Generac Power Systems Guardian 004373-6 Owner's Manual

Liquid-cooled, prepackaged standby generator.
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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
®
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 Guardian 004373-6

  • Page 1

    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 ® 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 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

    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 Unpacking/Inspection ...4 The Generator...4 Generator AC Connection Systems ...4 Prepackaged Transfer Switch ...4 Automatic System Operation ...4 Main Circuit Breaker ...5...

  • Page 4: Safety Rules

    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. SAVE THESE INSTRUCTIONS –...

  • Page 5: Electrical Hazards, Fire Hazards, Explosion Hazards

    • 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.

  • Page 6: Section 1 – General Information, Unpacking/inspection, The Generator, Generator Ac Connection Systems, Prepackaged Transfer Switch

    Section 1 — General Information Guardian Liquid-cooled 40 kW Generator UNPACKING/INSPECTION After unpacking, carefully inspect the contents for dam- age. • 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.

  • Page 7: Main Circuit Breaker, Engine Protective Devices, Specifications

    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: Model Number Circuit Breaker Rating 0043736 0046265 ENGINE PROTECTIVE DEVICES The engine has several safety switches that cause it to automatically shut down under the following condi- tions: low oil pressure, high coolant temperature, low coolant level, engine overspeed and overcrank.

  • Page 8: Fuel Requirements And Recommendations

    Section 1 — General Information Guardian Liquid-cooled 40 kW Generator 1.8.2 GENERATOR AND LOAD COMPATIBILITY The generator must be fully compatible with the rated voltage, number of phases and frequency of the con- nected electrical loads. The generator, connected elec- trical devices, or both, can be damaged if voltage, num- ber of phases and frequency are not compatible.

  • Page 9: Engine Oil Recommendations, Coolant, Emission Control System

    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 hav- ing the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change:...

  • Page 10: Section 2 – Installation, Basic Standby Electric System

    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.

  • Page 11: Emergency Circuit Isolation Method, Total Circuit Isolation Method, Grounding The Generator, Generator Ac Neutral Connections

    Figure 2.1 – Basic Standby Electric System 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 emer- gency circuit isolation method.

  • Page 12: Battery Installation

    Section 2 — Installation Guardian Liquid-cooled 40 kW Generator BATTERY INSTALLATION DANGER Standby generators installed with automatic trans- fer 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...

  • Page 13: Preparation Before Start-up

    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 safe- ty information in this manual, before attempting to oper- ate this (and related) equipment.

  • Page 14: Section 3 – Operation, Control Console Components, Using The Auto/off/manual Switch

    Section 3 — Operation Guardian Liquid-cooled 40 kW Generator 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 dur- ing operation.

  • Page 15: Automatic Transfer Operation, Sequence Of Automatic Operation, Engine Heater

    3.2.2 “OFF” POSITION This switch position shuts down the engine. This posi- tion 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.

  • Page 16: Weekly Exercise Cycle, Section 4 – Maintenance, Checking The Engine Oil Level

    Section 4 — Maintenance 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 con- nections. WEEKLY EXERCISE CYCLE The generator will start and exercise once every seven days.

  • Page 17: Changing The Engine Oil And Filter, Changing The Engine Air Cleaner

    CHANGING THE ENGINE OIL AND FILTER 4.2.1 ENGINE OIL RECOMMENDATIONS Use oil of API Service Class SG, SH or SJ. The recommended grade 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.

  • Page 18: Spark Plugs, Battery Maintenance, Cooling System

    Section 4 — Maintenance Guardian Liquid-cooled 40 kW Generator 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.

  • Page 19: Overload Protection For Engine Dc Electrical System, Engine Coolant, Miscellaneous Maintenance

    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.

  • Page 20: Out Of Service Procedure

    Section 4 — Maintenance Guardian Liquid-cooled 40 kW Generator 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.

  • Page 21: 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* LUBRICATION Oil level Oil filter...

  • Page 22: Section 5 – Troubleshooting, Troubleshooting Guide

    Section 5 — Troubleshooting Guardian Liquid-cooled 40 kW Generator TROUBLESHOOTING GUIDE PROBLEM The engine will not crank. The engine cranks but will not start. The engine starts hard and runs rough. The engine starts, but then shuts down. The AUTO/OFF/MANUAL switch is set to OFF , but the engine continues to run.

  • Page 23: Section 6 – Installation Diagram

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

  • Page 24: Section 7 – Electrical Data

    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 ®...

  • 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) ENGINE HEATER FUEL SOLENOID GND:...

  • Page 31

    12V BATTERY BLACK 120VAC BLACK WHITE UTILITY GREEN SUPPLY ONLY USED ON EMISSIONS MODELS Section 7 — Electrical Data Guardian Liquid-cooled 40 kW Generators Wiring Diagram - Drawing No. 0E2967 LEGEND: ACT: ACTUATOR ELECTRONIC GOVERNOR ALT: DC ALTERNATOR CONTROL CONTACTOR EC1: ENGINE CONNECTOR 1(BLACK) ENGINE HEATER...

  • Page 32: Section 8 – Exploded Views And Parts Lists

    Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators Mounting Base - Drawing No. 0E6976-A BLACK 30 Generac ® Power Systems, Inc. TO STARTER SOLENOID 16 1 12 19 To Oil Drain On Oil Pan.

  • Page 33

    ITEM PART NO. QTY. 0E6900 038804T 055414 0A4084 REF. 022129 045771 022237 029745 023152 043107 022145 027482 055597 052251 052257 052252 052259 052860 0536210098 052251A 044118 057823 057448 024310 0D4239D 038805H 022131 025507 061902 022413 022473 022097 022127 0A4010 052858 058665 059473 049820...

  • Page 34

    Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators Compartment - Drawing No. 0D8992-A 32 Generac ® Power Systems, Inc.

  • Page 35

    ITEM PART NO. QTY. 0C3594 0E3257 0A3359 022769 0C2522 (A) 0C2527 (A) 0C2528 (A) 0C2535 (A) 0C2536 (A) 0C2547 (A) 0F1255 (A) 0C2555 (A) 0C2560A 0D7904 (A) 0C2633 0C6749 060069 0C6748 080490 087233 0C4065 (A) 0C4064 (A) 0C4066 (A) 0C4067 (A) 0C4117A 27 ** 077992...

  • 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

    (Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generator ITEM PART NO. QTY. DESCRIPTION 0D5488 PANEL BTM & BACK CONTROL PANEL 0D1521A CONTROL PANEL, FRONT W/ SILK SCREEN 0D1522 PANEL,SIDE COVER CONTROL PANEL 067680 ASSY VOLTAGE REGULATOR 60HZ 0C8243 WASHER LOCK HDPDEUTSCH 0C8244...

  • 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

    (Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generator ITEM PART NO. QTY. DESCRIPTION 0D7397 PNL BTM & BACK CNTL PNL 04626 0D1521A CONTROL PANEL FRONT W/ SILK SCREEN 0D1522 PANEL SIDE COVER CONTROL PANEL 067680 ASSY VOLTAGE REGULATOR 60HZ 0C8243 WASHER LOCK HDP DEUTSCH 0C8244...

  • 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

    ITEM PART NO. QTY. 0E6353 0D5489 0E6427 023484N 0E6454 056739 0C2454 051715 0D3388 058710 0D5492 (048766) REF. 022985 0E6689 022264 052813 039253 022145 0D5840 022129 045771 022287 022473 022097 022127 0E4458 0E5586 0E5587 022237 022241 081320 048527 0D5464B 057073 0C2266 Section 8 —...

  • 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

    ITEM PART NO. QTY. 051768 051769 0A8240 039253 022129 082130D 0C4286 0A2601 0A2602 10 * 0A1138 11 * 021941 020808A 13 * 052624 14 * 070892 0A5580 0A1633 020729A 022131 022237 022511 068113 0E6353 043123 051779 046852 022145 039287 071641 071639 0A2110 022473...

  • Page 44

    Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators Engine – Drawing No. 0D6980-D 42 Generac ® Power Systems, Inc.

  • Page 45

    ITEM PART NO. QTY. 0A9046 0A9118A 070022 0A6021 059056A 0A9050 022237 045772 049226 051716 0A4244 0A4215 0A4231 059057 10" 0A2440 026568 099729A 061012 069939 035606 0A4930B 0A4084 029745 044101 023152 022131 058030 0A4085 0A3928 0C7947A 057794 0A4277 022241 057795A 048191 032303 0A3852 098239...

  • Page 46

    Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators Engine – Drawing No. 0A4304-N 44 Generac ® Power Systems, Inc.

  • Page 47

    ITEM PART NO. QTY. 0A9046 0A4084 0A4239 0A4240 0A5640 0A5640A 0A5639 0D3293A 077996 057823 035579 037065 022302 0A8584 052644 0A4278A 0A4930A 0A4085 0A3927 0C7947A 0A1232 0A7801B 021928 0C6239 0A4241 0C2885 0A5737C 022131 077456 044117 057823 057448 022129 022142 048614 022237 029745 042633 033819...

  • Page 48

    Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators 4.3L Radiator – Drawing No. 0D7992-E 46 Generac ® Power Systems, Inc.

  • Page 49

    ITEM PART NO. QTY. 0D7825A 0D8251 0D8252 024655 022097 022473 0D7174 0D7174A 0D7870 035685 047290 040173 036865 029032 052250 058443 029745 022237 022131 0D7850 076749 0D7975 090388 048031C 0C4341 30 * 0A6984 31 * 0D7942 32 * 0D7943 33 * 022413 34 * 022097...

  • Page 50

    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 2.5" DIA. CLAMP ASSEMBLY TO ENGINE TO ENGINE ITEM PART NO. QTY. DESCRIPTION 059902A CAP RAIN 2.50 / 2.69 0C9641 TUBE STRAIGHT 'A' GROUP 0C9650...

  • Page 51

    ITEM PART NO. QTY. 037561 0A4632A 0A4637 0A4632B 062522 022127 057796 057795A Section 8 — Exploded Views and Parts Lists Guardian Liquid-cooled 40 kW Generators 4.3L Air Cleaner – Drawing No. 0E0712-A DESCRIPTION NUT WING 1/4-20 NYLK PLATE AIR CLEANER TOP FILTER AIR 11.5"...

  • 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-B 50 Generac ® Power Systems, Inc.

  • Page 53

    (Model No. 0043733, 0043734 & 0043735) Guardian Liquid-cooled 40 kW Generators ITEM PART NO. QTY. 065907 026812 028238 0C7598 026490 026577 055944 028237 0E0521 022259 022145 022129 030795 025655 022132 051778 028641 057824 057422 043123 051779 082508 050279 026915 055934P 26** 0A5737C 0D1509...

  • 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-B 52 Generac ® Power Systems, Inc.

  • Page 55

    (Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generators ITEM PART NO. QTY. 065907 026812 022259 0C7598 026490 026577 0D2758 0E0521 028237 028238 022145 022129 030795 025655 022132 051778 028641 057824 057422 043123 051779 0C7820 050279 026915 055934P 26 ** 0A5737C 0D1509...

  • 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

    (Model No. 0046262, 0046263 & 0046264) Guardian Liquid-cooled 40 kW Generators ITEM PART NO. QTY. 059902A 0C9641 0D4208 0D5061 0C4126 0D5787 0A5215B 0E0699 0E0698 0C4170 0C4305 0C2454 0C3433A 022129 022145 045771 042907 080762 022237 022241 0E0701 0E0700 077879 0D4221 0D4512 043116 022471 022264...

  • Page 58

    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. 098290 0A3439 098958A 021888 082508 036409 043146 098941A 098942A 098225 022097 064526 029333A 074031...

  • Page 59

    ITEM PART NO. QTY. DESCRIPTION 0C4905 BARBED EL 45 FITTING 057822 CLAMP HOSE #8 .53-1.00 077043E CONDUIT FLEX 1" BLACK (15"LG) 050967 HOSE 5/8 ID RIA 250F (46"LG) 0A6283 HOSE PREFORMED BLOCK HEATER 057822 CLAMP HOSE #8 .53-1.00 0C4905 BARBED EL 45 3/8NPT X 5/8OD 042568 SCREW HHC M6-1.0 X 20 G8.8 022473...

  • 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

    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.

  • Page 63: 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 con- tinue for 24 consecutive months thereafter.

  • Page 64

    "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.

This manual also for:

Guardian 004626-5

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