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POWER SYSTEMS, INC.

Owner’s Manual

Liquid-cooled, Prepackaged

Standby Generators

Models:

004373-2 (40 kW/Single-phase

w/ 200 Amp
Transfer Switch)

004626-1 (40 kW/Single-phase

w/ 200 Amp
Transfer Switch
California Emissions)

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

DANGER

*This Manual Should

Remain With The Unit*

Содержание 004626-1

Страница 1: ...d Standby Generators Models 004373 2 40 kW Single phase w 200 Amp Transfer Switch 004626 1 40 kW Single phase w 200 Amp Transfer Switch California Emissions ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS...

Страница 2: ...ymbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment Generac strongly recommends that th...

Страница 3: ...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 2 8 6 Belt Tension 11 2 8 7 Electrical System 11 2 8 8 Rodent Protectio...

Страница 4: ...er 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...

Страница 5: ...e 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...

Страница 6: ...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 o...

Страница 7: ...ncy 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 5 OVERCRANK SHUTDOWN After...

Страница 8: ...20 cfh LP Gas 004373 2 004626 1 288 cfh 7 9gph 1 9 FUEL REQUIREMENTS AND RECOMMENDATIONS With LP gas use only the vapor withdrawal system This type of system uses the vapors formed above the liquid fu...

Страница 9: ...as 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 carburetor oxygen sensor ai...

Страница 10: ...on 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 FAR...

Страница 11: ...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 proce...

Страница 12: ...mmediately with water 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...

Страница 13: ...erate the engine with the oil level below the dipstick ADD mark See Specifications Page 5 and Engine Oil Recommendations Page 7 NOTE This engine is shipped from the manufacturer with SAE 15W 40 oil Th...

Страница 14: ...hours and tenths of hours Use the hourmeter along with the periodic maintenance schedule for your generator set 3 1 6 AUTO OFF MANUAL SWITCH See Section 3 2 3 1 7 FAULT INDICATOR LAMP This lamp goes O...

Страница 15: ...ch to activate and connect load circuits to the standby power supply load terminal lugs T1 T2 connect to terminal lugs E1 E2 Upon restoration of utility source voltage above a preset level generator c...

Страница 16: ...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 st...

Страница 17: ...d 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 Figure 4 2 Oil Filter 5 A...

Страница 18: ...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...

Страница 19: ...15 amp Fuse 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 pres...

Страница 20: ...off the utility power to the transfer switch 5 While the engine is still warm from running drain the oil completely Refill the crankcase with SAE 15W 40 oil having API Service Class SG SH or SJ 6 Att...

Страница 21: ...100 H COOLING Engine cooling system X M Coolant X Y Enclosure louvers X X W EXHAUST Exhaust system X EVERY 3 M Retorque Exhaust Manifold X FIRST 100 H AND EVERY 800 H BATTERY Charge and condition X R...

Страница 22: ...2 Clean re gap or replace plug s 3 Dirty Blocked air filter 3 Clean or replace as required The engine starts but then 1 Engine oil level low 1 Check oil and add oil as needed shuts down 2 Defective lo...

Страница 23: ...CAPACITOR CB1 CIRCUIT BREAKER EXCITATION GCU GOVERNOR CONTROLLER UNIT D1 DIODE 600V 12A HM HOURMETER F1 FUSE 15 AMPS TS1 TS2 TERMINAL STRIP S16 BVM METER BATTERY VOLTAGE AM METER AC OUTPUT CURRENT LE...

Страница 24: ...15A BLUE 15 SW2 S3 SW1 178 178 229 178 183 0 2 0 15C S3 S1 14 18 S16 14 65 15C 65 12 67 0 15C 00 67 67 S15 65 S16 VM 64 0 0 0 15 0 S1 6 2 57 57 11 58 7 3 58 S16 183 57 19 65 0 S3 BVM 0 14 S15 S15 14...

Страница 25: ...O X X X O X O O X O X O O O O O O O O O X O 1 2 3 OFF POSITION O X X X TO ENGINE CONNECTOR EH 85 6 S16 S15 S1 2 29 R1 D1 4 4 1 0 14 85 56 14 14 13 229 15 TS1 85 S16 PHASE SELECTOR SWITCH S16 S15 162 1...

Страница 26: ...4 183 4 VM 64 0 0 HZ AM 0 S15 S15 S16 6 S16 S16 00 2 6 S15 2 S16 6 2 1 1 2 1 9 8 7 F2 K P Q M O N L T R S U B X A V W F H J G D E C E PCB B D A 15C 15 START MANUAL 183 AUTO 239 15A 15C OFF 14 0 160 1...

Страница 27: ...Generac Power Systems Inc 25 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...

Страница 28: ...26 Generac Power Systems Inc 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...

Страница 29: ...Generac Power Systems Inc 27 Section 6 Electrical Data Model No 004373 2 Guardian Liquid cooled 40 kW Generator Electrical Schematic Stepper Motor Drawing No 0A5858...

Страница 30: ...RT CONNECTION CP CONTROL PANEL CONNECTOR LOWER PANEL NB NEUTRAL BLOCK E3 E1 CB2 00 DIRECT 390mm A S CP TS3 TS4 A R NB 57 S3 S15 S1 S16 58 S3 1 0 S15 4 0 57 57 58 0 11 44 33 5 22 58 6 2 FROM STANDARD G...

Страница 31: ...PE S1 AS 6 E TP Q 2 K 5 5 F RED 4 4 C AR 1 1 D T2 V 23 W 194 X T1 U N2 T N1 S 183 B 178 J TS3 TS3 TS4 TS4 NB NB 120 240 V 1 PHASE TO CONTROL PANEL CONNECTOR CP THERMAL PROTECTOR BYPASS Section 6 Elect...

Страница 32: ...AILURE TO WAIT 30 SEC OFF MANUAL SWITCH TO THE AUTO OFF MANUAL SWITCH TO THE AUTO 20 SECONDS AND THEN RELEASE 20 SECONDS AND THEN RELEASE TIME SWITCH TO ON POSITION FOR TIME SWITCH TO ON POSITION FOR...

Страница 33: ...C 0 200 ITEM PART NO QTY DESCRIPTION 32 070042 1 FREQUENCY METER 240V 55 65HZ 33 081988 1 DECAL EXERCISE INFO 34 0C1229 1 DECAL CUST CONN BOX 35 098647 1 ASSY L C ELECT GOV 36 0A3968 1 CAPACITOR FILTE...

Страница 34: ...TART IT WILL SHUT OFF AUTOMATICALLY WITHIN 2 MIN PUSH AND HOLD SET EXERCISE TIME SWITCH TO ON POSITION FOR 20 SECONDS AND THEN RELEASE OFF MANUAL SWITCH TO THE AUTO POSITION FAILURE TO WAIT 30 SEC MAY...

Страница 35: ...REQUENCY METER 240V 55 65HZ 33 081988 1 DECAL EXERCISE INFO ITEM PART NO QTY DESCRIPTION 34 0C1229 1 DECAL CUST CONN BOX 35 0D3440 1 CONTROLLER B C DPG 2103 36 0A3968 1 CAPACITOR FILTER ASY 37 048766...

Страница 36: ...RFACE ASSEMBLY 4 021888 1 LEVER STEPPER MOTOR 5 082508 2 BALL JOINT PLA 25 28 9 036409 2 NUT HEX 1 4 28 STEEL 11 043146 3 SCREW HHC M6 1 0 X 10 G8 8 12 098941A 2 HOUSING GOVERNOR CONNECT 13 098942A 2...

Страница 37: ...INGLE ITEM PART NO QTY DESCRIPTION 24 024310 1 PLUG STD PIPE 1 2 STEEL SQ HD 25 0A8785 4 PLUG BUTTON 3 DIA 26 0C4360 8 PLATE VARMINT 27 071693 16 WASHER FLAT 281 ID X 1 0 OD 28 0C2454 16 SCREW TH FRM...

Страница 38: ...5 43 40 22 39 7 8 36 13 5 10 11 33 19 31 4 35 26 34 3 34 14 30 28 44 27 9 1 21 43 25 46 40 41 26 17 34 16 38 15 47 29 18 2 Section 7 Exploded Views and Parts Lists Model Nos 004373 2 004626 1 Guardian...

Страница 39: ...ART NO QTY DESCRIPTION 23 0A4241 1 PULLEY GROOVED IDLER 24 0C2885 1 PULLEY TENSIONER 25 0A5737C 1 SPACER DC ALTERNATOR 34MM 26 022131 8 WASHER FLAT 3 8 M10 ZINC 27 077456 1 ADAPTOR M12 1 75 3 8 NPT 28...

Страница 40: ...38 Generac Power Systems Inc 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...

Страница 41: ...IPE 1 8 SOCKET HEAD 21 069939 1 HOUSING THERMOSTAT WATER INLET 22 035606 1 SENSOR HI COOLANT SHUTDOWN 23 0A4930B 1 HEAT SHIELD RIGHT 24 0A4084 1 MOUNT ENGINE 25 029745 3 SCREW HHC 3 8 16 X 1 G5 26 044...

Страница 42: ...EEL ADJUSTMENT THREAD IN SENSOR 6 UNTIL CONTACT IS MADE WITH RING GEAR THEN BACK OFF 1 2 TO 3 4 TURN AND TIGHTEN NUT DO NOT ROTATE ENGINE DURING THIS ADJUSTMENT CAUTION NOTE TO ENGINE 8 6 9 17 19 18 2...

Страница 43: ...31 12 WASHER FLAT 3 8 M10 ZINC 19 022237 11 WASHER LOCK 3 8 20 022511 11 SCREW HHC 3 8 16 X 1 1 4 G5 21 068113 1 CARRIER REAR BEARING 15 22 068115 1 LOWER PANEL 15 23 043123 4 WASHER LOCK M14 24 05177...

Страница 44: ...24 0C4066 A 1 DUCT BOTTOM 25 0C4067 A 1 DUCT FRONT PANEL 26 0C4117 A 1 DUCT FRONT TOP RH 28 0C2634A 1 ASSEMBLY COVER ACCESS 29 0C2454 76 SCREW TH FRM M6 1X16 N WA Z JS 30 022129 2 WASHER LOCK M8 5 16...

Страница 45: ...12 040173 2 CLAMP HOSE 5 5 62 62 13 049340 1 BARBED EL 90 1 4 NPT X 3 8 14 036865 1 DRAINCOCK 15 029032 1 HOSE 9 32 ID 64 LG 16 052250 3 TAPE FOAM 1 X 1 29 LG 17 058443 10 SCREW CRIMPTITE 1 4 20 X 5...

Страница 46: ...1 HOSE 3 8 ID SINGLE BRAID 9 15 0A4121 1 VALVE PCV 16 082508 1 BALL JOINT PLA 25 28 17 055934Z 1 CLAMP VINYL 1 13 X 406 Z 18 022097 1 WASHER LOCK M6 1 4 19 036409 2 NUT HEX 1 4 28 STEEL 20 0A4632B 1...

Страница 47: ...1 CLAMP VINYL 1 13 X 406 Z 18 0A6613 1 GASKET CARB IMPCO 225 19 036409 1 NUT HEX 1 4 28 STEEL 20 0A4632B 1 PLATE AIR CLEANR BOTTOM 21 0A4637 1 FILTER AIR 11 5 CA326 22 0C7820 1 MACHINING CARBURETOR A...

Страница 48: ...ITEM PART NO QTY DESCRIPTION 14 025655 1 PLUG STD PIPE 3 4 STEEL SQ HD 15 022132 2 WASHER FLAT 9 16 ZINC 16 051778 2 SCREW HHC M14 2 0 X 25 G8 8 17 028641 1 NIPPLE TOE 3 4 NPT X 2 18 057824 2 CLAMP H...

Страница 49: ...78 2 SCREW HHC M14 2 0 X 25 G8 8 17 028641 1 NIPPLE TOE 3 4 NPT X 2 18 057824 2 CLAMP HOSE 16 87 1 50 19 057422 1 HOSE 1 IN ID LP GAS 20 043123 2 WASHER LOCK M14 21 051779 2 NUT HEX M14 2 G8 YEL CHR 2...

Страница 50: ...HHC M6 1 0 X 16 G8 8 10 022097 4 WASHER LOCK M6 1 4 11 022473 4 WASHER FLAT 1 4 ZINC 12 049813 2 NUT HEX M6 X 1 00 G8 YEL CHR 13 042568 2 SCREW HHC M6 1 0 x 20MM G8 8 14 077043E 36 FLEXIBLE CONDUIT 1...

Страница 51: ...UARDIAN UNITS 7 0A4010 2 SCREW HHC M8 1 25 X 60 FT G8 8 8 052858 2 NUT LOCK FLANGE M8 1 25 9 049820 2 NUT LOCK HEX M8 1 25 NYLON INSERT 11 023152 1 SCREW HHC 3 8 16 X 3 4 G5 12 022131 1 WASHER FLAT M1...

Страница 52: ...ORQUES RECOMMENDED TERMINAL TIGHTENING TORQUES LUG TO CIRCUIT BREAKER LUG TO CIRCUIT BREAKER FASTEN COMPRESSION FASTEN COMPRESSION 52 52 40 40 40 40 ITEM ITEM NEUTRAL BLOCK NEUTRAL BLOCK CIRCUIT BREAK...

Страница 53: ...NUT HEX 1 4 20 STEEL 40 0D5574 1 CB 0200A 3P 600V S FD6 LL ITEM PART NO QTY DESCRIPTION 41 0D5595A 1 KIT CB MOUNT S FD 390S PARTS SHOWN BELOW I N S 42 50 42 0D5689 1 PLATE CB MOUNT S FD 390S 43 0D5693...

Страница 54: ...52 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Model No 004626 1 Guardian Liquid cooled 40 kW Generators Exhaust Muffler Drawing No 0D6976 A...

Страница 55: ...18 042907 16 SCREW HHC M8 1 25 X 16 G8 8 ITEM PART NO QTY DESCRIPTION 19 080762 8 BOLT U 3 8 16 X 2 62 20 022237 16 WASHER LOCK 3 8 21 022241 16 NUT HEX 3 8 16 STEEL 22 0D5187 1 SHIELD HEAT CROSSOVER...

Страница 56: ...ET EXHAUST SHIELD 11 0C4305 1 SHIELD A GRP HEAT ITEM PART NO QTY DESCRIPTION 12 0C2454 2 SCREW TH FRM M6 1 X 16 N WA Z JS 13 0C3433A 4 CLAMP BAND 2 5 14 022129 12 WASHER LOCK M8 5 16 15 022145 12 WASH...

Страница 57: ...Generac Power Systems Inc 55 Section 8 Notes Guardian Liquid cooled 40 kW Generators...

Страница 58: ...8 HOLES ON BOTTOM 1 R677 R26 66 TYP NOTE 5 NOTE 3 2397 94 37 37 1 44 794 31 28 STUB UP AREA 71 2 79 835 32 87 53 2 09 936 36 85 103 4 06 NATURAL GAS INLET 3 4 NPT FEMALE NOTE 9 454 17 87 A1 ALT AIR OU...

Страница 59: ...AY BE USED FOR CIRCUIT BREAKER STUB UP LOCATION 6 MAIN LINE CIRCUIT BREAKER 5 2 5 I D FLEX EXHAUST 3 EXHAUST MUFFLER SUPPORT BRACKETS SUPPLIED WITH OPTIONAL COMPARTMENT MODIFICATIONS REQUIRED FOR SEE...

Страница 60: ...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 wi...

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