Instruction/ maintenance manual of the product 0043736, 0046265 Generac
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POWER SYSTEMS, INC. ® ® Owner’ s Man ual Liquid-cooled, Prepac kaged Standb y Generator s Models: 0043736 (40 kW/Single-phase w/ 200 Amp T ransfer Switch) 0046265 (40 kW/Single-phase w/ 200 Amp T ransfer Switch Calif ornia Emissions) ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!! DEADL Y EXHAUST FUMES.
Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing the Guardian product line by Generac P ower Systems. This model is a compact, high performance, liquid- cooled, engine - driven gen- erator designed to automatically supply electrical power to operate critical loads during a utility power failure.
T able of Contents Guardian Liquid-cooled 40 kW Generator Generac ® Pow er Systems, Inc. 1 Introduction ........................Inside Front Cover Read This Manual Thoroughly ............................IFC Contents ..................................
2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The gen- erator can operate safely , efficiently and reliably only if it is properly installed, operated and maintained.
Generac ® Pow er Systems, Inc. 3 • 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.
4 Generac ® Pow er Systems, Inc. 1.1 U N P ACKING/I NSP ECTION After unpacking, carefully inspect the contents for dam- age. • This standby generator set has been factory installed in an all-weather , metal enclosure that is intended exclusively for outdoor installation.
1.6 MAI N CI RCU IT B R EAKER 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: 1.
6 Generac ® Pow er Systems, Inc. 1.8.2 GEN ERA T OR AN D L O AD COMP A T IBILI TY 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- trical devices, or both, can be damaged if voltage, num- ber of phases and frequency are not compatible.
1.1 0 ENGI N E OI L REC OMM EN D A TIONS The unit has been filled with 15W -40 engine oil at the factory . Use a high- quality detergent oil classified “F or Service CC, SD , SE or SF .” Detergent oils keep the engine cleaner and reduce carbon deposits.
8 Generac ® Pow er Systems, Inc. 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.
Generac ® Pow er Systems, Inc. 9 Figure 2.1 – Basic Standby Electric System 2.2 EM ERGENCY CI RCU IT IS OL A TION M E THOD This method prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator .
10 Generac ® Pow er Systems, Inc. 2.7 B A TTER Y I NS T ALLA TION 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 pr eset level.
2.8 P R EP AR A TION B EFOR E S T ART -U P The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor .
12 Generac ® Pow er Systems, Inc. 3.1 C ONTROL CONS OLE C OMPON ENTS The components of a liquid- cooled generator control console (Figure 3.1) are as follows: Figure 3.1 – Control Console 3.1.1 AC V OL TM ETER The voltmeter displays generator AC output voltage dur- ing operation.
3.2.2 “OF F” POSITION This switch position shuts down the engine. This posi- tion also prevents operation. 3.2.3 “MAN U AL ” POSITION Set the switch to MANU AL to crank and start the engine. Transfer to standby power will not automatically occur unless there is a utility failure.
Figure 3.2 – Engine Block Heater Refer to applicable wiring diagram(s) and electrical schematic(s) at the back of this manual for wiring con- nections. 3.6 WEEKL Y EXERCISE CY CLE The generator will start and exercise once every seven days. During this weekly exercise, the unit runs for approximately 20 minutes and shuts down.
4.2 CHANGI NG TH E ENGI N E OI L AN D FIL T E R 4.2.1 ENGI NE OI L R EC OMM EN D A TIONS Use oil of API Service Class SG, SH or SJ . The recommended oil grade for the engine is SAE 15W -40. NOTE: The unit is supplied with “break-in ” oil. See the “Service Schedule,” Section 4.
16 Generac ® Pow er Systems, Inc. 4 . 4 S P A RK PL UG S Reset the spark plug gap or replace the spark plugs as necessary . See Section 4.12. 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.
Generac ® Pow er Systems, Inc. 17 4.7 O VER L O AD P RO TECTION FOR ENGI N E DC ELE CTR ICAL SY S TEM 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.
18 Generac ® Pow er Systems, Inc. 4.1 1 OUT OF SERVICE P ROCEDU R E 4.1 1.1 R EMO V AL F ROM 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: 1.
Generac ® Pow er Systems, Inc. 19 Section 4 — Maintenance Guardian Liquid-cooled 40 kW Generator 4.1 2 SERVICE S CH EDU LE A TTENTION: It is recommended that all service work be performed by the nearest Generac/Guar dian Authorized Dealer .
20 Generac ® Pow er Systems, Inc. Section 5 — T roubleshooting Guardian Liquid-cooled 40 kW Generator 5.1 TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R E CTION The engine will not crank. 1. F use blown 1. Replace fuse. 2. Loose, corroded or defective 2.
Generac ® Pow er Systems, Inc. 21 Section 6 — Installation Diagram Guardian Liquid-cooled 40 kW Generator Drawing No. 0E7 0 1 5.
S 1 6 S 1 5 0 0 0 2 1 9 150 2 2 9 14 13 79 14 15 15 15 68 4 56 85 69 86 T S1 HZ - FRE Q UENCY METE R HZ TB1 - TERMINAL BL OC K S LE G EN D GCB GC B - GO VERN O R CO NTR O L B O AR D BL UE BL UE RED BLA CK P / N 986 4 7 22 Generac ® Pow er Systems, Inc.
Generac ® Pow er Systems, Inc. 23 AC TUAT O R B R O WN O RAN G E Y ELL O W B LA C K N . C . TO GO VERN O R HM C P EH T S1 , TS2 - TERMINAL STRIPS L P C - L O WER PANEL CO NNE C TI O N TS 2 R 1 - RESI.
A AM VM L1 15 12 3 5 6 2 4 1 B A 17 1 13 2 16 5 7 D 14 11 9 C AP E 3 4 TO L O WER PANEL ( CO NNE C T O R C P) U J B T S W V H X O G A N Q M E K F C D 4 5 10 12 3 TO EN G INE ( CO NNE C T O R EH) 6 11 .
Generac ® Pow er Systems, Inc. 25 S 1 5 N 00 P 1 7 8 K M S 1 23 N2 N1 T1 S R T2 X 19 4 G F B E 6 S 1 6 2 1 5 7 58 S3 N1 N2 T2 23 19 4 CUS T O MER CO NNE C TI O N CUS T O MER CO NNE C TI O N 1 2 0/ 24 0 V. 1-PHA S E E 1 T O E 3 24 0 V. E3 T O 00 E 1 T O 00 1 2 0 V.
N . C . EH HM C P 85 56 B LA C K AVR 14 13 14 85 56 85 0 4 6 5 N2 N1 14 13 1 4 14 13 85 0 85 56 RED P F C 14 85 85 6 4 4 B LA C K TR1 B L U E B LA C K B L U E RED B L U E 239 T2 T1 2 25 A 0 1 5 C T2 T.
Generac ® Pow er Systems, Inc. 27 B J X W S T V U A O N M Q F K G H E C D 5 4 3 6 C AP L1 8 9 1 2 10 11 12 7 P SW - SWITCH , PHASE SELECTOR S W2 - SWITCH , SET EXERCISE S W1 - SWITCH , AUTO/OFF/MANUA.
( - ) ( + ) (+) 1 2 3 1 2 E C1 OS * * F S WHITE EH G REE N BLA CK LE G END : O NLY US ED O N EMI SS I O N S M O DEL S 12 1 3 11 1 0 8 9 5 7 6 2 4 3 1 BAT 1 3 ALT 1 3 BLA CK G N D 0 1 3 * SM 1 6 RED RE.
Generac ® Pow er Systems, Inc. 29 T C AL T ID ( + ) ( - ) 14 A CT * 0 12V BATTER Y 0 H CT 85 WL S 0 1 60 1 61 CC MP1 85 * L OS F S 1 61 1 60 56 7 9/C LEA R 0/ BAR E 0/ BLA CK 0 85 0 85 0 14 7 9 1 3 1.
30 Generac ® Pow er Systems, Inc. Section 8 — Exploded Views and P arts Lists Guardian Liquid-cooled 40 kW Generators Mounting Base - Drawing No. 0E69 7 6 2 6 24 37 38 36 35 2 5 30 31 3 2 5 12 34 1 6 1 3 17 33 32 5 39 9 BLA CK RED 38 2 9 5 1 9 16 1 17 1 3 12 11 1 0 SO LEN O I D T O S TARTE R 7 2 2 8 27 To O il Drai n O n O il Pan .
Generac ® Pow er Systems, Inc. 31 ITEM P ART NO . QTY . DESCRIPTION 1 0E6900 1 MTG BASE 4.3L D/D PRE-P ACK 2 038804T 1 CABLE BA TT RED #1 X 31.00 3 055414 1 LUG SLDLSS #2-#8 X 17/64 CU 4 0A4084 2 MOUNT ENGINE (R&L) 5 022129 2 W ASHER LOCK M8-5/16 6 045771 2 NUT HEX M8-1.
32 Generac ® Pow er Systems, Inc. 22 FRAME BA SE 3 2 9 11 3 36 2 5 30 31 1 4 24 29 2 3 2 6 1 8 5 1 5 39 34 33 32 12 12 11 9 2 8 18 19 6 1 0 5 17 2 9 5 11 1 3 11 1 0 21 42 1 6 7 Section 8 — Exploded Views and P arts Lists Guardian Liquid-cooled 40 kW Generators Compartment - Drawing No.
Generac ® Pow er Systems, Inc. 33 ITEM P ART NO . QTY . DESCRIPTION 1 0C3594 10 ASSEMBL Y M6 HINGE 3 0A3359 40 SCREW BHSC M6-1.0 X 16 SS 4 0A3360 40 SHAKEPROOF INT M6 SS 5 0C2522 (A) 5 DOOR SMALL STD .
34 Generac ® Pow er Systems, Inc. 53 1 2 14 VIEW A - A 17 18 16 2 0 19 5 1 5 2 39 3 18 15 13 5 2 53 59 35 5 6 5 4 55 56 5 7 4 1 18 49 50 21 6 4 36 26 3 7 60 A A 9 5 1 5 2 53 60 23 43 29 42 6 1 6 1 24 28 25 41 27 50 49 45 46 3 I N S IDE. 3 0 1 P ANEL FA C E 58 63 58 18 49 50 6 2 22 + + - E VERY 7 DAYS , AT TIME SET.
Generac ® Pow er Systems, Inc. 35 ITEM P ART NO . QTY . DESCRIPTION 1 0D5488 1 P ANEL BTM & BACK CONTR OL P ANEL 2 0D1521A 1 CONTR OL P ANEL, FRONT W/ SILK SCREEN 3 0D1522 2 P ANEL,SIDE CO VER CO.
36 Generac ® Pow er Systems, Inc. Section 8 — Exploded Views and P arts Lists (Model No. 0046262, 00462 63 & 0046264) Guardian Liquid-cooled 40 kW Generator Control Panel – Drawing No.
Generac ® Pow er Systems, Inc. 37 ITEM P ART NO . QTY . DESCRIPTION 1 0D7397 1 PNL BTM & BA CK CNTL PNL 04626 2 0D1521A 1 CONTROL P ANEL FRONT W/ SILK SCREEN 3 0D1522 1 P ANEL SIDE CO VER CONTROL.
38 Generac ® Pow er Systems, Inc. Section 8 — Exploded Views and P arts Lists Guardian Liquid-cooled 40 kW Generators Connection Box – Drawing No.
Generac ® Pow er Systems, Inc. 39 Section 8 — Exploded Views and P arts Lists Guardian Liquid-cooled 40 kW Generators Connection Box – Drawing No. 0E6892-A ITEM P ART NO . QTY . DESCRIPTION 1 0E6353 1 LO WER P ANEL 15 2 0D5489 1 CO VER LO WER CONNECTION BO X 3 0E6427 1 PLA TE GLAND 4 023484N 2 BUSHING SNAP SB-2.
40 Generac ® Pow er Systems, Inc. 1 5 21 SC R O LL DETAI L T HREAD IN SENSOR ( 6 ) UNTIL CONTACT I S MADE WITH RING GEAR , THEN BACK OFF 1/ 2 T O 3/ 4 T U RN AND TI G HTEN N U T.
Generac ® Pow er Systems, Inc. 41 Section 8 — Exploded Views and P arts Lists Guardian Liquid-cooled 40 kW Generators Generator – Drawing No. 0E689 1 ITEM P ART NO . QTY . DESCRIPTION 1 051768 7 SCREW HHC M12-1.75 X 25 G8.8 2 051769 7 W ASHER LOCK M12 3 0A8240 2 FLEX PLA TE SAE10 4 039253 6 SCREW HHC M8-1.
42 Generac ® Pow er Systems, Inc. Section 8 — Exploded Views and P arts Lists Guardian Liquid-cooled 40 kW Generators Engine – Drawing No. 0D6980-B.
Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 1 0A9046 1 ENGINE 4.3L GM 2 0A9118A 1 FL YWHL 4.3L GM SAE 3 070022 1 W ASHER ST AR M12 EXT 4 0A6021 6 SCREW HHC 7/16-20 X 1 G8 6 059056A 1 ST ARTER 5.7L/7.4L GM 8 0A9050 2 BOL T ST ARTER 4.
44 Generac ® Pow er Systems, Inc. 12 40 24 6 31 32 37 34 4 20 2 3 4 5 4 3 40 22 7 8 36 1 3 5 1 0 11 33 1 9 31 4 35 3 34 14 30 2 8 44 27 9 1 21 4 3 2 5 46 4 0 41 2 6 17 1 6 38 1 5 47 2 Section 8 — Exploded Views and P arts Lists Guardian Liquid-cooled 40 kW Generators Engine – Drawing No.
Generac ® Pow er Systems, Inc. 45 ITEM P ART NO . QTY . DESCRIPTION 1 0A9046 1 ENGINE 4.3L GM 2 0A4084 2 MOUNT , ENGINE (R & L) 3 0A4239 1 PULLEY CRANKSHAFT 4 0A4240 1 PULLEY W A TER PUMP 5 0A5640 1 SP ACER F AN 50MM 4.
17 K IT PART N O . 0 D7 9 47 20 18 19 K IT PART N O . 0 D7 9 4 8 30 3 1 3 3 35 3 4 3 2 3 7 9 10 11 14 16 39 38 36 27 40 29 1 10 16 27 " A" 22 15 3 7 24 22 23 TO "A" K IT PART N O . 0 D 8 121 10 21 17 46 Generac ® Pow er Systems, Inc.
Generac ® Pow er Systems, Inc. 47 ITEM P ART NO . QTY . DESCRIPTION 1 0D7825 1 RADIA T OR COPPER BRASS 2 0D8251 1 F AN GU ARD BO TT OM 3 0D8252 1 F AN GU ARD T OP 4 024655 4 SCREW HHTT 1/4-20 X 1 CZ 5 022097 4 W ASHER LOCK M6-1/4 6 022473 4 W ASHER FLA T 1/4 ZINC 7 0D7174 1 VENTURI 4.
ITEM P ART NO . QTY . DESCRIPTION 1 059902A 1 CAP RAIN 2.50 / 2.69 2 0C9641 1 TUBE STRAIGHT 'A' GROUP 3 0C9650 1 MUFFLER 2-1/2" INLET/OUTLET 4 0C4114A 2 CLAMP BAND MUFFLER 6.5" 5 0C4126 2 BRA CKET MUFFLER MOUNTING 6 0D5787 1 TUBE ELBO W 90 DEG 2.
Generac ® Pow er Systems, Inc. 49 ITEM P ART NO . QTY . DESCRIPTION 1 037561 1 NUT WING 1/4-20 NYLK 2 0A4632A 1 PLA TE AIR CLEANER T OP 3 0A4637 1 FIL TER AIR 11.
Section 8 — Exploded Views and P arts Lists (Model No. 0043 7 33, 0043 73 4 & 0043 7 35) Guardian Liquid-cooled 40 kW Generators 4.3L Nat. Gas Fuel Syst em – Drawing No.
Generac ® Pow er Systems, Inc. 51 ITEM P ART NO . QTY . DESCRIPTION 1 065907 1 SUPPOR T SOLENOID NA T GAS 2 026812 3 ELBO W 90D 3/4 NPT 3 028238 2 BOL T U 5/16-18 X 1.
52 Generac ® Pow er Systems, Inc. 24 36 M ANIF O LD TO INTAKE 38 22 39 43 33 12 30 3 1 4 41 3 4 40 35 29 28 3 7 CO VER TO VALVE A TTA C H T O F AN SC R O LL ASS EMBLY P/ N 0 D 3509 21 33 12 2 44 25 17 20 2 24 1 4 5 18 10 6 12 11 3 7 19 2 8 9 6 5 17 18 12 11 27 15 16 14 23 13 Section 8 — Exploded Views and P arts Lists (Model No.
Generac ® Pow er Systems, Inc. 53 ITEM P ART NO . QTY . DESCRIPTION 1 065907 1 SUPPOR T SOLENOID NA T GAS 2 026812 3 ELBO W 90D 3/4NPT 3 022259 4 NUT HEX 5/16-18 STEEL 4 0C7598 1 ASSY NA TURAL GAS SO.
54 Generac ® Pow er Systems, Inc. Section 8 — Exploded Views and P arts Lists (Model No. 0046262, 00462 63 & 0046264) Guardian Liquid-cooled 40 kW Generators Exhaust – Drawing No.
Generac ® Pow er Systems, Inc. 55 ITEM P ART NO . QTY . DESCRIPTION 1 059902A 1 CAP RAIN 2.50 / 2.69 2 0C9641 1 TUBE STRAIGHT 'A' GROUP 3 0D4208 1 MUFFLER CA T AL YST 4.3L 4 0D5061 4 MOUNTING BAND A-GRP CA T AL YST 5 0C4126 2 BRA CKET MUFFLER MOUNTING 6 0D5787 1 TUBE ELBO W 90 DEG 2.
56 Generac ® Pow er Systems, Inc. Section 8 — Exploded Views and P arts Lists (Model No. 0043 7 33, 0043 73 4 & 0043 7 35) Guardian Liquid-cooled 40 kW Generators Electronic Governor – Drawing No.
Generac ® Pow er Systems, Inc. 57 ITEM P ART NO . QTY . DESCRIPTION 1 0C4905 1 BARBED EL 45 FITTING 2 057822 2 CLAMP HOSE #8 .53-1.00 3 077043E 1 CONDUIT FLEX 1" BLA CK (15"LG) 4 050967 1 HOSE 5/8 ID RIA 250F (46"LG) 5 0A6283 1 HOSE PREFORMED BLOCK HEA TER 6 057822 2 CLAMP HOSE #8 .
58 Generac ® Pow er Systems, Inc. Section 9 – Notes Guardian Liquid-cooled 40 kW Generators.
Generac ® Pow er Systems, Inc. 59 Section 9 – Notes Guardian Liquid-cooled 40 kW Generators.
60 Generac ® Pow er Systems, Inc. Section 1 0 – W arranty Guardian Liquid-cooled 40 kW Generators CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y S T A TEM ENT Y OU R W ARR ANT Y RIGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc.
Generac ® Pow er Systems, Inc. 61 Section 1 0 – W arranty Guardian Liquid-cooled 40 kW Generators EM IS SION CONTROL S Y STEM W AR R ANTY Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines.
Part No. 0E7018 Revision A (10/08/03) Printed in U.S.A. Section 1 0 – W arranty Guardian Liquid-cooled 40 kW Generators GEN ERAC PO WER SY S TEMS S T AN D ARD "T WO YEAR" LIM ITED W ARR AN.
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However, one of the most important roles played by the user manual is to help in solving problems with Generac 0043736, 0046265. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Generac 0043736, 0046265 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
