Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Nos. 004992-0 004992-1 37kW NG, 40kW LP This manual should remain with the unit.
INTRODUCTION Thank you for purchasing this model of the Guardian standby generator product line by Generac Power Systems, Inc. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.
Table of Contents Guardian 40kW Liquid-cooled Generators INTRODUCTION ................................................IFC SAFETY RULES ....................................................2 Section 3 — OPERATION ................................13 3.1 Using an Engineered “GTS” Transfer Switch ......13 3.2 Control Console Components..............................13 Section 1 — GENERAL INFORMATION ............4 3.3 Manual Transfer and Startup ..............................14 1.1 Generator .............
IMPORTANT SAFETY INSTRUCTIONS Guardian 40kW Liquid-cooled Generators ! SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. ! SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.
IMPORTANT SAFETY INSTRUCTIONS Guardian 40kW Liquid-cooled Generators • Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. • Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last. • Never use the generator or any of its parts as a step.
Section 1 - General Information Guardian 40kW Liquid-cooled Generators 1.1 GENERATOR 1.3 This equipment is a liquid-cooled, engine-driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been factory-installed in a weather resistant, all metal enclosure and is intended for outdoor installation only.
Section 1 - General Information Guardian 40kW Liquid-cooled Generators 1.6 NOTE: GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is necessary, refer to Section 1.12 for conversion. The Low Oil Pressure, High Coolant Temperature and Low Coolant Level are not monitored for the first 10 seconds of engine run time. Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.
Section 1 — General Information Guardian 40kW Liquid-cooled Generators Figure 1.6 - Low Coolant Level Sensor 1.7.7 LOW BATTERY The engine control board continually monitors the battery voltage and turns on the low battery LED if the battery voltage falls below 11.0 VDC for one minute. Low battery voltage is a non-latching alarm, which will automatically clear if the battery voltage rises above 11.0 VDC. 1.7.
Section 1 — General Information Guardian 40kW Liquid-cooled Generators Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges. 1.10 SPECIFICATIONS 1.10.1 GENERATOR SPECIFICATIONS Single-phase Model Rated Max. Cont. AC Power Output (kW) Rated voltage (volts) No.
Section 2 — Installation Guardian 40kW Liquid-cooled Generators DANGER ! Serious injury or damage may occur if not configured properly. Please consult an authorized service dealer with any questions. ! 1.13 TORQUE SPECIFICATIONS Tighten the bolts from the middle out, in a crisscross pattern. Cylinder Head ....................................50 ft.lb./105 ft.lb./105 ft.lb. Intake Manifold ....................................48 in.lb./84 in.lb./84 in.lb. Exhaust Manifold.................................
Section 2 — Installation Guardian 40kW Liquid-cooled Generators 2.2 ! After the system has been installed, do nothing that might render the installation in noncompliance with such codes, standards and regulations. 2.1.
Section 2 — Installation Guardian 40kW Liquid-cooled Generators Figure 2.1 – Basic Standby Electric System 2.7 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 the area.
Section 2 — Installation Guardian 40kW Liquid-cooled Generators 2.9 TRANSFER SWITCH SIGNAL CONNECTIONS 2.9.1 PRE-PACKAGED ATS If the generator is to be installed with a pre-packaged transfer switch, it is necessary to connect the control wires to the generator and set position two of the four-position dip switch to OFF. 2.10 BATTERY INSTALLATION DANGER ! Setting switch two to OFF allows the control PCB to perform the ATS control functions.
Section 2 — Installation Guardian 40kW Liquid-cooled Generators • Spilled electrolyte is to be washed down with an acid-neutralizing agent. A common practice is to use a solution of one pound (500 grams) 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. Lead acid batteries present a risk of fire because they generate hydrogen gas.
Section 3 - Operation Guardian 40kW Liquid-cooled Generators Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use. 3.2 Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear of any moving generator set components. The components of a home standby generator control console (Figure 3.1) are as follows: USING AN ENGINEERED “GTS” TRANSFER SWITCH Figure 3.
Section 3 — Operation Guardian 40kW Liquid-cooled Generators 3.2.3 15 AMP FUSE Fuse protects the control console’s DC control circuit against electrical overload. If the fuse has melted open because of an overload, engine cranking and startup cannot occur. If the fuse needs to be replaced, use only an identical 15-amp replacement fuse. (Type AGC) 3.2.4 4.0 AMP INLINE FUSE This fuse protects the battery charger against electrical overload.
Section 3 - Operation Guardian 40kW Liquid-cooled Generators AUTOMATIC OPERATION 3.7 WEEKLY EXERCISE CYCLE FUSE 15A MAIN US AUTO To set the system for fully automatic operation, proceed as follows: • Check that load circuits are connected to the utility power supply. • Set the AUTO/OFF/MANUAL switch to its AUTO position. • Set the generator main circuit breaker to its ON or Closed position. F US E FUSE 4A BAT. CHARGER E F Figure 3.2 - “Set Exercise Time” Switch F USE 3.
Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators 4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE DEALERS A. EVERY THREE MONTHS 1. 2. 3. 4. 5. 6. Check battery state of charge and condition. Inspect and test fuel system. Check transfer switch. Inspect exhaust system. Check engine ignition system. Check fan belts. B. ONCE EVERY SIX MONTHS 1. Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature). C. ONCE ANNUALLY 1. Test engine governor.
Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators • Add recommended coolant mixture as necessary. • Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact an authorized service dealer. Inspect cooling system and coolant recovery system for leaks.
Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators 7. Start engine and check for oil leaks. Figure 4.2 - Oil Filter 4.5.13 COOLANT CHANGE Every year, have an authorized service dealer drain, flush and refill the cooling system. See SPECIFICATIONS (Section 1.10) for cooling system recommendations. 4.6 MISCELLANEOUS MAINTENANCE 4.6.1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible.
Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators 4.6.3 BATTERY MAINTENANCE The battery should be inspected per the “Service Schedule,” Section 6. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. 2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES. 3.
Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators 4.7 SCHEDULED MAINTENANCE Following is a recommended maintenance schedule for Generac small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application.
Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators Maintenance Tasks Level 1 Recommended to be done monthly Level 2 Task Comp. (DateInitials) Required to be done 3 months/ Break-in Level 3 Task Comp. (DateInitials) Required to be done Semiannually Level 4 Task Comp. (DateInitials) Required to be done Annually Task Comp. (DateInitials) 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level.
Section 4 — Maintenance Guardian 40kW Liquid-cooled Generators Maintenance Tasks Level 1 Recommended to be done monthly 13. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary. 14.
Section 5 — Troubleshooting Guardian 40kW Liquid-cooled Generators TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 4 amp fuse blown. 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor. 4. Replace starter motor. 5. Remove, change or replace battery. 6. Replace fuse.
Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8115-A 24 Generac® Power Systems, Inc.
Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8115-A Generac® Power Systems, Inc.
Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E8116-A 26 Generac® Power Systems, Inc.
Section 6 - Electrical Data Guardian 40kW Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E8116-A Generac® Power Systems, Inc.
16 12 13 28 Generac® Power Systems, Inc. 9 34 35 18 8 42 43 7 6 5 TO ENGINE MOUNT 2 34 36 4 3 16 19 40 34 30 27 16 35 36 41 38 18 27 32 33 22 29 20 31 21 20 7 6 5 37 15 1 13 12 11 REAR BEARING CARRIER HARNESS WIRE TO STARTER CONTACTOR TO STARTER BOLT TO ENGINE 18 BLOCK 14 16 10 4 3 2 Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Mounting Base — Drawing No.
Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Mounting Base — Drawing No. 0E8084-A ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23* 24* 25* 26* 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 PART NO.
30 Generac® Power Systems, Inc. 3 30 32 31 LATCH DETAIL 38 31 32 4 34 18 17 43 2 41 4 37 4 35 53 25 RADIATOR 33 4 STATES FOAM IS ON FAR SIDE STATES FOAM IS ON NEAR SIDE 32 44 4 34 55 53 4 13 11 9 SEE LATCH DETAIL TO "A" TYPICAL OF ROOF PANEL THAT REQUIRE INSULATION. SECURE AS SHOWN.
Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Enclosure — Drawing No. 0E8439-E ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 50 * 51 52 53 54 55 56 57 58 PART NO.
Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Control Panel — Drawing No. 0E7118-G 32 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Control Panel — Drawing No. 0E7118-G ITEM PART NO. QTY. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0E7195 0E7196 0E7197 0E7193 0E7194 0E4494 082573 032300 022676 067682B 060015 054199 0C2657 099076 040213 0E9668 0E4905 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 17 18 19 20 21 067680 0E6875A 0E6881 * 0C5139 * 0E5142 * 1 1 REF. REF. REF.
Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Engine — Drawing No. 0E8121-D 34 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Engine — Drawing No. 0E8121-D ITEM PART NO. QTY.
Section 7 - Exploded Views and Parts 13 WATER PUMP 26 25 24 3 21 "A" 36 Generac® Power Systems, Inc. 23 24 1 10 20 4 10 5 TO THERMOSTAT HOUSING 15 0 16 19 16 22 15 2 14 8 17 9 14 7 6 17 18 14 O "A" Guardian 40kW Liquid-cooled Generators Radiator — Drawing No.
Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Radiator — Drawing No. 0E8102-E ITEM 1 2 3 4 5 6 7 8 9 10 13 14 15 16 17 18 19 20 21 22 23 24 25 26 PART NO. 0D7825A 0D7174C 0E7640 0E7924 0F2853 0D8252 0D8251 0E0726 076749 035685 069860C 058443 0C2454 052250 048031C 029032 0A2111 0E7640A 035461 065852 051756 022131 046526 045772 QTY. 1 1 1 1 1 1 1 1 1 4 1 17 5 2 1 1 1 1 1 1 4 8 4 4 DESCRIPTION RADIATOR COPPER BRASS VENTURI,3.
Section 7 - Exploded Views and Parts TO INTAKE MANIFOLD 43 6 1 39 15 18 19 TO "B" 14 19 38 Generac® Power Systems, Inc. TO ENGINE 45 42 16 2 4 41 40 5 11 17 6 9 13 12 6 8 3 27 2 31 30 29 32 13 37 38 36 "B" 35 34 20 21 23 23 24 22 25 44 33 Guardian 40kW Liquid-cooled Generators Fuel System — Drawing No.
Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Fuel System — Drawing No. 0E8122-F ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 PART NO.
Section 7 - Exploded Views and Parts 15 7 17 4 1 18 31 30 20 5 21 19 6 LEADS 7 2 8 14 9 24 12 * 3 13* 10 23 11 13 22 Guardian 40kW Liquid-cooled Generators Alternator — Drawing No. 0E5146-B 40 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Alternator — Drawing No. 0E5146-B ITEM PART NO. QTY.
Section 7 - Exploded Views and Parts Guardian 40kW Liquid-cooled Generators Muffler — Drawing No. 0E8068-E 7 21 13 12 10 1 11 5 22 10 11 10 12 23 13 14 22 TO COMPARTMENT 9 17 19 21 10 TO EXHAUST MANIFOLD 16 19 6 20 14 17 8 8 15 4 PART NO. 24 11 2 20 11 19 3 20 8 TO EXHAUST MANIFOLD 19 ITEM 15 11 18 QTY.
Section 8 — Installation Diagram OVERHEAD VIEW Guardian 40kW Liquid-cooled Generators Installation Diagram — Drawing No. 0E8422-A Generac® Power Systems, Inc.
Section 9 - Notes Guardian 40kW Liquid-cooled Generators 44 Generac® Power Systems, Inc.
Section 9 - Notes Guardian 40kW Liquid-cooled Generators Generac® Power Systems, Inc.
Section 10 – Warranty Guardian 40kW Liquid-cooled Generators GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN® "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below.
