Generac Portable Generator 004373 2 004626 1 User Manual

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

Generac Power Systems, Inc.

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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.

• 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.

Generac Power Systems, Inc.

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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.

Generac Power Systems, Inc.

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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.

Generac Power Systems, Inc.

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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

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

Models

0 04373-2 & 004626-1

Rated Maximum Continuous

AC Power Output (kW)*

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

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).

Generac Power Systems, Inc.

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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

Generac Power Systems, Inc.

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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

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

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,

10 Generac Power Systems, Inc.

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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.

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.

12 Generac Power Systems, Inc.

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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).

Generac Power Systems, Inc. 13

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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

14 Generac Power Systems, Inc.

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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.

Generac Power Systems, Inc. 15

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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.

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.

Generac Power Systems, Inc. 17

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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

EVERY 3 M

Oil

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*

100 H

EVERY 3 M

FIRST 100 H AND

EVERY 800 H

BATTERY

Charge and condition

FAN BELT

Tension and condition*

ENGINE

EVERY 3 M

Retorque cylinder head*

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

EVERY 500 H

EVERY 500 H AND Y

EVERY 500 H

EVERY 800 H

EVERY 6 M

500 H AND Y

EVERY 3 M

Overall condition

Exercise system

COMPLETE TUNE-UP*

TO BE COMPLETED BY A GENERAC/

GUARDIAN AUTHORIZED DEALER

Generac Power Systems, Inc. 19

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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 )

Generac Power Systems, Inc. 21

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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

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

1 5

1 5 A

1 4

1 3

7 9

1 5 C

R E D

2 2 5 A

B L A C K

DEUTSCH

A C T U A T O R

T O G O V E R N O R

22 Generac Power Systems, Inc.

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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

Y E L L O W

M P U S H I E L D

M P U -

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 )

Generac Power Systems, Inc. 23

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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

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

1 5

1 5 A

1 4

1 3

7 9

1 5 C

R E D

2 2 5 A

B L A C K

M P U S H I E L D

M P U -

M P U +

A C T -

A C T +

B A T -

7 9

1 6 1

1 6 0

DEUTSCH

B A T +

1 4

7 9

1 6 0

1 6 1

24 Generac Power Systems, Inc.

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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

Generac Power Systems, Inc. 25

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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

26 Generac Power Systems, Inc.

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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

Generac Power Systems, Inc. 27

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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

28 Generac Power Systems, Inc.

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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

RED

BRUSH UNITS

THERMAL PROTECTOR BYPASS

DPE

CT1

CT2

S16

S15

CB2

194

TS3

TS4

CUSTOMER CONNECTION

120/240-V. 1-PHASE

183

178

Generac Power Systems, Inc. 29

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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

P I N

30 Generac Power Systems, Inc.

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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

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

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

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

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

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

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

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.

Generac Power Systems, Inc. 31

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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

P I N

32 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

Control Panel - Drawing No. 0D6978-A

ITEM PART NO. QTY. DESCRIPTION

0D7397

0D1521A

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

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

REF

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

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

PANEL LEFT SIDE E

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

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

* 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

WIRE HARNESS

"A"

SECURE WIRE HARNESS

WITH TIE WRAP AS SHOWN.

EXISTING

ENGINE

HARDWARE

CARB. ARM

(REF.)

"A"

ITEM PART NO.QTY.

DESCRIPTION

098290

0A3439

098958A

021888

082508

036409

043146

098941A

098942A

098225

022097

064526

029333A

074031

051716

049226

076040

098647*

036409

0C2184

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

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

11 10

*27

*28

*27

To Oil Drain

On Oil Pan.

*26

*27

*28

*26

*27

*28

*27

*25

ITEM PART NO. QTY. DESCRIPTION

0C3250

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

* 25

* 26

* 27

* 28

* 29

024310

0A8785

0C4360

071693

0C2454

0C4753

022413

022473

022097

022127

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

055414

0A4084

022129

045771

022237

029745

043107

022145

027482

055597

052251

052257

052252

052259

052860

0536210098

052251A

044118

057823

057448

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.

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

0A9046

0A4084

0A4239

0A4240

0A5640

0A5640A

0A5639

0D3293A

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)

0A4241

0C2885

0A5737C

022131

077456

044117

057823

057448

022129

022142

048614

022237

029745

042633

033819

022241

0A5768

046526

049814

0C3756

045772

0D2514

052259

055934D

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

077996

057823

035579

037065

022302

0A8584

052644

0A4278A

0A4930A

0A4085

0A3927

0C7947

0A1232

0A7801B

021928

0C6239

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"

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

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

10"

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

022131

058030

0A4085

0A3928

0C7947

057794

0A4277

022241

057795

048191

032303

0A3852

098239

057522

0D2244M

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)

075885

THERMOSTAT 195 DEG

0D6979

0A4308

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

10*

11*

13*

14*

051768

051769

0A8240

039253

022129

082130D

0C4286

0A2601

0A2602

0A1138

021941

020808A

052624

070892

0A5580

0A1633

020729A

022131

022237

022511

068113

068115

043123

051779

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

046852

022145

039287

071641

071639

0A2110

022473

022746

031980

083549

0A4089

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

0A2491

0A2497

0A2496

056326

022097

045757

047411

0A2110

SHROUD ALTERNATOR SHEET METAL

SCREEN SHROUD SAE

BRACKET TENSIONER SAE SCROLL

TRIM VINYL BLACK 1/8 GP

8.4 FT

WASHER LOCK M6-1/4

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

* ROTOR REPLACEMENT PARTS

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

BASE

FRAME

ITEM

PART NO.

QTY.

DESCRIPTION

ASSEMBLY M6 HINGE

ITEM

PART NO.

QTY.

DESCRIPTION

0C3594

0A3359

0A3360

0C4066 (A)

0C4067 (A)

0C4117 (A)

0C2634A

0C2454

022129

042907

022473

022097

022127

0A9881

0C3393

0C3400 (A)

0C3397

066760

022145

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)

NUT HEX 1/4-20 STEEL

49.1 FT. GASKET DOOR RUBBER

SCREW SHOULDER

COVER EXHAUST HOLE

FASTENER RATCHET

39-3/8" STRIP SEALANT 1/8 X 1

WASHER FLAT 5/16 ZINC

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

"A"

TO "A"

KIT PART NO. 0D8121

ITEM

PART NO. QTY. DESCRIPTION

ITEM

PART NO. QTY. DESCRIPTION

0D7825

0D8251

0D8252

024655

022097

022473

0D7174

0D7174A

0D7870

035685

047290

040173

049340

036865

029032

052250

058443

029745

022237

022131

0D7850

RADIATOR COPPER BRASS

FAN GUARD, BOTTOM

FAN GUARD, TOP

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

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

* 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

REGULATOR

TO STEPPER

MOTOR

FRONT OF

ENGINE

TO ALTERNATOR

FAN SCROLL

ITEM

PART NO. QTY. DESCRIPTION

ITEM

PART NO. QTY. DESCRIPTION

064945

0A4120

033212

022129

052865

0A7631

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")

0A6344

047290

0A4121

082508

055934Z

022097

036409

0A4632B

0A4637

0A5763

0A4632A

062522

037561

061258

057796

057795

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

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

REGULATOR

FRONT OF

ENGINE

TO ALTERNATOR

FAN SCROLL

ITEM PART NO. QTY. DESCRIPTION

064945

0A4120

033212

022129

0C7059

0C7650A

029745

022237

026307

028641

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

055934Z

0A6613

036409

0A4632B

0A4637

0C7820

0A4632A

062522

037561

061258

057796

057795

0C7060

022152

064090

0C7908

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

057824

057422

0A6344

047290

0A4121

0D2803

44"

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

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

CARBURETOR

For LPG Vapor Withdrawal Turn

Regulator (Item 7)

Upside Down, Remove Items A & B

Then Replace End Cap.

END CAP

MOUNTING

BASE

LET

U 4

AXIMR

ITEM

PART NO. QTY. DESCRIPTION

ITEM

PART NO. QTY. DESCRIPTION

065907

026307

076691

043768A

026490

026577

055944

067018

0C2775

061910

022145

022129

030795

SUPPORT SOLENOID NAT GAS

ELBOW 90 DEG STREET 3/4

NIPPLE PIPE 3/4 NPT X 4.5 BLK IRN

SOLENOID GAS FUEL

025655

022132

051778

028641

057824

057422

043123

051779

027482

0C3168

022259

058359

0D1509

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

CARBURETOR

For LPG Vapor Withdrawal Turn

Regulator (Item 7)

Upside Down, Remove Items A & B

Then Replace End Cap.

END CAP

MOUNTING

BASE

ITEM PART NO. QTY. DESCRIPTION

065907

026307

076691

043768A

026490

026577

0D2758

028237

0C2775

028238

022145

022129

030795

025655

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

022132

051778

028641

057824

057422

043123

051779

027482

0C3168

022259

058359

0D2616

0D1509

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

DECAL INLET PRESSURE

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

Radiator

ITEM PART NO. QTY. DESCRIPTION

080723

035685

057822

084918C

*084918D

050967

0A6283

053660

084427

047411

022097

022473

049813

042568

**077043E

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

*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

RED

TO ENGINE BLOCK

BLACK

ITEM

PART NO. QTY. DESCRIPTION

058665

061902

059473

038805H

038804N

038804T

0A4010

052858

049820

023152

022131

025507

022237

BATTERY 12VDC 90-AH 27F (NOT PROVIDED)

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

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

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

068115

0D5489

023484N

056739

0D3388

058710

0D5492

(048766)

022985

068116

0D5840

022264

0C2212

022142

022145

022129

045771

022287

022473

022097

022127

0D5574

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

0D5595A

KIT CB MOUNT S(FD) 390S

PARTS SHOWN BELOW (I/N'S: 42-50)

0D5689

0D5693

022097

022287

022127

022473

081320

022237

048527

0D5463B

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

REF. BLOCK TERM 20A 2 X 6 X 1100V

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

SCREW SHC 3/8-16 X 3/4 G5

KIT NEUTRAL BLOCK 390/200-400A

PARTS SHOWN BELOW (I/N'S: 52-60)

0D5464B

057073

022152

033530

022237

022241

022145

022129

045771

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

WASHER LOCK M6-1/4

NUT HEX 1/4-20 STEEL

CB 0200A 3P 600V S FD6 LL

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

059902A

0C9641

0D4208

0D5061

0C4126

0D5787

0A5215B

0D5792

0D5793

0C4170

0C4305

0C2454

CAP RAIN 2.50 / 2.69

080762

022237

022241

0D5187

0D5190

077879

0D4221

0D4512

043116

022471

022264

038150

036918

049811

022097

049813

0D8780

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

SHIELD HEAT CROSSOVER 4.3L

SHIELD HEAT EXHAUST 4.3L

3 FT HOSE VACUUM 5/32

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

0C3433A

022129

022145

045771

042907

CLAMP BAND 2.5"

16 WASHER LOCK M8-5/16

20 WASHER FLAT 5/16 ZINC

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

2.5" Dia. Clamp Assembly

To Engine

Compartment

Front

To Engine

ITEM PART NO. QTY. DESCRIPTION

0C2454

0C3433A

022129

022145

0C9748

042907

080762

022237

022241

0D5187

0D5190

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

059902A

0C9641

0C9650

0C4114A

0C4126

0D5787

0A5215B

0D5792

0D5793

0C4170

0C4305

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

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

247 [9.73"]

204 [8.03"]

794 [31.28"]

STUB-UP

AREA

839 [33.01"]

TYP

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

NOTE 2

NOTE 6

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

(LEFT)

AC LOAD LEAD CONDUIT

INSIDE STUB-UP FOR

FUEL CONNECTIONS

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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