Generac Power Systems 004992-2 manual

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. 004992-2 37kW NG, 40kW LP[...]

2 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 reserves the right to change, al[...]

T able of Contents 40kW Liquid-cooled Generators 1 INTRODUCTION ................................................ IFC SAFETY RULES .................................................... 2 Section 1 — GENERAL INFORMA TION ............4 1.1 Generator ..............................................................4 1.2 Transfer Switch ..................[...]

2 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 to follow simple and funda- menta[...]

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 NEGA TIVE, NEG or (–) first[...]

4 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 outdoor installation only . Use th[...]

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. F uel pressure for an LP vapor [...]

6 Figure 1.6 - Low Coolant Level Sensor 1.7 .4 OVERSPEED SH UTDO WN 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. Should AC frequency exceed about 7[...]

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 ........[...]

8 Serious injury or damage may occur if not con- figured pr operly . Please consult an authorized 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. Intake Manif old ..................[...]

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 Association (NFP A), Batterymarch P ar[...]

10 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 utility power outages, consider [...]

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 control PCB to perform the A TS con[...]

12 • 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 liquid is to be flushed with wat[...]

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 CH When required, the pre -packa[...]

14 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 N E FUSE This fuse protects the[...]

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 provided (such as utility main [...]

16 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 Safety Devices (low oil pressur[...]

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 o have pressure cap tested, cont[...]

18 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 Schedule,” Section 6, for air cl[...]

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 batteries and, if necessary , fill wi[...]

20 Section 4 — Maintenance 40kW Liquid-cooled Generators 4.7 S CH EDU LED MAI NTENANCE The following is a recommended maintenance schedule for the manufacturer small standby and residential gen- erator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will nee[...]

21 Section 4 — Maintenance 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) Break-in Initials) annually Initials) Ann[...]

22 Section 4 — Maintenance 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) Break-in Initials) annually Initials) Ann[...]

23 Section 5 — T roubleshooting 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 star ter contactor . 3. Replace contacto[...]

24 Section 6 - Electrical Data 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8 1 1 5-A[...]

25 Section 6 - Electrical Data 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8 1 1 5-A[...]

26 Section 6 - Electrical Data 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E81 16-A[...]

27 Section 6 - Electrical Data 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E81 16-A[...]

28 CONT ACT OR WIRE HARNE SS 4 3 35 13 12 9 34 MOUNT ENGINE TO 18 8 7 6 5 16 34 42 43 2 35 36 41 40 16 6 7 5 19 16 28 30 27 35 34 39 36 33 27 29 22 20 32 38 18 31 20 21 S T ARTER TO S T ARTER BOL T TO BLOCK ENGINE 18 TO 11 1 12 10 14 REAR BEARING 15 37 13 CARRIER 3 4 16 2 Section 7 - Exploded Views and P arts 40kW Liquid-cooled Generators Mounting [...]

29 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 SCRE[...]

30 S TAT E S FOAM I S ON NEAR S IDE S TAT E S FOAM I S ON F AR S IDE 37 30 LA TCH DET AIL 31 31 32 34 38 32 3 4 27 43 18 17 39 41 4 2 DET AIL S EE LA TCH "B" 25 52 11 9 6 4 49 5 48 T O "A" S ECURE A S S HOWN. REQUIRE IN S ULA TION. TYPICAL OF ROOF P ANEL THA T 4 49 4 35 RADIA TOR S UPPORT 33 4 4 44 34 47 49 4 32 36 4 45 18 4 26 [...]

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 COMP ARTMENT SIDE 10 0F5552 1 SU[...]

32 Section 7 - Exploded Views and P arts 40kW Liquid-cooled Generators Control Panel — Drawing No. 0E7 11 8-K[...]

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 GC15 10 067682B 1 FUSE 4A SLO B[...]

34 18 46 32 19 65 52 ENGINE COME S WITH BRACKET HARD W ARE. D .C. AL TERNA TOR U S E 19 14 15 79 17 19 18 18 72 14 8 7 18 13 TO "C" 16 TO 60 "A" 19 17 22 21 "C" 20 3 69 58 BAFFLE REAR UPPER 61 "A" 26 75 64 74 76 38 17 24 25 73 23 "B" 66 63 62 E O I L E N G I N 9 1 14 13 28 27 2 10 57 19 19 18 17 44 [...]

35 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 ADAPT 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 YSLER 9 [...]

36 W ATER P U M P TO EN G INE 2 3 2 4 26 25 24 21 3 "A " 1 3 1 15 1 9 22 HOUS IN G T HERM OS TAT TO 10 4 10 20 10 5 16 16 2 14 15 8 7 14 17 17 6 9 14 1 8 TO "A" Section 7 - Exploded Views and P arts 40kW Liquid-cooled Generators Radiator — Drawing No. 0E8 1 02-F[...]

37 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 [...]

38 46 21 24 2 3 TO EN G INE 2 16 17 4 5 6 45 42 40 11 41 9 8 12 6 3 15 2 1 3 27 3 1 14 1 9 2 9 3 0 3 2 "B " TO "B " 1 3 3 6 3 7 38 20 1 9 1 8 3 5 3 4 M ANIF O LD INTAKE TO 44 4 3 25 22 6 1 39 33 Section 7 - Exploded Views and P arts 40kW Liquid-cooled Generators Fuel Syst em — Drawing No. 0E8 1 22-H[...]

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 M8-1.25 X 16 G8.8 9 0C2454 2 SCREW TH[...]

40 3 LOCKTIGHT LOCKTIGHT 7 15 17 8 7 6 18 4 16 LEAD S 5 2 9 13 21 19 20 14 10 11 12 30 1 31 Section 7 - Exploded Views and P arts 40kW Liquid-cooled Generators Alternator — Drawing No. 0F5 092-B[...]

41 ITEM P ART NO . QTY . DESCRIPTION 1 0F1659A 1 RO T OR 390 15KW 1P DIRECT HSB (2.5L FORD) 0F1657A 1 RO T OR 390 20KW 1P DIRECT HSB (2.5L FORD) 0F1655A 1 RO T OR 390 25KW 1P DIRECT HSB (2.5L FORD) 0F5073A 1 RO T OR 390__30AD1 HSB TECUM 0E7413A 1 RTR 390 40KW 1P DIRECT HSB 2 0F1660A 1 STR 390 15AD HSB (382MM LONG) (2.5L FORD) 0F1658A 1 STR 390 20AD[...]

42 Section 7 - Exploded Views and P arts 40kW Liquid-cooled Generators Muffler — Drawing No. 0F4894-B ITEM P ART NO . QTY . DESCRIPTION 1 0F0738 1 MUFFLER 7"X9"-(2)2"IN/2.5"OUT 2 0C9748 1 PLUG M18-1.50 3 0F0778 1 PIPE R/H SIDE EXHA UST MILD ST 4 0F0777 1 PIPE L/H SIDE EXHA UST MILD ST 5 0E5914 1 BRA CKET MUFFLER 3.0L FORD HSB [...]

43 Section 8 — Installation Diagram 40kW Liquid-cooled Generators Installation Diagram — Drawing No. 0E8422-A O VERHEAD VIEW[...]

44 Section 9 — Notes 40kW Liquid-cooled Generators[...]

45 Section 9 — Notes 40kW Liquid-cooled Generators[...]

Part No. 0F4942 Revision D (07/14/05) Printed in U.S.A. Section 1 0 – W arranty 40kW Liquid-cooled Generators GENERA C PO WER SYSTEMS "TWO YEAR" LIMITED W ARRANTY FOR GU ARDIAN ® "PREP A CKA GED EMERGENCY A UT OMA TIC ST ANDBY GENERA T ORS" F or a period of two years from the date of original sale, Generac P ower Systems, Inc[...]