3

32
33
34

9

12

14

11

35

12

5

11

BASE

32
29

FRAME

11

11

10

5

20

19

6

5

10

7

42

16

21

18

17

Generac®Power Systems, Inc. 43

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generators

Radiator – Drawing No. 0D4991-A

ITEM PART NO. QTY. DESCRIPTION

1 068928 1 RADIATOR 14 FIN/INCH
4 024655 4 SCREW HHTT 1/4-20 X 1 CZ
5 022097 4 WASHER LOCK M6-1/4
6 022473 4 WASHER FLAT 1/4 ZINC
7 097246A 1 VENTURI 16" DIA 35KW

097246B 1 VENTURI 18" DIA 45KW
8 0A5397 1 GUARD FAN 4.3L D.C.
9 0A4375 1 HOSE 4.3L STD LOWER

10 035685 4 CLAMP HOSE #28 1.32 - 2.25
11 047290 16" HOSE 3/8 ID SINGLE BRAID
12 040173 2 CLAMP HOSE #5.5 .62 - .62
13 049340 1 BARBED ELBOW 90 1/4 NPT X 3/8
14 036865 1 DRAINCOCK
15 029032 46" HOSE 9/32 ID
16 052250 2 TAPE FOAM 1 X 1
17 058443 9 SCREW CRIMPTITE 1/4-20 X 5/8
18 029745 4 SCREW HHC 3/8-16 X 1 G5
19 022237 4 WASHER LOCK 3/8
20 022131 4 WASHER FLAT 3/8-M10 ZINC
21 0A4374 1 HOSE 4.3L STD UPPER
22 076749 1 TANK COOLANT RECOVERY
23 080712 1 BRACKET COOLANT RECOVERY TANK
24 090388 1 SCREW HHTT M6-1.0 X 12 YC
27 048031C 1 CLAMP HOSE BAND 1/4
29 0C4341 2 SUPPORT RADIATOR A GROUP
30 046627 1 CAP RADIATOR

29

18

19

20

14

12

11

27

12

13

30

1

10

22

23

24

22

27

16

"A"

6

15

5

4

7

To "A"

21

8

10

10

17

9

ITEM PART NO. QTY. DESCRIPTION

1 064945 1 GASKET CARBURETOR ADAPTOR
2 0A4120 1 ADAPTOR CARBURETOR W/INLET
3 033212 4 SCREW HHC 5/16-18 X 1-1/4 G5
4 022129 4 WASHER LOCK M8-5/16
5 052865 1 CARBURETOR GASKET
6 0A7631 1 CARB. REWORK 4.3L (NATURAL

GAS + VAPOR)

0C5716 1 CARBURETOR, REWORK (LPG LIQUID)
7 029745 2 SCREW HHC 3/8-16 X 1 G5
8 022237 2 WASHER LOCK 3/8
9 026307 1 ELBOW 90 DEG STREET 3/4

10 028641 1 TOE NIPPLE 3/4 NPT x 2
11 057824 1 CLAMP HOSE #16 .87 - 1.50
12 057422 1 HOSE 1IN ID LP GAS (NATURAL

GAS + VAPOR) (3.6’)

057422 1 HOSE 1IN ID LP GAS (LPG LIQUID) (1’)

13 0A6344 1 BARBED ELBOW 90 1/8 NPT X 3/8
14 047290 1 HOSE 3/8 ID SINGLE BRAID (.75’)
15 0A4121 1 VALVE PCV

ITEM PART NO. QTY. DESCRIPTION

16 082508 1 BALL JOINT PLA .25-28
17 055934Z 1 CLAMP VINYL 1.13 X .406 Z
18 022097 1 WASHER LOCK M6-1/4
19 036409 2 NUT HEX 1/4-28 STEEL
20 0A4632B 1 PLATE AIR CLEANR BOTTOM
21 0A4637 1 FILTER AIR 11.5"
22 0A5763 1 ARM THROTTLE - REWORK
23 0A4632A 1 PLATE AIR CLEANER TOP
24 062522 1 STUD THR 1/4-20 X 3 G2 ZNC FULL
25 037561 1 NUT WING 1/4-20 NYLK
26 061258 1 GASKET AIR CLEANER
27 057796 1 GROMMET
28 057795 1 CONNECTOR C/C VENT

29* 0A5737B 1 SPACER DC ALT. 30LG (LP GAS)

0A5737C 1 SPACER DC ALT. (VAPOR & NATURAL

GAS)

* NOT SHOWN

44 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

(Model No. 004373-1) Guardian Liquid-cooled 40 kW Generators
Carburetor – Drawing No. 0A5764-E

USE FASTENER LOCATED ON
ALTERNATOR FAN SCROLL

1

13

FRONT OF
ENGINE

14

TO
REGULATOR

19

6

7

8

5

3

4

2

24

12

11

10

9

17

19

18

22

16

15

TO ALTERNATOR
FAN SCROLL

TO STEPPER
MOTOR

26

25

23

21

20

27

28

Generac®Power Systems, Inc. 45

ITEM PART NO. QTY. DESCRIPTION

1 064945 1 GASKET CARBURETOR ADAPTOR
2 0A4120 1 ADAPTOR CARBURETOR W/INLET
3 033212 4 SCREW HHC 5/16-18 X 1-1/4 G5
4 022129 4 WASHER LOCK M8-5/16
5 0C7059 1 GASKET GOVERNOR THROTTLE BODY
6 0C7650A 1 MIXER (ONLY) NATURAL GAS
7 029745 2 SCREW HHC 3/8-16 X 1 G5
8 022237 2 WASHER LOCK 3/8
9 026307 1 ELBOW 90 DEG STREET 3/4

10 028641 1 NIPPLE TOE (THREADED ONE END) 3/4

NPT X 2
11 057824 1 CLAMP HOSE #16 .87-1.50
12 057422 44" HOSE 1 IN ID LP GAS
13 0A6344 1 BARBED ELBOW 90 1/8 NPT X 3/8
14 047290 9" HOSE 3/8 ID SINGLE BRAID
15 0A4121 1 VALVE PCV
16 0D2803 1 ACTUATOR THROTTLE 42MM
17 055934Z 1 CLAMP VINYL 1.13 X .406 Z
18 0A6613 1 GASKET CARB IMPCO 225

ITEM PART NO. QTY. DESCRIPTION

19 036409 1 NUT HEX 1/4-28 STEEL
20 0A4632B 1 PLATE AIR CLEANR BOTTOM
21 0A4637 1 FILTER AIR 11.5"
22 0C7820 1 MACHINING CARBURETOR

ADAPTOR
23 0A4632A 1 PLATE AIR CLEANER TOP
24 062522 1 STUD THR 1/4-20 X 3 G2 ZNC FULL
25 037561 1 NUT WING 1/4-20 NYLK
26 061258 1 GASKET AIR CLEANER
27 057796 1 GROMMET
28 057795 1 CONNECTOR C/C VENT

29* 0A5737C 1 SPACER DC ALTERNATOR

30 0C7060 1 GASKET CARBURETOR ADAPTOR
31 022152 8 WASHER LOCK #10
32 064090 4 SCREW PHM SEMS #12-24 X 5/8 EX
33 0C7908 4 SCREW SHC #10-32 X 5/8 G8.8 NZ

* NOT SHOWN

Section 7 — Exploded Views and Parts Lists

(Model No. 004626-0) Guardian Liquid-cooled 40 kW Generators

Carburetor – Drawing No. 0D6977

USE FASTENER LOCATED ON
ALTERNATOR FAN SCROLL

TO
REGULATOR

19

6

18

22

24

9

12

11

10

17

31

25

23

32

TO ALTERNATOR
FAN SCROLL

31
33

FRONT OF
ENGINE

7

8

5

3

4

2

1

13

14

30

16

21

20

15

27

26

28

46 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

Guardian Liquid-cooled 40 kW Generators
Regulator – Drawing No. 0C2776-C

ITEM PART NO. QTY. DESCRIPTION

1 065907 1 SUPPORT SOLENOID NAT GAS
2 026307 3 ELBOW 90 DEG STREET 3/4
3 076691 1 NIPPLE PIPE 3/4NPTX4.5 BLK IRN
4 043768A 1 SOLENOID GAS FUEL
5 026490 1 NIPPLE PIPE 3/4 NPT X 2
6 026577 2 BUSHING REDUCER 1 TO 3/4
7 055944 1 REGULATOR NAT GAS LPG VAPOR
8 067018 1 SUPPORT REGULATOR

9 0C2775 1 BRACKET REGULATOR 4.3L
10 061910 4 SCREW HHTT #10-24 X 3/4 CZ
11 022145 6 WASHER FLAT 5/16 ZINC
12 022129 6 WASHER LOCK M8-5/16
13 030795 4 SCREW HHC 5/16-18 X 1 G5
14 025655 1 PLUG STD PIPE 3/4 STEEL SQ HD
15 022132 2 WASHER FLAT 9/16 ZINC
16 051778 2 SCREW HHC M14-2.0 X 25 G8.8

ITEM PART NO. QTY. DESCRIPTION

17 028641 1 NIPPLE TOE 3/4 NPT X 2
18 057824 2 CLAMP HOSE #16 .87 - 1.50
19 057422 1 HOSE 1IN ID LP GAS
20 043123 2 WASHER LOCK M14
21 051779 2 NUT HEX M14-2 G8 YEL CHR

22* 055934P 1 CLAMP VINYL 1.62 X .486 Z

23 027482 1 WASHER SHAKEPROOF EXT 5/16 STL
24 0C3168 1 WASHER LOCK SPECIAL 5/16
25 022259 1 NUT HEX 5/16-18 STEEL
26 058359 1 LUG RNGTNG INS 22-18 X 5/16 X .477

* NOT SHOWN
NOTE: ITEM #22 ATTACHES TO ALTERNATOR SCROLL

For LPG Vapor Withdrawal Turn

Regulator (Item 7)

Upside Down, Remove Items A & B

Then Replace End Cap.

B

A

END CAP

TO

CARBURETOR

18

19
18

17

6

7

5

4

2

3

25

2

21

20

12

1

26

6

11

8

10

23

9

15

11

16

12

14

2

13

MOUNTING
BASE

11

12

13

11

12

24

11

12

13

13

Generac®Power Systems, Inc. 47

ITEM PART NO. QTY. DESCRIPTION

1 065907 1 SUPPORT SOLENOID NAT GAS
2 026307 3 ELBOW 90 DEG STREET 3/4
3 076691 1 NIPPLE PIPE 3/4 NPT X 4.5 BLK IRN
4 043768A 1 SOLENOID GAS FUEL
5 026490 1 NIPPLE PIPE 3/4 NPT X 2
6 026577 2 BUSHING REDUCER 1 TO 3/4
7 0D2758 1 REGULATOR N/G (R600S)
8 028237 2 SADDLE 1-3/8

9 0C2775 1 BRACKET REGULATOR 4.3L
10 028238 2 BOLT U 5/16-18 X 1.50
11 022145 10 WASHER FLAT 5/16 ZINC
12 022129 10 WASHER LOCK M8-5/16
13 030795 4 SCREW HHC 5/16-18 X 1 G5
14 025655 1 PLUG STD PIPE 3/4 STEEL SQ HD
15 022132 2 WASHER FLAT 9/16 ZINC
16 051778 2 SCREW HHC M14-2.0 X 25 G8.8
17 028641 1 NIPPLE TOE 3/4 NPT X 2

ITEM PART NO. QTY. DESCRIPTION

18 057824 2 CLAMP HOSE #16 .87-1.50
19 057422 1 HOSE 1 IN ID LP GAS
20 043123 2 WASHER LOCK M14
21 051779 2 NUT HEX M14-2 G8 YEL CHR

22* 055934P 1 CLAMP VINYL 1.62 X .486 Z

23 027482 1 WASHER SHAKEPROOF EXT 5/16 STL
24 0C3168 1 WASHER LOCK SPECIAL 5/16
25 022259 5 NUT HEX 5/16-18 STEEL
26 058359 1 LUG RNGTNG INS

22-18 X 5/16 X .477
27 0D2616 1 SUPPORT REGULATOR
28 0D1509 1 DECAL,INLET PRESSURE

* NOT SHOWN

NOTE: ITEM #22 ATTACHES TO ALTERNATOR SCROLL

Section 7 — Exploded Views and Parts Lists

(Model No. 004626-0) Guardian Liquid-cooled 40 kW Generators

Carburetor – Drawing No. 0D4823-A

TO

21

20

CARBURETOR

10

6

7

6

5

4

2

3

25

26

12

2

11

23

1

27

11
12
25

18

19
18

17

2

8

9

11

12

13

MOUNTING
BASE

11

12

13

11

12

28

15

16

14

24

11

12

13

13

ITEM PART NO. QTY. DESCRIPTION

1 080723 1 HOSE CONNECTION TEE 1.75-.62
2 035685 2 CLAMP, HOSE #28 1.32-2.25
3 057822 4 CLAMP, HOSE #8 .53-1.00
4 084918C 1 HEATER, ENGINE 1800W 120V.

*084918D 1 HEATER, ENGINE 2000W 240V.
5 050967 1 HOSE, 5/8" I.D. RIA 250F (36”)
6 0A6283 1 HOSE, PREFORMED BLOCK HEATER
7 053660 1 BARBED ST.1/4" NPT x 5/8 I.D.
8 084427 1 BRACKET, HEATER
9 047411 2 SCREW HHC M6-1.0 X 16 G8.8

10 022097 4 WASHER, LOCK-M6-1/4
11 022473 4 WASHER, FLAT 1/4 ZINC
12 049813 2 NUT, HEX-M6 X 1.00 G8 YEL CHR
13 042568 2 SCREW, HHC-M6-1.0 x 20MM G8.8
14 **077043E 36" FLEXIBLE CONDUIT 1" BLACK

*USED ON "R" VOLTAGE GENERATORS ONLY

**ITEM #14 USED ONLY ON 4.3L UNITS

48 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generators
Engine Coolant Heater – Drawing No. 087434-D

Lower Radiator
Hose

To Water
Pump

To Engine

To Lower
Radiator

2

1

3

14

Block

7
3

6

5
13

3

11

3
4

11

10

9

8

10
12

Generac®Power Systems, Inc. 49

ITEM PART NO. QTY. DESCRIPTION

2 058665 1 BATTERY 12VDC 90-AH 27F (OPTIONAL)
3 061902 1 HOLD DOWN BATTERY
4 059473 1 HOLD DOWN BATTERY
5 038805H 1 CABLE BATTERY BLACK #1 X 23.00
6 038804N 1 CABLE BATTERY RED #1 X 15.00

038804T 1 CABLE BATTERY RED #1 X 31.00 (GEAR BOX-NON-GUARDIAN UNITS)
7 0A4010 2 SCREW HHC M8-1.25 X 60 FT G8.8
8 052858 2 NUT LOCK FLANGE M8-1.25
9 049820 2 NUT LOCK HEX M8-1.25 (NYLON INSERT)

11 023152 1 SCREW HHC 3/8-16 X 3/4 G5
12 022131 1 WASHER FLAT M10-3/8 ZINC
13 025507 1 WASHER SHAKEPROOF EXT 7/16 STL
14 022237 1 WASHER LOCK 3/8

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generators

Battery – Drawing No. A6708-F

TO STARTER

11

SOLENOID

12

13

5

RED

6

9

3

14

TO ENGINE BLOCK

9
4

BLACK

2

8

8

7

7

50 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generators
Lower Panel – Drawing No. 0D5334-B

13

43

41

44

40

40

44

3

44

BOTTOM OF

CONTROL PANEL

41

44

43

44

41

18

44

43

30

29

12

4

11

32

31

10

58

33

32

32

57

2

32

59

33

54

53

46

55

70

1

45

29

30

61

60

3

6

33

58

43

44

45

34

35

36

16

15

44

14

41

36

17

Generac®Power Systems, Inc. 51

ITEM PART NO. QTY. DESCRIPTION

1 068115 1 LOWER PANEL 15
2 0D5489 1 COVER LOWER CONNECTION BOX
3 040479 4 VIBRATION MOUNT 1.0 X 1.0 X 1/4-20
4 023484N 1 BUSHING SNAP SB-2.5-31
6 056739 1 RELAY SOLENOID 12VDC PNL MNT

10 058710 2 TRANSFORMER 200A TO 5A 5VA
11 048766 1 BLOCK TERM 20A 2 X 6 X 1100V
12 022985 2 WASHER FLAT #6 ZINC
13 068116 1 COVER LOWER PANEL 15
14 081418 1 COVER-CB KAP36000 15"
15 081419 1 COVER-CB TERM KAP 15"
16 081523U 1 CIRCT BRK 200 X 3 600V UL SQ D
17 042419 4 SCREW RHM 10-32 X 4
18 0D5840 1 DECAL CUSTOMER CONNECTN FOR TS
29 022264 13 WASHER LOCK M4
30 0C2212 4 SCREW PHTT M4-0.7 X 16 ZYC
31 022142 6 SCREW HHC 5/16-18 X 3/4 G5
32 022145 8 WASHER FLAT 5/16 ZINC
33 022129 12 WASHER LOCK M8-5/16
34 022158 10 NUT HEX #10-32 STEEL

ITEM PART NO. QTY. DESCRIPTION

35 022152 14 WASHER LOCK #10
36 023897 8 WASHER FLAT #10 ZINC
37 069232 4 SCREW RHM #10-32 X 3-3/4
39 022471 7 NUT HEX #8-32 STEEL
40 022507 8 SCREW HHC 1/4-20 X 1/2 G5
41 022287 27 SCREW HHC 1/4-20 X 3/4 G5
43 022473 19 WASHER FLAT 1/4 ZINC
44 022097 50 WASHER LOCK M6-1/4
45 022127 12 NUT HEX 1/4-20 STEEL
46 022259 6 NUT HEX 5/16-18 STEEL
53 069173 1 BUS BAR NEUTRAL STRP
54 057329 1 LUG SLDLSS 350-#6 X 13/32 AL/CU

062684 1 LUG SLDLSS 2/0-#12 X 11/32 CU
55 057073 2 JUNCTION BLOCK 3/8-16
57 039287 2 SCREW HHC M8-1.25 X 45 G8.8
58 045771 2 NUT HEX M8-1.25 G8 YEL CHR
59 022511 1 SCREW HHC 3/8-16 X 1-1/4 G5
60 022241 3 NUT HEX 3/8-16 STEEL
61 022237 3 WASHER LOCK 3/8
70 0D3388 1 DECAL REMOTE START CONNECTION

Section 7 — Exploded Views and Parts Lists

(Model Nos. 004373-1 & 004626-0) Guardian Liquid-cooled 40 kW Generators

Lower Panel – Drawing No. 0D5334-B

52 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

(Model No 004626-0) Guardian Liquid-cooled 40 kW Generators
Exhaust Muffler – Drawing No. 0D6976

Generac®Power Systems, Inc. 53

ITEM PART NO. QTY. DESCRIPTION

1 059902A 1 CAP RAIN 2.50 / 2.69
2 0C9641 1 TUBE STRAIGHT 'A' GROUP
3 0D4208 1 MUFFLER CATALYST 4.3L
4 0D5061 4 MOUNTING BAND A-GRP CATALYST
5 0C4126 2 BRACKET MUFFLER MOUNTING
6 0D5787 1 TUBE ELBOW 90 DEG 2.5"
7 0A5215B 2 PIPE FLEX 2.5"
8 0D5792 1 TUBE 2.5" SMALL TEE

9 0D5793 1 TUBE ELBOW 90 DEG 2.5" FLARED
10 0C4170 2 BRACKET EXHAUST SHIELD
11 0C4305 1 SHIELD A-GRP HEAT
12 0C2454 2 SCREW TH-FRM M6-1 X 16 N WA Z/JS
13 0C3433A 4 CLAMP BAND 2.5"
14 022129 16 WASHER LOCK M8-5/16
15 022145 20 WASHER FLAT 5/16 ZINC
16 045771 4 NUT HEX M8-1.25 G8 YEL CHR
18 042907 16 SCREW HHC M8-1.25 X 16 G8.8

ITEM PART NO. QTY. DESCRIPTION

19 080762 8 BOLT U 3/8-16 X 2.62
20 022237 16 WASHER LOCK 3/8
21 022241 16 NUT HEX 3/8-16 STEEL
22 0D5187 1 SHIELD HEAT CROSSOVER 4.3L
23 0D5190 1 SHIELD HEAT EXHAUST 4.3L
24 077879 1 HOSE VACUUM 5/32 (3’)
25 0D4221 1 KIT AIR/FUEL RATIO CONTROLLER
26 0D4512 1 BRACKET AIR/FUEL CONTROLLER
27 043116 2 SCREW HHC M6-1.0 X 12 G8.8
28 022471 5 NUT HEX #8-32 STEEL
29 022264 5 WASHER LOCK #8-M4
30 038150 8 WASHER FLAT #8 ZINC
31 036918 5 SCREW PPHM #8-32 X 1/2
32 049811 2 WASHER FLAT M6
33 022097 2 WASHER LOCK M6-1/4
34 049813 2 NUT HEX M6 X 1.0 G8 YEL CHR

Section 7 — Exploded Views and Parts Lists

(Model No 004626-0) Guardian Liquid-cooled 40 kW Generators

Exhaust Muffler – Drawing No. 0D6976

Section 7 — Exploded Views and Parts Lists

(Model No. 004373-1) Guardian Liquid-cooled 40 kW Generators
Generator – Drawing No. 0D5786

ITEM PART NO. QTY. DESCRIPTION

1 059902A 1 CAP RAIN 2.50 / 2.69
2 0C9641 1 TUBE STRAIGHT 'A' GROUP
3 0C9650 1 MUFFLER 2-1/2" INLET/OUTLET
4 0C4114A 2 CLAMP BAND MUFFLER 6.5"
5 0C4126 2 BRACKET MUFFLER MOUNTING
6 0D5787 1 TUBE ELBOW 90 DEG 2.5"
7 0A5215B 2 PIPE FLEX 2.5"
8 0D5792 1 TUBE 2.5" SMALL TEE

9 0D5793 1 TUBE ELBOW 90 DEG 2.5" FLARED
10 0C4170 2 BRACKET EXHAUST SHIELD
11 0C4305 1 SHIELD A-GRP HEAT

ITEM PART NO. QTY. DESCRIPTION

12 0C2454 2 SCREW TH-FRM M6-1 X 16 N WA Z/JS
13 0C3433A 4 CLAMP BAND 2.5"
14 022129 12 WASHER LOCK M8-5/16
15 022145 12 WASHER FLAT 5/16 ZINC
16 0C9748 1 PLUG M18-1.5
18 042907 12 SCREW HHC M8-1.25 X 16 G8.8
19 080762 8 BOLT U 3/8-16 X 2.62
20 022237 16 WASHER LOCK 3/8
21 022241 16 NUT HEX 3/8-16 STEEL
22 0D5187 1 SHIELD HEAT CROSSOVER 4.3L
23 0D5190 1 SHIELD HEAT EXHAUST 4.3L

54 Generac®Power Systems, Inc.

20

19

21
20

22

19

9

19

To Engine

2.5" Dia. Clamp Assembly

13

7

13

19

16

19

To Engine

21

23

8

Compartment

Front

14

18

7

To

15

13

15

14

5

18

21
20

19

19

5

10

1

2

19

6

19

3

18

12

15

14

11

4

4

10

Generac®Power Systems, Inc. 55

Section 8 — Notes

Guardian Liquid-cooled 40 kW Generators

56 Generac®Power Systems, Inc.

1

Hz

Section 9 — Installation Drawings

Guardian Liquid-cooled 40 kW Generators
Installation Drawing – Drawing No. 0D5335

NOTE 7

R677 [R26.66"]

TYP

247 [9.73"]

204 [8.03"]

839 [33.01"]

TYP

ALT
AIR
OU

220 [8.65"] STUB-UP AREA

STUB-UP AREA
SEE NOTE 8
AND CHART

794 [31.28"]

STUB-UP

A1

AREA

C

49 [1.92"]

TYP

MOUNTING HOLES

Ø13.5 [Ø0.53"]

8 HOLES ON BOTTOM

110 [4.33"] TYP.

570 [22.44"] TYP.

NOTE 9

1117 [43.98"]

ALT

TYP
AIR
OUT

NOTE 1

71 [2.79"]

140 [5.50"]

TOP OR PLAN VIEW

665 [26.19"]

37 [1.44"]

2397 [94.37"]

454 [17.87"]

NOTE 5

NOTE 3

AV Hz

NOTE 2

NOTE 6

103 [4.06"]

53 [2.09"]

835 [32.87"]

936 [36.85"]

LEFT SIDE VIEW

NATURAL GAS INLET
3/4" NPT FEMALE

OIL DRAIN
1/2" N.P.T. FEMALE

Generac®Power Systems, Inc. 57

Section 9 — Installation Drawings

Guardian Liquid-cooled 40 kW Generators

Installation Drawing – Drawing No. 0D5335

RECOMMENDED FUEL/ELECTRICAL STUB-UPS

(SEE TOP VIEW)

DESCRIPTION

AC LOAD LEAD CONDUIT

INSIDE STUB-UP FOR

FUEL CONNECTIONS

NOTE:

FUEL SYSTEM SET UP WITH OUTSIDE STUB UPS
(SEE LEFT SIDE VIEW). SMALL FUEL SYSTEM
MODIFICATIONS REQUIRED FOR
INSIDE STUB-UPS.

WEIGHT DATA

UNIT: 729.7 kg [1609 lbs]
STEEL COMPARTMENT: 208.6 kg [460 lbs]

UNITS: mm [INCHES]

965 [37.99"]

(LEFT)

INSIDE

BASE

A1
C

NOTES:

1. STANDARD BLOCK HEATER REQUIRES 120V AC CONNECTION

2. CONNECTION POINTS FOR AC LOAD LEADS, TRANSFER SWITCH, AND

ENGINE AUTOMATIC START/STOP CONTROL WIRES PROVIDED IN

AC CONNECTION PANEL.

3. EXHAUST MUFFLER SUPPORT BRACKETS SUPPLIED WITH OPTIONAL COMPARTMENT.

4. 12 VOLT NEGATIVE GROUND SYSTEM
BATTERY TRAY INSIDE DIMENSIONS: 178 X 342.5 [7" X 13.5"]

5. 2.5" I.D. FLEX EXHAUST

6. MAIN LINE CIRCUIT BREAKER.

7. DOORS MUST BE OPENED 90 DEG. TO BE REMOVED.

8. A1 MAY BE USED

9. SEE DRAWING C3850 FOR DUCT REMOVAL. REMOVAL OF FRONT
DUCT WILL PROVIDE ACCESS TO MUFFLER FOR SERVICING.

ENGINE SERVICE CONNECTIONS
INLET NATURAL GAS = 3/4" NPT COUPLING

OIL DRAIN = 1/2" NPT COUPLING
EXHAUST OUTLET -

FOR CIRCUIT BREAKER STUB-UP LOCATION.

2.5" OD MUFFLER OUTLET

1160 [45.67"]

877 [34.51"]

REAR VIEW

LIFTING EYE

(4 PLACES)

CENTER OF

GRAVITY

981 [38.62"]

(1) 12V BATTERY
SEE NOTE 4

158 [6.22"]

1930 [75.98"]

RIGHT SIDE VIEW

Part No. 0D4963 Revision 1 (12/20/01) Printed in U.S.A.

Section 10 – Warranty

Guardian Liquid-cooled 40 kW Generators

GENERAC POWER SYSTEMS "TWO YEAR" STANDARD WARRANT Y FOR GUARDIAN

®

"PREPACKAGED EMERGENCY AUTOMATIC STAN DBY GENER ATORS"

For a period of two years or 2000 hours of operation from the date of original sale, whichever occurs first, Generac Power
Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by
Generac or a Generac Authorized Warranty Service Dealer, is found to be defective under normal use and service, in accor­dance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be
returned to and examined by the nearest Generac Authorized Warranty Service Dealer. All transportation costs under the war­ranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to
Generac Guardian prepackaged emergency automatic standby generators sold and rated for use in "Standby" applications.

WARRANTY SCHEDULE

YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and
maintenance is required):

• Engine - All Components

• Alternator - All Components

• Transfer System - All Components
All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat Rate

Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Generac Guardian generators that utilize non-Generac replacement parts.

• Any Generac Guardian generators used as rental or trailer mounted applications.

• Units used for prime power in place of existing utility power where utility power is present or in place of utility power where
utility power service does not normally exist.

• Costs of normal maintenance, adjustments, installation and start-up.

• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with
all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty
will not cover repair when normal use has exhausted the life of a part(s) or engine.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Damage related to rodent infestation.

• Products that are modified or altered in a manner not authorized by Generac in writing.

• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or
replacement of the defective part(s).

• Failure due to misapplication.

• Telephone, cellular phone, facsimile, internet access or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit
warranty period.

• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.

• Rental equipment used while warranty repairs are being performed.

• Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLA CE OF ALL OTHER W ARRANTIES, EXPRESSED OR IMPLIED . SPECIFICALLY, GENERA C MAKES
NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or conse­quential damages, so the above limitation may not apply to you.

This warranty gives you specific legal rights. You also have other rights from state to state.

GENERAC®POWER SYSTEMS, INC.

P.O. BOX 297

WHITEWATER, WI 53190