Generac Power Systems 0043736, 0046265 Owner's Manual
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Generac Power Systems 0043736, 0046265 Owner's Manual

Generac Power Systems 0043736, 0046265 Owner's Manual

Liquid-cooled, prepackaged standby generators 40 kw/single-phase w/ 200 amp transfer switch; 40 kw/single-phase w/ 200 amp transfer switch california emissions
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Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Models: 0043736
(40 kW/Single-phase w/
200 Amp Transfer
Switch)
0046265
(40 kW/Single-phase w/
200 Amp Transfer
Switch California
®
POWER SYSTEMS, INC.
Emissions)
®
!
!
Not intended for use in critical life support applications.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT
INSTALLATION!!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.

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Summary of Contents for Generac Power Systems 0043736, 0046265

  • Page 1 Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Models: 0043736 (40 kW/Single-phase w/ 200 Amp Transfer Switch) 0046265 (40 kW/Single-phase w/ 200 Amp Transfer Switch California ® POWER SYSTEMS, INC. Emissions) ® Not intended for use in critical life support applications. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!! DEADLY EXHAUST FUMES.

  • Page 2: Introduction

    INTRODUCTION Thank you for purchasing the Guardian product line by Generac Power Systems. This model is a compact, high performance, liquid-cooled, engine-driven gen- erator 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.

  • Page 3: Table Of Contents

    Section 5 – Troubleshooting ...20 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 Generac ® Power Systems, Inc.

  • Page 4: Important Safety Instructions

    Generac ® Power Systems, Inc. GENERAL HAZARDS • 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.

  • Page 5: Electrical Hazards

    Keep the area surrounding the generator clean and free from debris. • Generac generator sets may operate using one of sev- eral types of fuels. All fuel types are potentially FLAM- MABLE and/or EXPLOSIVE and should be handled with care.

  • Page 6: Section 1 - General Information Guardian Liquid-Cooled 40 Kw Generator

    Each single winding can supply a 120VAC, 60-Hertz output. When Generac ® Power Systems, Inc. the two windings are connected in series, a 240VAC, 60- Hertz output results.

  • Page 7: Main Circuit Breaker

    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. 1.8.1 GENERATOR Models ...0043736, 0046265...

  • Page 8: Generator And Load Compatibility

    Cooling System Capacity ...4.5 U.S. gallons (17 L) Recommended Coolant ...Use a 50-50 mixture of Fuel Consumption Natural Gas ...720 cfh LP Gas ...288 cfh/7.9gph Generac ® Power Systems, Inc. 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.

  • Page 9: 1.10 Engine Oil Recommendations

    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 equip- ment. Section 1 — General Information Guardian Liquid-cooled 40 kW Generator 1.12 EMISSIONS CONTROL SYSTEM...

  • Page 10: Section 2 - Installation Guardian Liquid-Cooled 40 Kw Generator

    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.

  • Page 11: Emergency Circuit Isolation Method

    Figure 2.2 – Generator Grounding Lug (typical) GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED AC neutral. Grounding is recommended only at the main service entrance. TRANSFER SWITCH START SIGNAL CONNECTIONS 2.6.1 PRE-PACKAGED TYPE SWITCH...

  • Page 12: Battery Installation

    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. 10 Generac ® Power Systems, Inc. 2.7.1 VENTED BATTERIES The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes.

  • Page 13: Preparation Before Start-Up

    On acoustic units, cap plugs also are needed to stay within noise specification limits. Section 1.8, 1.10, “Engine Section 1.8, Section 2 — Installation Figure 2.3 - Base Frame Cap Plugs Generac ® Power Systems, Inc. 11...

  • Page 14: Section 3 - Operation Guardian Liquid-Cooled 40 Kw Generator

    Battery voltage should read approximately12.5 to 14.5 volts DC. A low battery voltage indicates the battery is discharging. 12 Generac ® Power Systems, Inc. 3.1.5 HOURMETER This indicates the time the engine-generator has operat- ed, in hours and tenths of hours.

  • Page 15: Automatic Transfer Operation

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

  • Page 16: Weekly Exercise Cycle

    • 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. 14 Generac ® Power Systems, Inc. If the battery terminals are disconnected or the con-...

  • Page 17: Changing The Engine Oil And Filter

    8. Check the oil level after checking for leaks to ensure that the oil is filled to the proper level. To replace the engine air cleaner, (Generac part num- ber 0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover.

  • Page 18: Spark Plugs

    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.

  • Page 19: Overload Protection For Engine Dc Electrical System

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

  • Page 20: 4.11 Out Of Service Procedure

    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. 18 Generac ® Power Systems, Inc. 4.11.2 RETURN TO SERVICE...

  • Page 21: 4.12 Service Schedule

    4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Generac/Guardian Authorized Dealer. SYSTEM/COMPONENT X = Action R = Replace/Adjust as Needed * = Notify Dealer if Repair is Needed. FUEL Fuel lines and connections*...

  • Page 22: Section 5 - Troubleshooting Guardian Liquid-Cooled 40 Kw Generator

    There is no AC output from the generator. There is no transfer to STANDBY after UTILITY source failure. *Contact the nearest Generac/Guardian Authorized Dealer for assistance. 20 Generac ® Power Systems, Inc. CAUSE 1. Fuse blown 2. Loose, corroded or defective battery cables 3.

  • Page 23: Section 6 - Installation Diagram Guardian Liquid-Cooled 40 Kw Generator

    Section 6 — Installation Diagram Guardian Liquid-cooled 40 kW Generator Drawing No. 0E7015 Generac ® Power Systems, Inc. 21...

  • Page 24: Section 7 - Electrical Data

    (Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generator Electrical Schematic (Stepper Motor) – Drawing No. 0A5858 BLACK P/N 98647 LEGEND GCB - GOVERNOR CONTROL BOARD HZ - FREQUENCY METER TB1 - TERMINAL BLOCKS 22 Generac ® Power Systems, Inc. BLUE BLUE...
  • Page 25 (Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generator Wiring Diagram — Pre-pack Panel (4.3L) – Drawing No. 0D4992-A ACTUATOR GOVERNOR Section 6 — Electrical Data Generac 225A BLACK ® Power Systems, Inc. 23...
  • Page 26 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 YELLOW ORANGE YELLOW BROWN BLACK (CONNECTOR ENGINE (CONNECTOR PANEL LOWER 24 Generac ® Power Systems, Inc.
  • Page 27 Section 7 — Electrical Data Guardian Liquid-cooled 40 kW Generator Wiring Diagram/Schematic – Lower Panel – Drawing No. 0D5997 (CONNECTOR PANEL CONTROL Generac ® Power Systems, Inc. 25...
  • Page 28 Section 7 — Electrical Data (Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generators Wiring Diagram - Control Panel - Drawing No. 0D6974 SHIELD MPU- MPU+ ACT- ACT+ BAT- BAT+ 26 Generac ® Power Systems, Inc. 225A BLACK...
  • Page 29 (Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generators Electrical Schematic - Control Panel - Drawing No. 0D6975 (CONNECTOR ENGINE Section 7 — Electrical Data YELLOW SHIELD MPU- MPU+ ACT- ACT+ (CONNECTOR PANEL LOWER Generac ® Power Systems, Inc. 27...
  • Page 30 Section 7 — Electrical Data Guardian Liquid-cooled 40 kW Generators Wiring Diagram - Drawing No. 0E2966 BLACK 28 Generac ® Power Systems, Inc. 0/BLACK 0/BARE 79/CLEAR LEGEND: ACT: ACTUATOR ELECTRONIC GOVERNOR ALT: DC ALTERNATOR BAT: BATTERY CONTROL CONTACTOR EC1: ENGINE CONNECTOR 1(BLACK)
  • Page 31 ENGINE CONNECTOR 1(BLACK) ENGINE HEATER FUEL SOLENOID COOLANT HIGH TEMP. SWITCH IGNITION COIL IGNITION DISTRIBUTOR LOS: LOW OIL PRESSURE SWITCH MP1: MAGNETIC PICKUP 1 STARTER CONTACTOR STARTER MOTOR WLS: WATER LEVEL SENSOR 0/BLACK 0/BARE 79/CLEAR Generac ® Power Systems, Inc. 29...

  • Page 32: Section 8 - Exploded Views And Parts Lists Guardian Liquid-Cooled 40 Kw Generators Mounting Base - Drawing No. 0E6976

    Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators Mounting Base - Drawing No. 0E6976 BLACK 30 Generac ® Power Systems, Inc. TO STARTER SOLENOID 12 19 To Oil Drain On Oil Pan.
  • Page 33 WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL SCREW HHC M8-1.25 X 60 G8.8 FT NUT LOCK FL M8-1.25 BATT 12VDC 90-AH 27F HOLD DOWN BATTERY NUT LOCK HEX M8-1.25 NYL INSRT BOOT BATTERY CABLE Generac ® Power Systems, Inc. 31...
  • Page 34 Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators Compartment - Drawing No. 0D8992 32 Generac ® Power Systems, Inc. BASE FRAME...
  • Page 35 SCREW HHC M8-1.25 X 16 G8.8 WASHER FLAT M6-1/4 ZINC WASHER LOCK M6-1/4 NUT HEX 1/4-20 STEEL GASKET DOOR RUBBER SCREW SHOULDER COVER EXHAUST HOLE FASTENER RATCHET STRIP SEALANT 1/8 X 1 WASHER FLAT 5/16 ZINC Generac ® Power Systems, Inc. 33...
  • Page 36 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 34 Generac ® Power Systems, Inc.

  • Page 37: Section 8 - Exploded Views And Parts Lists

    0D5324 REF. 0A9611 REF. 074908 0E3783 * PART OF CONTROL PANEL WIRE HARNESS Generac DESCRIPTION FREQUENCY METER 240V 55-65HZ DECAL EXERCISE INFO DECAL CUST CONN BOX ASSY L.C. ELECT GOV CAPACITOR FILTER ASY BLOCK TERM 20A 2 X 6 X 1100V...
  • Page 38 Section 8 — Exploded Views and Parts Lists (Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generator Control Panel – Drawing No. 0D6978-C 36 Generac ® Power Systems, Inc.
  • Page 39 0C2323 0A2284 0C1127 0D5324 0A9611 074908 0E3783 * PART OF CONTROL PANEL WIRE HARNESS Generac DESCRIPTION DECAL EXERCISE INFO DECAL CUST CONN BOX CONTROLLER, B-C #DPG-2103 CAPACITOR FILTER ASY BLOCK TERM 20A 2 X 6 X 1100V COVER PLATE AVR...
  • Page 40 Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators Connection Box – Drawing No. 0E6892-A 38 Generac ® Power Systems, Inc.
  • Page 41 COVER TERMINALS S (QJ 2P) WASHER LOCK 3/8 NUT HEX 3/8-16 STEEL SCREW SHC 1/4-20 X 4.5 G8.8 NZ SCREW SHC 3/8-16 X 3/4 G5 NEUTRAL BLOCK 390/200-400A JUNCTION BLOCK 3/8-16 SCREW PHTT M5-0.8 X 16 ZYC Generac ® Power Systems, Inc. 39...
  • Page 42 Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators Generator – Drawing No. 0E6891 40 Generac ® Power Systems, Inc.
  • Page 43 SHROUD ALTERNATOR SHEET METAL SCREEN SHROUD SAE BRACKET TENSIONER SAE SCROLL TRIM VINYL BLACK 1/8 GP WASHER LOCK M6-1/4 SCREW HHC M6-1.0 X 25 G8.8 SCREW HHC M6-1.0 X 16 G8.8 SCREW SWAGE 1/4-20 X 1/2 Z/YC Generac ® Power Systems, Inc. 41...
  • Page 44 Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators Engine – Drawing No. 0D6980-B 42 Generac ® Power Systems, Inc.
  • Page 45 PLATE FLEX GM CASTING ADAPTOR SENSOR COOLANT LEVEL ASSY MAGPICKUP (3/8-24 MALE) (MODEL 004626 0NLY) THERMOSTAT 195 DEG 40KW GUARDIAN WIRE HARNESS (NOT SHOWN FOR MOD. 004626-0) HARNESS 4.3L STD WIRE (NOT SHOWN FOR MOD. 004373-1) Generac ® Power Systems, Inc. 43...
  • Page 46 Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators Engine – Drawing No. 0A4304-L 44 Generac ® Power Systems, Inc.
  • Page 47 WASHER FLAT HEAVY DUTY WASHER LOCK M10 SCREW HHC M10-1.5 X 25 G8.8 BOLT TENSIONER PULLEY NUT HEX M10-1.5 G8 YEL CHR SPARK PLUG 5.7L GM WASHER FLAT M12 CLAMP VINYL 1.06 X .406 Z FILTER OIL Generac ® Power Systems, Inc. 45...
  • Page 48 Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators 4.3L Radiator – Drawing No. 0D7992-D 46 Generac ® Power Systems, Inc.
  • Page 49 SCREW HHC 1/4-20 X 1 G5 WASHER LOCK M6-1/4 WASHER FLAT 1/4 ZINC SCREEN FRONT SCREW HHTT 1/4-20 X 1 CZ WASHER LOCK M6-1/4 WASHER FLAT 1/4 ZINC CAP RADIATOR 13 PSI-FOR SERVICE ONLY Generac ® Power Systems, Inc. 47...
  • Page 50 TUBE, CROSS OVER 0E0698 TUBE, 90 ELBOW 0C4170 BRACKET EXHAUST SHIELD 0C4305 SHIELD A-GRP HEAT 0C2454 SCREW TH-FRM M6-1 X 16 N WA Z/JS 48 Generac ® Power Systems, Inc. COMPARTMENT FRONT ITEM PART NO. QTY. DESCRIPTION 0C3433A CLAMP BAND 2.5"...
  • Page 51 4.3L Air Cleaner – Drawing No. 0E0712 DESCRIPTION NUT WING 1/4-20 NYLK PLATE AIR CLEANER TOP FILTER AIR 11.5" CA326 PLATE,AIR CLEANR BOT STUD TH 1/4-20 X 3 G2 ZNC FULL NUT HEX 1/4-20 STEEL GROMMET CONNECTOR C/C VENT Generac ® Power Systems, Inc. 49...
  • Page 52 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 50 Generac ® Power Systems, Inc.

  • Page 53: Section 8 - Exploded Views And Parts Lists

    SCREW HHC 5/16-18 X 1-1/4 G5 ADAPTOR CARBURETOR W/INLET GASKET CARBURETOR ADAPTOR BARBED ELBOW 90 DEG 1/8 NPT X 3/8 VALVE PCV HOSE 3/8 ID SINGLE BRAID (10") NUT HEX 1/4-28 STEEL WASHER LOCK M6-1/4 ARM THROTTLE-REWORK Generac ® Power Systems, Inc. 51...
  • Page 54 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 52 Generac ® Power Systems, Inc.
  • Page 55 HOSE 3/8 ID SINGLE BRAID (10") GASKET CARBURETOR ADAPTOR ASSY THROTTLE PF42 WIRE CONN WASHER LOCK #10 SCREW SHC #10-32 X 5/8 G8.8 NZ GASKET CARB IMPCO 225 SCREW PHM SEMS #12-24 X 5/8 EX Generac ® Power Systems, Inc. 53...
  • Page 56 Section 8 — Exploded Views and Parts Lists (Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generators Exhaust – Drawing No. 0E1347-A 54 Generac ® Power Systems, Inc.
  • Page 57 WASHER LOCK #8-M4 WASHER FLAT #8 ZINC SCREW PPHM #8-32 X 1/2 WASHER FLAT M6 WASHER LOCK M6-1/4 NUT HEX M6 X 1.0 G8 YEL CHR DECAL IMPORTANT EXHAUST EMISSION INFO WASHER FLAT 3/8-M10 ZINC Generac ® Power Systems, Inc. 55...
  • Page 58 022097 064526 029333A 074031 051716 049226 076040 098647 036409 0C2184 56 Generac ® Power Systems, Inc. DESCRIPTION ASSEMBLY MOTOR STEPPER BRACKET GOVERNOR MOUNTING CONNECTOR INTERFACE ASSEMBLY LEVER STEPPER MOTOR BALL JOINT 1/4-28 NUT HEX 1/4-28 STEEL SCREW HHC M6-1.0 X 10 G8.8...
  • Page 59 NUT HEX M6 X 1.0 G8 YEL CHR 055934D CLAMP VINYL 1.06 X .406 Z (NOT SHOWN) 077043A CONDUIT FLEX .38 ID (42"LG) (NOT SHOWN) (USED ON HEATER CORD) 062303 ADAPTOR 1/4" NPT TO 3/8" NPT Generac ® Power Systems, Inc. 57 TO ENGINE BLOCK...

  • Page 60: Section 9 - Notes

    Section 9 – Notes Guardian Liquid-cooled 40 kW Generators 58 Generac ® Power Systems, Inc.
  • Page 61 Section 9 – Notes Guardian Liquid-cooled 40 kW Generators Generac ® Power Systems, Inc. 59...

  • Page 62: Section 10 - Warranty Guardian Liquid-Cooled 40 Kw Generators

    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.

  • Page 63: Emission Control System Warranty

    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”...

  • Page 64: Warranty Schedule

    GUARDIAN “EMERGENCY AUTOMATIC STANDBY GENERATORS” For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.

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