Generac Power Systems 004992-0, 004992-1, 37kW NG, 40kW LP Owner's Manual

Liquid-cooled, prepackaged standby generator.
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Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Nos.
004992-0
004992-1
37kW NG, 40kW LP
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

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   Summary of Contents for Generac Power Systems 004992-0, 004992-1, 37kW NG, 40kW LP

  • Page 1

    Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Nos. 004992-0 004992-1 37kW NG, 40kW LP This manual should remain with the unit. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

  • Page 2

    INTRODUCTION Thank you for purchasing this model of the Guardian standby generator product line by Generac Power 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.

  • Page 3: Table Of Contents

    INTRODUCTION ...IFC SAFETY RULES ...2 Section 1 — GENERAL INFORMATION ...4 Generator ...4 Transfer Switch ...4 Automatic System Operation ...4 Generator AC Connection Systems...4 Main Circuit Breaker ...4 Generator Fuel System ...5 Engine Protective Devices ...5 Unpacking ...6 Lifting the Generator ...6 1.10 Specifications ...7 1.11 Fuel Consumption ...7 1.12 Reconfiguring the Fuel System ...7...

  • Page 4: Safety Rules

    IMPORTANT SAFETY INSTRUCTIONS Guardian 40kW Liquid-cooled Generators 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, potential operators, and service and repair technicians for 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, Generator, Transfer Switch, Automatic System Operation, Generator Ac Connection Systems

    Section 1 - General Information Guardian 40kW Liquid-cooled Generators GENERATOR 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.

  • Page 7: Generator Fuel System, Engine Protective Devices

    GENERATOR FUEL SYSTEM 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. Fuel 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: Unpacking, Lifting The Generator

    Section 1 — General Information Guardian 40kW Liquid-cooled Generators Figure 1.6 - Low Coolant Level Sensor 1.7.4 OVERSPEED SHUTDOWN 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.

  • Page 9: Specifications, Fuel Consumption, Reconfiguring The Fuel System

    1.10 SPECIFICATIONS 1.10.1 GENERATOR SPECIFICATIONS Model Rated Max. Cont. AC Power Output (kW) Rated voltage (volts) No. of Rotor Poles Driven Speed of Rotor Rotor Excitation System Direct excited brush type Type of Stator Rotor/Stator Insulation 1.10.2 ENGINE SPECIFICATIONS Make...Chrysler Displacement ...3.9 liters Cylinder Arrangement ...V-6 Valve Arrangement ...Overhead Valve...

  • Page 10: Torque Specifications, Engine Oil Recommendations, Coolant Recommendations, Before Installation, Section 2 — Installation

    Section 2 — Installation Guardian 40kW Liquid-cooled Generators DANGER Serious injury or damage may occur if not configured properly. Please consult an author- ized service dealer with any questions. 1.13 TORQUE SPECIFICATIONS Tighten the bolts from the middle out, in a criss- cross pattern.

  • Page 11: Generator Location, Generator Mounting And Support, Basic Standby Electric System

    After the system has been installed, do nothing that might render the installation in noncompli- ance with such codes, standards and regula- tions. 2.1.1 NFPA STANDARDS The following published standards booklets pertain- ing to standby electric systems are available form the National Fire Protection...

  • Page 12: Emergency Circuit Isolation Method, Total Circuit Isolation Method, Grounding The Generator, Generator Ac Neutral Connections

    Section 2 — Installation Guardian 40kW Liquid-cooled Generators Figure 2.1 – Basic Standby Electric System EMERGENCY CIRCUIT ISOLATION METHOD 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 using the emer- gency circuit isolation method.

  • Page 13: Battery Installation

    TRANSFER SWITCH SIGNAL CONNECTIONS 2.9.1 PRE-PACKAGED ATS 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 ATS control functions.

  • Page 14: Preparation Before Start-up

    Section 2 — Installation Guardian 40kW Liquid-cooled Generators • 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.

  • Page 15: Section 3 — Operation, Using An Engineered "gts" Transfer Switch, Control Console Components

    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. USING AN ENGINEERED “GTS”...

  • Page 16: Manual Transfer And Startup, Engine Governor Adjustments

    Section 3 — Operation Guardian 40kW Liquid-cooled Generators 3.2.3 15 AMP FUSE 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. If the fuse needs to be replaced, use only an identical 15-amp replacement fuse.

  • Page 17: Retransfer And Shutdown, Automatic Operation, Weekly Exercise Cycle

    RETRANSFER AND SHUTDOWN 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: • Verify that utility power supply voltage to the trans- fer switch has been positively turned Off, using whatever means provided (such as utility main line circuit breaker).

  • Page 18: Section 4 — Maintenance, Cooling System, Overload Protection For Engine Dc Electrical System

    Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators MAINTENANCE PERFORMED BY AUTHORIZED SERVICE DEALERS A. EVERY THREE MONTHS 1. Check battery state of charge and condition. 2. Inspect and test fuel system. 3. Check transfer switch. 4. Inspect exhaust system. 5.

  • Page 19: Maintenance Owner/operator Can Perform

    • Add recommended coolant mixture as necessary. • Periodically 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.

  • Page 20: Miscellaneous Maintenance

    Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators 7. Start engine and check for oil leaks. Figure 4.2 - Oil Filter Oil Filter 4.5.11 CHANGING THE ENGINE AIR CLEANER To 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.

  • Page 21

    4.6.3 BATTERY MAINTENANCE 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 with DISTILLED WATER ONLY.

  • Page 22: Scheduled Maintenance

    Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators SCHEDULED MAINTENANCE Following 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 application.

  • Page 23

    Maintenance Level 1 Tasks Recom- mended to be done monthly 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level. Adjust as necessary. 4. Check the engine coolant thermal protection level.

  • Page 24

    Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators Maintenance Level 1 Tasks Recom- mended to be done monthly 13. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating...

  • Page 25: Section 5 — Troubleshooting

    TROUBLESHOOTING POINTS PROBLEM Engine won’t crank. Engine cranks, but won't start Engine starts hard, runs rough. Engine starts, then shuts down. AUTO/OFF/MANUAL Switch at, OFF engine continues to run No AC output from generator. Under normal operating conditions, if repair of generator set or replacement of any parts is necessary dur- ing the warranty period, you must contact an authorized service dealer.

  • Page 26: Section 6 — Electrical Data

    Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8115-A 24 Generac ® Power Systems, Inc.

  • Page 27

    Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8115-A Generac ® Power Systems, Inc. 25...

  • Page 28

    Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E8116-A ® 26 Generac Power Systems, Inc.

  • Page 29

    Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E8116-A Generac ® Power Systems, Inc. 27...

  • Page 30

    Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Mounting Base — Drawing No. 0E8084-A 28 Generac ® Power Systems, Inc.

  • Page 31

    ITEM PART NO. QTY. 0E7331 052860 052251 052257 052252 052259 052891 0536210214 074906 047411 055414 026850 022097 022473 049813 0A1694 025507 0E7359 027482 022129 045771 051756 046526 022131 055934M 049820 059473 061902 058665 REF. 038804D 038805J 021991 036833 022237 022131 075763 050331 050331A...

  • Page 32

    Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Enclosure — Drawing No. 0E8439-E 30 Generac ® Power Systems, Inc.

  • Page 33

    ITEM PART NO. QTY. 0E8411 0E8042 0E8041 0C2454 0E7807 0E7808 0E7809 0E8387 0E6986 0E7795 089961 0A2115 0E8404 0D2538A 0D2538 043116 022097 022473 0E7570 0E7571 070015 0E7662 0D2537A 0D2537 0D2023 0E7869 0E8001 0E8060 0E7966 0D3037A 0C7781 0E7794 0E8052 0D3037 0E8007 0E8008 0E7992 0E8055 026850...

  • Page 34

    Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Control Panel — Drawing No. 0E7118-G 32 Generac ® Power Systems, Inc.

  • Page 35

    ITEM PART NO. QTY. DESCRIPTION 0E7195 CONTROL BOX HSB 0E7196 COVER FRONT PANEL HSB 0E7197 COVER TOP PANEL HSB 0E7193 DECAL WARNINGS HSB 0E7194 DECAL CONTROLS HSB 0E4494 SWITCH ROC DPDT ON-OFF-ON 082573 SWITCH ROCKER DPST 125V SPD 032300 HOLDER FUSE 022676 FUSE 15A X AGC15 067682B...

  • Page 36

    Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Engine — Drawing No. 0E8121-D 34 Generac ® Power Systems, Inc.

  • Page 37

    ITEM PART NO. QTY. DESCRIPTION 0E5048A FLEXPLATE 3.9L HSB 0E7477 MACHINING, 3.9L ENGINE ADAPTOR 0E6703 COVER, FLYWHEEL ACCESS 0E8336 REWORK, 3.9L CHRYSLER ENGINE 0E7841 GASKET, THERMOSTAT ADAPTOR 0E7254 MACH, THERM ADAPTOR 3.9L CHRY 0E7956 BRACKET, IGNITION COIL 0E7953 COIL IGNITION 3.9L CHRYSLER 047411 SCREW HHC M6-1.0 X 16 G8.8 0E8591...

  • Page 38

    Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Radiator — Drawing No. 0E8102-E 36 Generac ® Power Systems, Inc.

  • Page 39

    ITEM PART NO. QTY. 0D7825A 0D7174C 0E7640 0E7924 0F2853 0D8252 0D8251 0E0726 076749 035685 069860C 058443 0C2454 052250 048031C 029032 0A2111 0E7640A 035461 065852 051756 022131 046526 045772 Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Radiator — Drawing No. 0E8102-E DESCRIPTION RADIATOR COPPER BRASS VENTURI,3.9L CRYSLR HSB 22"FAN...

  • Page 40

    Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Fuel System — Drawing No. 0E8122-F 38 Generac ® Power Systems, Inc.

  • Page 41

    ITEM PART NO. QTY. 033212 075580 0E8365 039253 022145 022129 045771 042907 0C2454 026307 0E1056 0E6584 057822 059194 064945 0D1509 050279 0E7839 0E6586 0E4394 040105 0E6382B 0F2119 0E6376B 042561 057822 0E7929 0A4637 0E6406 0E7702 0A4632A 037561 046580 0E8286 044118 049815 049226 051713 022097...

  • Page 42

    Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Alternator — Drawing No. 0E5146-B 40 Generac ® Power Systems, Inc.

  • Page 43

    ITEM PART NO. QTY. 0E5093A 0E7413A 0E5094A 0E7412A 0E5706 0E5048 0E5048A 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 092980 052625 0A2602 042558 0A2601 0E7226 045757 052857 051715 038150 077043F ROTOR REPLACEMENT PARTS 047248 070892 Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Alternator —...

  • Page 44

    Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Muffler — Drawing No. 0E8068-E TO EXHAUST MANIFOLD ITEM PART NO. QTY. DESCRIPTION 0E8616 MUFFLER 7" X 9" X 21" 2.5" IN & 0F1081 WYE, PIPE 3.9L CHRYSLER 0F1087 PIPE R/H SIDE 3.9L CHRYSLER 0E8026 PIPE L/H EXHAUST MANIFOLD...

  • Page 45

    Section 8 — Installation Diagram Guardian 40kW Liquid-cooled Generators Installation Diagram — Drawing No. 0E8422-A Generac ® Power Systems, Inc. 43...

  • Page 46: Section 9 — Notes

    Section 9 - Notes Guardian 40kW Liquid-cooled Generators 44 Generac ® Power Systems, Inc.

  • Page 47

    Section 9 - Notes Guardian 40kW Liquid-cooled Generators Generac ® Power Systems, Inc. 45...

  • Page 48

    "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 004992-0, Guardian 004992-1

Comments to this Manuals

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Latest comments:
  • Byron Woodall Aug 03, 2016 11:25:
    does generac ever have any cold solder joints in their circuit boards n the 4992-1 gen-set 40KW unit.
  • ROBERTO Dec 09, 2014 06:23:
    (1)COOLANT LEVER SENSOR GENERATOR KOHLER WITH JOHN DEERE ENGINE 4-CYLINDER​;

    KOHLER 37KW
    MODEL​# 40ROZJ61
    S​ERIAL# 368864

    EN​GINE SERIAL# CD4039D228​041
    ENGINE FAMILY# 4039DF

    MY EMAIL IS LTBP.ROBER​TO@GMAIL.C​OM