Generac Power Systems 004626-5 User Manual

Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Models: 004373-6
(40 kW/Single-phase w/ 200 Amp Transfer Switch)
004626-5
(40 kW/Single-phase w/ 200 Amp Transfer Switch California Emissions)
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT
INSTALLATION!!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
Not intended for use in critical life support applications.
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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 MANUAL THOROUGHLY
If any portion of this manual is not understood, contact 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 person­nel to special instructions 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:
0043736 and 0046265.
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, contact a Generac/Guardian Authorized Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs.
When contacting a Generac/Guardian Authorized Dealer 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. ______________
AUTHORIZED
DEALER LOCATION
To locate the nearest GENERAC/GUARDIAN
AUTHORIZED DEALER, please call this number:
1-800-333-1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER.
DANGER
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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
1.2 The Generator................................................4
1.3 Generator AC Connection Systems ................4
1.4 Prepackaged Transfer Switch ........................4
1.5 Automatic System Operation ........................4
1.6 Main Circuit Breaker ....................................5
1.7 Engine Protective Devices ..............................5
1.8 Specifications ................................................5
1.9 Fuel Requirements and
Recommendations..........................................6
1.10 Engine Oil Recommendations ........................7
1.11 Coolant ..........................................................7
1.12 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
2.7 Battery Installation ......................................10
2.8 Preparation Before Start-up ........................11
Section 3 – Operation ....................................12
3.1 Control Console Components ......................12
3.2 Using the Auto/Off/Manual Switch................12
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
4.3 Changing the Engine Air Cleaner ................15
4.4 Spark Plugs ................................................16
4.5 Battery Maintenance ....................................16
4.6 Cooling System ............................................16
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
4.11 Out of Service Procedure ............................18
4.12 Service Schedule..........................................19
Section 5 – Troubleshooting ........................20
5.1 Troubleshooting Guide ................................20
Section 6 – Installation Diagram ................21
Section 7 – Electrical Data ............................22
Section 8 – Exploded Views and
Parts Lists ....................................30
Section 9 – Notes ............................................58
Section 10 – Warranty ....................................60
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 using a procedure, work method or operating technique Generac does not specifically recommend, satisfy your­self that it is safe for others. Also make sure the proce­dure, work method or operating technique 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 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.
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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.
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This product contains or emits chemicals known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:
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DANGER
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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.
ELE
CTRICAL 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 generator 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 dry 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.
FIRE HAZARDS
• 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 fuel-gas 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 LIFTING THE GENERATOR
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 240VAC, 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 120VAC, 60-Hertz output. When
the two windings are connected in series, a 240VAC, 60­Hertz 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 PREPACKAGED TRANSFER SWITCH
The transfer switch shipped with this generator is rated 200 amps maximum at 120/240VAC single-phase. The enclosure of the transfer switch is NEMA 3R. This type of enclosure is intended for outdoor use but it can be mounted indoors. It also protects enclosed parts from windblown dust and water. The enclosure is sealed for dust, rain or sleet and is ice resistant.
Follow these rules:
• Install the transfer switch on a firm, sturdy support­ing structure.
• To prevent switch distortion, level the switch if nec­essary. This can be done by placing washers between the switch enclosure and mounting surface.
• Never install the switch where any corrosive sub­stance might drop onto the enclosure.
• Where practical, protect the switch against excessive moisture, dust, dirt, lint, and construction grit. Always prevent corrosive vapors from coming in con­tact with enclosure.
1.5 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.
Section 1 — General Information
Guardian Liquid-cooled 40 kW Generator
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Neutral Block
1.6 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:
1.7 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.
1.7.1 LOW OIL PRESSURE 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
1.7.2 HIGH COOLANT TEMPERATURE 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).
1.7.3 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).
1.7.4 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.
1.7.5 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.
1.7.6 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.
1.8 SPECIFICATIONS
1.8.1 GENERATOR
Models ..............................................0043736, 0046265
Rated Maximum Continuous
AC Power Output (kW)*..................................................40
Rated Voltage (volts) ................................................120/240
Rated Maximum Continuous
Current at 240 Volts, Single-phase (amps)................................167
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
Stator Insulation ....................................................Class “H”
Rotor Insulation ......................................................Class “F”
*Rated power of generator is subject to and limited by such factors as ambient tempera-
ture, 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 gener-
ator is limited by maximum engine power.
Section 1 — General Information
Guardian Liquid-cooled 40 kW Generator
Generac®Power Systems, Inc. 5
Model Number Circuit Breaker Rating
0043736 200-amp breaker 0046265 200-amp breaker
6 Generac®Power Systems, Inc.
1.8.2 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.
1.8.3 ENGINE
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 deionized water.
Fuel Consumption
Natural Gas ..............................................................720 cfh
LP Gas ..........................................................288 cfh/7.9gph
1.9 FUEL REQUIREMENTS
AND RECOMMENDATIONS
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 the fuel supplier for the Btu content of the 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.
1.9.1 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 1.3).
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 1.3 – Conversion to LP Gas Vapor
Section 1 — General Information
Guardian Liquid-cooled 40 kW Generator
1.10 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.
1.11 COOLANT
Use a mixture of half low silicate, ethylene glycol base antifreeze and half deionized water. Use only deionized 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 50-50 mixture.
Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result.
Ethylene glycol base antifreeze is poisonous. Do not use mouth to siphon coolant from the radia­tor, recovery bottle or any container. Wash hands thoroughly after handling. Never store used antifreeze in an open container because animals are attracted 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.
1.12 EMISSIONS CONTROL SYSTEM
(MODEL 0046265)
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 brake horse­power) 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 1.4 - Emissions Control System
1.12.1 AIR FUEL 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.
This genset must be installed on a level surface. The base frame must be level within 1/2 inch all around.
After the system has been installed, do nothing that might render the installation in noncompliance with such codes, standards and regulations.
NOTE:
For more information about the installation of a stand­by system, 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, STATIONARY 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 (EMERGENCY) 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. 0E5782) in conjunction with this generator.
Section 2 — Installation
Guardian Liquid-cooled 40 kW Generator
STANDBY GENERATOR 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 “Pre-packaged” 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.
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Figure 2.1 – Basic Standby Electric System
2.2 EMERGENCY CIRCUIT ISOLATION METHOD
This method 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 CIRCUIT 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 disconnect circuit breaker and the building distribution panel.
2.4 GROUNDING THE GENERATOR
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 the 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 TRANSFER SWITCH START SIGNAL CONNECTIONS
2.6.1 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 should be in a separate conduit from the main AC output wires.
2.6.2 “GTS” Type Engineered 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.
NOTE:
When using a GTS switch, it is necessary to connect a 240V AC supply to N1 and N2 terminals of the generator to provide for battery charging. Wires T1, T2, 23 and 194 should not be connected.
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Guardian Liquid-cooled 40 kW Generator
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2.7 BATTERY 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 acid-
neutralizing 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 Section 4.5, “Battery Maintenance”. All batteries must be at 100 percent state­of-charge 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.
Section 2 — Installation
Guardian Liquid-cooled 40 kW Generator
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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.
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 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 Section 1.8, “Specifications”, for more information.
2.8.3 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 Section 1.8, “Specifications” and Section 1.10, “Engine Oil Recommendations”.
NOTE:
This engine is shipped from the manufacturer with SAE 15W-40 oil. This oil should be changed after 30 hours of operation.
2.8.4 ENGINE COOLANT
Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See Section 1.8, “Specifications” and Section 1.11, “Coolant”.
2.8.5 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).
2.8.6 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.
2.8.7 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
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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 VOLTMETER
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). Frequency 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 the 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 AMP INLINE FUSE (NOT SHOWN)
This inline fuse is connected in the 15A line that runs between the AUTO/OFF/MANUAL switch and position 10 of the 076009A 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)
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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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 OPERATION
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 AUTO.
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 the engine-generator output.
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 HEATER
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. The block heater must be connected to a customer supplied 120V AC circuit.
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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 ENGINE OIL LEVEL
For oil capacities, see “Specifications,” Section 1.8. 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 “Full” mark. If nec­essary, add oil to the “Full” mark only. DO NOT FILL ABOVE THE “FULL” MARK.
3. Install the dipstick.
Figure 4.1 – Oil Dipstick and Fill
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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OUTLET
INLE
OIL FILL CAP
OIL DIPSTICK
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4.2 CHANGING THE ENGINE OIL AND FILTER
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, 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) for engine oil and filter change frequencies.
Drain the oil while the engine is still warm from run­ning. 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 clean 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 ENGINE AIR
CLEANER
To replace the engine air cleaner, (Generac part num­ber 0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover. (See Figure
4.3).
Figure 4.3 – Engine Air Cleaner
See the “Service Schedule,” Section 4.12, for recom­mended air cleaner maintenance.
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Air Cleaner
OIL FILTER
OIL DRAIN HOSE
TO BASE
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4.4 SPARK PLUGS
Reset the spark plug gap or replace the spark plugs as necessary. See Section 4.12.
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, 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. 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.
4.5.1 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.
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.
Section 4 — Maintenance
Guardian Liquid-cooled 40 kW Generator
0.045 inch (1.1 mm)
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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, 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.
• 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.
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, closing off any gap between the access holes and the wires.
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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. 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 the 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 30 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 the nearest Generac/Guardian Authorized Dealer for assistance.
Generac®Power Systems, Inc. 21
Section 6 — Installation Diagram
Guardian Liquid-cooled 40 kW Generator
Drawing No. 0E7015
S16
S15
9
9
S1
R
S
D
GO
D
UE
UE
CK
98647
22 Generac®Power Systems, Inc.
Section 7 — Electrical Data
(Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generator Electrical Schematic (Stepper Motor) – Drawing No. 0A5858
P/N
BLA
BL
T
2
1
LEGEN
B -
HZ - FREQUENCY METE
TB1 - TERMINAL BLOCK
VERNOR CONTROL BOAR
BL
Generac®Power Systems, Inc. 23
AC
O
O
G O C
C
TO GO
O
, C
O
CO
C
O
, ,
U
O
C
O
G
GU
O
S
C
S
C
S
S
C
U
O/
U
/O
S
C
S
S
C
O
S
O
U
S
S
G
C
C
O
GO
O
CO
O
U
,
,
,
,
OU C
CU
C
O
G
U
C
OR
C
CU
O
CO
O
G
U
U
BLAC
U
C
RED
225A
0
15C
239
56
178
15A
14
194
23
8
4
229
5
CK 5
229
U
U
229
0
0
0
1
4
150
69
86
8
68
56
218
9
6
6
5
5
U
8
8
229
178
6
5
6
6
5
5
6
U
5
6
5
6
6
U
6
5
5
8
8
8
C
U
U
C
G
SS
CO
C
O
,
US
5
S
Q
L
J
H
/
U
,
,
SU
U
US
9
2
1 8
Section 6 — Electrical Data
(Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generator
Wiring Diagram — Pre-pack Panel (4.3L) – Drawing No. 0D4992-A
E L
E L
1
1
1
7
1
1
E L
1
1
1
1
1
E
1
L
4
7
1
1
4
7
7
1
1
1
P
4
7
7
N1
4
7
1
4
1
7
4
1
1
AL
5C
FF
MAN
A
TART
7
7
W1
7
5
4
5
5
5C
. .
A 2
A
1
5
E L
7
1
1
2
5
E L
B
1
3 PHASE
1 PHASE
16
AP
LA
E L
E L
1
2
2
161
K
2
B1
9
E L
K
K
LA
LA
K
E L
ED WIRE END
N
LATE
SE BLUE WIRE FOR 240V
SE YELLOW WIRE FOR 208V
N
2
LA
R
N
N
LAT
E RE
LTA
V
R
BATTERY VOLTAGE
END
AC OUTPUT CURRENT
IT
E
W
K
WN
LA
R
RAN
ELL
TUAT
R
VERN
R
E
MATI T
APA
AP -
VM - METER
M - METER
VR - A
NIT
N
TI
LLER
NNE
NTR
R
A IN-LINE
VERN
INE HARNE
E 7.
-
H - EN
1 - FUSE 15A
2 - F
TI
NNE
FREQUENCY
RMETER
WER PANEL
- L
Z - METER
M - H
P
ITATI
LOWER PANEL
12A
IT BREAKER- EX
IR
1 - DIODE- 600V
B1 -
P - CONNECTION
LLER
NTR
AT
ARD
LT INDI
IT B
HT - FA
IR
B -
1 - LI
R
FF
T
E
AL
I
ELE
MAN
E
T
ET EXER
FIELD BOOST
H- PHA
H-
H- A
WIT
WIT
WIT
W -
1 - RESISTOR
W2 -
W1 -
24 VA
IN
EN
TILITY
RMER
AC OUTPUT VOLTAGE
F
TS2 - TERMINAL STRIPS
M - METER
S1
R1 - TRAN
TO LO
CO
CTOR C
TO
CO
CTO
C
S
3-7
3-7
S
S
C
O
S
C
O
2
OS
O
O
SU
U
US
,
,
,
R
,
,
,
, ,
C
CU
O
CO
O
,
C
C
O
C
CU
C
O
GO
O
CO
O
U
,
OU US
5
S
,
6
, ,
G
5
,
S
6
5
9
8
6
5
5
9
U
GO
O
U
O
C
O O
C
BRO
BLAC
U
O
Y
C
C
Y
8
U
5
5
6
6
8
6
U
C
U
U
C
U
O
C
O
G
GU
O
6
6
5
8
8
8
US
5
S
24 Generac®Power Systems, Inc.
Section 7 — Electrical Data
(Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generator Electrical Schematic — Pre-pack Panel (4.3L) – Drawing No. 0D4993-A
R
N
3 PHASE
1 PHASE
ED WIRE END
N
LATE
SE YELLOW WIRE FOR 208V
SE BLUE WIRE FOR 240V
N
END E
LAT
E RE
LTA
V
BATTERY VOLTAGE
AC OUTPUT CURRENT
MATI T
VM - METER
M - METER
VR - A
ITATI
12A
R
IT
AMP
IT BREAKER - EX
E 1
APA
IR
AP -
B1 -
1 - DIODE- 600V
1 - F
NIT
LLER
NTR
IN-LINE
R
AMP
VERN
E 7.
-
2 - F
LLER
NTR
ARD
IT B
FREQUENCY
FAULT INDICATOR
RMETER
IR
B -
Z - METER
M - H
1 - LIGHT
UTILITY SENSING 24VA
FIELD BOOST
PHASE SELECTO
SET EXERCISE
AUTO/OFF/MANUAL
1 - RESISTOR
SW - SWITCH
W2 - SWITCH
W1 - SWITCH
R1 - TRANSFORMER
AC OUTPUT VOLTAGE
TS2 - TERMINAL STRIP
M - METER
S1
R
VERN
7
4
4
7
R
AT T
7
7
4
E L
E L
WN IN
H
N
ITI
FF P
W2
. .
A 2
A
A
A
7
A 2
W1
7
A
7
4
7
B
AP
1
1
1
ELLOW
K
LA
K
LA
E
E
L
L
E
E
L
L
H
WIT
W
R T
ELE
E
HA
K
LA
RANGE
ELLOW
WN
K
N
ITI
2
K
LA
R T
LLER
NNE
NTR
T
NTA
- 14
- 18 - 14
-
2 -
4
7
2
2
1
1
1
1
1
2
1
1
T
22
R EH)
NNE
ENGINE (
1
1
NNE
P)
7
WER PANEL (
4
7
Generac®Power Systems, Inc. 25
5
8
K
M
S
X
6
O
CO
C
O
O
CO
C
O
0/
0
S
O
3
0
O
00 O
00
0
US
U
S
5
6
C
O
G
O
C
,
G
O
O
O
C
CU
S
O
C
CU
O
S
O ,
CO
O
CO
C
O
O
U
OC
C
)
S
5
6
5
O
S
G
C
G
S
8
S
CO
C
O
OS
S
O
G
(
)
US
O
G
SC
5
6
0/
0
S
TO CO
O
CO
CTOR C
C
G
S
C
C
O
C
G
G
Section 7 — Electrical Data
Guardian Liquid-cooled 40 kW Generator
Wiring Diagram/Schematic – Lower Panel – Drawing No. 0D5997
T
N
TI
ENERA
NNE
TART
TANDARD
M
R
-WIRE
4
390mm
LDER
H H
R
REW.
. T
.
LEAD 4
BEARIN
T T E
L
RUSH WITH RED
T
IRE
7
T2
T1
7
7
1
1
1
4
1
7
1
7
1
1
1
1
7
B2
P
4
R
R T
TAT
R R
R
= ALTERNAT
R = ALTERNAT
END E
V.
24
E
1 T
WER PANEL
R L T
NNE
TER
RMER
PRE-PACKAGED TRANSFER SWITCH CONNECTION
K
F
TE
N WINDIN
L PANEL
IT BREAKER - MAIN
TRAL BL
ITATI
NTR
IR
RRENT TRAN
P =
B = NE
P = THERMAL PR
B2 =
PE = EX
S3 = TERMINAL STRIP
T2 =
T1 &
N
TI
E
NNE
V. 1-PHA
MER T
24 2
V. 2
T
1 T
2-WIRE START CONNECTION
S4 = TERMINAL STRIP
RAM
DIA
IRIN
N
E
H
TI
KA
FER
WIT
NNE
RAN
REPA
NTR
L PANEL (
1
4
N
TI
NNE
E
1
MER
B2
T
-V. 1-PHA
24 2
HEMATI
NIT
H
R
NNE
P)
T2
4
7
1
T1
C
C
C
4
BLAC
U
C U
U
239
225A
0
15C
178
15E
14
8
6
6
9
5
5
U
6
5
6
5
C
5 6
6
229
5
219
83
229
178
8
6
5
8
6
8
5
5
6
6
6
5
6
K
/
U
O
14
0
160
161
79
0
160
161
79
0
0
0
446
6
5
5
,
,
SU
U
US
BAT
BAT
AC
AC
MPU
MPU
M
26 Generac®Power Systems, Inc.
Section 7 — Electrical Data
(Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generators Wiring Diagram - Control Panel - Drawing No. 0D6974
1
1
1
1
1
7
1
1
1
1
1
7
4
1
1
4
7
4
7
1
1
1
P
4
7
7
4
78
4
7
1
1
1
4
AL
MAN
TART
FF
T
7
W1
. .
W2
A 2
E
1
E L
7
1
1
2
5
E L
B
1
RD
AP
K
LA
PU SHIELD
-
+
T-
F
T+
-
+
4
1
2
B1
2 1
2
161
1
K
LA
2
K
LA
E L
E L
K
3 PHASE
1 PHASE
ED WIRE END
N
LATE
SE BLUE WIRE FOR 240V
SE YELLOW WIRE FOR 208V
N
Generac®Power Systems, Inc. 27
,
,
,
,
, ,
,
C
C
O
C
CU
C
O
C
O
O
CO
O
US
5
S
,
, ,
G
,
U
O
C
O
G
GU
O
TO LO
CO
CTOR C
8
C
S
C
OS
8 7 7
3
C
S
2
O
TO
CO
CTO
6
5
9
6
S
S
C
O
S
C
6
5
6
6
5
5
9
5
8
8
9
,
SU
U
US
8
AC
MPU
M
AC
8
C
,
U
C
5
6
6
U
5
C
Y
6
8
O
OS
O
MPU
160
79
0
161
0
0
161
79
160
0
US
5
S
Section 7 — Electrical Data
(Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generators
Electrical Schematic - Control Panel - Drawing No. 0D6975
1
3 PHASE
1 PHASE
ED WIRE END
N
LATE
SE YELLOW WIRE FOR 208V
SE BLUE WIRE FOR 240V
N
7
R
N
LAT
ITATI
E RE
LTA
V
R
BATTERY VOLTAGE
IT
AC OUTPUT CURRENT
IT BREAKER - EX
MATI T
END
1
E
VM - METER
M - METER
VR - A
APA
IR
AP -
B1 -
AMP
E 1
1 - F
IN-LINE
AMP
E 7.
2 - F
LLER
NTR
W
PHASE SELECTOR
FREQUENCY
FAULT INDICATOR
WER FL
- P
Z - METER
F
SW - SWITCH
1 - LIGHT
UTILITY SENSING 24VA
FIELD BOOST
SET EXERCISE
AUTO/OFF/MANUAL
TS2 - TERMINAL STRIP
R1 - TRANSFORMER
1 - RESISTOR
W2 - SWITCH
W1 - SWITCH
TS1
AC OUTPUT VOLTAGE
M - METER
7
7
4
.
WN IN
H
.
N
ITI
W2
FF P
A 2
4
E L
E L
ELLOW
K
2
LA
2
4
4
7
A
A
7
A 2
7
E
7
4
-
7
2
B
AP
1
1
1
2
H
1
WIT
W
R T
ELE
E
HA
1
PU SHIELD
-
+
F
T-
T+
N
ITI
T
NTA
-
ED
L
ATE
INDI
-11-
- 14
- 16 - 1
-11-
M
4
7
2
1
1
1
1
2
1
1
7
4
7
2
1
1
R EH)
NNE
ENGINE (
NNE
P)
WER PANEL (
)
)
1
2
C1
S
N
CK
:
S
3
0
3
3
CK
D
3
6
6
:
S:
:
C:
:
S:
:
60
3
9
61
)
OR
SSU
CH
OR
SOR
CH
C
OR
D
R
1
L
D
R
Y
C
Y
60
S
E
CK
CT
9/C
R
61
28 Generac®Power Systems, Inc.
Section 7 — Electrical Data
Guardian Liquid-cooled 40 kW Generators Wiring Diagram - Drawing No. 0E2966
E
1 1
1
1
WL
H
BLA
BAR
7
7
1
1
1
1
1
1
1
1
N
BLA
-
+
LEGEND ACT
ACTUATOR ELECTRONIC GOVERNOR D
ALTERNAT
LEA
120VA
TILIT
PPL
F
REE
BLA
NTROL CONTACT
EC1
ENGINE CONNECTOR 1(BLACK ENGINE HEATE
F
FUEL SOLENOI
ND
ROUN
LANT HIGH TEMP. SWIT
I
IGNITION COI IGNITION DISTRIBUT LOW OIL PRE MAGNETIC PICKUP
M
TARTE
WL
WATER LEVEL SEN
NLY USED ON EMISSIONS MODEL
RE SWIT
Generac®Power Systems, Inc. 29
T
(+)-)
CT
CT
S
60
61
OS
S
61
60
9/C
R
E
CK
9
3
C1
0
S
OR
1
OR
CH
)
L
SSU
CH
R
D
OR
SOR
:
OR
OR
OR
Y
Y
C
CK
CK
N
6
C
:
:
CT
:
C:
S:
OS:
:
3
3
Section 7 — Electrical Data
Guardian Liquid-cooled 40 kW Generators
Wiring Diagram - Drawing No. 0E2967
A
12V BATTER
BLA
H
WL
1 1
1
1
E
BLA
BAR
L
F
7
LEA
7
1
1
AL
I
1
1
1
LEGEND ACT
EC1
BLA
REE
120VA
TILIT
PPL
NLY USED ON EMISSIONS MODEL
FS H I
L
WL
ACTUATOR ELECTRONIC GOVERN DC ALTERNAT
NTROL CONTACT ENGINE CONNECTOR 1(BLACK ENGINE HEATE FUEL SOLENOI
LANT HIGH TEMP. SWIT IGNITION COI IGNITION DISTRIBUT LOW OIL PRE MAGNETIC PICKUP
TARTER CONTACT
M
TARTER MOT
WATER LEVEL SEN
RE SWIT
30 Generac®Power Systems, Inc.
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators Mounting Base - Drawing No. 0E6976-A
0
8
6
5
5
6
3
CK
9
9
3
0
D
R
8
.
n
3
8
5
9
0
2
BLA
2
TO STARTE
LENOI
2
1
1
1
1
1
2
To Oil Drai
n Oil Pan
1
2
1
1
2
1
2
Generac®Power Systems, Inc. 31
ITEM PART NO. QTY. DESCRIPTION
10E6900 1 MTG BASE 4.3L D/D PRE-PACK 2 038804T 1 CABLE BATT RED #1 X 31.00 3 055414 1 LUG SLDLSS #2-#8 X 17/64 CU 4 0A4084 REF. MOUNT ENGINE (R&L) 5 022129 2 WASHER LOCK M8-5/16 6 045771 2 NUT HEX M8-1.25 G8 YEL CHR 7 022237 7 WASHER LOCK 3/8 8029745 6 SCREW HHC 3/8-16 X 1 G5
9 023152 1 SCREW HHC 3/8-16 X 3/4 G5 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 1 HOSE 5/8 ID TYPE 3 SINGLE (11"LG) 24 024310 1 PLUG STD PIPE 1/2 STEEL SQ HD 25 0D4239D 1 KIT VARMIT GUARD 4.3L PRE-PACK 26 038805H 1 CABLE BATT BLK #1 X 23.00 27 022131 1 WASHER FLAT 3/8-M10 ZINC 28 025507 1 WASHER SHAKEPROOF EXT 7/16 STL 29 061902 1 HOLD DOWN BATTERY 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 34 0A4010 2 SCREW HHC M8-1.25 X 60 G8.8 FT 35 052858 2 NUT LOCK FL M8-1.25 36 058665 1 BATT 12VDC 90-AH 27F 37 059473 1 HOLD DOWN BATTERY 38 049820 2 NUT LOCK HEX M8-1.25 NYL INSRT 39 075763 1 BOOT BATTERY CABLE
Section 7 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators
Mounting Base - Drawing No. 0E6976-A
32 Generac®Power Systems, Inc.
)
S
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators Compartment - Drawing No. 0D8992-A
E A
2
4
ONE PER SIDE
1
6
Generac®Power Systems, Inc. 33
ITEM PART NO. QTY. DESCRIPTION
1 0C3594 10 ASSEMBLY M6 HINGE
2 0E3257 4 SCREW TH-FRM M6 W/CAP SHKPRF W
3 0A3359 40 SCREW BHSC M6-1.0 X 16 SS 4 * 022769 5 WASHER SHAKEPROOF INT #10
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 0F1255 (A) 4 BRACE SIDE TOP AND BOTTOM 12 0C2555 (A) 2 SIDE SUPPORT 13 0C2560A 1 ROOF ONE-PC WELD ALUMINUM 15 0D7904 (A) 1 FRONT BRACE TOP 16 0C2633 5 PLATE STRIKER 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 23 0C4064 (A) 1 DUCT FRONT RH 24 0C4066 (A) 1 DUCT BOTTOM 25 0C4067 (A) 1 DUCT FRONT PANEL 26 0C4117A 1 DUCT FRONT TOP RH ALUMINUM
27 ** 077992 28 NUT HEX LOCK M6-1.0 SS NY INS
28 0C2634A 1 ASSEMBLY COVER ACCESS 29 0C2454 72 SCREW TH-FRM M6-1 X 16 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 1 WASHER FLAT M6-1/4 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.
* ONE PER PADDLE HANDLE ** ALUMINUM ENCLOSURE NOTE: ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 2 & 29 THREAD
FORMING FASTENER AND ITEM 27 LOCK NUT. LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS. ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER.
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators
Compartment - Drawing No. 0D8992-A
34 Generac®Power Systems, Inc.
A
S
C
,
988
Section 8 — Exploded Views and Parts Lists
(Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generator Control Panel 4.3L – Drawing No. 0D4995-F
4
IDE. N
E
ANEL FA
1
AT TIME SET.
VERY 7 DAYS
1
2
2
2
1
1
1
7
4
2
1
0
7
4
2
-
2
Generac®Power Systems, Inc. 35
ITEM PART NO. QTY. DESCRIPTION
1 0D5488 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 VOLTAGE REGULATOR 60HZ 5 0C8243 1 WASHER LOCK HDPDEUTSCH 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 REF. 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 6 WASHER FLAT #6 ZINC 54 036918 4 SCREW PPHM #8-32 X 1/2 55 022264 4 WASHER LOCK M4 56 038150 4 WASHER FLAT #8 ZINC 57 022471 4 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 REF. FUSE & HOLDER LITTEL 7.5A 63* 0A9611 REF. FUSE 7.5AXBK/AGC7.5NX W/22670
64 074908 1 SCREW HHTT M5-0.8 X 10 BP
65 0E3783 1 DECAL, WARNING REMOVE FUSE
* PART OF CONTROL PANEL WIRE HARNESS
Section 8 — Exploded Views and Parts Lists
(Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generator
Control Panel 4.3L – Drawing No. 0D4995-F
36 Generac®Power Systems, Inc.
Section 8 — Exploded Views and Parts Lists
(Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generator Control Panel – Drawing No. 0D6978-C
Generac®Power Systems, Inc. 37
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 VOLTAGE REGULATOR 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 0E3550 1 CHASSIS, UNIVERSAL 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 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 32 070042 1 FREQUENCY METER 240V 55-65HZ
ITEM PART NO. QTY. DESCRIPTION
33 081988 1 DECAL EXERCISE INFO 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 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 W/22670
64 074908 4 SCREW HHTT M5-0.8 X 10 BP
65 0E3783 1 DECAL, WARNING REMOVE FUSE
* PART OF CONTROL PANEL WIRE HARNESS
Section 8 — Exploded Views and Parts Lists
(Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generator
Control Panel – Drawing No. 0D6978-C
38 Generac®Power Systems, Inc.
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators Connection Box – Drawing No. 0E6892-A
Generac®Power Systems, Inc. 39
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators
Connection Box – Drawing No. 0E6892-A
ITEM PART NO. QTY. DESCRIPTION
1 0E6353 1 LOWER PANEL 15 2 0D5489 1 COVER LOWER CONNECTION BOX 3 0E6427 1 PLATE GLAND 4 023484N 2 BUSHING SNAP SB-2.5-31 5 0E6454 1 BRACKET NEUTRAL 6 056739 1 RELAY SOLENOID 12VDC PNL MNT 7 0C2454 2 SCREW THF M6-1X16 N WA Z/JS 8 051715 2 NUT HEX M4-0.7 G8 YEL CHR
9 0D3388 1 DECAL REMOTE START CONNECTION 10 058710 2 TRANSFORMER 200A TO 5A 5VA 11 0D5492 1 HARNESS LOWER PANEL 4.3L GRDN
(048766) REF. BLOCK TERM 20A 2 X 6 X 1100V 12 022985 2 WASHER FLAT #6 ZINC 13 0E6689 1 COVER LOWER 14 022264 2 WASHER LOCK M4 15 052813 2 SCREW HHC M4-0.7 X 20 G8.8 16 039253 4 SCREW HHC M8-1.25 X 20 G8.8 17 022145 6 WASHER FLAT 5/16 ZINC 18 0D5840 1 DECAL CUSTOMER CONNECTN FOR TS 19 022129 5 WASHER LOCK M8-5/16 20 045771 5 NUT HEX M8-1.25 G8 YEL CHR 21 022287 28 SCREW HHC 1/4-20 X 3/4 G5 22 022473 36 WASHER FLAT 1/4 ZINC 23 022097 34 WASHER LOCK M6-1/4 24 022127 6 NUT HEX 1/4-20 STEEL 25 0E4458 1 CB 0200A 240V 2P S QJ22B200HL 26 0E5586 1 PLATE CB MOUNT S (QJ 2P) 390S 27 0E5587 1 COVER TERMINALS S (QJ 2P) 28 022237 4 WASHER LOCK 3/8 29 022241 2 NUT HEX 3/8-16 STEEL 30 081320 2 SCREW SHC 1/4-20 X 4.5 G8.8 NZ 31 048527 2 SCREW SHC 3/8-16 X 3/4 G5 32 0D5464B 1 NEUTRAL BLOCK 390/200-400A 33 057073 2 JUNCTION BLOCK 3/8-16 34 0C2266 4 SCREW PHTT M5-0.8 X 16 ZYC
40 Generac®Power Systems, Inc.
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(
)
,
O
3/
U
G
U
O
O
G
U
G
S
JUS
U
O
JUS
G
G O
S
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators Generator – Drawing No. 0E6891
R
TAT
EAD
LL DETAI
4
R
7
2
INE FLYWHEEL
EN
1
TMENT.
AD
T.
THI
RIN
THEN BACK OFF
HTEN N
UNTIL CONTACT 6
INE D
TMENT
INE
EN
TE:
RN AND TI
4 T
2 T
HREAD IN SENSOR
S MADE WITH RING GEAR
N:
TI A
TATE EN
T R
N
lLYWHEEL AD
Generac®Power Systems, Inc. 41
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators
Generator – Drawing No. 0E6891
ITEM PART NO. QTY. DESCRIPTION
1 051768 7 SCREW HHC M12-1.75 X 25 G8.8 2 051769 7 WASHER LOCK M12 3 0A8240 2 FLEX PLATE SAE10 4039253 6 SCREW HHC M8-1.25 X 20 G8.8 5 022129 7 WASHER LOCK M8-5/16 6 082130D 1 ASSEMBLY MAG PICKUP 72"
7 0C4286 1 ASSEMBLY FAN W/PRESS DISC 10.75 X 3 8 * 0A2601 1 SCREW HHC M16-2.0 X 45 G8.8 9 * 0A2602 1 WASHER FLAT .688 ID X 3.25 OD
10 * 0A1138 1 KEY SQ 3/8 X 2-1/2 STEEL 11 * 021941 1 COUPLER 390 SAE
12 020808A 1 ROTOR 390 40 1P DIRECT 13 * 052624 1 BEARING BALL 6212 SEALED 14 * 070892 1 SLIP RING -MACHINED-
15 0A5580 4 SCREW HHC M14-2.0 X 140 G8.8
16 0A1633 4 WASHER 390 SAE ALT.
17 020729A 1 STATOR 390 40 AD2 SAE
18 022131 12 WASHER FLAT 3/8-M10 ZINC
19 022237 11 WASHER LOCK 3/8
20 022511 11 SCREW HHC 3/8-16 X 1-1/4 G5
21 068113 1 CARRIER REAR BEARING 15"
22 0E6353 1 LOWER PANEL 15
23 043123 4 WASHER LOCK M14
24 051779 4 NUT HEX M14-2.0 G8 YEL CHR
25 046852 1 SCREW HHTT #10-32 X 1/4 CZ
26 022145 1 WASHER FLAT 5/16 ZINC
27 039287 4 SCREW HHC M8-1.25 X 45 G8.8 FT
28 071641 1 BRUSH HOLDER ASSEMBLY
29 071639 1 HOLDER BRUSH SUPPORT
30 0A2110 2 SCREW SWAGE 1/4-20 X 1/2 Z/YC
31 022473 8 WASHER FLAT 1/4 ZINC
32 022746 1 SCREW HHC 3/8-16 X 1-3/4 G5
33 031980 2 TIE WRAP UL 14.6 X .14 NATL
34 083549 1 SLEEVE RUBBER
35 0A4089 1 ASSEMBLY SCROLL 390 SAE
KIT 0A4089 PAR T S 36 0A2491 2 SHROUD ALTERNATOR SHEET METAL 37 0A2497 2 SCREEN SHROUD SAE 38 0A2496 2 BRACKET TENSIONER SAE SCROLL 39 056326 8.4 FT TRIM VINYL BLACK 1/8 GP 40 022097 6 WASHER LOCK M6-1/4 41 045757 2 SCREW HHC M6-1.0 X 25 G8.8 42 047411 4 SCREW HHC M6-1.0 X 16 G8.8 43 0A2110 12 SCREW SWAGE 1/4-20 X 1/2 Z/YC
* ROTOR REPLACEMENT PARTS
42 Generac®Power Systems, Inc.
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators Engine – Drawing No. 0D6980-D
Generac®Power Systems, Inc. 43
ITEM PART NO. QTY. DESCRIPTION
10A9046 1 ENGINE 4.3L GM 20A9118A 1 FLYWHL 4.3L GM SAE 3 070022 1 WASHER STAR M12 EXT 4 0A6021 6 SCREW HHC 7/16-20 X 1 G8 6059056A 1 STARTER 5.7L/7.4L GM 80A9050 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 THERMOSET 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 25 029745 3 SCREW HHC 3/8-16 X 1 G5 26 044101 2 BRACKET SUPPORT SPARK PLUG WIRE 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 0C7947A 2 U BOLT 3/8-16 2.5" I.D. 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 057795A 1 BARBED EL 90 3/4 PLASTIC 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 0E0561 1 ASSY WATER LEVEL SENSOR 42 0D2244M 1 ASSY MAGPICKUP (3/8-24 MALE) (MODEL 004626 0NLY) 43 075885 1 THERMOSTAT 195 DEG 44 0C7947B 2 SADDLE 2 1/2"
* 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)
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators
Engine – Drawing No. 0D6980-D
44 Generac®Power Systems, Inc.
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators Engine – Drawing No. 0A4304-N
8
4
1
4
7
1
2
Generac®Power Systems, Inc. 45
ITEM PART NO. QTY. DESCRIPTION
10A9046 1 ENGINE 4.3L GM
2 0A4084 2 MOUNT ENGINE (R & L)
3 0A4239 1 PULLEY CRANKSHAFT
4 0A4240 1 PULLEY WATER PUMP
5 0A5640 1 SPACER FAN 50MM 4.3L (35KW 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 0C7947A 2 U BOLT 3/8-16 2.5" I.D. 19 0A1232 1 DC ALTERNATOR ASSEMBLY 20 0A7801B 1 PULLEY PLOY-V 82 OD. 21 021928 1 BRACKET ALT. SUPPORT 22 0C6239 1 BRACKET MOUNTING WELD ASSEMBLY 23 0A4241 1 PULLEY GROOVED IDLER 24 0C2885 1 PULLEY TENSIONER 25 0A5737C 1 SPACER DC ALTERNATOR 34MM 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 BOLT TENSIONER PULLEY 43 045772 2 NUT HEX M10-1.5 G8 YEL CHR 44 0A37970172 8 SPARK PLUG 45 052259 1 WASHER FLAT M12 46 055934D 1 CLAMP VINYL 1.06 X .406 Z 47 0A37970001 1 FILTER OIL 48 0A1646 1 WASHER FLAT M16 49 056739 1 RELAY SOLENOID 12VDC PNL MNT (NOT SHOWN) 50 0C7947B 2 SADDLE 2 1/2"
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators
Engine – Drawing No. 0A4304-N
O
0
9
O
0
9
8
O
0
8
46 Generac®Power Systems, Inc.
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators
4.3L Radiator – Drawing No. 0D7992-E
2
121 D
.
"A"
IT PART N
47
D7 .
IT PART N
"
2
4
D7 .
4
IT PART N
1
Generac®Power Systems, Inc. 47
ITEM PART NO. QTY. DESCRIPTION
1 0D7825A 1 RADIATOR COPPER BRASS 2 0D8251 1 FAN GUARD BOTTOM 3 0D8252 1 FAN GUARD TOP 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 0D7174 1 VENTURI 4.3L 22" FAN
0D7174A 1 VENTURI 4.3L 17" FAN 9 0D7870 1 RADIATOR HOSE LOWER
10 035685 4 CLAMP HOSE #28 1.32 - 2.25 11 047290 1 HOSE 3/8 ID SINGLE BRAID 12 040173 2 CLAMP HOSE #5.5 .62 - .62 14 036865 1 DRAINCOCK 15 029032 1 HOSE 9/32 ID (64" LG) 16 052250 3 TAPE FOAM 1 X 1 (29" LG) 17 058443 10 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 0D7850 1 RADIATOR HOSE UPPER 22 076749 1 BOTTLE COOLANT RECOVERY 23 0D7975 1 WATER BOTTLE BRACKET 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 GRP 30 * 0A6984 1 BRACKET AIR DUCT TOP/BOT 31 * 0D7942 1 SUPPORT AIR DUCT RH SIDE 32 * 0D7943 1 SUPPORT AIR DUCT LH SIDE 33 * 022413 8 SCREW HHC 1/4-20 X 1 G5 34 * 022097 8 WASHER LOCK M6-1/4 35 * 022473 8 WASHER FLAT 1/4 ZINC 36 ** 0D7924 1 SCREEN FRONT 37 ** 024655 4 SCREW HHTT 1/4-20 X 1 CZ 38 ** 022097 4 WASHER LOCK M6-1/4 39 ** 022473 4 WASHER FLAT 1/4 ZINC
40 090283 1 CAP RADIATOR 13 PSI-FOR SERVICE ONLY
* OPTIONAL WITH KIT 0D7948
** OPTIONAL WITH KIT 0D7947
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators
4.3L Radiator – Drawing No. 0D7992-E
ITEM PART NO. QTY. DESCRIPTION
1059902A 1 CAP RAIN 2.50 / 2.69 20C9641 1 TUBE STRAIGHT 'A' GROUP 30C9650 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" 80E0699 1 TUBE, CROSS OVER
9 0E0698 1 TUBE, 90 ELBOW 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
ITEM PART NO. QTY. DESCRIPTION
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 6 BOLT U 3/8-16 X 2.62 20 022237 12 WASHER LOCK 3/8 21 022241 12 NUT HEX 3/8-16 STEEL 22 0E0701 1 SHIELD, CROSSOVER HEAT 23 0E0700 1 SHIELD, EXHAUST HEAT 24 022131 8 WASHER FLAT 3/8-M10 ZINC
48 Generac®Power Systems, Inc.
E
Section 8 — Exploded Views and Parts Lists
(Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generators
4.3L Exhaust – Drawing No. 0E0704-A
.5" DIA. CLAMP ASSEMBLY
MPARTMENT
ENGIN
FRONT
ENGINE
Generac®Power Systems, Inc. 49
ITEM PART NO. QTY. DESCRIPTION
1 037561 1 NUT WING 1/4-20 NYLK
2 0A4632A 1 PLATE AIR CLEANER TOP
3 0A4637 1 FILTER AIR 11.5" CA326
4 0A4632B 1 PLATE,AIR CLEANR BOT
5 062522 1 STUD TH 1/4-20 X 3 G2 ZNC FULL
6 022127 1 NUT HEX 1/4-20 STEEL
7 057796 1 GROMMET
8 057795A 1 BARBED EL 90 3/4 PLASTIC
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators
4.3L Air Cleaner – Drawing No. 0E0712-A
Section 8 — Exploded Views and Parts Lists
(Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generators
4.3L Nat. Gas Fuel System – Drawing No. 0E7011-B
O S
O
50 Generac®Power Systems, Inc.
R
TEPPER
T
7
VER
LD
INTAKE
ANIF
4
Generac®Power Systems, Inc. 51
ITEM PART NO. QTY. DESCRIPTION
1 065907 1 SUPPORT SOLENOID NAT GAS
2 026812 3 ELBOW 90D 3/4 NPT
3 028238 2 BOLT U 5/16-18 X 1.50
4 0C7598 1 ASSY NATURAL GAS SOLENOID
5 026490 2 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 028237 2 SADDLE 1-3/8
9 0E0521 1 SUPPORT REGULATOR 10 022259 4 NUT HEX 5/16-18 STEEL 11 022145 6 WASHER FLAT 5/16 ZINC 12 022129 6 WASHER LOCK M8-5/16 13 030795 2 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 2 NIPPLE TOE 3/4 NPT X 2 18 057824 2 CLAMP HOSE #16 .87 - 1.50 19 057422 1 HOSE 1IN ID LP GAS (42" LG) 20 043123 2 WASHER LOCK M14 21 051779 2 NUT HEX M14-2 G8 YEL CHR 22 082508 REF BALL JOINT PLA .25-28 23 050279 1 DECAL FUEL INLET NG 24 026915 3 NIPPLE CLOSE 3/4 X 1.375 25 055934P 1 CLAMP VINYL 1.62 X .486 Z
26** 0A5737C REF SPACER D.C. ALT. (29MM LONG) (NOT SHOWN)
27 0D1509 1 DECAL INLET PRESSURE 28 061258 1 GASKET AIR CLEANER 29 0A7631 1 CARB. REWORK 4.3L 30 029745 2 SCREW HHC 3/8-16 X 1 G5 31 022237 2 WASHER LOCK 3/8 32 052865 1 GASKET CARBURETOR 33 033212 2 SCREW HHC 5/16-18 X 1-1/4 G5 34 0A4120 1 ADAPTOR CARBURETOR W/INLET 35 064945 1 GASKET CARBURETOR ADAPTOR 36 044074 1 BARBED STR 1/8NPT X 3/8 37 0A4121 1 VALVE PCV 38 047290 1 HOSE 3/8 ID SINGLE BRAID (10") 39 036409 1 NUT HEX 1/4-28 STEEL 40 022097 1 WASHER LOCK M6-1/4 41 0A5763 1 ARM THROTTLE-REWORK
**NOT SHOWN
Section 8 — Exploded Views and Parts Lists
(Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generators
4.3L Nat. Gas Fuel System – Drawing No. 0E7011-B
52 Generac®Power Systems, Inc.
E
O 0
3509 SC
O
L
C
O
Section 8 — Exploded Views and Parts Lists
(Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generators
4.3L Nat. Gas Fuel System – Drawing No. 0E7013-B
L
R
H T
TTA
AN
EMBLY
D
N
7
VER
LD
INTAK
ANIF
4
1
Generac®Power Systems, Inc. 53
ITEM PART NO. QTY. DESCRIPTION
1 065907 1 SUPPORT SOLENOID NAT GAS
2 026812 3 ELBOW 90D 3/4NPT
3 022259 4 NUT HEX 5/16-18 STEEL
4 0C7598 1 ASSY NATURAL GAS SOLENOID
5 026490 2 NIPPLE PIPE 3/4 NPT X 2
6 026577 2 BUSHING REDUCER 1 TO 3/4
7 0D2758 1 REGULATOR N/G (R600S)
8 0E0521 1 SUPPORT REGULATOR
9 028237 2 SADDLE 1-3/8 10 028238 2 BOLT U 5/16-18 X 1.50 11 022145 6 WASHER FLAT 5/16 ZINC 12 022129 6 WASHER LOCK M8-5/16 13 030795 2 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 2 NIPPLE TOE 3/4 NPT X 2 18 057824 2 CLAMP HOSE #16 .87 - 1.50 19 057422 1 HOSE 1IN ID LP GAS (44" LG) 20 043123 2 WASHER LOCK M14 21 051779 2 NUT HEX M14-2 G8 YEL CHR 22 0C7820 1 MACHINING, CARBURETOR ADAPTOR 23 050279 1 DECAL FUEL INLET LPG 24 026915 3 NIPPLE CLOSE 3/4 X 1.375 25 055934P 1 CLAMP VINYL 1.62 X .486 Z
26 ** 0A5737C REF SPACER, D.C. ALT. (29MM LONG)
27 0D1509 1 DECAL INLET PRESSURE 28 061258 1 GASKET AIR CLEANER 29 0C7650A 1 MIXER (EMISSIONS) NATURAL GAS 30 029745 2 SCREW HHC 3/8-16 X 1 G5 31 022237 2 WASHER LOCK 3/8 32 0C7059 1 GASKET GOVERNOR THROTTLE BODY 33 033212 4 SCREW HHC 5/16-18 X 1-1/4 G5 34 0A4120 1 ADAPTOR CARBURETOR W/INLET 35 064945 1 GASKET CARBURETOR ADAPTOR 36 044074 1 BARBED STR 1/8NPT X 3/8 37 0A4121 1 VALVE PCV 38 047290 1 HOSE 3/8 ID SINGLE BRAID (10") 39 0C7060 1 GASKET CARBURETOR ADAPTOR 40 0D3485 1 ASSY THROTTLE PF42 WIRE CONN 41 022152 4 WASHER LOCK #10 42 0C7908 4 SCREW SHC #10-32 X 5/8 G8.8 NZ 43 0A6613 1 GASKET CARB IMPCO 225 44 064090 4 SCREW PHM SEMS #12-24 X 5/8 EX
** NOT SHOWN
Section 8 — Exploded Views and Parts Lists
(Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generators
4.3L Nat. Gas Fuel System – Drawing No. 0E7013-B
54 Generac®Power Systems, Inc.
Section 8 — Exploded Views and Parts Lists
(Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generators Exhaust – Drawing No. 0E1347-A
Generac®Power Systems, Inc. 55
ITEM PART NO. QTY. DESCRIPTION
1059902A 1 CAP RAIN 2.50 / 2.69
20C9641 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 0E0699 1 TUBE, CROSS OVER
9 0E0698 1 TUBE, 90 ELBOW 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 19 080762 6 BOLT U 3/8-16 X 2.62 20 022237 12 WASHER LOCK 3/8 21 022241 12 NUT HEX 3/8-16 STEEL 22 0E0701 1 SHIELD, CROSSOVER HEAT 23 0E0700 1 SHIELD, EXHAUST HEAT 24 077879 1 HOSE VACUUM 5/32 (36"LG) 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 35 0D8780 1 DECAL IMPORTANT EXHAUST EMISSION INFO 36 022131 8 WASHER FLAT 3/8-M10 ZINC
*NOTE: COMPONENT INSTALLED AT WAUKESHA FACILITY
Section 8 — Exploded Views and Parts Lists
(Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generators
Exhaust – Drawing No. 0E1347-A
56 Generac®Power Systems, Inc.
Section 8 — Exploded Views and Parts Lists
(Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generators Electronic Governor – Drawing No. 0A2615-F
ITEM PART NO. QTY. DESCRIPTION
1098290 1 ASSEMBLY MOTOR STEPPER
2 0A3439 1 BRACKET GOVERNOR MOUNTING
3098958A 1 CONNECTOR INTERFACE ASSEMBLY
4 021888 1 LEVER STEPPER MOTOR
5 082508 2 BALL JOINT 1/4-28
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 - NEOPRENE LIQUID COATING (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
Generac®Power Systems, Inc. 57
ITEM PART NO. QTY. DESCRIPTION
1 0C4905 1 BARBED EL 45 FITTING
2 057822 2 CLAMP HOSE #8 .53-1.00
3 077043E 1 CONDUIT FLEX 1" BLACK (15"LG)
4 050967 1 HOSE 5/8 ID RIA 250F (46"LG)
5 0A6283 1 HOSE PREFORMED BLOCK
HEATER 6 057822 2 CLAMP HOSE #8 .53-1.00 7 0C4905 1 BARBED EL 45 3/8NPT X 5/8OD 8 042568 4 SCREW HHC M6-1.0 X 20 G8.8 9 022473 4 WASHER FLAT 1/4-M6 ZINC
10 084918A 1 HEATER ENG 1000W 120V
*084918B 1 HEATER BLOCK 1000W 240V
ITEM PART NO. QTY. DESCRIPTION
11 084427 1 BRACKET HEATER W/WELDNUTS 12 022097 4 WASHER LOCK M6-1/4 13 049813 2 NUT HEX M6 X 1.0 G8 YEL CHR 14 055934D 1 CLAMP VINYL 1.06 X .406 Z (NOT
SHOWN)
15 077043A 1 CONDUIT FLEX .38 ID (42"LG) (NOT
SHOWN) (USED ON HEATER CORD)
16 062303 1 ADAPTOR 1/4" NPT TO 3/8" NPT
*USED ON 50HZ VOLTAGE GENERATORS ONLY. **USED ON NATURAL GAS & L/P VAPOR UNITS ONLY.
6
3
0
T
OUSING
6
5
6
E
OCK
Section 8 — Exploded Views and Parts Lists
Guardian Liquid-cooled 40 kW Generators
Engine Coolant Heater – Drawing No. 0E2352-A
TO THERMOSTA
H
TO ENGIN BL
**1
**
**
**
**
1
1
58 Generac®Power Systems, Inc.
Section 9 – Notes
Guardian Liquid-cooled 40 kW Generators
Generac®Power Systems, Inc. 59
Section 9 – Notes
Guardian Liquid-cooled 40 kW Generators
60 Generac®Power Systems, Inc.
Section 10 – Warranty
Guardian Liquid-cooled 40 kW Generators
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modifi­cation or improper maintenance of your engine.
Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, dur­ing such warranty period, any emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:
As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect , improper maintenance or unap­proved modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.
You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a prob­lem occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility. To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe impor­tant rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty serv­ice, evidence must be presented showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the fol­lowing address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190
Part 1
Generac®Power Systems, Inc. 61
Section 10 – Warranty
Guardian Liquid-cooled 40 kW Generators
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines:
(a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on
the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall con­tinue for 24 consecutive months thereafter.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or
equipment and to each subsequent purchaser/owner that each of its engines is ...
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its
authority, and
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a war-
ranted emissions-related part to fail to be identical in all material respects to the part as described in the engine man­ufacturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no
charge to the owner at a Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsi-
ble for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or “grey market” part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
*Generac engine types covered by this warranty statement include the following:
1) Prepackaged Standby Generator
2) Auxiliary Power Unit (APU) Generator
3) Standby Generator
Part 2
1) Fuel Metering System:
1.2) LPG/Natural Gas carburetion assembly and its internal components.
a) Fuel controller (if so equipped) b) Mixer and its gaskets (if so equipped) c) Carburetor and its gaskets (if so equipped) d) Primary gas regulator (if so equipped) e) LP liquid vaporizer (if so equipped)
2) Air Induction System including:
a) Intake pipe/manifold b) Air cleaner
3) Ignition System including: a) Spark plug b) Ignition module
4) Catalytic Muffler Assembly (if so equipped) including: a) Muffler gasket b) Exhaust manifold
5) Crankcase Breather Assembly including: a) Breather connection tube
Part No. 0E7018 Revision D (06/02/05) Printed in U.S.A.
Section 10 – Warranty
Guardian Liquid-cooled 40 kW Generators
GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN
®
"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"
For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Guardian 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 Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty. Nicks, scrapes, dents or scratches to the painted enclosure should be repaired promptly by the owner. All warranty expense allowances are subject to the conditions defined in Guardian's Warranty Policies, Procedures and Flat Rate Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Guardian generators that utilize non-Guardian/Generac replacement parts.
• Guardian generators utilizing non-Guardian/Generac automatic transfer switches.
• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by Generac Power Systems.
• Any 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.
• Steel enclosures that are rusting due to the improper installation, location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised.
• 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 and/or insect 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.
• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)
• Overnight freight costs for replacement part(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC 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
Revision (02/01/05)
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