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Generac Power Systems 004992-1, 004992-0 manual

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Table of contents for the manual

  • Page 1

    Owner’ s Man ual ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!! This manual should remain with the unit. Liquid-cooled, Prepac kaged Standb y Generators Model Nos. 004992-0 004992-1 37kW NG, 40kW LP[...]

  • Page 2

    Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the Guardian standby generator product line by Generac P ower Systems, Inc. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ- ten. However , the manufacturer re[...]

  • Page 3

    T able of Contents Guardian 40kW Liquid-cooled Generators Generac ® Pow er Systems, Inc. 1 INTRODUCTION ................................................ IFC SAFETY RULES .................................................... 2 Section 1 — GENERAL INFORMA TION ............4 1.1 Generator .............................................................[...]

  • Page 4

    2 Generac ® Pow er 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 genera- tor can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many acci- dents are caused by failing t[...]

  • Page 5

    Generac ® Pow er 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[...]

  • Page 6

    4 Generac ® Pow er Systems, Inc. 1.1 GEN ER A T OR This equipment is a liquid- cooled, engine - driven gen- erator set. The generator is designed to supply elec- trical power that operates critical electrical loads during utility power failure. The unit has been facto- ry-installed in a weather resistant, all metal enclosure and is intended for ou[...]

  • Page 7

    Generac ® Pow er Systems, Inc. 5 1.6 GEN ER A T OR F U EL SY S TEM The unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is neces- sary , refer to Section 1.12 for conversion. F uel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges.[...]

  • Page 8

    6 Generac ® Pow er Systems, Inc. Figure 1.6 - Low Coolant Level Sensor 1.7 .4 O VERSPEED SH UTDOWN The engine control board receives AC frequency sig- nals from an engine run winding in the alternator . Should AC frequency exceed about 72 Hertz for three seconds or 75 Hertz instantaneously , the engine shuts down and the overspeed LED turns on. Sh[...]

  • Page 9

    1.1 0 SP ECIF ICA TIONS 1.1 0.1 GEN ER A T OR SP ECIF ICA TIONS 1.1 0.2 ENGI N E SP E CI F ICA TIONS Make..................................................................................................Chr ysler Displacement ....................................................................................3.9 liters Cylinder Arrangement ........[...]

  • Page 10

    8 Generac ® Pow er Systems, Inc. Serious injury or damage may occur if not configured pr operly . Please consult an author- ized service dealer with any questions. 1.1 3 T ORQU E SP ECIF ICA TIONS Tighten the bolts from the middle out, in a criss- cross pattern. Cylinder Head ....................................50 ft.lb./105 ft.lb ./105 ft.lb. Int[...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 After the system has been installed, do nothing that might render the installation in noncompli- ance with such codes, standards and r egula- tions. 2.1.1 N F P A ST A N DAR DS The following published standards booklets pertain- ing to standby electric systems are available form the National Fire P rotection Associ[...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. Figure 2.1 – Basic Standby Electric System 2.5 EM ERGENCY CI RCU IT IS OL A TION M E THOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator . If the generator is powering only crit- ical loads, within the wattage/amperage capacity , dur- ing [...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 2.9 TR ANSF ER SWIT CH SIGNAL CO N N EC T I O N S 2.9.1 P RE-P ACKAGED A TS If the generator is to be installed with a pre -packaged transfer switch, it is necessary to connect the control wires to the generator and set position two of the four -position dip switch to OFF . Setting switch two to OFF allows the con[...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. • 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) bicarbon- ate 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 [...]

  • Page 15

    Generac ® Pow er Systems, Inc. 13 Make sure the generator battery is fully charged, prop- erly installed and interconnected, and ready for use. Check to ensure that there are no loose electrical con- nections. Restrain any loose wires to keep them clear of any moving generator set components. 3.1 USI NG AN ENGI N EER ED “G TS” TR ANSF ER SWIT [...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. 3.2.3 1 5 AMP F USE F use 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 . If the fuse needs to be replaced, use only an identical 15-amp replacement fuse. (T ype AGC) 3.2.4 4.0 AM P IN LI[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 3.5 R E TR ANSF ER AN D SH UTDOWN When utility power source voltage has been restored, electrical loads may be transferred back to that source and the generator can be shut down as fol- lows: • V erify that utility power supply voltage to the trans- fer switch has been positively turned Off, using whatever means[...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. 4.1 MAI NTENANCE P ER FOR M ED B Y AUTHOR IZED SERVICE DEALERS A. EVER Y THR EE MONTHS 1. Check battery state of charge and condition. 2. Inspect and test fuel system. 3. Check transfer switch. 4. Inspect exhaust system. 5. Check engine ignition system. 6. Check fan belts. B. ONCE EVER Y SIX MONTHS 1. T est Engine[...]

  • Page 19

    Generac ® Pow er Systems, Inc. 17 • Add recommended coolant mixture as necessary . • P eriodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly . Coolant should be at bottom of radiator filler neck. If coolant level is low , inspect gasket in radiator pressure cap. Replace cap, if necessary . T [...]

  • Page 20

    18 Generac ® Pow er Systems, Inc. 7. Start engine and check for oil leaks. Figure 4.2 - Oil Filter 4.5.1 1 CHANGI NG TH E ENGI NE AI R CLEAN ER T o replace the engine air cleaner , (part number 0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover . See the “Service Sc[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 4.6.3 BA TTER Y MAI NTENANCE The battery should be inspected per the “Service Schedule,” Section 6. 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 batte[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators 4.7 S CH EDU LED MAI NTENANCE F ollowing is a recommended maintenance schedule for Generac small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service[...]

  • Page 23

    Generac ® Pow er Systems, Inc. 21 Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators Maintenance Level 1 Level 2 Le vel 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp. to be done Comp . Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly Initials) [...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators Maintenance Level 1 Level 2 Le vel 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp. to be done Comp . Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly Initials) [...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 Section 5 — T roubleshooting Guardian 40kW Liquid-cooled Generators TROU B LE SHOO TI NG POI NTS P ROBLEM CAUSE CORR E CTION Engine won’t crank. 1. 15 amp fuse b lown. 1. Replace fuse. 2. Loose or corroded or def ective 2. Tighten, clean or replace batter y cables . batter y cables as necessary . 3. Def ective[...]

  • Page 26

    24 Generac ® Pow er Systems, Inc. Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8 1 1 5-A[...]

  • Page 27

    Generac ® Pow er Systems, Inc. 25 Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8 1 1 5-A[...]

  • Page 28

    26 Generac ® Pow er Systems, Inc. Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E81 16-A[...]

  • Page 29

    Generac ® Pow er Systems, Inc. 27 Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E81 16-A[...]

  • Page 30

    CONTACTOR WIRE H ARNE SS 4 3 35 13 12 9 34 TO MOU NT E N G INE 18 8 6 7 5 16 3 4 43 42 2 36 41 40 16 6 7 5 19 16 30 27 35 3 4 36 33 27 29 22 20 3 2 38 18 31 20 21 TO S TARTER S TARTER BO LT TO E N G INE B L OC K 18 TO 11 1 12 10 1 4 R EAR BEARIN G 15 3 7 13 C ARRIER 3 4 16 2 28 Generac ® Pow er Systems, Inc. Section 7 - Exploded Views and P arts G[...]

  • Page 31

    ITEM P ART NO . QTY . DESCRIPTION 1 0E7331 1 WELDMENT MTG BASE 3.9L CR YSLR 2 052860 4 NUT FLANGED HEX M12-1.75 3 052251 4 DAMPENER VIBRA TION 40 BLUE 4 052257 4 SP ACER .49 X .62 X 1.87 PWDR/ZNC 5 052252 4 DAMPENER VIBRA TION 6 052259 4 W ASHER FLA T M12 7 052891 4 SCREW HHC M12-1.75 X 80 G8.8 8 0536210214 1 ASSY WIRE 15.0" 9 074906 1 SCREW H[...]

  • Page 32

    30 Generac ® Pow er Systems, Inc. S TATE S F O AM I S O N NEAR S IDE S TATE S F O AM I S O N FAR S ID E 3 7 30 L AT C H DETAIL 3 1 3 1 3 2 34 38 3 2 3 4 43 18 17 41 4 2 DETAIL S EE LAT CH "B " 25 5 2 11 9 6 4 5 5 4 TO "A" S E CU RE A S S H O WN. R E Q UIRE INSULATION. T YPI C AL O F R OO F PANEL THAT 4 R ADIAT OR 53 35 33 4 44 [...]

  • Page 33

    Generac ® Pow er Systems, Inc. 31 ITEM P ART NO . QTY . DESCRIPTION 1 0E8411 1 INT AKE DUCT HSB 2 0E8042 1 DUCT DISCHARGE RH FRONT 3 0E8041 1 DUCT DISCHARGE LH FRONT 4 0C2454 62 SCREW TH-FRM M6-1 X 16 N W A Z/JS 5 0E7807 1 BAFFLE REAR BOTT OM 6 0E7808 1 POST CORNER LH REAR 7 0E7809 1 POST CORNER RH REAR 8 0E8387 1 BAFFLE REAR T OP 9 0E6986 2 DOOR [...]

  • Page 34

    32 Generac ® Pow er Systems, Inc. Section 7 - Exploded Views and P arts Guardian 40kW Liquid-cooled Generators Control Panel — Drawing No. 0E7 11 8-G[...]

  • Page 35

    Generac ® Pow er Systems, Inc. 33 ITEM P ART NO . QTY . DESCRIPTION 1 0E7195 1 CONTROL BO X HSB 2 0E7196 1 CO VER FR ONT P ANEL HSB 3 0E7197 1 CO VER TOP P ANEL HSB 4 0E7193 1 DECAL W ARNINGS HSB 5 0E7194 1 DECAL CONTROLS HSB 6 0E4494 1 SWITCH ROC DPDT ON-OFF-ON 7 082573 1 SWITCH R OCKER DPST 125V SPD 8 032300 2 HOLDER FUSE 9 022676 1 FUSE 15A X A[...]

  • Page 36

    Section 7 - Exploded Views and P arts Guardian 40kW Liquid-cooled Generators Engine — Drawing No. 0E81 21 -D 34 Generac ® Pow er Systems, Inc.[...]

  • Page 37

    ITEM P ART NO . QTY . DESCRIPTION 1 0E5048A 1 FLEXPLA TE 3.9L HSB 2 0E7477 1 MA CHINING, 3.9L ENGINE AD APT OR 3 0E6703 1 CO VER, FL YWHEEL ACCESS 4 0E8336 REF REWORK, 3.9L CHR YSLER ENGINE 5 0E7841 2 GASKET , THERMOST A T AD APT OR 6 0E7254 1 MA CH, THERM AD APT OR 3.9L CHR Y 7 0E7956 1 BRA CKET , IGNITION COIL 8 0E7953 1 COIL IGNITION 3.9L CHR YS[...]

  • Page 38

    17 WATER PUMP 24 23 26 24 25 21 3 "A" 13 1 15 19 22 TO T HERM OS TAT HOUS IN G 10 4 10 20 0 5 16 16 2 14 8 15 7 14 18 6 9 1 7 14 O "A" Section 7 - Exploded Views and P arts Guardian 40kW Liquid-cooled Generators Radiator — Drawing No. 0E8 1 02-E 36 Generac ® Pow er Systems, Inc.[...]

  • Page 39

    ITEM P ART NO . QTY . DESCRIPTION 1 0D7825A 1 RADIA TOR COPPER BRASS 2 0D7174C 1 VENTURI,3.9L CR YSLR HSB 22"F AN 3 0E7640 1 RADIA TOR SUPPOR T L/H SIDE 4 0E7924 1 HOSE LOWER RADIA T OR 5 0F2853 1 HOSE, RADIA TOR UPPER, 3.9L 6 0D8252 1 F AN GUARD , T OP 7 0D8251 1 F AN GUARD , BO TT OM 8 0E0726 1 BRACKET , W A TER BO TTLE 1.5L MIT 9 076749 1 T[...]

  • Page 40

    38 Generac ® Pow er Systems, Inc. 2 1 23 24 23 TO EN G INE 2 16 17 4 5 6 45 42 40 1 1 4 1 9 8 12 6 3 15 2 13 27 3 1 14 1 9 29 30 3 2 "B " TO "B " 13 36 3 7 38 20 19 18 35 3 4 M ANIF O LD INTAKE TO 44 43 25 22 6 1 39 33 Section 7 - Exploded Views and P arts Guardian 40kW Liquid-cooled Generators Fuel Syst em — Drawing No. 0E8 [...]

  • Page 41

    Generac ® Pow er Systems, Inc. 39 ITEM P ART NO . QTY . DESCRIPTION 1 033212 4 SCREW HHC 5/16-18 X 1-1/4 G5 2 075580 1 FLANGE FUEL INLET 3 0E8365 1 ASSY REG. 3.9L N/G-LPV 1800RPM 4 039253 2 SCREW HHC M8-1.25 X 20 G8.8 5 022145 2 W ASHER FLA T 5/16 ZINC 6 022129 8 W ASHER LOCK M8-5/16 7 045771 2 NUT HEX M8-1.25 G8 YEL CHR 8 042907 2 SCREW HHC M8-1.[...]

  • Page 42

    40 Generac ® Pow er Systems, Inc. 4 15 7 17 8 7 1 18 20 3 1 30 5 21 19 L EAD S 6 2 14 12 24 9 22 * 2 3 13* 3 10 13 11 Section 7 - Exploded Views and P arts Guardian 40kW Liquid-cooled Generators Alternator — Drawing No. 0E5 1 46-B[...]

  • Page 43

    Generac ® Pow er Systems, Inc. 41 ITEM P ART NO . QTY . DESCRIPTION 1 0E5093A 1 RO T OR 390 30KW 1P DIRECT HSB 0E7413A 1 RO T OR 390 40KW 1P DIRECT HSB 2 0E5094A 1 STR-390--35AD1 HSB (382MM LONG)(3.0LFORD) 0E7412A 1 STR-390--40AD HSB (433MM LONG)(3.9L CHRYSLER) 3 0E5706 1 REAR BEARING CARRIER 390/DRCT 4 0E5048 REF FLEXPLA TE 3.0L FORD 0E5048A REF [...]

  • Page 44

    ITEM P ART NO . QTY . DESCRIPTION 1 0E8616 1 MUFFLER 7" X 9" X 21" 2.5" IN & OUT 2 0F1081 1 WYE, PIPE 3.9L CHR YSLER 3 0F1087 1 PIPE R/H SIDE 3.9L CHR YSLER 4 0E8026 1 PIPE L/H EXHA UST MANIFOLD 5 0E5914 1 BRA CKET MUFFLER 3.0L FORD HSB 6 0E8702 1 PIPE MUFFLER INLET 7 0E8727 1 PIPE MUFFLER OUT 8 036797 3 BOL T U 5/16-18 X 2.[...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 Section 8 — Installation Diagram Guardian 40kW Liquid-cooled Generators Installation Diagram — Drawing No. 0E8422-A O VERHEAD VIEW[...]

  • Page 46

    44 Generac ® Pow er Systems, Inc. Section 9 - Notes Guardian 40kW Liquid-cooled Generators[...]

  • Page 47

    Generac ® Pow er Systems, Inc. 45 Section 9 - Notes Guardian 40kW Liquid-cooled Generators[...]

  • Page 48

    Part No. 0E8359 Revision F (01/24/05) Printed in U.S.A. Section 1 0 – W arranty Guardian 40kW Liquid-cooled Generators GENER AC PO WER SY S TEMS "T WO YEAR" LIM ITED W ARR ANTY FOR GUARDIAN® "PR EP ACK A GED EM ERGENCY AUT OMA TIC S T ANDBY GENER A T ORS" F or a period of two years from the date of original sale, Generac P ow[...]