®
POWER SYSTEMS, INC.
Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Models:
004373-2 (40 kW/Single-phase
w/ 200 Amp
*This Manual Should
Remain With The Unit*
Transfer Switch)
004626-1 (40 kW/Single-phase
w/ 200 Amp
Transfer Switch
California Emissions)
®
POWER SYSTEMS, INC.
®
DANGER
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
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Table of Contents
Guardian Liquid-cooled 40 kW Generator
2.8.6 Belt Tension ....................................11
2.8.7 Electrical System ............................11
2.8.8 Rodent Protection ............................11
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
Section 3 – Operation ..................................12
3.1 Control Console Components ......................12
3.1.1 AC Voltmeter ..................................12
3.1.2 AC Ammeter ..................................12
3.1.3 AC Frequency Meter ......................12
3.1.4 DC Voltmeter..................................12
3.1.5 Hourmeter......................................12
3.1.6 Auto/Off/Manual Switch..................12
3.1.7 Fault Indicator Lamp......................12
3.1.8 15-amp Fuse ..................................12
3.1.9 7.5 Amp Inline Fuse ......................12
3.1.10 Voltage-phase Selector Switch ........12
3.1.11 Set Exercise Time Switch ..............12
Safety Rules ......................................................2
Section 1 – General Information..................4
1.1 Unpacking/Inspection ..................................4
1.1.1 Lifting the Generator........................4
1.2 The Generator..............................................4
1.3 Generator AC Connection Systems ..............4
1.4 Prepackaged Transfer Switch ......................4
1.5 Automatic System Operation........................4
1.6 Main Circuit Breaker ..................................5
1.7 Engine Protective Devices ............................5
1.7.1 Low Oil Pressure Switch ..................5
1.7.2 High Coolant
3.2 Using the Auto/Off/Manual Switch..............12
3.2.1 “Auto” Position................................12
3.2.2 “Off” Position..................................13
3.2.3 “Manual” Position ..........................13
3.3 Automatic Transfer Operation....................13
3.4 Sequence of Automatic Operation ..............13
3.5 Engine Heater ..............................................13
3.6 Weekly Exercise Cycle ................................14
Temperature Switch ........................5
1.7.3 Low Coolant Level Switch ................5
1.7.4 Overspeed Shutdown ......................5
1.7.5 Overcrank Shutdown ......................5
1.7.6 DC Fuse............................................5
1.8 Specifications ..............................................5
1.8.1 Generator ........................................5
1.8.1.1 Generator Load
and Compatibility ....................6
1.8.2 Engine..............................................6
1.9 Fuel Requirements
and Recommendations ............................6
1.9.1 Conversion to LP Gas Vapor ............6
1.10 Engine Oil Recommendations ......................7
1.11 Coolant ........................................................7
1.12 Emission Control System ............................7
Section 4 – Maintenance ............................14
4.1 Checking the Engine Oil Level....................14
4.2 Changing the Engine Oil and Filter ............15
4.2.1 Engine Oil Recommendations ........15
4.2.2 Oil and Filter Change Procedure......15
4.3 Changing the Engine Air Cleaner................15
4.4 Spark Plugs................................................16
4.5 Battery Maintenance ..................................16
4.6 Cooling System ..........................................17
4.7 Overload Protection for
Engine DC Electrical System......................17
4.8 DC Fuse ....................................................17
4.9 Engine Coolant ..........................................17
4.10 Miscellaneous Maintenance........................17
4.10.1 Cleaning the Generator ..................17
4.10.2 Rodent Protection ..........................18
4.11 Out of Service Procedure ............................18
4.11.1 Removal From Service....................18
4.11.2 Return to Service............................18
4.12 Service Schedule........................................19
Section 2 – Installation ..................................8
2.1 Basic Standby Electric System ....................8
2.2 Emergency Circuit Isolation Method ............9
2.3 Total Circuit Isolation Method......................9
2.4 Grounding the Generator ............................9
2.5 Generator AC Neutral Connections ..............9
2.6 Transfer Switch Start Signal Connections....9
2.6.1 Pre-Packaged Type Switch..................9
2.6.2 “GTS” Type Switch ............................9
2.7 Battery Installation ....................................10
2.7.1 Vented Batteries ..............................10
2.8 Preparation Before Start-up ......................10
2.8.1 Prior to Initial Start-up ....................11
2.8.2 Transfer Switch ..............................11
2.8.3 Fuel System ....................................11
2.8.4 Generator Set Lubrication ..............11
2.8.5 Engine Coolant ................................11
Section 5 – Troubleshooting ......................20
Section 6 – Electrical Data ....................21-29
Section 7 – Exploded Views and
Parts Lists ............................30-54
Section 8 – Notes ..........................................55
Section 9 – Installation Drawings........56-57
Section 10 – Warranty ..................Back Cover
®
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Important Safety Instructions
Guardian Liquid-cooled 40 kW Generator
SAVE THESE INSTRUCTIONS – Th e m a n u fa ct u r er su ggest s t h a t t h ese r u les for sa fe
op er a t ion be cop ied a n d p ost ed in p ot en t ia l h a za r d a r ea s. Sa fet y sh ou ld be st r essed t o a ll
op er a t or s a n d p ot en t ia l op er a t or s of t h is equ ip m en t .
!
!
!
!
SAVE THESE INSTRUCTIONS – Th is m a n u a l con t a in s im p or t a n t in st r u ct ion s t h a t sh ou ld be
followed d u r in g in st a lla t ion a n d m a in t en a n ce of t h e gen er a t or a n d ba t t er ies.
!
!
!
!
GENERAL HAZARDS
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
• For
safety
reasons,
Generac
recommends
that the installation, initial start-up and maintenance
of this equipment is carried out by
Generac/Guardian Authorized Dealer.
a
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electrical
and building codes. Comply with regulations the
Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the gener-
ator is installed, operated and serviced in accordance
with the manufacturer’s instructions and recommen-
dations. Following installation, do not do anything
that might render the unit unsafe or in noncompli-
ance with the aforementioned codes, standards, laws
and regulations.
• The engine exhaust fumes contain carbon monoxide,
which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. For that reason, ade-
quate ventilation must be provided. Exhaust gases
must be piped safely away from any building or
enclosure that houses the generator to an area where
people, animals, etc., will not be harmed. This
exhaust system must be installed properly, in strict
compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive belts,
fans, and other moving or hot parts. Never remove
any drive belt or fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating
air is critical in any room or building housing the gen-
erator to prevent buildup of explosive gases and to
ensure correct generator operation. Do not alter the
installation or permit even partial blockage of ventila-
tion provisions, as this can seriously affect safe oper-
ation of the generator.
!
!
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar
with this Ow ner’s Ma nua l and with the unit. The gen-
erator can operate safely, efficiently and reliably only if
it is properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and fun-
damental rules or precautions.
Generac cannot possibly anticipate every possible
circumstance that might involve a hazard. The warn-
ings in this manual, and on tags and decals
affixed to the unit are, therefore, not all-inclusive. If you
use a procedure, work method or operating technique
Generac does not specifically recommend, you must
satisfy yourself that it is safe for you and others. You
also must make sure the procedure, work method or
operating technique that is chosen does not render the
generator unsafe.
DANGER
Despite the safe design of this generator,
!
operating this equipment imprudently, neglecting its
maintenance or being careless can cause
possible injury or death. Permit only responsible and
capable persons to operate or maintain this equip-
ment.
Potentially lethal voltages are generated by these
machines. Ensure all steps are taken to render the
machine safe before attempting to work on the
generator.
• Keep the area around the generator clean and unclut-
tered. Remove any materials that could become haz-
ardous.
• When working on this equipment, remain alert at all
times. Never work on the equipment when you are
physically or mentally fatigued.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running gen-
erators.
!
®
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Important Safety Instructions
Guardian Liquid-cooled 40 kW Generator
• Inspect the generator regularly, and promptly repair • Generators installed with an automatically transfer
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.
Reconnect that cable last.
• Never use the generator or any of its parts as a step.
Stepping on the unit can stress and break parts, and
may result in dangerous operating conditions from
leaking exhaust gases, fuel leakage, oil leakage, etc.
switch will crank and start automatically when nor-
mal (utility) source voltage is removed or is below an
acceptable preset level. To prevent such automatic
start-up and possible injury to personnel, disable the
generator’s automatic start circuit (battery cables,
etc.) before working on or around the unit. Then,
place a “Do Not Operate” tag on the generator control
panel and on the transfer switch.
• In case of accident caused by electric shock, immedi-
ately shut down the source of electrical power. If this
is not possible, attempt to free the victim from the
live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement, such
as a rope or board, to free the victim from the live
conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric
shock, or may get caught in moving components
causing injury.
ELECTRICAL HAZARDS
• All generators covered by this manual produce dan-
gerous electrical voltages and can cause fatal electri-
cal shock. Utility power delivers extremely high and
dangerous voltages to the transfer switch as does the
standby generator when it is in operation. Avoid con-
tact with bare wires, terminals, connections, etc.,
while the unit is running. Ensure all appropriate cov-
ers, guards and barriers are in place before operating
the generator. If work must be done around an oper-
ating unit, stand on an insulated, dry surface to
reduce shock hazard.
FIRE HAZARDS
• Keep a fire extinguisher near the generator at all
times. DO NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid can
deteriorate wiring insulation. Keep the extinguisher
properly charged and be familiar with its use. If there
are any questions pertaining to fire extinguishers,
consult the local fire department.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• If people must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing
this equipment, place insulative mats over a dry
wooden platform. Work on the equipment only while
standing on such insulative mats.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts of the
generator to be connected to an approved earth
ground and/or grounding rods. This grounding will
help prevent dangerous electrical shock that might be
caused by a ground fault condition in the generator
set or by static electricity. Never disconnect the
ground wire.
• Wire gauge sizes of electrical wiring, cables and cord
sets must be adequate to handle the maximum elec-
trical current (ampacity) to which they will be sub-
jected to.
• Before installing or servicing this (and related) equip-
ment, make sure that all power voltage supplies are
positively turned off at their source. Failure to do so
will result in hazardous and possibly fatal electrical
shock.
• Connecting this unit to an electrical system normally
supplied by an electric utility shall be by means of a
transfer switch so as to isolate the genrator electric
system from the utility electric system while in oper-
ation. Failure to isolate the two electric system power
sources from each other by such means will result in
damage to the generator and may also result in injury
or death to utility power workers due to backfeed of
electrical energy.
EXPLOSION HAZARDS
• Properly ventilate any room or building housing the
generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel
or oil spills immediately. Ensure that no combustible
materials are left in the generator compartment, or
on or near the generator, as FIRE or EXPLOSION
may result. 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
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulating
the storage and handling of fuels. Inspect the unit’s
fuel system frequently and correct any leaks imme-
diately. Fuel supply lines must be properly installed,
purged and leak tested according to applicable fuel-
gas codes before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids
such as natural gas and liquid propane (LP) gas are
extremely EXPLOSIVE. Natural gas is lighter than
air, and LP gas is heavier than air; install leak detec-
tors accordingly.
®
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Section 1 — General Information
Guardian Liquid-cooled 40 kW Generator
When the two windings are connected in series, a 240-
volt, 60-Hertz AC output results. Typically, the two “hot”
leads in the circuit are Wires 11 and 44. The neutral
leads are the junction of Wires 22 and 33.
1.1 UNPACKING/INSPECTION
After unpacking, carefully inspect the contents
for damage.
• This standby generator set has been factory installed
in an all-weather, metal enclosure that is intended
exclusively for outdoor installation.
Figure 1.1 – Single-phase
Generator AC Connection System
If this generator is used to power electrical load
circuits normally powered by a utility power
source, code requires to install a transfer switch.
The transfer switch must effectively isolate the
electrical system from the utility distribution sys-
tem when the generator is operating (NEC 701).
Failure to isolate an electrical system by such
means will result in damage to the generator and
also may result in injury or death to utility power
workers due to backfeed of electrical energy.
Neutral Block
If any loss or damage is noted at time of delivery, have
the person(s) making the delivery note all damage on
the freight bill or affix his or her signature under the
consignor's memo of loss or damage.
1.4 PREPACKAGED TRANSFER SWITCH
The transfer switch shipped with this generator is rated
200 amps maximum at 120/240 volts AC single-phase.
The enclosure of the transfer switch is NEMA 3R. This
type of enclosure is intended for indoor or outdoor use.
If there is loss or damage after delivery, separate the
damaged materials and contact the carrier for claim
procedures.
Follow these rules:
• Install the transfer switch on a firm, sturdy support-
ing structure.
“Concealed damage” is understood to mean damage to
the contents of a package that is not in evidence at the
time of delivery, but is discovered later.
• To prevent switch distortion, level the switch if nec-
essary.
This can be done by placing washers
between the switch enclosure and mounting surface.
• Never install the switch where any corrosive sub-
stance might drop onto the enclosure.
1.1.1 LIFTING THE GENERATOR
ꢀ
• Where practical, protect the switch against excessive
moisture, dust, dirt, lint, and construction grit.
Always prevent corrosive vapors from coming in con-
tact with enclosure.
When lifting or hoisting equipment is used, be
careful not to touch overhead power lines.
The generator’s weight of more than 2,000
!
pounds requires proper tools and equipment, and
1.5 AUTOMATIC SYSTEM OPERATION
When this generator, along with its transfer switch, has
been installed and interconnected, a circuit board in the
generator panel continuously monitors utility power
source voltage. Should that voltage drop below a preset
value, and remain at such a low state for a preset amount
of time, the generator cranks and starts. After the gener-
ator starts, the transfer switch transfers load circuits so
the generator can power them.
qualified personnel to be used in all phases of
handling and unpacking.
1.2 THE GENERATOR
This liquid-cooled, Guardian generator set is designed
to supply electrical power to operate critical electrical
loads during utility power failure. Use this generator as
a source of electrical power for the operation of 120
and/or 240-volt, single-phase loads.
When utility source voltage has been restored, the
switch transfers back to the utility source voltage, and
the generator then shuts down after a brief cool-down
time.
1.3 GENERATOR AC
CONNECTION SYSTEMS
Figure 1.1 represents a single-phase, four-wire genera-
tor AC connection system. The stator assembly in this
system consists of a pair of stationary windings with
two leads brought out of each winding. Each single
winding can supply a 120-volt, 60-Hertz AC output.
®
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Section 1 — General Information
Guardian Liquid-cooled 40 kW Generator
1.7.3 LOW COOLANT LEVEL SWITCH
ꢀ
1.6 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:
Should the engine coolant level drop below the level of the
high coolant temperature switch, it is possible for the
engine to overheat without automatic shut down. To pre-
vent such overheating without automatic shut down, the
engine has a low coolant level sensor. If the engine coolant
drops too low, the engine automatically shuts down
(Figure 1.2).
Model Number
004373-2
Circuit Breaker Rating
200-amp breaker
200-amp breaker
004626-1
1.7 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.
1.7.4 OVERSPEED SHUTDOWN
ꢀ
The control module assembly (CMA) circuit board on
liquid-cooled units receives AC frequency (rpm) signals
directly from the stator AC power windings. Should AC
frequency exceed approximately 72 Hertz, circuit board
action will automatically shut down the engine.
1.7.1 LOW OIL PRESSURE SWITCH
ꢀ
This switch is normally closed (N.C.) but is held open by
engine oil pressure during engine running. Should oper-
ating oil pressure drop below approximately 10 psi (68
kPa), the switch contacts close, and the engine shuts down
automatically (Figure 1.2).
1.7.5 OVERCRANK SHUTDOWN
ꢀ
After 90 seconds of crank-rest cycles (about seven sec-
onds cranking/seven seconds at rest), this function ends
cranking if the engine fails to start in that 90-second
span.
Figure 1.2 – Engine Protective Devices
1.7.6 DC FUSE
ꢀ
This fuse is located on the front panel of the control sys-
tem. It protects the panel wiring and components from
damaging overload. Always remove this fuse before
commencing work on the generator. 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 SPECIFICATIONS
1.8.1 GENERATOR
N
Models
0 04373-2 & 004626-1
Rated Maximum Continuous
AC Power Output (kW)*
40
Rated Voltage (volts)
120/240
Rated Maximum Continuous
Current at 240 Volts,
167
Single-phase (amps)
Number of Rotor Poles
Driven Speed of Rotor (rpm)
Type of Stator
4
1,800
Four-wire
Rotor Excitation System
Direct Excited
Brush-type System
1.7.2 HIGH COOLANT TEMPERATURE SWITCH
ꢀ
Stator Insulation
Rotor Insulation
*Rated power of generator is subject to and limited by such factors as ambient tempera-
ture, altitude, engine condition and other factors. Engine power will decrease about 3.5
percent for each 1,000 feet above sea level; and also will decrease an additional 1 percent
for each 6° C (10° F) above 15.5° C (60° F) ambient. Maximum output power of the gener-
ator is limited by maximum engine power.
Class “H”
Class “F”
This normally open (N.O.) thermostatic switch has a
sensing tip that is immersed in captive coolant. Should
the coolant temperature exceed approximately 121° C
(250° F), the switch contacts close, which causes the
engine to shut down automatically (Figure 1.2).
®
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Section 1 — General Information
Guardian Liquid-cooled 40 kW Generator
1.8.1.1 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- This type of system uses the vapors formed above the
trical devices, or both, can be damaged if voltage, num-
ber of phases and frequency are not compatible.
ꢀ
1.9 FUEL REQUIREMENTS
AND RECOMMENDATIONS
With LP gas, use only the vapor withdrawal system .
liquid fuel in the storage tank.
Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at
least 2,520 Btus per cubic foot for LP gas. Ask your fuel
supplier for the Btu content of your fuel.
Not e:
Th is m an u al assu m es t h at t h e st an dby gen erat or
h as been properly select ed, in st alled an d in t ercon -
n ect ed by a com pet en t , qu alified elect rician or
in st allat ion con t ract or. On ce t h e in st allat ion is
com plet e, do n ot h in g t h at m ay resu lt in n on com -
pat ibilit y bet ween t h e gen erat or an d con n ect ed
elect rical loads.
Fuel pressure for both natural gas and liquid propane
setups should be 11 inches to 14 inches of water column
(0.6 psi) at all load ranges.
Gaseous fuels such as natural gas and liquid
propane (LP) gas are highly explosive. Even the
slightest spark can ignite such fuels and cause an
explosion. No leakage of fuel is permitted. Natural
gas, which is lighter than air, tends to collect in
high areas; LP gas is heavier than air and tends to
settle in low areas – install leak detectors accord-
ingly.
1.8.2 ENGINE
ꢀ
Make........................................................General Motors
Displacement ................................4.3 liters (262 cu. in.)
Cylinder Arrangement ................................................V-6
Valve Arrangement..................................Overhead Valves
Firing Order ..................................................1-6-5-4-3-2
Number of Main Bearings..............................................4
Compression Ratio..............................................9.4-to-1
No. of Teeth on Flywheel............................................168
Ignition System ................................................Electronic
Ignition Timing at 1,800 rpm ..............40 degrees BTDC
Rated Horsepower at 1,800 rpm..................................67
Spark Plug Gap ..............................0.045 inch (1.1 mm)
Recommended Spark Plugs ......AC 41-932 or equivalent
Oil Pressure ......................................................30-50 psi
Crankcase Oil Capacity ..............4.5 U.S. quarts (4.25 L)
Recommended Engine Oil............................SAE 15W-40
Type of Cooling System ......Pressurized, closed recovery
Cooling Fan ..................................................Pusher Type
Cooling System Capacity ..............4.5 U.S. gallons (17 L)
Recommended Coolant ..................Use a 50-50 mixture of
ethylene glycol and soft water.
1.9.1 CONVERSION TO LP GAS VAPOR
The generator is shipped from the factory configured for
using natural gas as fuel. To convert the fuel system to LP
gas, proceed as follows (Figure 1.3).
ꢀ
1. Remove end cap from the pressure reducer valve.
2. Turn the tension screw counterclockwise until all ten-
sion is removed from the inner spring.
3. Install and tighten the end cap.
4. Invert the pressure reducer valve. In other words, turn
it upside down (end cap facing downward).
5. Purge and leak test the entire fuel system according to
gaseous fuel codes. NO LEAKS can appear at any point
in the system.
Fu el Con su m pt ion
Figure 1.3 – Conversion to LP Gas Vapor
Natural Gas
004373-2 & 004626-1 ........................................720 cfh
LP Gas
004373-2 & 004626-1..............................288 cfh/7.9gph
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Section 1 — General Information
Guardian Liquid-cooled 40 kW Generator
carburetor, oxygen sensor, air-fuel ratio controller, sole-
noid valve and gas regulator. These items are not sub-
ject to periodic maintenance or adjustment.
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:
This model is of a size (greater than 50 brakehorse-
power) that may require a review by air permitting
authorities prior to installation and operation. Consult
the local air management district for details and specif-
ic requirements.
Temperature
Above 80º F (27º C)
32º to 80º F (-1º C to 27º C) SAE 20W-20 or 15W-40
Below 32º F (0º C) SAE 10W or 15W-40
Oil Grade(Recommended)
Figure 1.4 - Emissions Control System
SAE 30W or 15W-40
Any attempt to crank or start the engine before it
has been properly serviced with the recommended
oil may result in an engine failure.
!
1.11 COOLANT
Use a mixture of half low silicate, ethylene glycol base
antifreeze and half soft water. Use only soft water and
only low silicate antifreeze. If desired, add a high qual-
ity rust inhibitor to the recommended coolant mixture.
When adding coolant, always add the recommended 50-
50 mixture.
1.12.1 AIR FUEL RATIO CONTROLLER
ꢀ
Do not remove the radiator pressure cap while the
engine is hot or serious burns from boiling liquid or
steam could result.
The air fuel ratio controller is an advanced micro-
processor designed to work with a three-way catalyst
and a feedback (rich bias) carburetor to provide close-
loop fuel management. Its digital adaptive control is
able to compensate for variations in fuel mixtures and
engine tunes. It is time based activated. (For example, it
will activate after 45 seconds from receiving the power
signal.) The part number for the air fuel ratio controller
is 0D4221.
Ethylene glycol base antifreeze is poisonous. Do not
use mouth to siphon coolant from the radiator, recov-
ery bottle or any container. Wash hands thoroughly
after handling. Never store used antifreeze in an
open container because animals are atracted to the
smell and taste of antifreeze even though it is poison-
ous to them.
Principle of Operation: The oxygen sensor, installed on
the exhaust pipe, between the engine and the catalytic
muffler (closer to the engine), continuously monitors
the exhaust gas composition. A feedback signal is sent
from the oxygen sensor to the air fuel ratio controller,
which controls the fuel system to maintain the optimal,
stoichiometric air fuel ratio. The air fuel mixture to the
engine is controlled by biasing the diaphragm in the fuel
regulator using vacuum (from the carburetor). This
vacuum signal is directed to the fuel regulator via the
control valve. The air fuel ratio controller determines
the amount of vacuum signal sent to the fuel regulator.
The more vacuum sent to the regulator, the more
restricted the fuel flow will be, therefore the leaner the
air fuel mixture.
Do not use any chromate base rust inhibitor with eth-
ylene glycol base antifreeze, or chromium hydroxide
(“green slime”) will form and cause overheating.
Engines that have been operated with a chromate
base rust inhibitor must be chemically cleaned before
adding ethylene glycol base antifreeze. 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 equipment.
1.12 EMISSIONS CONTROL SYSTEM
(Model 004626-1)
This model is equipped with an active exhaust emis-
sions control system to comply with certain California
air district regulations for natural gas emergency gener-
ating sets, including the South Coast Air Quality
Management District. Do not tamper with or disable
any part of this system, including the exhaust catalyst,
®
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Section 2 — Installation
Guardian Liquid-cooled 40 kW Generator
STANDBY GENERATOR INSTALLATION
DANGER
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 “GTS” 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.
OTHER PUBLISHED STANDARDS
N
In addition to NFPA standards, the following informa-
tion pertaining to the installation and use of standby
electric systems is available:
If an open bottom is used, the engine-generator is
to be installed over non-combustible materials
and should be located such that combustible
materials are not capable of accumulating under
the generator set.
• Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85 John
Street, New York, N.Y. 10038.
• AGRICULTURAL WIRING HANDBOOK, obtainable
from the Food and Energy Council, 909 University
Avenue, Columbia, MO, 65201.
• ASAE EP-364.2, INSTALLATION AND MAINTE-
NANCE OF FARM STANDBY ELECTRIC POWER,
available from the American Society of Agricultural
Engineers, 2950 Niles Road, St. Joseph, MI 49085.
• A52.1, AMERICAN NATIONAL STANDARD FOR
CHIMNEYS, FIREPLACES AND VENTING SYS-
TEMS, available from the American National
Standard Institute, 1430 Broadway, New York, N.Y.
10018.
Only qualified, competent installation contractors or
electricians thoroughly familiar with applicable codes,
standards and regulations should install this standby
electric power system. The installation must comply
strictly with all codes, standards and regulations per-
taining to the installation.
After the system has been installed, you must not do
anything that might render the installation in noncom-
pliance with such codes, standards and regulations.
NOTE:
For more information about the installation of a stand-
by system, you can order Engine-Generator Standby
Electric Power Systems Installer’s Guide and
Reference Manual (part #046622) from a Generac
Authorized Service Dealer.
• NEC HANDBOOK available from the National Fire
Protection Association, 1 Batterymarch Park,
PO Box 9146, Quincy, MA 02269-9959.
2.1 BASIC STANDBY ELECTRIC SYSTEM
Figure 2.1 shows a schematic diagram of a basic stand-
by electric system. Both the UTILITY power supply and
the STANDBY (generator) output are connected to an
approved transfer switch. The transfer switch is
required by electrical code and serves the following
functions:
NFPA STANDARDS
N
The following published standards booklets pertaining
to standby electric systems are available form the
National Fire Protection Association (NFPA),
Batterymarch Park, Quincy, MA 02269:
• Permits the LOAD circuits to be connected to only one
power supply at a time.
• NFPA No. 37, STATIONARY COMBUSTION ENGINES
AND GAS TURBINES.
• Prevents electrical backfeed between STANDBY
• NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS
power and the UTILITY power circuits.
FOR HEALTH CARE FACILITIES.
Notice that both the STANDBY and the UTILITY power
supplies to the transfer switch are protected against
overload by a main line circuit breaker.
• NFPA No. 220, STANDARD TYPES OF BUILDING
CONSTRUCTION
• NFPA No. 68, GUIDE FOR EXPLOSION VENTING
• NFPA No. 70, NATIONAL ELECTRICAL CODE.
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE.
NOTE:
Generac recommends the use of a Generac Power
Systems “pre-packaged” type transfer switch (Part
No. 0D4406) in conjunction with this generator.
• NFPA No. 10, INSTALLATION, MAINTENANCE AND
USE OF PORTABLE FIRE EXTINGUISHERS.
®
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Section 2 — Installation
Guardian Liquid-cooled 40 kW Generator
Figure 2.1 – Basic Standby Electric System
DANGER
Do not connect the ground wire to any pipe that
carries a flammable or explosive substance – FIRE
or an EXPLOSION may result.
Proper grounding helps protect personnel against electri-
cal shock in the event of a ground fault condition in the
generator or in connected electrical devices. In addition,
grounding helps dissipate static electricity that often
builds up in ungrounded devices.
Figure 2.2 – Generator Grounding Lug (typical)
2.2 EMERGENCY CIRCUIT ISOLATION
METHOD
This prevents overloading the generator by keeping elec-
trical loads below the wattage/amperage capacity of the
generator. If the generator is powering only critical
loads, within its wattage/amperage capacity, during util-
ity power outages, consider using the emergency circuit
isolation method.
Critical electrical loads are grouped together and wired
into a separate “Emergency Distribution Panel.” Load
circuits powered by that panel are within the
wattage/amperage capacity of the generator set. When
this method is used, it is difficult to overload the gener-
ator. The transfer switch must meet the following
requirements:
2.5 GENERATOR AC NEUTRAL
CONNECTIONS
Generac uses an UNGROUNDED AC neutral. Grounding
is recommended only at the main service entrance.
• It must have an ampere rating equal to or greater
than the total amperage rating of the emergency dis-
tribution panel circuit.
2.6 TRANSFER SWITCH START SIGNAL
CONNECTIONS
• It must be installed between the building’s main distri-
2.6.1 Pre-Packaged Type Switch
bution panel and the emergency distribution panel.
Connect the six signal wires from the automatic trans-
fer switch to the engine generator control, which is
located on the upper right side and inside the lower
control panel. Match wires 23, 194, N1, N2, T1 and T2
in the transfer switch to the corresponding wires on the
terminal strip in the lower panel. The conductors for
these wires must be in seperate conduit from the main
AC output wires.
2.3 TOTAL CIRCUIT ISOLATION METHOD
When a generator capable of powering all electrical
loads in the circuit is to be installed, use the “Total
Circuit Isolation Method.” It is possible for the genera-
tor to be overloaded when this isolation method is
employed. The following apply to the transfer switch in
this type of system.
• Ampere rating of the transfer switch must be equal to
or greater than the ampere rating of the normal
incoming utility service.
• The transfer switch must be installed between the
utility service entrance and the building distribution
panel.
2.6.2 “GTS” Type Engineered Switch
Connect the two-wire start signal from the automatic
transfer switch to the automatic start connection, which is
located in the right hand corner inside the lower panel.
Match wires 178 and 183 in the transfer switch to 178
and 183 on the terminal strip in the control panel. The
conductors for the two-wire start circuit must be in their
own conduit.
2.4 GROUNDING THE GENERATOR
The National Electrical Code requires the frame and
external electrically conductive parts of this equipment
to be properly connected to an approved earth ground
and/or grounding rods. For that purpose, a GROUND
LUG (Figure 2.2) is provided on the generator mounting
base. Consult a qualified electrician for grounding
requirements in your area. Grounding procedures must
meet local regulations.
NOTE:
Wh en u sin g a GTS swit ch , it is n ecessary t o con -
n ect a 2 4 0 V AC su pply t o N1 an d N2 t erm in als
of t h e gen erat or t o provide for bat t ery ch argin g.
Wir e s T1 , T2 , 2 3 a n d 1 9 4 s h ou ld n ot be
con n ect ed.
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Section 2 — Installation
Guardian Liquid-cooled 40 kW Generator
• Where electrolyte contacts the eyes, flush thoroughly
and immediately with water and seek medical atten-
tion, and
• 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) bicarbonate 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. The resulting liquid is
to be flushed with water and the area dried.
2.7 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 per-
sonnel, do not connect battery cables until the
normal source voltage at the transfer switch is cor-
rect and the system is ready to be placed into
operation.
!
Lead acid batteries present a risk of fire because
they generate hydrogen gas. The following proce-
dures are to be followed:
Storage batteries give off explosive hydrogen gas.
This gas can form an explosive mixture around
the battery for several hours after charging. The
slightest spark can ignite the gas and cause an
explosion. Such an explosion can shatter the bat-
tery and cause blindness or other injury. Any area
that houses a storage battery must be properly
ventilated. Do not allow smoking, open flame,
sparks or any spark producing tools or equipment
near the battery.
• DO NOT SMOKE when near batteries,
• DO NOT cause flame or spark in battery area, and
• Discharge static electricity from body before touching
batteries by first touching a grounded metal surface.
Servicing of batteries is to be performed or supervised
by personnel knowledgeable of batteries and the
required precautions. Keep unauthorized personnel
away from batteries.
For recommended batteries, see “Battery Maintenance”
page 16. All batteries must be at 100 percent state-of-
charge before they are installed on the generator.
Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe burns.
Do not permit fluid to contact eyes, skin, clothing,
painted surfaces, etc. Wear protective goggles,
protective clothing and gloves when handling a
battery. If fluid is spilled, flush the affected area
immediately with clear water.
!
!
!
When using maintenance-free batteries, it is not neces-
sary to check the specific gravity or electrolyte level.
Have these procedures performed at the intervals spec-
ified in Section 4, “Maintenance.” A negative ground sys-
tem is used. Battery connections are shown on the
wiring diagrams. Make sure all batteries are correctly
connected and terminals are tight. Observe battery
polarity when connecting batteries to the generator set.
Do not dispose of the battery in a fire. The
battery is capable of exploding.
Note:
Damage will result if the battery connections are
reversed.
Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
and eyes.
The battery represents a risk of high short circuit
current. When working on the battery, always
2.8 PREPARATION BEFORE START-UP
The instructions in this section assume that the standby
remove watches, rings or other metal objects, and generator has been properly installed, serviced, tested,
only use tools that have insulated handles.
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.
2.7.1 VENTED BATTERIES
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically con-
ductive and corrosive. The following procedures
are to be observed:
• Wear full eye protection and protective clothing,
• Where electrolyte contacts the skin, wash it off
immediately with water,
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Section 2 — Installation
Guardian Liquid-cooled 40 kW Generator
2.8.1 PRIOR TO INITIAL START-UP
2.8.6 Belt Tension
Check the engine fan belt tension and condition prior to
placing the unit into service and at recommended
intervals. Belt tension is correct when a force of approx-
imately 22 pounds (10 kg), applied midway between
pulleys, deflects the belt about 3/8- to 5/8-inch (10 to 16
mm).
Prior to initially starting the generator, it must be
properly prepared for use. Any attempt to crank
or start the engine before it has been properly
serviced with the recommended types and quanti-
ties of engine fluids (oil, coolant, fuel, etc.) may
result in an engine failure.
!
2.8.7 Electrical System
Make sure the generator is properly connected to an
approved earth ground and/or ground rod.
Before starting the generator for the first time, the
installer must complete the following procedures. For
follow-up maintenance information and/or service inter-
vals, please refer to Section 4, “Maintenance.”
Make sure the generator battery is fully charged, proper-
ly 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.
2.8.2 Transfer Switch
If this generator is used to supply power to any electri-
cal system normally powered by an electric utility, the
National Electrical Code requires that a transfer switch
be installed. The transfer switch prevents electrical
backfeed between two different electrical systems. (For
additional information, see the applicable transfer
switch manual for this unit.) The transfer switch, as
well as the generator and other standby components,
must be properly located and mounted in strict compli-
ance with applicable codes, standards and regulations.
2.8.8 Rodent Protection
Make sure the four 3-inch diameter cap plugs (part #
0A8785) are properly installed in the tie-down holes in
the side rails of the unit’s base frame (Figure 2.3). The
cap plugs are shipped in a plastic bag located in the
lower connection box. These plugs are needed to pre-
vent rodents from accessing the interior of the genera-
tor set. On acoustic units, cap plugs also are needed to
stay within noise specification limits.
2.8.3 Fuel System
Make sure the fuel supply system to the generator (a)
delivers the correct fuel at the correct pressure and (b)
is properly purged and leak tested according
to code. No fuel leakage is permitted. See
“Specifications” (Page 6) for more information.
Figure 2.3 - Base Frame Cap Plugs
2.8.4 Generator Set Lubrication
Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level below
the dipstick “ADD” mark. See “Specifications” (Page 5)
and “Engine Oil Recommendations” (Page 7).
NOTE:
Th is en gin e is sh ipped from t h e m an u fact u rer wit h
SAE 1 5 W-4 0 oil. Th is oil sh ou ld be ch an ged aft er
3 0 h ou rs of operat ion .
2.8.5 Engine Coolant
Have the engine cooling system properly filled with the
recommended coolant mixture. Check the system for
leaks and other problems. See “Specifications” (Page 5)
and “Coolant” (Page 7).
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Section 3 — Operation
Guardian Liquid-cooled 40 kW Generator
3.1.6 AUTO/OFF/MANUAL SWITCH
See Section 3.2.
ꢀ
3.1 CONTROL CONSOLE COMPONENTS
The components of a liquid-cooled generator control
console (Figure 3.1) are as follows:
3.1.7 FAULT INDICATOR LAMP
ꢀ
Figure 3.1 – Control Console
This lamp goes ON when one or more of the following
engine faults occurs and when engine shuts down.
• Low oil pressure
• High coolant temperature
• Low coolant level • Overcrank
• Overspeed
3.1.8 15-AMP FUSE
ꢀ
This fuse protects the control console’s DC control cir-
cuit against electrical overload. If the fuse has melted
open because of an overload, engine cranking and start-
up cannot occur. Replace the fuse with an identical AGC
15-amp replacement fuse.
15
3.1.9 7.5 AMP INLINE FUSE (NOT SHOWN)
ꢀ
3.1.1 AC VOLTMETER
ꢀ
This inline fuse is connected in the 15A line that runs
between the Auto/Off/Manual switch and position 10 of
the 76009A PCB. This fuse protects the start, fuel, field
boost, and transfer outputs from the PCB and will open
if there is excessive current draw on any one of these
outputs.
The voltmeter displays generator AC output voltage dur-
ing operation. Voltage is regulated by a solid-state volt-
age regulator and is proportional to AC frequency. Refer
to the unit’s DATA PLATE for rated AC voltage.
3.1.2 AC AMMETER
ꢀ
This indicates current draw of connected electrical
loads during operation. DO NOT EXCEED THE UNIT’S
RATED MAXIMUM CONTINUOUS CURRENT. Refer to
the unit DATA PLATE.
3.1.10 VOLTAGE-PHASE SELECTOR SWITCH
This switch permits selection between either line-to-line
or line-to-neutral voltage and amperage readings on the
console AC voltmeter and AC ammeter.
ꢀ
3.1.3 AC FREQUENCY METER
ꢀ
3.1.11 SET EXERCISE TIME SWITCH
This switch allows to program the generator to start and
exercise automatically. (See Section 3.6, page 14)
ꢀ
This indicates generator AC output frequency in Hertz
(cycles per second). Frequency is proportional to engine
speed. Units with a four-pole rotor, supply 60 Hertz at
1,800 rpm. The frequency reading with no electrical
loads connected (no-load condition) should be between
60-62 Hertz.
3.2 USING THE AUTO/OFF/MANUAL
SWITCH
3.1.4 DC VOLTMETER
ꢀ
3.2.1 “AUTO” POSITION
ꢀ
The generator is equipped with a belt-driven DC alter-
nator, which maintains battery state of charge when the
engine operates. The control module assembly (CMA)
also incorporates a trickle charge circuit that maintains
battery state of charge during nonoperating periods.
Battery voltage should read approximately12.5 to 14.5
volts DC. A low battery voltage indicates the battery is
discharging.
Selecting this switch position activates fully automatic
system operation. It also allows the unit to start and
exercise the engine every seven days with the setting of
the exercise timer.
3.1.5 HOURMETER
ꢀ
This indicates the time the engine-generator has operat-
ed, in hours and tenths of hours. Use the hourmeter
along with the periodic maintenance schedule for your
generator set.
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Section 3 — Operation
Guardian Liquid-cooled 40 kW Generator
Upon restoration of utility source voltage above a preset
level, generator circuit board action signals the transfer
switch to transfer loads back to that power supply. After
retransfer, the engine is signalled to shut down.
3.2.2 “OFF” POSITION
This switch position shuts down the engine. This posi-
tion also prevents operation.
ꢀ
The actual sequence of operation is controlled by
sensors and timers on a control logic circuit board, as
follows:
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.
ꢀ
A.Utility Voltage Dropout Sensor
• This sensor monitors utility source voltage.
• If utility source voltage drops below about 60 per-
cent of the nominal supply voltage, the sensor ener-
gizes a 15-second timer.
• Once the timer has expired, the engine will crank
and start.
With the switch set to AUTO, the engine may
!
crank and start at any time without warning.
Such automatic starting normally occurs when
utility power source voltage drops below a preset
level or during the normal exercise cycle. To pre-
vent possible injury that might be caused by such
sudden starts, always set the switch to OFF and
remove the fuse before working on or around the
generator or transfer switch. Then, place a “Do
Not Operate” tag on the generator panel and on
the transfer switch.
B.Engine Warm-up Time Delay
• This mechanism lets the engine warm up for about
10 seconds before the load is transferred to a stand-
by source.
C.Standby Voltage Sensor
• This sensor monitors generator AC output voltage.
When the voltage has reached 50 percent of the
nominal rated voltage, transfer to standby can
occur.
3.3 AUTOMATIC TRANSFER OPERATION
To select automatic operation, do the following:
D.Utility Voltage Pickup Sensor
• This sensor monitors utility power supply voltage.
When that voltage is restored above 80 percent of
the nominal source voltage, a retransfer time delay
starts timing.
1. Make sure the transfer switch main contacts are set
to their “Utility” position, i.e., loads connected to the
utility power source.
E.Retransfer Time Delay
2. Be sure that normal utility power source voltage is
available to transfer switch terminal lugs N1 and N2.
3. Set the generator’s Auto/Off/Manual switch to AUTO.
4. Set the generator’s main circuit breaker to its ON
(or closed) position.
• This timer runs for about 15 seconds.
• At end of a 15-second delay, circuit board action de-
energizes transfer relay in the transfer switch.
• Retransfer to utility power source then occurs.
F. Engine Cool-down Timer
With the preceding steps complete, the generator will
start automatically when utility source voltage drops
below a preset level. After the unit starts, loads are
transferred to the standby power source. Refer to
“Sequence of Automatic Operation.”
• When the load is transferred back to utility power
source, the engine cool-down timer starts timing.
• The timer will run for about one minute, and the
generator will then shut down.
3.5 ENGINE HEATER
3.4 SEQUENCE OF AUTOMATIC OPERATION
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.
The generator’s control panel houses a control logic cir-
cuit board. This board constantly monitors utility
power source voltage. Should that voltage drop below a
preset level, circuit board action will signal the engine to
crank and start. After the engine starts, the circuit
board signals the transfer switch to activate and connect
load circuits to the standby power supply (load terminal
lugs T1/T2 connect to terminal lugs E1/E2).
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Section 4 — Maintenance
Guardian Liquid-cooled 40 kW Generator
the transfer switch that indicates the day and time
the generator will be exercising.
NOTE:
Figure 3.2 – Engine Block Heater
OUTLET
If t h e bat t ery t erm in als are discon n ect ed or t h e
con t rol pan el fu se is rem oved, t h e exercise t im er
n eeds t o be reset for au t om at ic exercise operat ion .
Figure 3.3 – “Set Exercise” Switch on Control Panel
INLET
Refer to applicable wiring diagram(s) and electrical
schematic(s) at the back of this manual for wiring con-
nections.
3.6 WEEKLY EXERCISE CYCLE
The generator will start and exercise once every seven
days. During this weekly exercise, the unit runs for
approximately 20 minutes and shuts down. Transfer of
loads to generator output does not occur during the
exercise unless power is lost during the exercise period.
4.1 CHECKING THE ENGINE OIL LEVEL
For oil capacities, see “Specifications,” Section 1.7.2,
Page 6. For engine oil recommendations, see Section
4.2.1. To check the engine oil level, proceed as follows
(Figure 4.1):
To select the day of the week and time of day for exer-
cising, proceed as follows:
1. Remove the dipstick and wipe it dry with a
clean cloth.
2. Install the dipstick cap; then, remove it again. The
oil level should be at the dipstick “Full” mark. If nec-
essary, add oil to the “Full” mark only. DO NOT FILL
ABOVE THE “FULL” MARK.
• Set the Auto/Off/Manual switch to OFF.
• Set generator’s main circuit breaker to its OFF (or
open) position.
• Locate the rocker switch on the control panel identi-
fied with the words “Set Exercise Time” (Figure 3.3).
• Push “Set Exercise Time” switch to the ON position
for 20 to 30 seconds and then release. The switch will
spring back into its original position when released.
• Wait 30 seconds before setting the Auto/Off/
Manual switch to the AUTO position.
3. Install the dipstick.
Never operate the engine with the oil level below
!
the “Add” mark on the dipstick. Doing this could
NOTE:
damage the engine.
Th e u n it will exercise 2 0 m in u t es before it is set .
Exam ple: Set – Noon ; Exercise – 1 1 :4 0 a.m .
If you switch the Auto/Off/Manual switch is
switched too soon, the engine may start. If
!
engine does start, it will shut down automatically
in about two (2) minutes.
• Set the generator’s main circuit breaker to its ON (or
closed) position.
• The generator is now programmed to start and exer-
cise every seven days thereafter, on the day and at the
time of day the switch was activated.
• Place a sign on the generator’s control panel and on
®
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Section 4 — Maintenance
Guardian Liquid-cooled 40 kW Generator
Figure 4.1 – Oil Dipstick and Fill
Figure 4.2 – Oil Filter
OIL DIPSTICK
OIL FILL CAP
OIL FILTER
OIL DRAIN HOSE
4.2 CHANGING THE ENGINE OIL AND FILTER
TO BASE
4.2.1 Engine Oil Recommendations
Use oil of API Service Class SG, SH or SJ. The
recommended oil grade for the engine is
SAE 15W-40.
ꢀ
5. Apply a light coating of engine oil to the seal of
new oil filter. Install the filter and tighten by hand
only. DO NOT OVERTIGHTEN.
6. Remove the oil fill cap (Figure 4.1). Add the recom-
mended oil (see Section 4.2.1). DO NOT FILL
ABOVE THE DIPSTICK “FULL” MARK. Crankcase
oil capacity is 4.5 U.S. quarts (4.25 L).
NOTE:
Th e u n it is su pplied wit h “break -in ” oil. See t h e
“Service Sch edu le,” Sect ion 4 .1 2 (Page 1 9 ), for
t h e first requ ired oil ch an ge.
After refilling the crankcase with oil, always
check the oil level on the dipstick. Never
!
Any attempt to crank or start the engine before
operate the engine with the oil level below the
“Add” mark on the dipstick. Doing this could
damage the engine.
!
it has been properly serviced with the recom-
mended oil may result in an engine failure.
4.2.2 Oil and Filter Change Procedure
To change the oil and filter, proceed as follows:
7. Start the engine and check for oil leaks.
8. Check the oil level after checking for leaks to
ensure that the oil is filled to the proper level.
ꢀ
Refer to the “Service Schedule,” (Section 4.12, Page 19)
for engine oil and filter change frequencies.
4.3 CHANGING THE ENGINE AIR CLEANER
Drain the oil while the engine is still warm from run-
ning. This means, warm up the engine, shut it down
and drain it immediately as follows:
To replace the engine air cleaner, (Generac part num-
ber 0A4637, simply remove the air cleaner cover and
replace the air filter making sure it is positioned
properly before reattaching the cover. (See Figure
4.3, page 16)
1. Remove the oil drain hose from its retaining clip,
located on the generator base frame.
2. Loosen and remove the oil drain hose cap, located
on the base frame end of the hose. Drain the oil
completely into a suitable container.
3. When all of the oil has drained, install and tighten
the oil drain hose cap.
4. Turn the oil filter (Generac part number
0A37970001, Figure 4.2) counterclockwise and
remove it. Properly dispose of the old filter.
®
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Section 4 — Maintenance
Guardian Liquid-cooled 40 kW Generator
3. Have the state of charge and condition checked.
This should be done with an automotive-type bat-
tery hydrometer or load test.
Figure 4.3 – Engine Air Cleaner
Air Cleaner
DANGER
Standby generators installed with automatic
transfer switches will crank and start automatical-
ly when normal (utility) source voltage is removed
or is below an acceptable preset level. To prevent
such automatic start-up and possible injury to per-
sonnel, do not connect battery cables until the
normal source voltage at the transfer switch is
correct and the system is ready to be placed into
operation.
See the “Service Schedule,” Section 4.12, Page 19, for rec-
ommended air cleaner maintenance.
Storage batteries give off explosive hydrogen gas.
This gas can form an explosive mixture around
!
4.4 SPARK PLUGS
Reset the spark plug gap or replace the spark plugs as
necessary. See Section 4.12, Page 19.
the battery for several hours after charging. The
slightest spark can ignite the gas and cause an
explosion. Such an explosion can shatter the bat-
tery and cause blindness or other injury. Any area
that houses a storage battery must be properly
ventilated. Do not allow smoking, open flame,
sparks or any spark producing tools or equipment
near the battery.
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. Do not “blast”
the spark plugs to clean.
2. Remove the spark plugs and check the condition.
Replace the spark plugs if worn or if reuse is ques-
tionable. See the “Service Schedule,” Section 4.12,
Page 19, for recommended inspection.
3. Check the spark plug gap using a feeler gauge.
Adjust the gap to 0.045 inch (1.1 mm) by carefully
bending the ground electrode (Figure 4.4).
Battery electrolyte fluid is an extremely caustic
!
sulfuric acid solution that can cause severe burns.
Do not permit fluid to contact eyes, skin, clothing,
painted surfaces, etc. Wear protective goggles,
protective clothing and gloves when handling a
battery. If fluid is spilled, flush the affected area
immediately with clear water.
Figure 4.4 – Setting the Spark Plug Gap
Do not dispose of the battery in a fire. The bat-
tery is capable of exploding.
Do not open or mutilate the battery. Released
!
electrolyte can be toxic and harmful to the skin
and eyes.
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.
Battery replacement
Generac uses a Group 27F vented type battery that has
600 CCA @ 0º F. Generac’s part number is 058665.
4.5 BATTERY MAINTENANCE
The battery should be inspected per the “Service
Schedule,” Section 4.12, Page 19. The following proce-
dure should be followed for inspection:
Not e:
Th e BCI n u m ber sh ou ld be locat ed direct ly on t h e
bat t ery.
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. DO NOT USE TAP WATER IN BATTERIES.
®
16 Generac Power Systems, Inc.
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Section 4 — Maintenance
Guardian Liquid-cooled 40 kW Generator
Figure 4.4 – Location of 15-amp Fuse
4.6 COOLING SYSTEM
Air intake and outlet openings in the generator compart-
ment must be open and unobstructed for continued prop-
er operation. This includes such obstructions as high
grass, weeds, brush, leaves and snow.
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it to
shut down.
The exhaust system of this product gets extremely
hot and remains hot after shutdown. High grass,
weeds, brush, leaves, etc. must remain clear of the
exhaust. Such materials may ignite and burn from
the heat of the exhaust system.
15
4.7 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.
4.9 ENGINE COOLANT
Check the coolant level in the coolant recovery bottle.
• Add the recommended coolant mixture as
necessary. See Section 1.10 on Page 7.
• Periodically remove the radiator pressure cap to make
sure the coolant recovery system is functioning
properly. Coolant should be at the bottom of the radia-
tor filler neck. If the coolant level is low, inspect the
gasket in the radiator pressure cap. Replace the cap, if
necessary. To have the pressure cap tested, contact a
Generac/Guardian Authorized Dealer. Inspect the cool-
ing system and coolant recovery system for leaks.
If a circuit breaker opens or a fuse element melts,
you should find the cause of the overload before
resetting the circuit breaker or replacing the fuse.
4.8 DC FUSE
4.10 MISCELLANEOUS MAINTENANCE
The generator panel’s 15-amp AGC fuse (Figure 4.4) pro-
tects the DC control circuit against overload. The fuse is
wired in series with the battery output lead to the panel.
If the fuse element has melted open, cranking or starting
the engine cannot occur. Replace the fuse using only an
identical 15-amp AGC replacement.
4.10.1 Cleaning the Generator
ꢀ
Keep the generator as clean and as dry as possible. Dirt
and moisture that accumulate on internal generator
windings have an adverse effect on insulation resist-
ance.
Periodically, clean the generator’s exterior surfaces. A
soft brush may be used to loosen caked on dirt. Use a
vacuum system or dry, low pressure air to remove any
accumulations of dirt. The generator is housed inside
an all-weather enclosure; clean the enclosure with a
soft, damp cloth or sponge and water.
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.
Finally, have the insulation resistance of stator and rotor
windings checked. If insulation resistances are excessive-
ly low, the generator may require drying.
®
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Section 4 — Maintenance
Guardian Liquid-cooled 40 kW Generator
6. Attach a tag to the engine indicating the viscosity
and classification of the oil in the crankcase.
7. Remove the spark plug(s) and spray fogging agent
into the spark plug(s) threaded openings. Reinstall
and tighten the spark plug(s).
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.
4.10.2 Rodent Protection
ꢀ
The intrusion of rodents into the generator set can
cause a wide range of problems, from failure of the unit
to start, to personal injury and, in extreme circum-
stances, short circuit or fire. Although the unit was
designed to limit this problem, further precautions can
be taken by the owner to help minimize both the chance
of rodent entry and the extent of any damage. The fol-
lowing inspection should be performed.
9. Clean and wipe the entire generator.
1. The base frame of the unit contains an optional fuel
inlet location and four lifting holes that are capped at
the factory. These caps are sometimes removed for
transportation during installation but always should
be replaced afterwards. Check that they are secured in
place. The same applies for any access ports in the
roof of the enclosure. If any of these caps are missing,
contact a Generac/Guardian Authorized Dealer.
2. Inside the generator set, the chance of rodent entry
into the control panel is greatly reduced by the inclu-
sion of adjustable wire connectors. Check that the
wire connector screws are tight, thus closing off any
gap between the access holes and the wires.
4.11.2 Return To Service
To return the unit to service after storage, proceed
as follows:
ꢀ
1. Verify that utility power is turned off to the transfer
switch and that the Auto/Off/Manual switch is set to
OFF.
2. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recommended
oil is used in engine. See Section 4.2.1 (Page 14). If
necessary, drain and refill with the proper oil.
3. Check the battery. Fill all cells to the proper level
with distilled water. DO NOT USE TAP WATER IN
THE BATTERY. Remove the battery before charging.
Recharge the battery to 100 percent state of charge,
or, if defective, replace the battery with a 12-volt DC
Group 27F battery rated for 90 amp hours (part #
058665).
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:
4. Clean and wipe the entire generator.
5. Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected incor-
rectly.
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line
and allow the unit to shut down.
6. Open the fuel shutoff valve.
3. Once the unit has shut down, it will signal a fault on 7. Start the unit by moving the Auto/Off/Manual switch
the control panel.
to MANUAL. Allow the unit to warm up thoroughly.
4. Set the Auto/Off/Manual switch to OFF and turn off 8. Stop the unit and set the Auto/Off/Manual switch to
the utility power to the transfer switch.
AUTO.
5. While the engine is still warm from running, drain 9. Turn on the utility power to the transfer switch.
the oil completely. Refill the crankcase with SAE
15W-40 oil having API Service Class SG, SH or SJ.
10. The generator is now ready for service.
®
18 Generac Power Systems, Inc.
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Section 4 — Maintenance
Guardian Liquid-cooled 40 kW Generator
4.12 SERVICE SCHEDULE
ATTENTION: It is recommended that all service work
be performed by your nearest Generac/Guardian Authorized Dealer.
SYSTEM/ COMPONENT
PROCEDURE
FREQUENCY
X = Action
Inspect
Change
Clean
W = Weekly
M = Monthly
Y = Yearly
R = Replace/Adjust as Needed
* = Notify Dealer
if Repair is Needed.
H = Hours
FUEL
Fuel lines and connections*
LUBRICATION
Oil level
X
X
EVERY 3 M
M
Oil
X
X
FIRST 9 H,
EVERY 150 H / 6 M
Oil filter
FIRST 9 H,
EVERY 150 H / 6 M
Oil line leakage*
COOLING
Engine cooling system*
Coolant
Enclosure louvers
EXHAUST
Exhaust system
Retorque Exhaust Manifold*
X
X
X
100 H
M
Y
W
X
X
X
X
X
EVERY 3 M
FIRST 100 H AND
EVERY 800 H
BATTERY
Charge and condition
FAN BELT
Tension and condition*
ENGINE
X
X
R
R
EVERY 3 M
EVERY 3 M
Retorque cylinder head*
X
X
FIRST 100 H AND
EVERY 800 H
FIRST 100 H AND
EVERY 800 H
Retorque intake manifold*
Starter motor*
DC alternator*
Air cleaner*
Compression*
Valve clearance*
Governor*
Safety devices*
Spark plugs
Ignition system*
GENERAL
X
X
X
X
X
X
X
X
X
R
R
R
EVERY 500 H
EVERY 500 H AND Y
EVERY 500 H
EVERY 800 H
EVERY 800 H
Y
R
R
R
R
R
EVERY 6 M
500 H AND Y
EVERY 3 M
Overall condition
Exercise system
COMPLETE TUNE-UP*
X
X
M
W
Y
TO BE COMPLETED BY A GENERAC/
GUARDIAN AUTHORIZED DEALER
®
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Section 5 — Troubleshooting
Guardian Liquid-cooled 40 kW Generator
5.1 TROUBLESHOOTING GUIDE
PROBLEM
The engine will not crank.
CAUSE
CORRECTION
1. Replace fuse.
2. Tighten, clean or replace
as necessary.
1. Fuse blown
2. Loose, corroded or defective
battery cables
3. Defective starter contactor
4. Defective starter motor
5. Dead Battery
3. *
4. *
5. Charge or replace battery.
The engine cranks but
will not start.
1. Out of fuel
1. Replenish fuel.
2. *
3. *
2. Defective fuel solenoid (FS)
3. Open #14 wire from
engine control board
4. Defective spark plug(s)
5. Dirty/Blocked air filter
4. Clean, re-gap or replace plug(s).
5. Clean or replace as required.
The engine starts hard
and runs rough.
1. Air cleaner
1. Check, clean or replace air cleaner.
plugged or damaged
2. Defective spark plug(s)
3. Dirty/Blocked air filter
2. Clean, re-gap or replace plug(s).
3. Clean or replace as required.
The engine starts, but then
shuts down.
1. Engine oil level low
2. Defective low oil
pressure switch
1. Check oil and add oil as needed.
2. *
3. Defective high temperature
switch
4. Defective control board
5. Low coolant level
3. *
4. *
5. Check coolant level, repair leaks
and refill.
The Auto/Off/Manual switch
is set to OFF, but the engine
continues to run.
1. Defective switch
2. Defective control board
1. *
2. *
There is no AC output from
the generator.
1. Generator main line circuit
breaker open
2. Generator internal failure
1. Reset circuit breaker
to ON (or closed).
2. *
There is no transfer to
standby after utility
source failure.
1. Generator main line circuit
breaker open
2. Defective transfer switch coil
3. Defective transfer relay
4. Transfer relay circuit open
5. Defective control logic board
1. Reset circuit breaker
to ON (or closed).
2. *
3. *
4. *
5. *
*Con t act you r n earest Gen erac/ Gu ardian Au t h orized Dealer for assist an ce.
®
20 Generac Power Systems, Inc.
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Section 6 — Electrical Data
(Model No. 004373-2) Guardian Liquid-cooled 40 kW Generator
Electrical Schematic (Control Panel) – Drawing No. 0D4993-B
Y E L L O W
O R A N G E
Y E L L O W
B R O W N
B L A C K
T O E N G I N E ( C O N N E C T O R E H )
T O L O W E R P A N E L ( C O N N E C T O R C P )
®
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Section 6 — Electrical Data
(Model No. 004373-2) Guardian Liquid-cooled 40 kW Generator
Wiring Diagram (Control Panel) – Drawing No. 0D4992-A
1 7 8
2 2 9
4
8 5
2 3
1 9 4
2 1 9
2 1 8
1 5 0
8 6
5 6
1 4
8 5
6 9
6 8
1 7 8
1 5 A
2 3 9
5 6
2 2 9
2 2 9
2 2 9
4
1 5
1 5 A
1 5 A
1 4
1 4
1 3
7 9
0
1 5 C
R E D
2 2 5 A
0
0
B L A C K
6
5
4
3
2
1
DEUTSCH
7
8
9
10
11
12
A C T U A T O R
T O G O V E R N O R
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Section 6 — Electrical Data
(Model No. 004626-1) Guardian Liquid-cooled 40 kW Generator
Schematic (Control Panel) – Drawing No. 0D6975
1 6 0
1 6 1
7 9
0
0
Y E L L O W
M P U S H I E L D
M P U -
0
0
M P U +
7 9
A C T -
1 6 1
A C T +
1 6 0
T O E N G I N E ( C O N N E C T O R E H )
T O L O W E R P A N E L ( C O N N E C T O R C P )
®
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Section 6 — Electrical Data
(Model No. 004626-1) Guardian Liquid-cooled 40 kW Generator
Wiring Diagram (Control Panel) – Drawing No. 0D6974
1 7 8
2 2 9
4
8 5
2 3
1 9 4
2 1 9
2 1 8
1 5 0
8 6
5 6
1 4
8 5
6 9
6 8
1 7 8
1 5 E
2 3 9
5 6
2 2 9
2 2 9
2 2 9
4
1 5
1 5 A
1 5 A
1 4
1 4
1 3
7 9
0
1 5 C
R E D
2 2 5 A
0
0
B L A C K
M P U S H I E L D
0
M P U -
M P U +
A C T -
A C T +
B A T -
0
7 9
1 6 1
6
5
4
3
2
1
1 6 0
DEUTSCH
0
7
8
9
10
11
12
B A T +
1 4
0
0
7 9
1 6 0
1 6 1
®
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Section 6 — Electrical Data
(Model Nos. 004373-2 & 004262-1) Guardian Liquid-cooled 40 kW Generator
Electrical Schematic — Engine (4.3L) – Drawing No. 0A4592-B
®
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Section 6 — Electrical Data
(Model Nos. 004373-2 & 004262-1) Guardian Liquid-cooled 40 kW Generator
Wiring Diagram — Engine (4.3L) – Drawing No. 0A4591-B
®
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Section 6 — Electrical Data
(Model No. 004373-2) Guardian Liquid-cooled 40 kW Generator
Electrical Schematic – Stepper Motor – Drawing No. 0A5858
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Section 6 — Electrical Data
(Model Nos. 004373-2 & 004262-1) Guardian Liquid-cooled 40 kW Generators
Wiring Diagram - Lower Panel - Drawing No. 0D5997
®
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Section 6 — Electrical Data
(Model Nos. 004373-2 & 004262-1) Guardian Liquid-cooled 40 kW Generators
Electrical Schematic - Lower Panel - Drawing No. 0D5997
1
D
1
AR
RED
4
C
4
BRUSH UNITS
6
F
THERMAL PROTECTOR BYPASS
5
5
6
2
E
DPE
22
TP
S1
K
AS
Q
44
33
11
00
M
S3
57
N
O
CT1
0
58
CT2
S16
0
A
G
S15
CB2
H
194
23
X
W
V
U
T
T2
NB
E1
E3
TS3
TS4
CUSTOMER CONNECTION
120/240-V. 1-PHASE
T1
N2
N1
183
178
S
B
J
®
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Section 7 — Exploded Views and Parts Lists
(Model No. 004373-2) Guardian Liquid-cooled 40 kW Generators
Control Panel - Drawing No. 0D4995-C
+
-
0
0
0
P I N
Q
R
P
S
O
E
A
F
D
T
N
G
C
U
M
H
B
J
V
L
W
K
X
®
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Section 7 — Exploded Views and Parts Lists
(Model No. 004373-2) Guardian Liquid-cooled 40 kW Generators
Control Panel - Drawing No. 0D4995-C
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
8
9
0D1523
0D1521A
0D1522
067680**
0C8243
0C8244
048467
057907
064008
055444
030468
049939
070370
022158
023762
023897
076009ASRV
040213
027744
082573
076020
032300
022676
064009
061945
076037
070081
070043
070045
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
PANEL BTM & BACK CONTROL PANEL
CONTROL PANEL, FRONT W/ SILK SCREEN
PANEL,SIDE COVER CONTROL PANEL
ASSY VOLTAGE REGULATOR 60HZ
WASHER LOCK HDP DEUTSCH
NUT, HDP DEUTSCH
CIRCT BRK 7 X 1 ETA 46-500-P
RES WW LUG 10R 10% 25W
COVER CON PNL TOP (NOT SHOWN)
HEATSINK
WASHER STEP NYLON .20
RECTIFIER MSC 12A 600V 1N1206R
WASHER MICA .203
NUT HEX #10-32 STEEL
WASHER SHAKEPROOF EXT #10 STL
32
33
34
35
36
37
39
41
42
43
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62*
63*
070042
081988
0C1229
098647**
0A3968
048766
083264
057335
076061
029333
040479
022507
022127
022097
033121
022152
036902
022155
022985
036918
022264
038150
022471
022188
036908
0C2428
0C2323
0D5324
0A9611
1
1
1
1
1
FREQUENCY METER 240V 55-65HZ
DECAL EXERCISE INFO
DECAL CUST CONN BOX
ASSY L.C. ELECT GOV
CAPACITOR FILTER ASY
REF BLOCK TERM 20A 2 X 6 X 1100V
TFMR ASM,CMA 240/12V
REF BLOCK TERM 20A 20 X 6 X 1100V
1
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
1
6
4
4
4
4
DECAL, TERM. STRIP
TIE WRAP 7.4" X .19" NATL UL
VIB MNT 1.0 X 1.0 X 1/4-20
SCREW HHC 1/4-20 X 1/2 G5
NUT HEX 1/4-20 STEEL
WASHER LOCK M6-1/4
14 SCREW HHC #10-32 X 1/2
14 WASHER LOCK #10
15 WASHER FLAT #10 ZINC
1
4
1
1
1
1
1
1
1
1
1
1
1
PP LOGIC ASM 50/60HZ
PCB SUPPORT SNAP-IN 1/4"
GROMMET 3/4 X 5/32 X 5/16
SWITCH ROCKER DPST 125V SPD
SWITCH TOG DPDT 15/10 SP
HOLDER FUSE
4
6
8
8
8
8
8
6
2
4
4
1
SCREW PPHM #6-32 X 1/2
WASHER LOCK #6
WASHER FLAT #6 ZINC
SCREW PPHM #8-32 X 1/2
WASHER LOCK #8-M4
WASHER FLAT #8 ZINC
NUT HEX #8-32 STEEL
NUT HEX #6-32 STEEL
SCREW PPHM #6-32 X 1-1/4
SCREW PHTT #6-32 X 1/2 ZYC
SCREW PHTT #6-32 X 5/8 ZYC
FUSE & HOLDER LITTEL 7.5A
FUSE 15A X AGC15
LIGHT 12VDC .02A LED RED PILOT
SWITCH SELECTOR 6A AMP/V
VOLTMETER DC 8-18V
HOURMETER
VOLTMETER AC 0-300
AMMETER AC 0-200
REF. FUSE 7.5AXBK/AGC7.5NX
* PART OF CONTROL PANEL WIRE HARNESS
** SERVICE REPLACEMENT PART IS SAME PART NUMBER
WITH “0SRV” ADDED.
®
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Section 7 — Exploded Views and Parts Lists
(Model No. 004626-1) Guardian Liquid-cooled 40 kW Generators
Control Panel - Drawing No. 0D6978-A
+
-
0
0
0
P I N
Q
R
P
S
O
E
A
F
D
T
N
G
C
U
M
H
B
J
V
L
W
K
X
®
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Section 7 — Exploded Views and Parts Lists
(Model No. 004626-1) Guardian Liquid-cooled 40 kW Generators
Control Panel - Drawing No. 0D6978-A
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
0D7397
0D1521A
1
1
PNL BTM & BACK CNTL PNL 04626
CONTROL PANEL FRONT W/ SILK
SCREEN
PANEL SIDE COVER CONTROL PANEL
ASSY VOLTAGE REGULATOR 60HZ
WASHER LOCK HDP DEUTSCH
NUT, HDP DEUTSCH
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62*
63*
0C1229
0D3440
0A3968
048766
0A1441B
083264
0A1441C
057335
076061
029333
040479
022507
022127
022097
033121
022152
036902
022155
022985
036918
022264
038150
022471
022188
0C2428
0C2323
0A2284
0C1127
0D5324
0A9611
1
1
1
REF
1
1
1
REF
1
6
4
4
4
4
14
14
4
6
8
8
8
8
8
6
8
4
4
DECAL CUST CONN BOX
CONTROLLER, B-C #DPG-2103
CAPACITOR FILTER ASY
BLOCK TERM 20A 2 X 6 X 1100V
COVER PLATE AVR
TFMR ASM,CMA 240/12V
COVER PLATE EGOV
BLOCK TERM 20A 20 X 6 X 1100V
DECAL TERM. STRIP
TIE WRAP 7.4" X .19" NATL UL
VIB MNT 1.0 X 1.0 X 1/4-20
SCREW HHC 1/4-20 X 1/2 G5
NUT HEX 1/4-20 STEEL
WASHER LOCK M6-1/4
SCREW HHC #10-32 X 1/2
WASHER LOCK #10
SCREW PPHM #6-32 X 1/2
WASHER LOCK #6
3
4
5
6
7
0D1522
067680**
0C8243
0C8244
0A6321
048467
057907
064008
0A6323
055444
030468
049939
070370
022158
023762
023897
076009ASRV
040213
0A3394
082573
076020
032300
022676
064009
061945
076037
070081
070043
070045
070042
081988
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
15
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
PANEL LEFT SIDE E
8
9
CIRCT BRK 7 X 1 ETA 46-500-P
RES WW LUG 10R 10% 25W
COVER CON PNL TOP (NOT SHOWN)
CHASSIS AVR & E-GOV
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
HEATSINK
WASHER STEP NYLON .20
RECTIFIER MSC 12A 600V 1N1206R
WASHER MICA .203
NUT HEX #10-32 STEEL
WASHER SHAKEPROOF EXT #10 STL
WASHER FLAT #10 ZINC
PP LOGIC ASM 50/60HZ
PCB SUPPORT SNAP-IN 1/4"
DECAL, ELEC GOVERNOR
SWITCH ROCKER DPST 125V SPD
SWITCH TOG DPDT 15/10 SP
HOLDER FUSE
WASHER FLAT #6 ZINC
SCREW PPHM #8-32 X 1/2
WASHER LOCK #8-M4
WASHER FLAT #8 ZINC
NUT HEX #8-32 STEEL
NUT HEX #6-32 STEEL
SCREW PHTT #6-32 X 1/2 ZYC
SCREW PHTT #6-32 X 5/8 ZYC
SCREW SWAGE 8-32 X 1/2 Z/YC
DECAL AVR COVER
FUSE & HOLDER LITTEL 7.5A
FUSE 7.5AXBK/AGC7.5NX
FUSE 15A X AGC15
LIGHT 12VDC .02A LED RED PILOT
SWITCH SELECTOR 6A AMP/V
VOLTMETER DC 8-18V
HOURMETER
VOLTMETER AC 0-300
AMMETER AC 0-200
FREQUENCY METER 240V 55-65HZ
DECAL EXERCISE INFO
1
4
1
* PART OF CONTROL PANEL WIRE HARNESS
** SERVICE REPLACEMENT PART IS SAME PART NUMBER
WITH “0SRV” ADDED.
®
Generac Power Systems, Inc. 33
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Section 7 — Exploded Views and Parts Lists
(Model No. 004373-2) Guardian Liquid-cooled 40 kW Generator
Electronic Governor – Drawing No. 0A2615-F
ITEM (18) NEOPRENE
COATING
14
13
3
12
17
WIRE HARNESS
1
"A"
9
11
SECURE WIRE HARNESS
WITH TIE WRAP AS SHOWN.
15
16
15
4
9
23
EXISTING
ENGINE
HARDWARE
19
20
CARB. ARM
(REF.)
24
5
22
21
2
15
11
14
13
"A"
3
12
ITEM PART NO.QTY.
DESCRIPTION
1
2
3
4
5
098290
0A3439
098958A
021888
082508
036409
043146
098941A
098942A
098225
022097
064526
029333A
074031
051716
049226
076040
098647*
036409
0C2184
1
1
1
1
2
2
3
2
2
4
4
1
1
-
2
2
2
1
2
1
ASSEMBLY MOTOR STEPPER
BRACKET GOVERNOR MOUNTING
CONNECTOR INTERFACE ASSEMBLY
LEVER STEPPER MOTOR
BALL JOINT PLA .25-.28
NUT HEX 1/4-28 STEEL
SCREW HHC M6-1.0 X 10 G8.8
HOUSING GOVERNOR CONNECT
COVER CONN HOUSING
SCREW FHM #2 X 5/8 SELF TAP
WASHER LOCK M6-1/4
SCREW TAP HWH #6-25 X 3/8 ZINC
TIE WRAP 7.4" X .19" BLACK UL
LIQUID NEOPRENE (NOT SHOWN)
NUT HEX M5-0.8 G8 YEL CHR
WASHER LOCK M5
9
11
12
13
14
15
16
17
18
19
20
21
22
23
24
SCREW PPHM M5-0.8 X 16
ASSEMBLY L.C. ELECTRONIC GOVERNOR
NUT HEX 1/4-28 STEEL
STUD THR 1/4-28 X 3-1/2 G2 ZINC
* SERVICE REPLACEMENT PART IS SAME PART NUMBER WITH “KSRV” ADDED.
®
34 Generac Power Systems, Inc.
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generator
Mounting Base – Drawing No. 0C4399-D
*26
19
11 10
12
18
4
*27
6
5
5
18
20
15
6
12
8
7
*28
19
11
14
15
10
1
*27
To Oil Drain
On Oil Pan.
21
23
16
17
13
22
*26
*27
*28
24
*26
*27
29
3
*28
33
32
*27
12
31
30
16
17
13
*25
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
0C3250
1
ASSEMBLY BASE MOUNTING
(DIRECT-COUPLED)
LUG SLDLSS #2-#8 X 17/64 CU
MOUNT ENGINE (R&L)
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK 3/8
SCREW HHC 3/8-16 X 1 G5
SCREW HHC M8-1.25 X 25 G8.8
WASHER FLAT 5/16 ZINC
WASHER SHAKEPROOF EXT 5/16 STL
SCREW HHC M12-1.75 X 85 G8.8
DAMPENER VIBRATION 40 BLUE
SPACER .49 X .62 X 1.87 PWDR/ZINC
DAMPENER VIBRATION
WASHER FLAT M12
NUT LOCKING M12-1.75
ASSEMBLY GROUNDWIRE 10"/3/8
DAMPENER VIBRATION 50 WHITE
BARBED STRAIGHT 1/2 NPT X 5/8
CLAMP HOSE #10 .56 - 1.06
HOSE 5/8 ID TYPE 3 SINGLE
24
* 25
* 26
* 27
* 28
* 29
30
31
32
33
024310
0A8785
0C4360
071693
0C2454
0C4753
022413
022473
022097
022127
1
4
8
16
16
1
1
1
1
1
PLUG STD PIPE 1/2 STEEL SQ HD
PLUG BUTTON 3" DIA.
PLATE VARMINT
WASHER FLAT .281 ID X 1.0 OD
SCREW TH-FRM M6-1 X 16 N WA Z/JS
PLUG 3/4 BUTTON
SCREW HHC 1/4-20 X 1 G5
WASHER FLAT 1/4 ZINC
WASHER LOCK M6-1/4
3
4
5
6
7
055414
0A4084
022129
045771
022237
029745
043107
022145
027482
055597
052251
052257
052252
052259
052860
0536210098
052251A
044118
057823
057448
1
2
2
2
6
6
2
2
3
4
2
4
4
4
4
1
2
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
NUT HEX 1/4-20 STEEL
NOTES: 1) * ITEMS 25, 26, 27, 28 & 29 ARE INCLUDED FOR
UNITS WITH ENCLOSURES ONLY. NOT INCLUDED
WITH OPEN SETS.
2) ITEM 25 (PLUG BUTTON 3" DIA.) IS USED AFTER
SHIPPING. HOLES ARE TO REMAIN UNCOVERED
FOR SHIPPING PURPOSES. PLUGS CAN BE
FOUND IN THE MANUAL BAG LOCATED INSIDE
THE LOWER CONNECTION BOX.
1
2
11"
®
Generac Power Systems, Inc. 35
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generator
Engine Common Parts – Drawing No. 0A4304-L
®
36 Generac Power Systems, Inc.
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generator
Engine Common Parts – Drawing No. 0A4304-L
ITEM PART NO.QTY. DESCRIPTION
ITEM PART NO.QTY. DESCRIPTION
1*
2
3
4
5
0A9046
0A4084
0A4239
0A4240
0A5640
0A5640A
0A5639
0D3293A
1
2
1
1
1
1
1
1
ENGINE 4.3L GM
MOUNT, ENGINE (R & L)
PULLEY CRANKSHAFT
PULLEY WATER PUMP
SPACER FAN 50MM 4.3L (35KW UNITS ONLY)
SPACER FAN 62MM (45KW UNITS ONLY)
FAN 17" REVRS ROT (35KW UNITS ONLY)
FAN COOLING 22" DIA REVRS ROT
(45KW UNITS ONLY)
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
0A4241
0C2885
0A5737C
022131
077456
044117
057823
057448
022129
022142
048614
022237
029745
042633
033819
022241
0A5768
046526
049814
0C3756
045772
0D2514
052259
055934D
1
1
1
8
1
1
1
1
8
4
4
12
4
3
1
4
1
5
2
1
2
8
1
1
PULLEY GROOVED IDLER
PULLEY TENSIONER
SPACER DC ALTERNATOR 34MM
WASHER FLAT 3/8-M10 ZINC
ADAPTOR M12-1.75 3/8 NPT
BARBED STRAIGHT 3/8 NPT X 5/8
CLAMP HOSE #10 .56 - 1.06
HOSE 5/8 ID TYPE 3 SINGLE (12")
WASHER LOCK M8-5/16
SCREW HHC 5/16-18 X 3/4 G5 (45KW)
SCREW HHC 5/16-24 X 3/4 G5
WASHER LOCK 3/8
SCREW HHC 3/8-16 X 1 G5
SCREW HHC 3/8-24 X 1 G5
SCREW HHC 3/8-16 X 4 G5
NUT HEX 3/8-16 STEEL
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
6
7
8
9
077996
057823
035579
037065
022302
0A8584
052644
0A4278A
0A4930A
0A4085
0A3927
0C7947
0A1232
0A7801B
021928
0C6239
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
CAP HOSE
CLAMP HOSE #10 .56 - 1.06
BUSHING REDUCER 1/4 TO 1/8
SCREW HHC 7/16-20 X 2-1/4 G5
WASHER LOCK 7/16
SWITCH OIL PRESSURE
SPACER .5 X 1.5 X .25 STL/ZINC
BELT SERPENTNE 72.5"
10
11
12
13
14
15
16
17
18
19
20
21
22
HEAT SHIELD LEFT
GASKET EXHAUST MANIFOLD
MANIFOLD LEFT EXHAUST
BOLT U 3/8-16 X 2.50
DC ALTERNATOR ASSEMBLY
PULLEY PLOY-V 82 OD.
BRACKET ALT. SUPPORT
BRACKET MOUNTING WELD ASSEMBLY
0A37970001 1
*For internal engine parts use Engine Parts Manual P/N 0D3749.
®
Generac Power Systems, Inc. 37
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generators
Engine Parts – Drawing No. 0D6980-A
®
38 Generac Power Systems, Inc.
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generators
Engine Parts – Drawing No. 0D6980-A
ITEM
PART NO. QTY. DESCRIPTION
ITEM
PART NO. QTY. DESCRIPTION
1
2
3
4
6
8
9
0A9046
0A9118A
070022
0A6021
059056A
0A9050
022237
045772
049226
051716
0A4244
0A4215
0A4231
059057
0A2440
026568
099729A
061012
069939
035606
0A4930B
0A4084
029745
044101
023152
1
1
1
6
1
2
17
1
1
1
1
1
1
10"
2
2
1
1
1
ENGINE 4.3L GM
FLYWHL 4.3L GM SAE
WASHER STAR M12 EXT
SCREW HHC 7/16-20 X 1 G8
STARTER 5.7L/7.4L GM
BOLT STARTER 4.3L
WASHER LOCK 3/8
NUT HEX M10-1.5 G8 YEL CHR
WASHER LOCK M5
NUT HEX M5-0.8 G8 YEL CHR
CONNECTOR COIL TO DISTRIBUTOR
DIP STICK 4.3L GM
TUBE DIP STICK 4.3L
HOSE 3/4 ID SAE-30R2
GASKET THERMOSET
SCREW HHC 3/8-16 X 2-3/4 G5
HOUSING THERM IMPREX
PLUG STD PIPE 1/8 SOCKET HEAD
HOUSING THERMOSTAT/WATER INLET
SENSOR HI COOLANT SHUTDOWN
HEAT SHIELD RIGHT
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
022131
058030
0A4085
0A3928
0C7947
057794
0A4277
022241
057795
048191
032303
0A3852
098239
057522
0D2244M
2
2
1
1
2
2
1
4
1
2
6
3
1
1
1
WASHER FLAT 3/8-M10 ZINC
RETAINER PLUG WIRES
GASKET EXHAUST MANIFOLD
MANIFOLD RIGHT EXHAUST
BOLT U 3/8-16 X 2.50
RETAINER SPARK PLUG WIRES
WIRES SPARK PLUG 4.3L
NUT HEX 3/8-16 STEEL
CONNECTOR C/C VENT
PIN DOWEL M10 X 24
SCREW HHC 3/8-16 X 3-1/2 G5
PLATE FLEX GM
CASTING ADAPTOR
SENSOR COOLANT LEVEL
ASSY MAGPICKUP (3/8-24 MALE)
(MODEL 004626 0NLY)
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
43
075885
1
THERMOSTAT 195 DEG
1
1
1
3
2
2
*
*
0D6979
0A4308
1
1
40KW GUARDIAN WIRE HARNESS (NOT
SHOWN FOR MOD. 004626-0)
HARNESS 4.3L STD WIRE (NOT SHOWN
FOR MOD. 004373-1)
MOUNT ENGINE
SCREW HHC 3/8-16 X 1 G5
BRACKET SUPPORT SPARK PLUG WIRE
SCREW HHC 3/8-16 X 3/4 G5
®
Generac Power Systems, Inc. 39
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generators
Generator – Drawing No. 0D9490
®
40 Generac Power Systems, Inc.
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generators
Generator – Drawing No. 0D9490
ITEM
PART NO. QTY. DESCRIPTION
ITEM
PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8*
9*
10*
11*
12
13*
14*
15
16
17
18
19
20
21
22
23
24
051768
051769
0A8240
039253
022129
082130D
0C4286
0A2601
0A2602
0A1138
021941
020808A
052624
070892
0A5580
0A1633
020729A
022131
022237
022511
068113
068115
043123
051779
7
7
2
6
7
1
1
1
1
1
1
1
1
1
4
4
1
SCREW HHC M12-1.75 X 25 G8.8
WASHER LOCK M12
FLEX PLATE SAE10
SCREW HHC M8-1.25 X 20 G8.8
WASHER LOCK M8-5/16
25
26
27
28
29
30
31
32
33
34
35
046852
022145
039287
071641
071639
0A2110
022473
022746
031980
083549
0A4089
1
1
4
1
1
2
8
1
2
1
1
SCREW HHTT #10-32 X 1/4 CZ
WASHER FLAT 5/16 ZINC
SCREW HHC M8-1.25 X 45 G8.8 FT
BRUSH HOLDER ASSEMBLY
HOLDER BRUSH SUPPORT
SCREW SWAGE 1/4-20 X 1/2 Z/YC
WASHER FLAT 1/4 ZINC
SCREW HHC 3/8-16 X 1-3/4 G5
TIE WRAP UL 14.6 X .14 NATL
SLEEVE RUBBER
ASSEMBLY MAG PICKUP 72"
ASSEMBLY FAN W/PRESS DISC 10.75 X 3
SCREW HHC M16-2.0 X 45 G8.8
WASHER FLAT .688 ID X 3.25 OD
KEY SQ 3/8 X 2-1/2 STEEL
COUPLER 390 SAE
ROTOR 390 40 1P DIRECT
BEARING BALL 6212 SEALED
SLIP RING -MACHINED-
SCREW HHC M14-2.0 X 140 G8.8
WASHER 390 SAE ALT.
STATOR 390 40 AD2 SAE
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK 3/8
ASSEMBLY SCROLL 390 SAE
KIT 0A4089 PARTS
36
37
38
39
40
41
42
43
0A2491
0A2497
0A2496
056326
022097
045757
047411
0A2110
2
2
2
SHROUD ALTERNATOR SHEET METAL
SCREEN SHROUD SAE
BRACKET TENSIONER SAE SCROLL
TRIM VINYL BLACK 1/8 GP
8.4 FT
6
2
4
WASHER LOCK M6-1/4
12
11
11
1
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
SCREW HHC 3/8-16 X 1-1/4 G5
CARRIER REAR BEARING 15"
LOWER PANEL 15
WASHER LOCK M14
NUT HEX M14-2.0 G8 YEL CHR
12
* ROTOR REPLACEMENT PARTS
4
®
Generac Power Systems, Inc. 41
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generators
Compartment – Drawing No. 0D8992
28
26
13
29
23
32
33
34
25
31
30
44
15
43
39
22
11
9
29
12
24
8
11
36
7
11
35
1
42
10
4
3
12
16
5
21
20
1
5
4
19
18
3
6
17
11
5
10
BASE
FRAME
32
29
ITEM
PART NO.
QTY.
DESCRIPTION
ASSEMBLY M6 HINGE
ITEM
PART NO.
QTY.
DESCRIPTION
1
3
4
5
6
7
8
9
10
11
12
13
15
16
17
18
19
20
21
22
23
0C3594
0A3359
0A3360
10
40
40
5
1
1
1
1
2
4
2
1
1
5
20
5
20
20
5
1
1
24
25
26
28
29
30
31
32
33
34
35
36
39
42
43
44
0C4066 (A)
0C4067 (A)
0C4117 (A)
0C2634A
0C2454
022129
042907
022473
022097
022127
0A9881
0C3393
0C3400 (A)
0C3397
066760
022145
1
1
1
1
76
2
2
15
1
DUCT BOTTOM
DUCT FRONT PANEL
DUCT FRONT TOP RH
ASSEMBLY COVER ACCESS
SCREW TH-FRM M6-1X16 N WA Z/JS
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 16 G8.8
WASHER FLAT M6-1/4 ZINC
WASHER LOCK M6-1/4
SCREW BHSC M6-1.0 X 16 SS
SHAKEPROOF INT M6 SS
DOOR SMALL STD. WELD
CORNER POST LH REAR
CORNER POST RH REAR
CORNER POST LH FRONT
CORNER POST RH FRONT
REAR BRACE TOP & BOTTOM
SIDE BRACE TOP & BOTTOM
SIDE SUPPORT
ROOF ONE-PIECE WLDMT
FRONT BRACE TOP
PLATE STRIKER
SCREW PPHM M4-0.7 X 12 SS
PADDLE HANDLE LOCK
NUT LOCK HEX M4-0.7 SS NYL INS
WASHER FLAT #8 SS
RIVET POP 3/16 X 1/4
DUCT FRONT LH
0C2522 (A)
0C2527 (A)
0C2528 (A)
0C2535 (A)
0C2536 (A)
0C2547 (A)
0C2550 (A)
0C2555 (A)
0C2560 (A)
0D7904 (A)
0C2633
0C6749
060069
0C6748
080490
087233
0C4065 (A)
0C4064 (A)
1
NUT HEX 1/4-20 STEEL
49.1 FT. GASKET DOOR RUBBER
2
1
4
SCREW SHOULDER
COVER EXHAUST HOLE
FASTENER RATCHET
39-3/8" STRIP SEALANT 1/8 X 1
WASHER FLAT 5/16 ZINC
2
OPTIONAL COMPARTMENT MATERIALS:
ALL P/N'S WITH AN "A" SUFFIX INDICATE
ALUMINUM MATERIAL OPTION.
DUCT FRONT RH
®
42 Generac Power Systems, Inc.
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generators
Radiator – Drawing No. 0D7992-B
KIT PART NO. 0D7947
37 38 39
KIT PART NO. 0D7948
30
22
15
24
36
35
29
31
23
34
33
32
1
27
10
31
27
22
"A"
16
7
12
6
16
5
4
12
11
3
17
14
20
TO "A"
19
21
18
2
10
17
10
KIT PART NO. 0D8121
9
ITEM
PART NO. QTY. DESCRIPTION
ITEM
PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
0D7825
0D8251
0D8252
024655
022097
022473
0D7174
0D7174A
0D7870
035685
047290
040173
049340
036865
029032
052250
058443
029745
022237
022131
0D7850
1
1
1
4
4
4
1
1
1
4
1
2
1
1
1
3
10
4
4
4
1
RADIATOR COPPER BRASS
FAN GUARD, BOTTOM
FAN GUARD, TOP
22
23
24
27
29
30 *
31 *
32 *
33 *
34 *
35 *
36**
37**
38**
39**
076749
0D7975
090388
048031C
0C4341
0A6984
0D7942
0D7943
022413
022097
022473
0D7924
024655
022097
022473
1
1
1
1
2
1
1
1
8
8
8
1
4
4
4
BOTTLE, COOLANT RECOVERY
WATER BOTTLE BRACKET
SCREW HHTT M6-1.0 X 12 YC
CLAMP HOSE BAND 1/4
SUPPORT RADIATOR A GRP
BRACKET AIR DUCT TOP/BOT
SUPPORT AIR DUCT RH SIDE
SUPPORT AIR DUCT LH SIDE
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
SCREW HHTT 1/4-20 X 1 CZ
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
VENTURI 4.3L 22" FAN
VENTURI 4.3L 17" FAN
RADIATOR HOSE LOWER
CLAMP HOSE #28 1.32 - 2.25
HOSE 3/8 ID SINGLE BRAID
CLAMP HOSE #5.5 .62 - .62
BARBED EL 90 1/4 NPT X 3/8
DRAINCOCK
HOSE 9/32 ID (64"LG)
TAPE FOAM 1 X 1 (29"LG)
SCREW CRIMPTITE 1/4-20 X 5/8
SCREW HHC 3/8-16 X 1 G5
WASHER LOCK 3/8
WASHER FLAT 3/8-M10 ZINC
RADIATOR HOSE UPPER
9
10
11
12
13
14
15
16
17
18
19
20
21
* OPTIONAL WITH KIT 0D7948
** OPTIONAL WITH KIT 0D7947
®
Generac Power Systems, Inc. 43
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Section 7 — Exploded Views and Parts Lists
(Model No. 004373-2) Guardian Liquid-cooled 40 kW Generators
Carburetor – Drawing No. 0A5764-G
USE FASTENER LOCATED ON
ALTERNATOR FAN SCROLL
TO
25
REGULATOR
19
24
12
11
23
21
20
6
7
10
9
17
TO STEPPER
8
19
18
5
22
16
MOTOR
3
4
2
1
13
FRONT OF
ENGINE
15
14
27
28
26
TO ALTERNATOR
FAN SCROLL
ITEM
PART NO. QTY. DESCRIPTION
ITEM
PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
064945
0A4120
033212
022129
052865
0A7631
1
1
4
4
1
1
GASKET CARBURETOR ADAPTOR
ADAPTOR CARBURETOR W/INLET
SCREW HHC 5/16-18 X 1-1/4 G5
WASHER LOCK M8-5/16
GASKET CARBURETOR
CARB. REWORK 4.3L (NATURAL GAS +
VAPOR)
CARBURETOR REWORK (LPG LIQUID)
SCREW HHC 3/8-16 X 1 G5
WASHER LOCK 3/8
ELBOW 90 DEG STREET 3/4
NIPPLE TOE 3/4 NPT X 2
CLAMP HOSE #16 .87 - 1.50
HOSE 1IN ID LP GAS (NATURAL GAS +
VAPOR) (42")
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
0A6344
047290
0A4121
082508
055934Z
022097
036409
0A4632B
0A4637
0A5763
0A4632A
062522
037561
061258
057796
057795
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
BARBED ELBOW 90 DEG 1/8 NPT X 3/8
HOSE 3/8 ID SINGLE BRAID (9")
VALVE PCV
BALL JOINT PLA .25-28
CLAMP VINYL 1.13 X .406 Z
WASHER LOCK M6-1/4
NUT HEX 1/4-28 STEEL
PLATE AIR CLEANER BOTTOM
FILTER AIR 11.5"
ARM THROTTLE-REWORK
PLATE AIR CLEANER TOP
STUD TH 1/4-20 X 3 G2 ZNC FULL
NUT WING 1/4-20 NYLK
GASKET AIR CLEANER
GROMMET
0C5716
029745
022237
026307
028641
057824
057422
1
2
2
1
1
1
1
7
8
9
10
11
12
057422
1
HOSE 1IN ID LP GAS (LPG LIQUID) (12")
CONNECTOR C/C VENT
®
44 Generac Power Systems, Inc.
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Section 7 — Exploded Views and Parts Lists
(Model No. 004626-1) Guardian Liquid-cooled 40 kW Generators
Carburetor – Drawing No. 0D6977-B
USE FASTENER LOCATED ON
ALTERNATOR FAN SCROLL
TO
REGULATOR
19
24
12
11
10
6
9
25
17
18
22
23
21
20
31
32
30
16
5
7
8
31
33
3
4
2
1
13
FRONT OF
ENGINE
15
27
28
26
14
TO ALTERNATOR
FAN SCROLL
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
064945
0A4120
033212
022129
0C7059
0C7650A
029745
022237
026307
028641
1
1
4
4
1
1
2
2
1
1
GASKET CARBURETOR ADAPTOR
ADAPTOR CARBURETOR W/INLET
SCREW HHC 5/16-18 X 1-1/4 G5
WASHER LOCK M8-5/16
GASKET GOVERNOR THROTTLE BODY
MIXER (ONLY) NATURAL GAS
SCREW HHC 3/8-16 X 1 G5
WASHER LOCK 3/8
ELBOW 90 DEG STREET 3/4
NIPPLE TOE (THREADED ONE END) 3/4
NPT X 2
CLAMP HOSE #16 .87-1.50
HOSE 1 IN ID LP GAS
17
18
19
20
21
22
23
24
25
26
27
28
30
31
32
33
055934Z
0A6613
036409
0A4632B
0A4637
0C7820
0A4632A
062522
037561
061258
057796
057795
0C7060
022152
064090
0C7908
1
1
1
1
1
1
1
1
1
1
1
1
1
8
4
4
CLAMP VINYL 1.13 X .406 Z
GASKET CARB IMPCO 225
NUT HEX 1/4-28 STEEL
PLATE AIR CLEANR BOTTOM
FILTER AIR 11.5" CA326
MACHINING CARBURETOR ADAPTOR
PLATE AIR CLEANER TOP
STUD THR 1/4-20 X 3 F THR G2 ZNC
NUT WING 1/4-20 NYLK
GASKET AIR CLEANER
GROMMET
CONNECTOR C/C VENT
GASKET CARBURETOR ADAPTOR
WASHER LOCK #10
10
11
12
13
14
15
16
057824
057422
0A6344
047290
0A4121
0D2803
1
44"
1
9"
1
BARBED ELBOW 90 1/8 NPT X 3/8
HOSE 3/8 ID SINGLE BRAID
VALVE PCV
SCREW PHM SEMS #12-24 X 5/8 EX
SCREW SHC #10-32 X 5/8 G8.8 NZ
1
ACTUATOR THROTTLE 42MM
®
Generac Power Systems, Inc. 45
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Section 7 — Exploded Views and Parts Lists
(Model No. 004373-2) Guardian Liquid-cooled 40 kW Generators
Regulator – Drawing No. 0C2776-D
TO
CARBURETOR
18
For LPG Vapor Withdrawal Turn
Regulator (Item 7)
Upside Down, Remove Items A & B
19
Then Replace End Cap.
A
B
18
END CAP
17
6
7
6
2
5
4
2
8
9
11
12
3
13
25
12
26
11
MOUNTING
BASE
10
23
2
21
1
20
11
12
T
LET
E
09
13
N
O
15
D1
I
N
2
M
U 4
1
AXIMR
S
H
"
M
I
X
E
M
U
S
E
R
P
11
12
13
14
24
27
11
12
13
15
16
ITEM
PART NO. QTY. DESCRIPTION
ITEM
PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
065907
026307
076691
043768A
026490
026577
055944
067018
0C2775
061910
022145
022129
030795
1
3
1
1
1
2
1
1
1
4
6
6
4
SUPPORT SOLENOID NAT GAS
ELBOW 90 DEG STREET 3/4
NIPPLE PIPE 3/4 NPT X 4.5 BLK IRN
SOLENOID GAS FUEL
14
15
16
17
18
19
20
21
23
24
25
26
27
025655
022132
051778
028641
057824
057422
043123
051779
027482
0C3168
022259
058359
0D1509
1
2
2
1
2
1
2
2
1
1
1
1
1
PLUG STD PIPE 3/4 STEEL SQ HD
WASHER FLAT 9/16 ZINC
SCREW HHC M14-2.0 X 25 G8.8
NIPPLE TOE 3/4 NPT X 2
CLAMP HOSE #16 .87 - 1.50
HOSE 1IN ID LP GAS
WASHER LOCK M14
NUT HEX M14-2 G8 YEL CHR
WASHER SHAKEPROOF EXT 5/16 STL
WASHER LOCK SPECIAL 5/16
NUT HEX 5/16-18 STEEL
LUG RNGTNG INS 22-18 X 5/16 X .477
DECAL INLET PRESSURE
NIPPLE PIPE 3/4 NPT X 2
BUSHING REDUCER 1 TO 3/4
REGULATOR NAT GAS LPG VAPOR
SUPPORT REGULATOR
BRACKET REGULATOR 4.3L
SCREW HHTT #10-24 X 3/4 YC
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
SCREW HHC 5/16-18 X 1 G5
®
46 Generac Power Systems, Inc.
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Section 7 — Exploded Views and Parts Lists
(Model No. 004626-1) Guardian Liquid-cooled 40 kW Generators
Regulator – Drawing No. 0D4823-B
TO
CARBURETOR
18
For LPG Vapor Withdrawal Turn
Regulator (Item 7)
Upside Down, Remove Items A & B
Then Replace End Cap.
19
A
B
18
END CAP
17
10
6
7
6
2
5
4
8
2
27
9
3
11
12
25
12
26
11
13
11
12
25
2
23
MOUNTING
BASE
21
1
20
11
12
13
11
12
13
28
14
24
11
12
15
13
16
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
065907
026307
076691
043768A
026490
026577
0D2758
028237
0C2775
028238
022145
022129
030795
025655
1
3
1
1
1
2
1
2
1
SUPPORT SOLENOID NAT GAS
ELBOW 90 DEG STREET 3/4
NIPPLE PIPE 3/4 NPT X 4.5 BLK IRN
SOLENOID GAS FUEL
NIPPLE PIPE 3/4 NPT X 2
BUSHING REDUCER 1 TO 3/4
REGULATOR N/G (R600S)
SADDLE 1-3/8
BRACKET REGULATOR
BOLT U 5/16-18 X 1.53
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
SCREW HHC 5/16-18 X 1 G5
PLUG STD PIPE 3/4 STEEL SQ HD
15
16
17
18
19
20
21
23
24
25
26
27
28
022132
051778
028641
057824
057422
043123
051779
027482
0C3168
022259
058359
0D2616
0D1509
2
2
1
2
1
2
2
1
1
5
1
1
1
WASHER FLAT 9/16 ZINC
SCREW HHC M14-2.0 X 25 G8.8
NIPPLE TOE 3/4 NPT X 2
CLAMP HOSE #16 .87-1.50
HOSE 1 IN ID LP GAS
WASHER LOCK M14
NUT HEX M14-2 G8 YEL CHR
WASHER SHAKEPROOF EXT 5/16 STL
WASHER LOCK SPECIAL 5/16
NUT HEX 5/16-18 STEEL
LUG RNGTNG INS 22-18 X 5/16 X .477
SUPPORT REGULATOR
2
10
10
4
DECAL INLET PRESSURE
1
®
Generac Power Systems, Inc. 47
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generators
Engine Coolant Heater – Drawing No. 087434-D
Lower Radiator
Hose
To Water
Pump
To Engine
Block
To Lower
1
3
2
14
Radiator
7
3
6
5
13
3
11
3
4
11
10
10
12
9
8
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
080723
035685
057822
084918C
*084918D
050967
0A6283
053660
084427
047411
022097
022473
049813
042568
**077043E
1
2
4
1
1
1
1
1
1
2
4
4
2
2
36"
HOSE CONNECTION TEE 1.75-.62
CLAMP, HOSE #28 1.32-2.25
CLAMP, HOSE #8 .53-1.00
HEATER, ENGINE 1800W 120V.
HEATER, ENGINE 2000W 240V.
HOSE, 5/8" I.D. RIA 250F (36”)
HOSE, PREFORMED BLOCK HEATER
BARBED ST. 1/4" NPT x 5/8 I.D.
BRACKET, HEATER
SCREW HHC M6-1.0 X 16 G8.8
WASHER, LOCK-M6-1/4
WASHER, FLAT 1/4 ZINC
NUT, HEX-M6 X 1.00 G8 YEL CHR
SCREW, HHC-M6-1.0 x 20MM G8.8
FLEXIBLE CONDUIT 1" BLACK
5
6
7
8
9
10
11
12
13
14
*USED ON "R" VOLTAGE GENERATORS ONLY
**ITEM #14 USED ONLY ON 4.3L UNITS
®
48 Generac Power Systems, Inc.
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generators
Battery – Drawing No. A6708-F
TO STARTER
SOLENOID
6
11
12
5
9
13
RED
3
14
TO ENGINE BLOCK
BLACK
2
9
4
8
8
7
7
ITEM
PART NO. QTY. DESCRIPTION
2
3
4
5
6
058665
061902
059473
038805H
038804N
038804T
0A4010
052858
049820
023152
022131
025507
022237
1
1
1
1
1
1
2
2
2
1
1
1
1
BATTERY 12VDC 90-AH 27F (NOT PROVIDED)
HOLD DOWN BATTERY
HOLD DOWN BATTERY
CABLE BATTERY BLACK #1 X 23.00
CABLE BATTERY RED #1 X 15.00
CABLE BATTERY RED #1 X 31.00 (GEAR BOX-NON-GUARDIAN UNITS)
SCREW HHC M8-1.25 X 60 FT G8.8
NUT LOCK FLANGE M8-1.25
NUT LOCK HEX M8-1.25 (NYLON INSERT)
SCREW HHC 3/8-16 X 3/4 G5
WASHER FLAT M10-3/8 ZINC
WASHER SHAKEPROOF EXT 7/16 STL
WASHER LOCK 3/8
7
8
9
11
12
13
14
®
Generac Power Systems, Inc. 49
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generators
Lower Panel – Drawing No. 0D8848-A
3 8 1 8 3
8 7 1 7 8
F
F
O
®
50 Generac Power Systems, Inc.
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Section 7 — Exploded Views and Parts Lists
(Model Nos. 004373-2 & 004626-1) Guardian Liquid-cooled 40 kW Generators
Lower Panel – Drawing No. 0D8848-A
ITEM
PART NO. QTY. DESCRIPTION
ITEM
PART NO. QTY. DESCRIPTION
1
2
4
6
9
068115
0D5489
023484N
056739
0D3388
058710
0D5492
(048766)
022985
068116
0D5840
022264
0C2212
022142
022145
022129
045771
022287
022473
022097
022127
0D5574
1
1
2
1
1
2
1
LOWER PANEL 15
COVER LOWER CONNECTION BOX
BUSHING SNAP SB-2.5-31
RELAY SOLENOID 12VDC PNL MNT
DECAL REMOTE START CONNECTION
TRANSFORMER 200A TO 5A 5VA
HARNESS LOWER PANEL 4.3L GRDN
41
0D5595A
1
KIT CB MOUNT S(FD) 390S
PARTS SHOWN BELOW (I/N'S: 42-50)
42
43
44
45
46
47
48
49
50
51
0D5689
0D5693
022097
022287
022127
022473
081320
022237
048527
0D5463B
1
1
12
8
12
4
4
PLATE CB MOUNT S (FD) 390S
COVER CB TERMINALS S (FD 3P)
WASHER LOCK M6-1/4
SCREW HHC 1/4-20 X 3/4 G5
NUT HEX 1/4-20 STEEL
WASHER FLAT 1/4 ZINC
SCREW SHC 1/4-20 X 4.5 G8.8 NZ
WASHER LOCK 3/8
10
11
REF. BLOCK TERM 20A 2 X 6 X 1100V
2
1
1
2
2
4
4
4
12
13
18
29
30
31
32
33
34
35
36
37
38
40
WASHER FLAT #6 ZINC
COVER LOWER PANEL 15
DECAL CUSTOMER CONNECTN FOR TS
WASHER LOCK M4
SCREW PHTT M4-0.7 X 16 ZYC
SCREW HHC 5/16-18 X 3/4 G5
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC 1/4-20 X 3/4 G5
WASHER FLAT 1/4 ZINC
3
3
SCREW SHC 3/8-16 X 3/4 G5
KIT NEUTRAL BLOCK 390/200-400A
PARTS SHOWN BELOW (I/N'S: 52-60)
52
53
54
55
56
57
58
59
60
0D5464B
057073
022152
033530
022237
022241
022145
022129
045771
1
2
4
4
2
2
2
1
1
NEUTRAL BLOCK 390/200-400A
JUNCTION BLOCK 3/8-16
WASHER LOCK #10
SCREW PHM #10-32 X 5/8 CAD
WASHER LOCK 3/8
NUT HEX 3/8-16 STEEL
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
4
19
23
23
4
WASHER LOCK M6-1/4
NUT HEX 1/4-20 STEEL
CB 0200A 3P 600V S FD6 LL
1
®
Generac Power Systems, Inc. 51
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Section 7 — Exploded Views and Parts Lists
(Model No 004626-1) Guardian Liquid-cooled 40 kW Generators
Exhaust Muffler – Drawing No. 0D6976-A
®
52 Generac Power Systems, Inc.
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Section 7 — Exploded Views and Parts Lists
(Model No 004626-1) Guardian Liquid-cooled 40 kW Generators
Exhaust Muffler – Drawing No. 0D6976-A
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
059902A
0C9641
0D4208
0D5061
0C4126
0D5787
0A5215B
0D5792
0D5793
0C4170
0C4305
0C2454
1
1
1
4
2
1
2
1
1
2
1
2
CAP RAIN 2.50 / 2.69
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
080762
022237
022241
0D5187
0D5190
077879
0D4221
0D4512
043116
022471
022264
038150
036918
049811
022097
049813
0D8780
8
BOLT U 3/8-16 X 2.62
TUBE STRAIGHT 'A' GROUP
MUFFLER CATALYST 4.3L
MOUNTING BAND A-GRP CATALYST
BRACKET MUFFLER MOUNTING
TUBE ELBOW 90 DEG 2.5"
PIPE FLEX 2.5"
16 WASHER LOCK 3/8
16 NUT HEX 3/8-16 STEEL
1
1
SHIELD HEAT CROSSOVER 4.3L
SHIELD HEAT EXHAUST 4.3L
3 FT HOSE VACUUM 5/32
1
1
2
5
5
8
5
2
2
2
1
KIT AIR/FUEL RATIO CONTROLLER
BRACKET AIR/FUEL CONTROLLER
SCREW HHC M6-1.0 X 12 G8.8
NUT HEX #8-32 STEEL
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
TUBE 2.5" SMALL TEE
TUBE ELBOW 90 DEG 2.5" FLARED
BRACKET EXHAUST SHIELD
SHIELD A-GRP HEAT
SCREW TH-FRM M6-1 X 16 N WA
Z/JS
10
11
12
13
14
15
16
18
0C3433A
022129
022145
045771
042907
4
CLAMP BAND 2.5"
16 WASHER LOCK M8-5/16
20 WASHER FLAT 5/16 ZINC
4
NUT HEX M8-1.25 G8 YEL CHR
16 SCREW HHC M8-1.25 X 16 G8.8
®
Generac Power Systems, Inc. 53
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Section 7 — Exploded Views and Parts Lists
(Model No. 004373-2) Guardian Liquid-cooled 40 kW Generators
Generator – Drawing No. 0D5786
20
19
21
1
21
20
2.5" Dia. Clamp Assembly
21
20
2
22
23
19
19
6
19
19
3
13
9
7
13
19
19
13
19
18
7
14
8
18
15
14
11
4
16
5
15
To Engine
10
To
Compartment
Front
19
15
To Engine
12
14
4
18
5
10
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
12
13
14
15
16
18
19
20
21
22
23
0C2454
0C3433A
022129
022145
0C9748
042907
080762
022237
022241
0D5187
0D5190
2
4
12
12
1
12
8
16
16
1
SCREW TH-FRM M6-1 X 16 N WA Z/JS
CLAMP BAND 2.5"
WASHER LOCK M8-5/16
WASHER FLAT 5/16 ZINC
PLUG M18-1.5
SCREW HHC M8-1.25 X 16 G8.8
BOLT U 3/8-16 X 2.62
WASHER LOCK 3/8
1
2
3
4
5
6
7
8
9
059902A
0C9641
0C9650
0C4114A
0C4126
0D5787
0A5215B
0D5792
0D5793
0C4170
0C4305
1
1
1
2
2
1
2
1
1
2
1
CAP RAIN 2.50 / 2.69
TUBE STRAIGHT 'A' GROUP
MUFFLER 2-1/2" INLET/OUTLET
CLAMP BAND MUFFLER 6.5"
BRACKET MUFFLER MOUNTING
TUBE ELBOW 90 DEG 2.5"
PIPE FLEX 2.5"
TUBE 2.5" SMALL TEE
NUT HEX 3/8-16 STEEL
SHIELD HEAT CROSSOVER 4.3L
SHIELD HEAT EXHAUST 4.3L
TUBE ELBOW 90 DEG 2.5" FLARED
BRACKET EXHAUST SHIELD
SHIELD A-GRP HEAT
10
11
1
®
54 Generac Power Systems, Inc.
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Section 8 — Notes
Guardian Liquid-cooled 40 kW Generators
®
Generac Power Systems, Inc. 55
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Section 9 — Installation Drawings
Guardian Liquid-cooled 40 kW Generators
Installation Drawing – Drawing No. 0D5335
NOTE 7
220 [8.65"] STUB-UP AREA
R677 [R26.66"]
TYP
STUB-UP AREA
SEE NOTE 8
AND CHART
ALT
AIR
OU
247 [9.73"]
204 [8.03"]
794 [31.28"]
STUB-UP
AREA
839 [33.01"]
TYP
A1
C
140 [5.50"]
TYP
49 [1.92"]
TYP
MOUNTING HOLES
Ø13.5 [Ø0.53"]
8 HOLES ON BOTTOM
ALT
AIR
OUT
NOTE 1
71 [2.79"]
110 [4.33"] TYP.
570 [22.44"] TYP.
37 [1.44"]
665 [26.19"]
TOP OR PLAN VIEW
2397 [94.37"]
454 [17.87"]
NOTE 3
NOTE 5
NOTE 9
V
A
Hz
NOTE 2
NOTE 6
1
1117 [43.98"]
103 [4.06"]
53 [2.09"]
NATURAL GAS INLET
3/4" NPT FEMALE
835 [32.87"]
936 [36.85"]
OIL DRAIN
1/2" N.P.T. FEMALE
LEFT SIDE VIEW
®
56 Generac Power Systems, Inc.
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Section 9 — Installation Drawings
Guardian Liquid-cooled 40 kW Generators
Installation Drawing – Drawing No. 0D5335
NOTES:
RECOMMENDED FUEL/ELECTRICAL STUB-UPS
(SEE TOP VIEW)
1. STANDARD BLOCK HEATER REQUIRES 120V AC CONNECTION
2. CONNECTION POINTS FOR AC LOAD LEADS, TRANSFER SWITCH, AND
ENGINE AUTOMATIC START/STOP CONTROL WIRES PROVIDED IN
AC CONNECTION PANEL.
3. EXHAUST MUFFLER SUPPORT BRACKETS SUPPLIED WITH OPTIONAL COMPARTMENT.
4. 12 VOLT NEGATIVE GROUND SYSTEM
INSIDE
BASE
DESCRIPTION
A1
(LEFT)
AC LOAD LEAD CONDUIT
INSIDE STUB-UP FOR
FUEL CONNECTIONS
C
BATTERY TRAY INSIDE DIMENSIONS: 178 X 342.5 [7" X 13.5"]
5. 2.5" I.D. FLEX EXHAUST
6. MAIN LINE CIRCUIT BREAKER.
7. DOORS MUST BE OPENED 90 DEG. TO BE REMOVED.
8. A1 MAY BE USED
NOTE:
FUEL SYSTEM SET UP WITH OUTSIDE STUB UPS
(SEE LEFT SIDE VIEW). SMALL FUEL SYSTEM
MODIFICATIONS REQUIRED FOR
FOR CIRCUIT BREAKER STUB-UP LOCATION.
9. SEE DRAWING C3850 FOR DUCT REMOVAL. REMOVAL OF FRONT
DUCT WILL PROVIDE ACCESS TO MUFFLER FOR SERVICING.
INSIDE STUB-UPS.
WEIGHT DATA
ENGINE SERVICE CONNECTIONS
UNIT: 729.7 kg [1609 lbs]
STEEL COMPARTMENT: 208.6 kg [460 lbs]
INLET NATURAL GAS = 3/4" NPT COUPLING
OIL DRAIN = 1/2" NPT COUPLING
EXHAUST OUTLET -
2.5" OD MUFFLER OUTLET
UNITS: mm [INCHES]
965 [37.99"]
(1) 12V BATTERY
SEE NOTE 4
LIFTING EYE
(4 PLACES)
1160 [45.67"]
158 [6.22"]
CENTER OF
GRAVITY
981 [38.62"]
877 [34.51"]
REAR VIEW
1930 [75.98"]
RIGHT SIDE VIEW
®
Generac Power Systems, Inc. 57
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Section 10 – Warranty
Guardian Liquid-cooled 40 kW Generators
GENERAC POWER SYSTEMS "TWO YEAR" STANDARD 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) 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. Any equip-
ment that the purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized
Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and pre-
paid by the purchaser/owner. This warranty applies only to Generac Guardian prepackaged emergency automatic standby gen-
erators sold and rated for use in "Standby" applications.
WARRANTY SCHEDULE
YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and
maintenance is required):
• Engine - All Components
• Alternator - All Components
• Transfer System - All Components
All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat Rate
Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Generac Guardian generators that utilize non-Generac replacement parts.
• Any Generac Guardian generators used as rental or trailer mounted applications.
• Units used for prime power in place of existing utility power where utility power is present or in place of utility power where
utility power service does not normally exist.
• Costs of normal maintenance, adjustments, installation and start-up.
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with
all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty
will not cover repair when normal use has exhausted the life of a part(s) or engine.
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent infestation.
• Products that are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or
replacement of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit
warranty period.
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Overnight freight costs for replacement part(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES
NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or conse-
quential damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
GENERAC® POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190
Part No. 0D8908
Revision 0 (03/06/02)
Printed in U.S.A.
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