Generac Power Systems Guardian 004992-2 Owner's Manual
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Generac Power Systems Guardian 004992-2 Owner's Manual

Liquid-cooled, prepackaged standby generators 37kw ng, 40kw lp
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Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Nos.
004992-2
37kW NG, 40kW LP
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

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  • Page 1 Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Nos. 004992-2 37kW NG, 40kW LP This manual should remain with the unit. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

  • Page 2: Introduction

    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: General Hazards

    IMPORTANT SAFETY INSTRUCTIONS 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

    • 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 40Kw Liquid-Cooled Generators

    • Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and cor- rosive vapors. Model Rating 004992-2 37,000 NG 40,000 LP When this generator, along with a transfer switch, has been installed and interconnected, a circuit board in the generator panel constantly monitors UTILITY power source voltage.

  • Page 7: Generator Fuel System

    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

    Section 1 — General Information 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

    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: Section 2 - Installation 40Kw Liquid-Cooled Generators

    Section 2 — Installation 40kW Liquid-cooled Generators DANGER Serious injury or damage may occur if not con- figured properly. Please consult an authorized 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

    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

    Section 2 — Installation 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: Transfer Switch Start Signal Connections

    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 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

    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: Amp Inline Fuse

    Section 3 — Operation 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

    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 40Kw Liquid-Cooled Generators

    Section 4 — Maintenance 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. Check engine ignition system. 6.

  • 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: Coolant Change

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

  • Page 23: Maintenance Tasks

    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 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: Troubleshooting Points

    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 40Kw Liquid-Cooled Generators Wiring Diagram - Engine - Drawing No. 0E8115-A

    Section 6 - Electrical Data 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8115-A...
  • Page 27 Section 6 - Electrical Data 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8115-A...
  • Page 28 Section 6 - Electrical Data 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E8116-A...
  • Page 29 Section 6 - Electrical Data 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E8116-A...

  • Page 30: Section 7 - Exploded Views And Parts Lists

    Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Mounting Base — Drawing No. 0E8084-B...
  • 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 40kW Liquid-cooled Generators Enclosure — Drawing No. 0F4931-C...

  • Page 33: Section 7 - Exploded Views And Parts

    ITEM PART NO. QTY. 0E8411 0E8042 0E8041 0C2454 0E7807 0E7808 0E7809 0E8387 0E6986 0F5552 089961 0A2115 0E8404 0D2538A 0D2538 078115 022097 022473 0E7570 0E7571 070015 0E7662 0D2537A 0D2537 0D2023 0E7869 0E8001 0F5551 0E7966 0D3037A 0C7781 0E7794 0E8052 0D3037 0E8007 0E8008 0F4938 0E8055 026850...
  • Page 34 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Control Panel — Drawing No. 0E7118-K...
  • 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 40kW Liquid-cooled Generators Engine — Drawing No. 0E8121-H BAFFLE REAR UPPER "A" "C" "A" "C" D.C. ALTERNATOR BRACKET HARDWARE. COMES WITH ENGINE "B" "B"...
  • 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 40kW Liquid-cooled Generators Radiator — Drawing No. 0E8102-F...
  • 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 40kW Liquid-cooled Generators Radiator — Drawing No. 0E8102-F DESCRIPTION RADIATOR COPPER BRASS VENTURI,3.9L CRYSLR HSB 22"FAN...
  • Page 40 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Fuel System — Drawing No. 0E8122-H...
  • 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 0E7929 0A4637 0E6406 0E7702 0A4632A 037561 046580 0E8286 044118 049815 049226 051713 022097 057796...
  • Page 42 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Alternator — Drawing No. 0F5092-B...
  • Page 43 ITEM PART NO. QTY. 0F1659A 0F1657A 0F1655A 0F5073A 0E7413A 0F1660A 0F1658A 0F1656A 0F5074A 0E7412A 0E5706 0E5048 0E5048B 0E5048A 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 092980 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F ROTOR REPLACEMENT PARTS 047248 070892 Section 7 - Exploded Views and Parts...
  • Page 44 Section 7 - Exploded Views and Parts 40kW Liquid-cooled Generators Muffler — Drawing No. 0F4894-B ITEM PART NO. QTY. DESCRIPTION 0F0738 MUFFLER 7"X9"-(2)2"IN/2.5"OUT 0C9748 PLUG M18-1.50 0F0778 PIPE R/H SIDE EXHAUST MILD ST 0F0777 PIPE L/H SIDE EXHAUST MILD ST 0E5914 BRACKET MUFFLER 3.0L FORD 0E0170C...

  • Page 45: Section 8 - Installation Diagram 40Kw Liquid-Cooled Generators

    Section 8 — Installation Diagram 40kW Liquid-cooled Generators Installation Diagram — Drawing No. 0E8422-A...

  • Page 46: Section 9 - Notes 40Kw Liquid-Cooled Generators

    Section 9 — Notes 40kW Liquid-cooled Generators...
  • Page 47 Section 9 — Notes 40kW Liquid-cooled Generators...

  • Page 48: Section 10 - Warranty 40Kw Liquid-Cooled Generators

    Section 10 – Warranty 40kW Liquid-cooled Generators GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN "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.

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