Summary of Contents for Generac Power Systems 004992-0, 004992-1, 37kW NG, 40kW LP
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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!!
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.
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 –...
• 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.
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.
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.
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.
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...
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.
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...
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.
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.
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.
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”...
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.
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).
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.
• 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.
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.
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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.
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.
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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.
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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...
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.
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Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Control Panel — Drawing No. 0E7118-G 32 Generac ® Power Systems, Inc.
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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...
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Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Engine — Drawing No. 0E8121-D 34 Generac ® Power Systems, Inc.
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Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Fuel System — Drawing No. 0E8122-F 38 Generac ® Power Systems, Inc.
"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.