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Generac Power Systems 004992-0, 004992-1 Скачать руководство пользователя страница 40

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators
Fuel System — Drawing No. 0E8122-F

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Содержание 004992-0, 004992-1

Страница 1: ...s Manual ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model Nos 004992 0 004992 1 37kW NG 40kW LP ...

Страница 2: ...ol points out potential explosion hazard This symbol 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 the operator read this Owner s Manual and thor oughly understand all instructions before using this equipment Generac also strongly recommends instructing ...

Страница 3: ...n Method 10 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Transfer Switch Start Signal Connections 10 2 10 Battery Installation 11 2 11 Preparation Before Start Up 12 Section 3 OPERATION 13 3 1 Using an Engineered GTS Transfer Switch 13 3 2 Control Console Components 13 3 3 Manual Transfer and Startup 14 3 4 Engine Governor Adjustm...

Страница 4: ... gener ator is installed operated and serviced in accordance with the manufacturer s instructions and recommen dations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentration...

Страница 5: ...erator is operating 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 Generators installed with an automatic transfer switch will crank and start automatically when NOR MAL UTILITY source voltage is removed or is below an a...

Страница 6: ...t excessive moisture dust dirt lint construction grit and cor rosive vapors 1 3 AUTOMATIC SYSTEM OPERATION When this generator along with a transfer switch has been installed and interconnected a circuit board in the generator panel constantly monitors UTILITY power source voltage Should that voltage drop below a preset value and remain at such a low state for a preset amount of time the generator...

Страница 7: ...SSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below about 8 10 psi 55 68 kPa the switch contacts close the engine shuts down automatically and the low oil pressure LED is turned ON Figure 1 4 NOTE The Low Oil Pressure High Coolant Temperature and Low Coolant Level are not monitored for the first 10 s...

Страница 8: ...ondition however if the engine is already running when the low battery condition occurs the engine will continue to run as long as possible Battery voltage is NOT monitored during the crank cycle 1 7 8 ALARM RESET If the engine control board shuts down the generator for any of the above reasons the engine remains stopped until the alarm is cleared by placing the AUTO OFF MANUAL switch into the OFF...

Страница 9: ... vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges 1 12 RECONFIGURING THE FUEL SYSTEM Fuel pressure for both natural gas and liquid propane set ups should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges NOTE All models are configured for natural gas from the factory To reconfigure the fuel system from NG to LP vapor follow t...

Страница 10: ... rec ommend that any soluble oil inhibitor is NOT USED for this equipment 1 16 BEFORE INSTALLATION Before installing this equipment check the ratings of both the generator and the transfer switch Read Emergency Isolation Method and Total Circuit Isolation Method in Sections 2 5 and 2 6 The generator s rated wattage amperage capacity must be adequate to handle all electrical loads that the unit wil...

Страница 11: ...ntilating air always is available Consider these factors Install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it This genset must be installed on a level surface The ...

Страница 12: ...ribution panel In accordance wtih electrical code an approved means of service disconnect must be installed between the normal incoming utiltiy service entrance and the transfer switch 2 7 GROUNDING THE GENERATOR The National Electrical Code requires the frame and external electrically conductive parts of this equip ment to be properly connected to an approved earth ground and or grounding rods Fo...

Страница 13: ...o prevent such automatic start up and possible injury to personnel do not connect battery cables until certain that normal source voltage at the transfer switch is correct and the system is ready to be placed into operation 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 ...

Страница 14: ... or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information and or service intervals please refer to Section 4 Maintenance 2 11 2 TRANSFER SWITCH If t...

Страница 15: ...the generator is installed in conjunction with an engineered GTS type transfer switch refer to the applicable transfer switch manual for exact oper ating parameters and timing sequences 3 2 CONTROL CONSOLE COMPONENTS The components of a home standby generator control console Figure 3 1 are as follows Figure 3 1 Home Standby Generator Panel 3 2 1 AUTO OFF MANUAL SWITCH Use this three position switc...

Страница 16: ...to the Standby EMER GENCY power source side and start the engine man ually refer to the Owner s Manual of the particular transfer switch 3 4 ENGINE GOVERNOR ADJUSTMENTS Engine speed governing is also controlled by the engine control board Connector J2 on the engine control board interfaces with a governor driver mod ule and the Bosch throttle body The engine governor has been set by the factory du...

Страница 17: ...approximately 12 minutes If utility should fail during this exercise period the engine control board will transfer the load to the generator output and continue to run until util ity returns On the day and at the time of day chosen for the gen erator to exercise set the weekly exercise cycle as fol lows 1 Place the AUTO OFF MANUAL switch in the AUTO position 2 Press and hold the Set Exercise switc...

Страница 18: ... extremely hot and remain 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 3 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 ...

Страница 19: ... months Replace any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 3 4 inch Adjust belt tension as required 4 5 9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor DANGER Do not attempt to adjust the gover nor Only qualified service dealers should adjust the governor Excessively high...

Страница 20: ...cumulations 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 inspected by an authorized service dealer That deal er will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the ...

Страница 21: ... 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 the fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely di...

Страница 22: ...event an over current condi tion from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to ensure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ...

Страница 23: ...l Correct as necessary 5 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiri...

Страница 24: ...nd abnormal operating conditions Correct as necessary 14 Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 Change the engine oil 16 Replace the engine oil filter s 17 Replace the engine air filter s 18 Replace the engine fuel f...

Страница 25: ...cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defective Low Coolant Level Switch 7 Replace Switch AUTO OFF MANUAL Switch at 1 Defective AUTO OFF MANUAL switch 1 Replace switch OFF engine continues to run ...

Страница 26: ...24 Generac Power Systems Inc Section 6 Electrical Data Guardian 40kW Liquid cooled Generators Wiring Diagram Engine Drawing No 0E8115 A ...

Страница 27: ...Generac Power Systems Inc 25 Section 6 Electrical Data Guardian 40kW Liquid cooled Generators Wiring Diagram Engine Drawing No 0E8115 A ...

Страница 28: ...26 Generac Power Systems Inc Section 6 Electrical Data Guardian 40kW Liquid cooled Generators Electrical Schematic Engine Drawing No 0E8116 A ...

Страница 29: ...Generac Power Systems Inc 27 Section 6 Electrical Data Guardian 40kW Liquid cooled Generators Electrical Schematic Engine Drawing No 0E8116 A ...

Страница 30: ...6 7 5 19 16 30 27 35 34 36 33 27 29 22 20 32 38 18 31 20 21 TO STARTER STARTER BOLT TO ENGINE BLOCK 18 TO 11 1 12 10 14 REAR BEARING 15 37 13 CARRIER 3 4 16 2 28 Generac Power Systems Inc Section 7 Exploded Views and Parts Guardian 40kW Liquid cooled Generators Mounting Base Drawing No 0E8084 A ...

Страница 31: ... M8 5 16 22 045771 1 NUT HEX M8 1 25 G8 YEL CHR 23 051756 1 SCREW HHC M10 1 5 X 20 G8 8 24 046526 1 WASHER LOCK M10 25 022131 1 WASHER FLAT 3 8 M10 ZINC 26 055934M 1 CLAMP VINYL 75 X 343 Z 27 049820 2 NUT HEX LOCK M8 1 25 NY INS 28 059473 1 HOLD DOWN BATTERY 29 061902 1 HOLD DOWN BATTERY 30 058665 REF BATT 12VDC 90 AH 27F 31 038804D 1 CABLE BATT RED 4 X 20 00 32 038805J 1 CABLE BATT BLK 1 X 30 00 ...

Страница 32: ...4 TO A SECURE AS SHOWN REQUIRE INSULATION TYPICAL OF ROOF PANEL THAT 4 RADIATOR 53 35 33 4 44 34 55 55 53 4 32 36 4 57 5 5 5 5 18 4 4 29 A 22 9 8 12 13 16 17 20 52 54 B 53 7 11 56 5 5 6 6 5 10 14 15 19 51 21 58 28 1 16 42 40 17 18 23 57 5 5 5 5 41 17 4 2 PLCS TO B 10 39 26 18 Section 7 Exploded Views and Parts Guardian 40kW Liquid cooled Generators Enclosure Drawing No 0E8439 E ...

Страница 33: ...NG 91 LG 26 0E7869 2 BRACKET STIFFENING BACK 27 0E8001 1 MUFFLER BOX 28 0E8060 1 ROOF W GAS SPRING MNT 3 0L FRD 29 0E7966 1 BRACE FRONT TOP 30 0D3037A 1 LATCH 1 4 TURN NONLOCKING 31 0C7781 2 PAWL DOOR HSB 32 0E7794 1 SUPPORT LH SIDE 33 0E8052 1 MUFFLER BOX TOP 34 0D3037 1 LATCH QUARTER TURN LOCKING 35 0E8007 1 POST CORNER LH FRONT 36 0E8008 1 POST CORNER RH FRONT 37 0E7992 1 BRACE FRONT BOTTOM 38 ...

Страница 34: ...32 Generac Power Systems Inc Section 7 Exploded Views and Parts Guardian 40kW Liquid cooled Generators Control Panel Drawing No 0E7118 G ...

Страница 35: ... QN CIRCUIT BREAKER 33 0E7539A 1 DECAL TB1 HSB CONTROL PANEL ITEM PART NO QTY DESCRIPTION 34 0D4698 REF BLOCK TERM 20A 6 X 3 X 1100V 35 0E7252 1 BRACKET CB 221 5 X 102 36 0C1229 1 DECAL WARNING ELECTRICAL SHOCK 37 0C1127 1 DECAL AVR COVER 38 0A1441B 1 COVER PLATE AVR 39 0E7128 1 HARNESS CNTRL PNL 3 0L FORD NOT SHOWN 40 0E7358 8 SCREW PPPH HI LO 4 24 X 3 8 41 074908 6 SCREW HHTT M5 0 8 X 10 BP 42 0...

Страница 36: ...Section 7 Exploded Views and Parts Guardian 40kW Liquid cooled Generators Engine Drawing No 0E8121 D 34 Generac Power Systems Inc ...

Страница 37: ...RE 10PSI 2POL ITEM PART NO QTY DESCRIPTION 39 050873A 1 PLUG PIPE 1 4 CSK W VIBRA SL 40 031919 1 PLUG STD PIPE 3 8 COUNTER SUNK 41 022145 6 WASHER FLAT 5 16 M8 ZINC 42 030795 6 SCREW HHC 5 16 18 X 1 G5 43 051756 5 SCREW HHC M10 1 5 X 20 G8 8 44 046526 6 WASHER LOCK M10 45 0A1232A 1 ASSEMBLY D C ALTERNATOR 46 0A7801B 1 PULLEY POLY V 82 OD 47 045772 1 NUT HEX M10 1 5 G8 YEL CHR 48 022403 2 SCREW HHC...

Страница 38: ...5 21 3 A 13 1 15 19 22 TO THERMOSTAT HOUSING 10 4 10 20 0 5 16 16 2 14 8 15 7 14 18 6 9 17 14 O A Section 7 Exploded Views and Parts Guardian 40kW Liquid cooled Generators Radiator Drawing No 0E8102 E 36 Generac Power Systems Inc ...

Страница 39: ...4 058443 17 SCREW CRIMPTITE 1 4 20 X 5 8 15 0C2454 5 SCREW TH FRM M6 1X16 N WA Z JS 16 052250 2 TAPE FOAM 1 X 1 27 LG 17 048031C 1 CLAMP HOSE BAND 1 4 18 029032 1 HOSE 9 32 ID 30 LG 19 0A2111 1 SCREW SWAGE 10 32 X 5 16 Z YC 20 0E7640A 1 RADIATOR SUPPORT R H SIDE 21 035461 1 BARBED STR 1 4NPT X 3 8 22 065852 1 SPRING CLIP HOLDER 37 62 23 051756 4 SCREW HHC M10 1 5 X 20 G8 8 24 022131 8 WASHER FLAT ...

Страница 40: ...E 2 16 17 4 5 6 45 42 40 11 41 9 8 12 6 3 15 2 13 27 31 14 19 29 30 32 B TO B 13 36 37 38 20 19 18 35 34 MANIFOLD INTAKE TO 44 43 25 22 6 1 39 33 Section 7 Exploded Views and Parts Guardian 40kW Liquid cooled Generators Fuel System Drawing No 0E8122 F ...

Страница 41: ...R 21 040105 1 HOSE COOL 2IN ID 20R4 2 LG 22 0E6382B 1 VENTURI HOLDER W 40MM ACTUATOR 23 0F2119 2 O RING 45 63 ID X 2 62 WIDTH 24 0E6376B 1 VENTURI 28 ID THROTTLE W CHOK 25 042561 2 CLAMP HOSE 36 1 88 2 75 26 057822 1 CLAMP HOSE 8 53 1 00 27 0E7929 1 BASE AIR CLEANER PLATE 28 0A4637 1 FILTER AIR 11 5 CA326 29 0E6406 1 HOLDER VENTURI 30 0E7702 1 HOLD DOWN AIR CLEANER 31 0A4632A 1 PLATE AIR CLEANER T...

Страница 42: ...enerac Power Systems Inc 4 15 7 17 8 7 1 18 20 31 30 5 21 19 LEADS 6 2 14 12 24 9 22 23 13 3 10 13 11 Section 7 Exploded Views and Parts Guardian 40kW Liquid cooled Generators Alternator Drawing No 0E5146 B ...

Страница 43: ... M14 2 0 X 540 G5 ZINC 3 9L CHRYSLER 10 043123 4 WASHER LOCK M14 11 051779 4 NUT HEX M14 2 0 G8 YEL CHR 12 0E7587 1 ASSY BRUSH HOLDER 390 HSB 13 023365 5 WASHER SHAKEPROOF INT 8 14 092980 4 SCREW PPHM M4 0 7 X 25 15 052625 4 SCREW SHC M10 1 5 X 35 G12 9 16 0A2602 1 WASHER FLAT 688 ID X 3 25 OD 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0A2601 1 SCREW HHC M16 2 0 X 45 G8 8 19 0E7226 1 GUARD STATOR 390 20 ...

Страница 44: ...2860 4 NUT TOP LOCK FL M12 1 75 15 052891 4 SCREW HHC M12 1 75 X 80 G8 8 16 0E8816 2 EXHAUST FLANGE 2 PIPE 17 051769 4 WASHER LOCK M12 18 0E0170 1 EXHAUST BLANKET 705MM 19 049808 8 WASHER FLAT M12 20 024114 6 NUT HEX 5 16 24 STEEL 21 080762 2 BOLT U 3 8 16 X 2 62 22 0E8726 2 STRAP MUFFLER 23 039288 1 SCREW HHC M8 1 25 X 55 G8 8 24 0F0170A 1 EXHAUST BLANKET 875MM 25 082361 REF INSULATION EXAUST 3 3...

Страница 45: ...Generac Power Systems Inc 43 Section 8 Installation Diagram Guardian 40kW Liquid cooled Generators Installation Diagram Drawing No 0E8422 A OVERHEAD VIEW ...

Страница 46: ...44 Generac Power Systems Inc Section 9 Notes Guardian 40kW Liquid cooled Generators ...

Страница 47: ...Generac Power Systems Inc 45 Section 9 Notes Guardian 40kW Liquid cooled Generators ...

Страница 48: ...ue to the improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised 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 periodi...

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