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Guardian Technologies 004992-2 Portable Generator User Manual

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4. MP B opp ao P BRB Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Enclosure Drawing No 0F4931 C DESCRIPTION INTAKE DUCT HSB DUCT DISCHARGE RH FRONT DUCT DISCHARGE LH FRONT SCREW TH FRM M6 1 X 16 N WA Z JS BAFFLE REAR BOTTOM POST CORNER LH REAR POST CORNER RH REAR BAFFLE REAR TOP DOOR COMPARTMENT SIDE SUPPORT R H SIDE FOAM STRIP 3 4 WIDE X 3 16 THK 40 LG WASHER NYLON 257 BRACKET STIFFENER LH FRONT HINGE LIFT OFF TYPE B KNUCKLE HINGE LIFT OFF TYPE B PIN WASHER SELF LOCKING DOME WASHER LOCK 6 1 4 WASHER FLAT 1 4 M6 ZINC GAS SPRING BALL STUD GAS SPRING MOUNT NUT HEX 5 16 18 LOCK SCREW WING M6 1 00 X 25 HINGE LIFT OFF TYPE A KNUCKLE HINGE LIFT OFF TYPE A PIN TRIM VINYL SELF GRIPPING 91 LG BRACKET STIFFENING BACK MUFFLER BOX ROOF W SHOCK MOUNT BRACE FRONT TOP LATCH 1 4 TURN NONLOCKING PAWL DOOR HSB SUPPORT LH SIDE MUFFLER BOX TOP LATCH QUARTER TURN LOCKING POST CORNER LH FRONT POST CORNER RH FRONT BRACE FRONT BOTTOM DUCT DISCHARGE MID FRONT WASHER SHAKEPROOF EXT 1 4 STL ASSY WIRE 14AWG 7 5 0 GRN YEL ASSY WIRE 14AWG 7 5 0 GRN YEL NUT HEX M6 X 1 0 G8 YEL CHR BRACKET STIFFENER LH FRONT TRIM VINYL SELF GRIPPING 165 5 LG Al ROOF PANEL 2 Al SUPPORT RH PANEL Al SUPPORT LH PANEL Al CORNER POST PANEL 2 Al CORNER POST PANEL 1 KIT INSULATION 3 9L HSB Al ROOF PANEL 1 Al DOOR PANEL SCREW
5. 6 1 0 X 12 08 8 ALL ITEMS NOTATED WITH Al ARE COMPONENTS OF 0 8442 LISTS 31 ih Section 7 Exploded Views and Parts 40kW Liquid cooled Generators 0 Control Panel Drawing No 0 7118 1 RECTIFIER ASSEMBLY MICA SCALE NONE Wm Q 24496497 A WARNING JAVR BEHIND cover ITEM S oc olx cx 2X cil CO
6. C 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 PART NO QTY 0E7195 0E7196 0E7197 0E7193 0E7194 0E4494 082573 032300 022676 067682B 060015 054199 0 2657 099076 040213 0 9668 067680 0 6875 0E6881 005139 005142 0 3161 054450 005070 0 2514 0 9457 0 7539 046357 003719 057073 0 7283 0 3628 0 3664 0 7539 004698 0 7252 001229 La cla la la Sp cla ca cla la la ca REF REF REF DESCRIPTION CONTROL BOX HSB COVER FRONT PANEL HSB COVER TOP PANEL HSB DECAL WARNINGS HSB DECAL CONTROLS HSB SWITCH ROC DPDT ON OFF ON SWITCH ROCKER DPST 125V SPD HOLDER FUSE FUSE 15A X AGC15 FUSE 4A SLO BLO GLASS FITTING CONDUIT 90D 3 8 DECAL DANGER HIGH VOLTAGE TRANSFRMR 16V 6VA TRANSFORMER 16V 56VA PCB SUPPORT SNAP IN 1 4 ASSY PCB HSB CONTROLLER ASSY VOLTAGE REGULATOR 60HZ RELAY 12VDC C FORM W DIODE SOCKET RELAY CONN DEUTSCH RECEPT GY FLN CONN DEUTSCH RECEPT WDGE BLKHD ASSY BOSCH GOV DRIVER CIRCT BRK 5 5 X 1 ETA 46 500 P ASSY 2A 12V UL BATTERY CHARGER FITTING CONDUIT STR 1 1 2 DECAL NEUTRAL DECALCUSTOMER CNNCTN XFER SW BLOCK TERM 20A 6 X 6 X 1100V DECAL CUSTOMER CNNCTN JUNCTION BLOCK 3 8 16 CB 0150A2P240V S QN2 LL CB 0200A2P240V S QN2 LL BASE QN CIRCUIT BREAKER DECAL TB1 HSB CONTROL PANEL BLOCK TERM 20A 6 X 3 X 1100V BRACKET CB 221 5 X 102 DECAL WARNING ELECTRICAL SHOCK Section 7 Exploded Views an
7. DESCRIPTION RADIATOR COPPER BRASS VENTURI 3 9L CRYSLR HSB 22 FAN RADIATOR SUPPORT L H SIDE HOSE LOWER RADIATOR HOSE RADIATOR UPPER 3 9L FAN GUARD TOP FAN GUARD BOTTOM BRACKET WATER BOTTLE 1 5L MIT TANK COOLANT RECOVERY CLAMP HOSE 28 1 32 2 25 HOSE OIL DRAIN ASSY 21 SCREW CRIMPTITE 1 4 20 X 5 8 SCREW TH FRM M6 1X16 N WA Z JS TAPE FOAM 1 X 1 2740 CLAMP HOSE BAND 1 4 HOSE 9 32 ID 30 LG SCREW SWAGE 10 32 X 5 16 2 RADIATOR SUPPORT R H SIDE BARBED STR 1 4 X 3 8 SPRING CLIP HOLDER 37 62 SCREW HHC 10 1 5 X 20 G8 8 WASHER FLAT 3 8 M10 ZINC WASHER LOCK M10 NUT HEX M10 1 5 G8 YEL CHR LISTS 37 PARTS 40kW Liquid cooled Generators 0 Fuel System Drawing No 0 8122 MANIFOLD T ITEM PS COON O QO O1 CO PS O1 CO cO 033212 075580 0E8365 039253 022145 022129 045771 042907 002454 026307 0E1056 0 6584 057822 059194 064945 001509 050279 0 7839 0 6586 0 4394 040105 0 6382 0 2119 0E6376B 042561 0E7929 0A4637 0E6406 0E7702 0A4632A 037561 046580 0E8286 044118 049815 049226 051713 02
8. GUARDIAN by Generac Power Systems Inc Owner s Manual Liquid cooled Prepackaged Standby Generators Model Nos 004992 2 37kW NG 40kW LP MM MM AARAA 144411 2 27 This manual should remain with the unit caution ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION 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 writ ten However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest authorized service dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert per sonnel to special instructions about a particular serv ice or operation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows A Dd A After this heading read instructions that if not strictly complied with will result in severe person al inju
9. Pusher Type Cooling System Capacity 5 0 U S gallons 19 3 liters Recommended Coolant Use a 50 50 mixture of ethylene glycol base and de ionized water 1 11 FUEL CONSUMPTION Natural Gas of Load 25 50 75 100 me hr 41 7 7 11 0 142 ft hr 143 1 271 1 388 5 502 0 LP Vapor of Load 25 50 75 100 me hr 17 3 3 47 6 0 ft hr 60 7 115 0 164 9 213 0 NOTE Fuel consumption is given at rated maximum con tinuous power output when using natural gas rated at 1000 Btu per cubic foot LP gas is rated at 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient temperature engine condi tions and other environmental factors Section 1 General Information GENERAL 40kW Liquid cooled Generators INFORMATION 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 Fuel pressure for an LP 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 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
10. ANAAAN m nmm a ee 1000 01700 sje lle J He LLL tt 1 W 3 225 1 1 3 ne e _I ei I DIP SWITCH e POSITION 1 POSITION 2 ef UNUSED 5060 2 GTS ATS Select GIS GTS ATS OFF ATS standard mode m soconz OFF 6092 STABILITY J eyes 3 5 RETRANSFER AND SHUTDOWN When utility power source voltage has been restored electrical loads may be transferred back to that source and the generator can be shut down as fol lows Verify that utility power supply voltage to the trans fer switch has been positively turned Off using whatever means provided such as utility main line circuit breaker Set the generator s main circuit breaker to its OFF or OPEN position Let the generator engine run at no load for a few minutes to stabilize internal unit temperatures On the generator console set the AUTO OFF MANUAL switch to OFF Wait for engine to come to a complete stop For transfer to utility position refer to the Owner s Manual of the particular transfer switch Turn on the utility power supply to the transfer switch usi
11. Check engine crankcase oil level Figure 4 1 month ly or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Section 1 14 for recom mended oils Figure 4 1 Oil Dipstick and Oil Fill Cap Oil Dipstick Oil Fil 4 4 2 BATTERY FLUID Check battery electrolyte fluid at least once weekly Fluid should cover separators in all battery cells If fluid level is low add distilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY 4 4 5 ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications Section 1 10 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 45 MAINTENANCE OWNER OPERATOR CAN PERFORM 4 5 1 CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels in Section 4 4 4 5 2 CHECK BATTERY Check batt
12. See Torque Specs Section 1 13 EVERY 500 OPERATING HOURS Service air cleaner Check starter 3 Check engine DC alternator 42 COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Section 4 Maintenance 40kW Liquid cooled Generators DIRNE jS vN jA Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See Section 6 for installation drawings and vent locations warninc amp The exhaust system parts from this product get amp 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 16 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 amp fuse These overcurrent protection devices will open if the circuit is overloaded caution amp If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse 4 4 CHECKING FLUID LEVELS 441 CHECK ENGINE OIL
13. Adjust belt tension as required 4 5 9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor A DIG A A DANGER Do not attempt to adjust the gover nor Only qualified service dealers should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incorrect frequency and or volt age Only qualified service technicians should adjust the governed speed 4 5 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized service dealers for engine oil and filter change frequencies Drain the oil while the engine is still warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 2 Loosen and remove DRAIN HOSE CAP Drain oil completely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and re install into its retaining clip 4 Turn OIL FILTER Figure 4 2 counterclockwise and remove Dispose of old filter 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVERTIGHTEN 6 Remove OIL FILL CAP Ad
14. QTY 1 0E7331 1 2 052860 4 3 052251 4 4 052257 4 5 052252 4 6 052259 4 7 052891 4 8 0536210214 1 9 074906 1 10 047411 1 11 055414 1 12 026850 2 13 022097 1 14 022473 1 15 049813 1 16 0A1694 4 18 025507 3 19 0E7359 2 20 027482 2 21 022129 1 22 045771 1 23 051756 1 24 046526 1 25 022131 1 26 055934 1 27 049820 2 28 059473 1 29 061902 1 30 058665 REF 31 038804D 1 32 038805J 1 33 021991 1 34 036833 6 35 022237 6 36 022131 6 37 075763 1 38 050331 1 39 050331A 1 40 0A4010 2 41 052858 2 42 065852 1 43 045764 1 NOT SHOWN USED TO HOLD DOWN I N 32 Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Mounting Base Drawing No 0E8084 B DESCRIPTION WELDMENT MTG BASE 3 9L CRYSLR NUT FLANGED HEX M12 1 75 DAMPENER VIBRATION 40 BLUE SPACER 49 X 62 X 1 87 PWDR ZNC DAMPENER VIBRATION WASHER FLAT M12 SCREW HHC M12 1 75 X 80 G8 8 ASSY WIRE 15 0 SCREW HHTT 6 1 0 X 20 BP SCREW HHC M6 1 0 X 16 BP LUG SLDLSS 2 8 X 17 64 CU WASHER SHAKEPROOF EXT 1 4 STL WASHER LOCK 6 1 4 WASHER FLAT M6 1 4 ZINC NUT HEX M6 1 0 G8 YEL CHR 1 1 2 BUTTON PLUG WASHER SHAKEPROOF EXT 7 16 STL ENGINE MOUNT 3 9L CHRYSLER WASHER SHAKEPROOF EXT 5 16 STL WASHER LOCK 8 5 16 NUT HEX 8 1 25 G8 YEL CHR SCREW M10 1 5 X 20 G8 8 WASHER LOCK M10 WASHER FLAT 3 8 M10 ZINC CLAMP VINYL 75 X 343 Z NUT HEX LOCK 8 1 25 NY INS HOLD DOWN BATTERY HOLD DOWN BATTERY BATT 12VDC 90 AH 27F NOT IN
15. perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the control panel AUTO OFF MANUAL switch to the OFF position Remove the control panel fuse Turn off the battery charger Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent 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 ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit and requires approximately 2 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an authorized service dealer 3 An operational 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 semi annually or following each 50 hours of operation of the unit and requires approximately 1 5 man hours per unit
16. EXCITATION Swe SWITCH SET EXERCISER Dl DIODE FIELD BOOST TRI TRANSFORMER 1 56 VA 240 16 VAC DPE DISPLACED PHASE EXCITATION TRO TRANSFORMER 2 6 VA 240 16 VAC 66 0 RLT 0 6 14 14 BCW 15 14 55066 14 F2 13A 13 4 BA 1 0A SER DY aie L AVR 15 13 1 4 i 4 12 66 6 5 c e3 5H 5 9 6 224A 224 6 3162 005 229 L 0 1 2 DPE CB2 abe MN C o al gt T ZORDS 9 Ra 204 SW2 13 5 2 1 4 144 6 23 11 155 7 is c 11 33 44 178 IG 78 4 224 19 243233 15 3 239 239 12 lt 194 sunun El 00 2 183 OFF POSITION NB TRANSFER SWITCH L173 CUSTOMER CONNECTION 20 240V 1 Section 6 Electrical Data 40kW Liquid cooled Generators ELECTRICAL Electrical Schematic Engine Drawing No 0E8116 A
17. Gap SET PLUG GAP AT 1 01 mm 0 040 inch 18 4 5 13 COOLANT CHANGE Every year have an authorized service dealer drain flush and refill the cooling system See SPECIFICA TIONS Section 1 10 for cooling system recommen dations 46 MISCELLANEOUS MAINTENANCE 4 6 1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean generator 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 inspected by an authorized service dealer That deal er wil 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 insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying 4 6 2 BATTERY All lead acid storage batteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumpe
18. 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 dry 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 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 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 These generator sets may operate using one of seve
19. 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 battery 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 A 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 the fluid is spilled flush the affected area immediately with clear water A Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging warninc amp A Be sure the Auto Off Manual switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off 3 or sparking may occur at the battery posts as the cables are attached and cause an explosion MAINTENANCE o Section 4 Maintenance 40kW Liquid cooled Generators 4 6 4 BATT
20. cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating It is also recommend 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 will power The critical essential loads may need to be grouped together and wired into a sepa rate emergency distribution panel The standard transfer switch has no sensing or con trolling circuit boards Instead the generator control console houses a Printed Circuit Board Assembly which controls all phases of operation including engine start up and load transfer 2 1 STANDBY GENERATOR INSTALLATION A Dd A A Connecting this generator to an electrical sys tem normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the electric system from the utility distri bution system when the generator is operating Failure to isolate the electric system by these means will result in damage to the generator a
21. least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary Change the engine oil filter s filter s Replace the engine fuel filter s on diesel engine driven units and re prime the fuel system Check the engine spark plugs on gas engine driven units Clean and re gap or replace as necessary Perform a 5 minute no load operational run of the unit looking for any post service problems Return the unit to standby L I I required Task Comp Date Initials Section 5 Troubleshooting TROUBLESHOOTING 40kW Liquid cooled Generators TROUBLESHOOTING POINTS CAUSE PROBLEM Engine won t crank Engine cranks but won t start Engine starts hard runs rough Engine starts then shuts down AUTO OFF MANUAL Switch at OFF engine continues to run No AC output from generator 1 2 oar Qr eG 15 amp fuse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery 4 amp fuse blown Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Flame arrestor air cleaner plugged damaged Plugged fuel line Defective spark plugs Engine oil level is low Engine is overheated Defective Low Oil Pressu
22. 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 ventilat ing air is critical to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of 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 physically or mentally fatigued 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 la
23. these steps 1 Turn the main gas supply off 2 Remove the carburetor fuel hose from the outlet port Port 1 of the demand regulator Figure 1 8 Remove the brass hose fitting from the outlet port Port 1 of the demand regulator Remove pipe plug from Port 2 Install brass hose fitting into Port 2 Install pipe plug into Port 1 Connect carburetor gas hose to brass fitting Tighten all clamps and plugs Make sure fuel supply is of the proper pressure and type for configuration 10 Reverse the procedure to convert back to natural gas Figure 1 8 Reconfigure the Fuel System Port 1 Port 2 FUEL HOSE t BRASS HOSE BRASS HOSE Lp PLUG FITTING SA PLUG FITTING CORSO 2 4 i OUT OUT 3 1 PORT2 e HOUSING HOUSING p PORTS y LP FUEL SYSTEM NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made INSTALLATION Section 2 Installation 40kW Liquid cooled Generators A Dd A Serious injury or damage may occur if not con A figured properly Please consult an authorized service dealer with any questions 1 15 TORQUE SPECIFICATIONS Tighten the bolts from the middle out in a criss cross pattern Cylinder Head 50 ft lb 105 ft lb 105 ft Ib Intake Manifold 48 in lb 84 in
24. tion 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 GROUNDING LUG 2 8 GENERATOR AC NEUTRAL CONNECTIONS The manufacturer uses UNGROUNDED tral Grounding is recommended only at the main service entrance If the neutral wire is grounded and one of the phase loads becomes grounded the exces sive current opens the load circuit breaker or col lapses the generator field The actual result depends on the electrical characteristics of the particular installed generator warninc amp A Failure to connect the generator neutral prop erly will result in unbalanced line to neutral voltages Resulting high voltages will cause equipment damage 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 Setting switch two to OFF allows the control PCB to perform the ATS control functions Control system interconnections consist of N1 and N2 and leads 23 and 194 Control system intercon nection leads must be run in a conduit that is sepa rate from the AC power lead Recommended wire gauge sizes for this wiring depends on the length of the wire as
25. to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an authorized service dealer 4 A mid level 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 annually or following each 100 hours of operation of the unit and requires approximately 4 0 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an authorized service dealer 20 Section 4 Maintenance 40kW Liquid cooled Generators MAINTENANCE 2 O Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp tobe done Comp be done Comp Required Comp to be Date 3 months Date Semi Date be done Date monthly Initials Break in Initials annually Initials Annually Initials 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 Adjust as necessary 4 Check the engine coolant thermal protection level Correct as necessary 5 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the ai
26. 2097 057796 057795A 052223 061012 0E9295 0F3994 0E7121 QTY 2 l l cla RRP Po oO psp oO POND 9 Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Fuel System Drawing 0 8122 DESCRIPTION SCREW HHC 5 16 18 X 1 1 4 G5 FLANGE FUEL INLET ASSY REG 3 9L N G LPV 1800RPM SCREW HHC 8 1 25 X 20 08 8 WASHER FLAT 5 16 ZINC WASHER LOCK 8 5 16 NUT HEX M8 1 25 G8 YEL CHR SCREW HHC 8 1 25 X 16 G8 8 SCREW TH FRM 6 1 X 16 NWA 7 15 ELBOW 90D STREET 3 4 FUEL HOSE ASSY NAT GASIL PV BRACKET REGULATOR 3 0L FORD HSB CLAMP HOSE 8 53 1 00 HOSE 5 8 ID LPG amp NG 36 LG GASKET CARB ADAPTOR DECAL INLET PRESSURE DECAL FUEL INLET NG MACHINING CARBURETOR ADAPTOR GASKET BOSCH 32 amp 40 ACTUATOR BOSCH 40 GOVERNOR HOSE COOL 2IN ID 20R4 2 LG VENTURI HOLDER W 40MM ACTUATOR O RING 45 63 ID X 2 62 WIDTH VENTURI 28 ID THROTTLE W CHOK CLAMP HOSE 36 1 88 2 75 BASE AIR CLEANER PLATE FILTER AIR 11 5 CA326 HOLDER VENTUR HOLD DOWN AIR CLEANER PLATE AIR CLEANER TOP NUT WING 1 4 20 NYLK SCREW SHC 6 1 0 X 45 G12 9 STREET EL 45DEG 1 2 NPT BRASS BARBED STR 1 2NPT X 5 8 SCREW HHC M5 0 8 X 16 08 8 WASHER LOCK 5 WASHER FLAT M5 WASHER LOCK 6 1 4 GROMMET BARBED EL 90 3 4 PLASTIC HOSE 1 2 ID SAE 30R2 FUEL OIL PLUG STD PIPE 1 8 SOCKET HEAD ASSY THROTTLE 28
27. 42568 1 SCREW HHC 6 1 0 X 20 G8 8 16 049813 3 NUT HEX M6 X 1 0 G8 YEL CHR 54 061652 1 SCREW HHC M10 1 5 X 85 G8 8 17 036833 11 SCREW 3 8 16 X 1 G8 55 031578 1 SCREW HHC 3 8 16 X 1 1 2 G8 18 022131 21 WASHER FLAT 3 8 M10 ZINC 56 082120 1 SPACER 41 X 75 X 39 ST ZNC 19 022237 14 WASHER LOCK 3 8 57 023645 5 SCREW SHC 3 8 16 X 1 25 G8 8 Z 20 0E6729 1 STARTER DELCO REMY 12V 58 0E9974 1 CAP VINYL 3 8 ID X 1 DP BLK 21 022129 11 WASHER LOCK 8 5 16 59 0D3488A 1 BELT SERPENTINE 69 39 22 049821 3 SCREW SHC 8 1 25 X 30 G12 9 60 0E7954 1 CABLE IGN COIL 3 9L CHRYSLER 23 057073 1 JUNCTION BLOCK 3 8 16 61 0E8309 1 ASSY IGNITION MODULE 3 9L 24 052677 1 WASHER NYLON 50 X 87 X 06 62 029187 2 SPACER 19 X 31 X 50 PL 25 066849 2 SCREW 5 0 8 X 16 63 032712 2 SCREW HHTT 10 32 X 1 75 CZ 26 056739 1 RELAY SOLENOID 12VDC PNL MNT 64 054455 1 ADP OIL DRN 1 2 20 27 0D2244M 1 ASSY MAGPICKUP 3 8 24 MALE 65 0 8606 2 SCREW PPH TAPPING 4 X 3 8 LG 28 087599 1 PLUG PLASTIC 3 8 NPT 66 0E8642 REF ASSEMBLY RESISTOR 29 0E0992B REF PLUG EXPANSION 21 32 OD 67 0E8597 1 HARNESS 3 9L CHRYSLER ENGINE WATER PUMP QTY 1 NOT SHOWN 30 0 0992 REF PLUG EXPANSION 14 1 OD 68 0E8755 1 HARNESS IGNITION 3 9L CHRY INJCTOR HOLE QTY 6 NOT SHOWN 31 0E7754 1 COOLING FAN 10 BLADE KYSAIR 69 0 8731 1 PLATE FLEX DISK SPACER 32 0 7854 1 CLUTCH COOLING 70 026076 1 SCREW SHC 3 8 16 X 1 5 G8 8 NZ 33 0E7855 1 TENSIONER W BRACKET 72 0F1444A 2 HEAT SHEILD L H SID
28. ANUAL 4A FUSE SWITCH BATTERY 15A FUSE CHARGER MAIN POWER 5 2 1 AUTO OFF MANUAL SWITCH Use this three position switch as follows Set the switch to AUTO for fully automatic opera tion See Automatic Operation Section 3 5 Set switch to MANUAL position to crank and start the generator engine Set switch to OFF position to shut down an oper ating engine With OFF selected operation will not be possible A DH A A With switch set to AUTO engine can crank and start suddenly without warning Such automat ic start up normally occurs when utility source voltage drops below a pre set level To prevent possible injury that might be caused by such sudden starts set AUTO OFF MANUAL switch to OFF before working on or around the unit Then place DO NOT OPERATE tag on con trol console 5 2 2 FAULT INDICATOR LEDS These LEDs turn ON when one of the following engine faults occurs and the engine shuts down Low Oil Pressure Overcrank Low Battery Overspeed RPM Sensor Loss High Coolant Temperature Low Coolant Level See Section 1 7 for further explanation of engine pro tection functions 13 OPERATION Section 3 Operation gt 40kW Liquid cooled Generators 5 2 5 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 need
29. CLUDED CABLE BATT RED 4 X 20 00 CABLE BATT BLK 1 X 30 00 EARTH STRAP SCREW HHC 3 8 16 X 1 G8 WASHER LOCK 3 8 WASHER FLAT 3 8 ZINC BOOT BATTERY CABLE BATTERY POST COVWER BLACK BATTERY POST COVWER RED SCREW HHC 8 1 25 60 G8 8 FT NUT TOP LOCK FL 8 1 25 SPRING CLIP HOLDER 37 62 SCREW HHTT M4 0 7 X 8 BP PARTS 50 90 PARTS 50 LISTS Section 7 Exploded Views and Parts 40kW Liquid cooled Generators 0 Enclosure Drawing No 0F4931 C TYPICAL OF ROOF PANEL THAT REQUIRE INSULATION SECURE AS SHOWN STATES FOAM IS ON FAR SIDE O STATES FOAM IS ON NEAR SIDE 4 NL 2 LLI a lt 4 30 ITEM 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 46 47 48 49 50 51 52 53 0E8411 0E8042 0E8041 002454 0E7807 0E7808 0E7809 0E8387 0E6986 0F5552 089961 0A2115 0E8404 0D2538A 0D2538 078115 022097 022473 0E7570 0E7571 070015 0E7662 0D2537A 0D2537 0D2023 0E7869 0E8001 0F5551 0E7966 0D3037A 007781 0E7794 0E8052 0D3037 0E8007 0E8008 0F4938 0E8055 026850 0912970063 0912970064 049813 0E8665 0D2023 0E7829N 0E7829T 0E7829S 0E7829R 0E7829P 0E8442 0E7829A 0E7829B 043116 QTY k ll HPD S
30. E 34 0E7952 1 PULLEY CRANKSHAFT 3 9L 73 002454 2 SCREW THF M6 1 X 16 N WA 2 5 CRYSLR 74 043790 1 BARBED EL 90 3 8 NPT X 3 8 35 0E0561 1 ASSY WATER LEVEL SENSOR C E 75 0698600 1 HOSE OIL DRAIN ASSY 21 PL 76 048031J REF HOSE CLAMP BAND 5 8 36 035606 1 SENSOR HI COOLANT SHUTDOWN 77 0F1444 1 HEAT SHIELD R H SIDE 37 061012 1 PLUG STD PIPE 1 8 SOCKET HEAD 78 026925 1 PLUG STD PIPE 3 8 STEEL SQ HD 38 0A8584 1 SWITCH OIL PRESSURE10 PSI 79 026257 1 SCREW SHC 3 8 16 X 2 G8 8 NZ 2POL 39 050873A 1 PLUG PIPE 1 4 CSK W VIBRA SL 35 PARTS 50 LISTS Section 7 Exploded Views and Parts 40kW Liquid cooled Generators 0 Radiator Drawing No 0E8102 F N TO A w 4 Qc AS WMA SS N NSSSNSSSSSS 2 16 TO THERMOSTAT HOUSING 4 TO ENGINE WATER PUMP Sa 36 ITEM OnNoarwh N O1 O 007825 007174 0 7640 0 7924 0 2853 008252 008251 0 0726 076749 035685 069860 058443 002454 052250 048031C 029032 0A2111 0 7640 035461 065852 051756 022131 046526 045772 QTY ps lx a Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Radiator Drawing 0 8102
31. ERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 27F 700 0 deg F NOTE The BCI number should be located directly on the battery PERIODIC REPLACEMENT PARTS Part Number Oil Filter 0E7415 Radiator Cap 046627 0A4637 Spark Plug Champion RC12LC4 19 S Section 4 Maintenance MAINTENANCE 40kW Liquid cooled Generators O0 47 SCHEDULED MAINTENANCE The following is a recommended maintenance schedule for the manufacturer small standby and residential gen erator 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 Use calendar time from the previous maintenance interval to determine the next required main tenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to ensure it is ready to operate when required and to identify any poten tial problem areas Performed monthly this inspectin requires approximately 5 man hours per unit to complete This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury
32. Engine Drawing No 0 8121 BAFFLE REAR UPPER Z Ne 26 CF D C ALTERNATOR BRACKET HARDWARE 34 TH ENGINE u 5 5 63 6 l e 48 COMES WI 35 Ay y Cem 65 Section 7 Exploded Views and Parts CG urs 40kW Liquid cooled Generators Engine Drawing No 0E8121 H 0 QTY DESCRIPTION PARTNO QTY DESCRIPTION 1 0E5048A 1 FLEXPLATE 3 9L HSB 40 031919 1 PLUG STD PIPE 3 8 COUNTER 2 0E7477 1 MACHINING 3 9L ENGINE ADAPTOR SUNK 3 0E6703 1 COVER FLYWHEEL ACCESS 4 022145 6 WASHER FLAT 5 16 M8 ZINC 4 0E8336 REF REWORK 3 9L CHRYSLER ENGINE 42 030795 6 SCREW HHC 5 16 18 X 1 G5 5 0E7841 2 GASKET THERMOSTAT ADAPTOR 43 051756 5 SCREW HHC M10 1 5 X 20 G8 8 6 0E7254 1 MACH THERM ADAPTOR 3 9L CHRY 44 046526 6 WASHER LOCK M10 7 0E7956 1 BRACKET IGNITION COIL 45 0A1232A 1 ASSEMBLY D C ALTERNATOR 8 0E7953 1 COIL IGNITION 3 9L CHRYSLER 46 0A7801B 1 PULLEY POLY V 82 OD 9 047411 4 SCREW 6 1 0 X 16 G8 8 47 045772 1 NUT HEX 10 1 5 G8 YEL CHR 10 0E8591 6 BOLT AUTO TRANS CRANKSHAFT 48 022403 2 SCREW HHC 5 16 18 X 2 G5 11 0E7921 1 BRACKET ALTERNATOR 49 0E7950 1 TUBE DIPSTICK 3 9L CHRYSLER 12 0E7749 1 FAN SPACER ENGINE COOLING 50 0E7951 1 DIPSTICK OIL LEVEL 3 9L CRYSLR 13 022097 7 WASHER LOCK 6 1 4 51 0E8445 1 BRACKET DIPSTICK TUBE 14 022473 10 WASHER FLAT 1 4 M6 ZINC 52 0E7415 1 OIL FILTER 3 9L CHRYSLER 15 049721 2 SCREW HHC 6 1 0 X 35 G8 8 BLK 53 0
33. I 3ONV3V312 X000 093 L ZvZ1 681 2 31UN 335 S310H ONILNNOW ADA ELE DTA al 7 aWvad dAL LZ IE 908 LETI 20 7 131100 3313308 S 2 131100 LSNWHX3 2 9nld 13315 8 NIvad 110 3 7D31NDO i 71 590 WANLYN 131 1 ES SNOTLOSNNOO 321 435 3 19 3 h S31DH q ONILNAOW dAL LETE 6 3338 LIDOMIO INITNIYW E 119 lt 42 A9 06 31vIDWWDOOV TIIM AVAL 71 88 X S EI S vee X S 2r SNDISN3WIG 3015 Av3l 1194 W31SAS 3 11993 LIOA 21 2 8 15 INVd TOSLNOD NI Q3GIADSd 18915 31D0W38 1 0761 S SvT D HOLIMS 333SNV31 50931 0901 OW 304 SLNIOd NDII123NNOO I 4 1 SION tme 5 Sod vl 4 S31DH ONILNNOW LIT 82 8 21 See dn gniS LG 21 ES 06 GWAHYSAO 43 NOTES 44 Section 9 Notes 40kW Liquid cooled Generators Section 9 Notes 40kW Liquid cooled Generators NOTES 45 Section 10 Warranty WARRANTY 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 Gen
34. IQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 2 12 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following infor mation pertaining to the installation and use of standby electric systems is available NOTE It is essential to use the latest version of any stan dard to ensure correct and current information 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 INSTALLATION f Section 2 Installation 40kW Liquid cooled Generators 2 2 GENERATOR LOCATION Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating 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 u
35. Ib 84 in Ib Exhaust Manifold 25 ft lb 1 14 ENGINE OIL RECOMMENDATIONS The unit has been filled with 5W 20 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE SE Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Temperature Above 80 F 27 C Oil Grade Recommended SAE 15W 40 SAE 15W 40 SAE 15W 40 32 to 80 F 1 to 27 C Below 32 F 0 C NOTE Synthetic oil is highly recommended in any ele ment with temperatures above 90 F or below 30 E caution Any attempt to crank or start the engine before A it has been properly serviced with the recom mended oil may result in an engine failure 1 15 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and half de ionized water Cooling system capacity is about 20 U S quarts 19 3 liters Use only de ionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the recommended coolant mixture When adding coolant always add the recommended 50 50 mix ture caution A A Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chromi umhydroxide green slime forms and will
36. LER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 OR Locate us on the web at www guardiangenerators com INTRODUCTION SAFETY RULES Section 1 GENERAL INFORMATION Transfer Switch Automatic System Operation Generator AC Connection Systems Main Circuit Breaker Generator Fuel System Engine Protective Devices Q BR Lifting the Generator Specifications Fuel Consumption N Reconfiguring the Fuel System Torque Specifications Engine Recommendations ol Coolant Recommendations Before Installation Section 2 INSTALLATION Standby Generator Installation M Lm om om om 4 2 4 4 om om 2 Generator Location Generator Mounting and Support Basic Standby Electric System Emergency Circuit Isolation Method Total Circuit Isolation Method Grounding the Generator Generator AC Neutral Connections Transfer Switch Start Signal Connections Battery Installation Preparation Before Start Up Table of Contents TABLE 40kW Liquid cooled Generators ones Section 3 OPERATION 13 3 1 Using an Engineered GTS Transfer Switch 13 3 2 Control Console Components 13 3 3 Manual Transfer and 5 14 3 4 Engine Governor Adjustments 14 3 5 Retransf
37. MM PCV VALVE 2 5L FORD O RING 47 625 ID X 2 38 WIDTH PARTS 50 90 PARTS 50 LISTS Section 7 Exploded Views and Parts 40kW Liquid cooled Generators 0 Alternator Drawing No 0F5092 B LOCKTIGHT rove Su q Wee 12 LOCKTIGHT 40 ITEM gt 11 12 13 14 15 16 17 18 19 20 21 ROTOR REPLACEMENT PARTS 30 31 PART NO 0 1659 0 1657 0 1655 0 5073 0E7413A OF1660A 0 1658 0 1656 0 5074 0E7412A 0 5706 0 5048 0 5048 0 5048 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 092980 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F 047248 070892 QTY la la la la la la la la ca REF REF REF F F F gt RRO Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Alternator Drawing No 0F5092 B DESCRIPTION ROTOR 390 15KW 1P DIRECT HSB 2 5L FORD ROTOR 390 20KW 1P DIRECT HSB 2 5L FORD ROTOR 390 25KW 1P DIRECT HSB 2 5L FORD ROTOR 390__30AD1 HSB TECUM RTR 390 40KW 1P DIRECT HSB STR 390 15AD HSB 382MM LONG 2 5L FORD STR 390 20AD HSB 382MM LONG 2 5L FORD STR 390 25AD HSB 382MM LONG 2 5L FORD STR 390__30AD1 HSB TECUM STR 390 40AD HSB 433MM LONG REAR BEARING CARRIER 390 DRCT FLEXPLATE 3 0L FORD FLEXPLATE 2 5L FORD FLEXPLATE HSB 3 9L CHRYSLER FL
38. P MUFFLER 9 039253 2 SCREW HHC 8 1 25 X 20 8 8 23 039288 1 SCREW 8 1 25 X 55 8 8 10 022145 6 WASHER FLAT 5 16 M8 ZINC 24 0 5612 1 PIPE R H SIDE EXHAUST MILD ST 11 022129 11 WASHER LOCK 8 5 16 25 OF 6262 1 PIPE L H SIDE EXHAUST MILD ST 12 045771 3 NUT HEX 8 1 25 G8 YEL CHR 13 002454 4 SCREW TH FRM M6 1 X 16 N WA ZJS 42 INSTALLATION Section 8 Installation Diagram 40kW Liquid cooled Generators Installation Diagram Drawing No 0 8422 T3NVd 5532292 MATA 3015 E 4NINJIUD34 3599 LET9 8651 Swe Lee XHICIA TW33ADD adl 3018 89 0 LdN v E NUILO3NNDO 71304 001 1 91003 3SV8 L G EE 0S8 09v d SYI IVANLYN LT9vJ 90 11 S3HONIJ ww 151 i 3 o Co 501 OSET 219 lINn 3015 891 VIVI IHDI3M E E 1304 0S 1 OR 719130 3293 T3NVd DSINDO 3 oa 5 d T SL 31DN 33S 310 335 TH3AU A To l 5 5 9 9 4 19 31 T1vH3AU 1 7971 8 EE6
39. ROUND SENSING LOW AMP RI 50 WATT RESISTOR GND2 GROUND CPDWER HIGH AMP SM STARTER MOTOR GOV ELEC GOVERNOR ACTUATOR WLS COOLANT LEVEL SWITCH 25 ELECTRICAL DATA Section 6 Electrical Data 40kW Liquid cooled Generators Electrical Schematic Engine Drawing No 0E8116 A LEGEND AR ALTERNATOR ROTOR LEGEND CONT 1 AS ALTERNATOR STATOR Fl FUSE POWER 15 AGC TYPE AVR AUTOMATIC VOLTAGE REGULATOR F2 FUSE B C 4 AGC TYPE BA BRUSH ASSEMLY GENERATOR ICT TERMINAL BLOCK INTERCONNECT B C BATTERY CHARGER NB NEUTRAL BLOCK BCW BATTERY CAHRGE WINDING RLI RELAY 1 CIRCUIT BREAKER OUTPUT 541 SWITCH AUTO OFF MANUAL CIRCUIT BREAKER
40. YWHEEL ASSY 3 0L HSB LG GEAR REVCOR FAN 10 75 X 2 W PRESS DIS WASHER LOCK M10 SCREW 10 1 5 X 16 08 8 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD amp 2 5L FORD STUD M14 2 0 X 540 G5 ZINC WASHER LOCK M14 NUT HEX M14 2 0 G8 YEL CHR ASSY BRUSH HOLDER 390 HSB WASHER SHAKEPROOF INT 8 SCREW PPHM 4 0 7 X 25 SCREW SHC 10 1 5 X 30 G12 9 WASHER FLAT 688 ID X 3 25 OD KEY SQ 3 8 X 1 STEEL SCREW HHC M16 2 0 X 45 G8 8 WASHER LOCK 8 M4 WASHER FLAT 8 ZINC CONDUIT FLEX 1 1 4 30 LG 3 0L FORD amp 3 9L CHRYSLER CONDUIT FLEX 1 1 4 18 LG 2 5L FORD BALL BEARING 45 MM SLIP RING MACHINED LISTS LISTS Gt Section 7 Exploded Views and Parts 40kW Liquid cooled Generators Muffler Drawing No 0F4894 B TO EXHAUST MANIFOLD 9 25 g 1 18 DESCRIPTION PARTNO QTY DESCRIPTION 1 0F0738 1 MUFFLER 7 X9 2 2 IN 2 5 OUT 14 052860 4 NUT TOP LOCK FL M12 1 75 2 0C9748 1 PLUG M18 1 50 15 052891 4 SCREW HHC M12 1 75 X 80 G8 8 3 0F0778 1 PIPE R H SIDE EXHAUST MILD ST 16 0E8816 1 EXHAUST FLANGE 2 PIPE 4 0F0777 1 PIPE L H SIDE EXHAUST MILD ST 17 051769 4 WASHER LOCK M12 5 0E5914 1 BRACKET MUFFLER 3 0L FORD 18 0E0170B 1 EXHAUST BLANKET 800MM HSB 19 049808 8 WASHER FLAT M12 6 0E0170C 1 EXHAUST BLANKET 675MM 20 022259 8 NUT HEX 5 16 18 STEEL 7 0 6258 1 PIPE MUFFLER OUT 21 080762 1 BOLT U 3 8 16 X 2 62 8 036797 4 BOLT U 5 16 18 X 2 25 22 0E8726 2 STRA
41. ard will NOT activate the transfer output The control board WILL monitor all engine condi tions and shut down on all the faults listed in this document Pos2 OFF ATS Application Included switch The control board will perform all of the automat ic features listed in this document The two wire start connections should NOT be used GTS Mode Operation When in GTS mode the control board will respond as follows based on the AUTO OFF MANUAL switch position OFF The generator will not start and run in this position MANUAL The control board will start and run the generator whenever the switch is in the manual posi tion AUTO The control board will monitor the two wire start circuit When a two wire start is issued the con trol board will immediately start and run the genera tor Whe the two wire start is removed the control board will immediately stop the generator NOTE If 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 Section 3 Operation OPERATION 40kW Liquid cooled Generators oa 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 pom RED LED SET EXECISER GREEN LED TIME SWITCH AUTO OFF M
42. at might be caused by a ground fault condi tion 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 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 generator electric system from the electric utility distribution system when the generator 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 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS 40kW Liquid cooled Generators Generators installed with an automatic transfer switch will crank and start automatically when NOR MAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automat ic 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
43. atteries must be at 100 percent state of charge before they are installed on the generator When using maintenance free batteries it is not nec essary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in Section 4 Maintenance A negative ground system is used Battery connections are shown on the wiring diagrams Make sure all batter ies are correctly connected and terminals are tight Observe battery polarity when connecting batteries to the generator set NOTE Damage will result if the battery connections are made in reverse 2 11 PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed serv iced tested 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 safety information in this manual before attempting to operate this and related equip ment 2 11 1 PRIOR TO INITIAL START UP caution A 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 quantities of engine fluids oil coolant fuel etc may result in an engine failure 12 Before starting the generator for the first time the installer must complete the following proc
44. d Parts 40kW Liquid cooled Generators ITEMS INCLUDED AS PART OF I N 39 PARTS 50 LISTS Control Panel Drawing No 0E7118 K 0 QTY DESCRIPTION 37 001127 1 DECAL AVR COVER 38 0A1441B 1 COVER PLATE AVR 39 0E7128 1 HARNESS CNTRL PNL NOT SHOWN 40 0E7358 8 SCREW PPPH HI LO 4 24 X 3 8 4 074908 6 SCREW HHTT 5 0 8 10 BP 42 005141 1 CONN DEUTSCH GASKET 8 12 POS DT 43 002699 11 SCREW 6 32 X 3 8 ZYC 44 002323 4 SCREW PHTT 6 32 X 5 8 ZYC 45 022155 15 WASHER LOCK 6 46 002265 4 SCREW 4 0 7 X 12 ZYC 47 022264 4 WASHER LOCK 8 M4 49 020911 2 SCREW PPHM 5 0 8 X 30 ZINC 50 066849 2 SCREW HHTT 5 0 8 X 16 51 022152 4 WASHER LOCK 10 52 023897 3 WASHER FLAT 10 ZINC 53 051716 2 NUT HEX 5 0 8 YEL CHR 54 090388 2 SCREW HHTT M6 1 0 X 12 ZINC 55 042568 4 SCREW 6 1 0 X 20 G8 8 56 022097 8 WASHER LOCK 6 1 4 57 022473 6 WASHER FLAT 1 4 M6 ZINC 58 0441140187 2 WIRE ASSY 3 X 2 3 16 TABS 59 070370 2 WASHER MICA 203 60 023762 1 WASHER SHAKEPROOF EXT 10 STL 61 055444 1 HEATSINK 62 030468 1 WASHER STEP NYLON 20 63 049939 1 RECTIFIER MSC 12A 600V 1N1206R 64 022158 1 NUT HEX 10 32 STEEL 65 022985 1 WASHER FLAT 6 ZINC 66 038750 2 SCREW M6 1 0 X 30 G8 8 67 0A2115 4 WASHER NYLON 257 68 002454 4 SCREW THF M6 1 X 16 N WA 2 5 69 0 6146 1 HANG TAG 2 WIRE START NOT SHOWN 33 ih Section 7 Exploded Views and Parts LISTS 40kW Liquid cooled Generators 0
45. d recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters caution A After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 17 MAINTENANCE 2 09 Section 4 Maintenance 40kW Liquid cooled Generators 7 Start engine and check for oil leaks Figure 4 2 Oil Filter 4 5 11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 0A4637 remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover See the Service Schedule Section 6 for air cleaner maintenance 4 5 12 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary See Section 6 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and com mercial solvent 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 questionable See the Service Schedule Section 6 for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 1 01 mm 0 040 inch by carefully bending the ground electrode Figure 4 3 Figure 4 3 Setting the Spark Plug
46. d start the engine man ually refer to the Owner s Manual of the particular transfer switch 14 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 during final testing of the generator and in most cases should not be adjusted If however adjustments are necessary or a new engine control board is installed in the generator the following procedure should be followed Figure 3 2 1 Set all three potentiometers pots fully counter clockwise 2 Under no load condition increase the GAIN pot as much as possible without causeing instability 3 Apply 1 4 1 2 3 4 and full load to the unit Decrease the GAIN pot if there is instability at any load point 4 Under full load condition increase the stability pot until the unit returns to 60 Hertz or 50 Hertz in 50 Hertz applications 5 Reduce load to 3 4 1 2 1 4 and no load Decrease the stability pot if there is instability at any load point 6 Adjust differential pot to make the recovery to load changes even faster and minimize load change undershoot and overshoot If it is set too high it may introduce oscillations at some load It can be set to zero full CCW if a small amount causes oscillations at some load Figure 3 2 Engine Governor Adjustment
47. e equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an authorized service dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See the authorized service dealer for service aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by an authorized service dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs contact an authorized service dealer for assistance Service technicians are factory trained and are capa ble of handling all service needs When contacting an authorized service dealer about parts and service always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit AUTHORIZED SERVICE DEA
48. edures For follow up maintenance information and or service intervals please refer to Section 4 Maintenance 2 11 2 TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems 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 compliance with applicable codes standards and regulations 2 11 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 Section 1 10 for more information 2 11 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 Section 1 10 and Engine Oil Recommendations Section 1 14 NOTE This engine is shipped from the manufacturer with 5W 20 oil This oil should be changed after 30 hours of operation 2 11 5 ENGINE COOLANT Have the engine c
49. er and Shutdown 15 3 6 Automatic Operation 15 3 7 Weekly Exercise 2 15 Section 4 MAINTENANCE 16 4 1 Maintenance Performed by Authorized Service Facilities 4 2 Cooling System eese 4 3 Overload Protection for Engine DC Electrical System eee 16 4 4 Checking Fluid Levels 16 4 5 Maintenance Owner Operator Perform s u a IRE Ree S OH ERE er CREER 17 4 6 Miscellaneous Maintenance 18 4 7 Scheduled Maintenance 20 Section 5 TROUBLESHOOTING 23 Section 6 ELECTRICAL DATA 24 Section 7 EXPLODED VIEWS AND PARTS LISTS 28 Section 8 INTALLATION DIAGRAM 43 Section 9 8 44 Section 10 WARRANTY Back Cover SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS 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 instruct
50. erac will at its option repair or replace any part which upon examination inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer is found to be defective Any equipment that the purchaser owner claims to be defective must be examined by the nearest Guardian Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Guardian prepackaged emergency automatic standby generators 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 main tenance is required Engine All Components Alternator All Components Transfer System All Components Steel enclosures are warranted against rusting for the first year of ownership only Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty Nicks scrapes dents or scratches to the painted enclosure should be repaired promptly by the owner All warranty expense allowances are subject to the conditions defined in Guardian s Warranty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Guardian generators that utilize non Guardian Generac replacement parts Guardian generators utilizing non Guardian Generac automatic tra
51. ery fluid level each week as outlined under Check Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary 4 5 5 EXERCISE SYSTEM If the unit is not set up for automatic operation start the generator engine at least once every seven days and let it run at least 12 minutes See Section 3 6 Weekly Exercise Cycle 4 5 4 INSPECT COOLING SYSTEM Inspect engine cooling system at least once each month Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness 4 5 5 CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels in Section 4 4 4 5 6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks 4 5 7 INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks security damage MAINTENANCE o Section 4 Maintenance 40kW Liquid cooled Generators 4 5 8 CHECK FAN BELT Inspect fan belts every three 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
52. ions that should be followed during installation and maintenance of the generator and batteries WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm A 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 Owner s Manual and with the unit The genera tor can operate safely efficiently and reliably only if it is properly installed operated and maintained Many acci dents are caused by failing to follow simple and funda mental rules or precautions The manufacturer cannot anticipate every possible cir cumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique that the manufac turer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique chosen does not render the generator unsafe A DX A A 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 ca
53. its to be connected to only one power supply at a time Prevents electrical backfeed between the generator and the UTILITY power circuits Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker INSTALLATION Ihe Section 2 Installation 40kW Liquid cooled Generators Figure 2 1 Basic Standby Electric System MAIN LINE CIRCUIT BREAKER UTILITY DANG POWER SUPPLY 4 TRANSFER SWITCH pes TO LOAD CIRCUITS STANDBY GENERATOR I OUTPUT MAIN LINE CIRCUIT BREAKER 2 5 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage amperage capacity of the generator If the generator is powering only crit ical loads within the wattage amperage capacity dur ing utility power outages consider using the emer gency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are with in the wattage amperage capacity of the generator set When this method is used it is difficult to overload the generator The transfer switch must meet the fol lowing requirements It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit Have it installed between the building s main dis trib
54. nd may also result in injury or death to utility workers due to backfeed of electrical energy If an open bottom is used the engine genera tor is to be installed over non combustible materials and should be located such that com bustible materials are not capable of accumu lating under the generator set 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 regula tions pertaining to the installation caution After the system has been installed do nothing A that might render the installation in noncompli ance with such codes standards and regula tions 2 1 STANDARDS The following published standards booklets pertain ing to standby electric systems are available form the National Fire Protection Association NFPA Batterymarch Park Quincy MA 02269 NOTE It is essential to use the latest version of any stan dard to ensure correct and current information NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES NFPA No 76A ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES 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 L
55. ng whatever means provided such as a utility main line circuit breaker The utility power source now powers the loads 3 6 AUTOMATIC OPERATION To set the system for fully automatic operation pro ceed 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 Closed position 3 7 WEEKLY EXERCISE CYCLE The engine control board will start and run the gen erator once every seven days for 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 switch for three seconds then release Section 3 Operation OPERATION 40kW Liquid cooled Generators ix At this time all five red LEDs will flash for approxi mately 10 seconds then the engine will start and run for its 12 minute exercise period then shut down The generator will now start and run each week at the same time If DC power to the control board is lost the weekly exercise setting will be lost This is indicated by all five red LEDs continually flashing In this state the generato
56. ngine shuts down automatically and the low oil pressure LED is turned ON Figure 1 4 Section 1 General Information 40kW Liquid cooled Generators GENERAL INFORMATION NOTE The Low Oil Pressure High Coolant Temperature and Low Coolant Level are not monitored for the first 10 seconds of engine run time Figure 1 4 Low Oil Pressure Switch 1 72 HIGH COOLANT TEMPERATURE SWITCH Normally open N O thermostatic switch has sens ing tip which is immersed in captive coolant Should coolant temperature exceed about 230 F 110 C the switch contacts close This causes the engine to shut down automatically and turns on the high coolant temperature low coolant level LED Figure 1 5 Figure 1 5 High Coolant Temperature Switch ES 1 7 5 LOW COOLANT LEVEL SWITCH Should engine coolant level drop below the level of the high coolant temperature switch it is possible for the engine to overheat without automatic shutdown To prevent such overheating without automatic shut down the engine has a low coolant level sensor If the engine coolant drops too low the engine automatical ly shuts down and turns on the high coolant temper ature low coolant level LED Figure 1 6 on page 6 5 40kW Liquid cooled Generators Figure 1 6 Low Coolant Level Sensor 1 74 OVERSPEED SHUTDOWN The engine control board receives AC frequency sig nals from an engine run winding in the alternator Should AC frequenc
57. nit 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 base frame must be level within 1 2 inch all around Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow five feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install the generator as close as possible to the transfer switch This reduces the length of wiring and conduit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REG ULATE THE DISTANCE 2 3 GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a concrete slab with 1 4 inch masonry type anchor bolts Be sure the bolts are long enough to retain the compartment The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides See Section 6 for generator major dimensions 2 4 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 on page 10 shows a schematic diagram of a basic standby electric system Both the UTILITY power supply and the STANDBY GENERATOR out put are connected to an approved transfer switch The transfer switch is required by electrical code and serves the following functions Allows the LOAD circu
58. non latching alarm which will automatically clear if the battery voltage rises above 11 0 VDC The control system will not attempt to start the engine if there is a low battery condition 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 position 1 79 DC FUSE These fuses are located on the front panel of the con trol system They protect the panel wiring and com ponents from damaging overload Always remove the 15 amp main fuse before working on the generator The unit will not start or crank if this fuse is blown Replace the fuse with one of the same size type and rating main AGC 15 battery charger AG4 1 8 UNPACKING 1 81 UNPACKING PRECAUTIONS Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping colli sion etc 1 8 2 INSPECTION After unpacking carefully inspect the generator for any damage that may have occurred during ship ment If loss or damage is noted at the time of deliv ery have the person s making delivery note all dam age on the freight bill or affix his signature under the consignor s memo of l
59. nsfer switches Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems Any 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 Steel enclosures that are rusting due 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 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 and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential
60. nt of any parts is necessary dur ing the warranty period you must contact an authorized service dealer Failure to have the repair or replace ment performed by the authorized service dealer will result in non coverage of warranty repair cost Section 6 Electrical Data 40kW Liquid cooled Generators Wiring Diagram Engine Drawing No 0E8115 A ELECTRICAL DATA e O CB2 162 1 1 0 VR 2 168 0 3 11 1B1 ofo A 4 0 Teh o 44 0 HOSS 6 6 14 16 4 4 7 eeo D1 224 22 4 oS TR2 m 55 UU 00 A 0 CPN ou 225A 0 m
61. on 1 12 for conversion 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 Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges NOTE A seperate gas line and regulator may be needed to assure proper gas pressure to the generator Improper gas pressure can cause hard starting and affect engine durability warninc amp A Gaseous fuels such as natural and LP propane gas are highly explosive Even the slightest spark can ignite such fuels and cause an explo sion 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 1 7 ENGINE PROTECTIVE DEVICES The engine has several safety switches which cause the engine to automatically shut down under the fol lowing conditions low oil pressure high coolant tem perature engine overspeed low coolant level or over crank Figure 1 3 Figure 1 3 Engine Protective Devices Low Oil Pressure Switch High Coolant Temperature Switch O PI a Low Coolant Level Sensor 1 71 LOW OIL PRESSURE 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 e
62. ooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications Section 1 10 and Coolant Section 1 15 2 11 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 approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inch 10 to 16 mm 2 11 7 ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground and or ground rod Make sure the generator battery is fully charged prop erly 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 3 1 USING AN ENGINEERED GTS TRANSFER SWITCH When required the pre packaged standby generator can be installed with an engineered GTS type auto matic transfer switch In this application the GTS is responsible for utility sensing weekly exercising and load transferring Position two of the four position dip switch is used to turn over this control to the GTS Pos2 ON GTS Application The control board will NOT monitor utility The control board will NOT perform a weekly exer cise The five red LEDs will not flash in this mode The control bo
63. 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 Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc 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 consequential damages so the above limitation may not apply to yo
64. oss or damage 1 9 LIFTING THE GENERATOR warninc amp A When lifting or hoisting equipment is used be careful not to touch overhead power lines The generators weight of more than 1400 pounds requires proper tools equipment and qualified personnel to be used in all phases of handling and unpacking 1 10 SPECIFICATIONS 1 10 1 GENERATOR SPECIFICATIONS Single phase Model 4992 2 Rated Max Cont AC Power Output kW 37 NG 40 LP Rated voltage volts 120 240 No of Rotor Poles 4 Driven Speed of Rotor 1800 Rotor Excitation System Direct excited brush type Type of Stator 4 Wire Rotor Stator Insulation Class F H 1 10 2 ENGINE SPECIFICATIONS Qc Chrysler Displacemerit nt i erem enden 3 9 liters Cylinder Arrangement sese V 6 Valve Arrangement eee Overhead Valve Firing Order Number of Main Bearings nnn 4 Compression Ratio sees 9 1 to 1 No of Teeth on Flywheel Ignition Timing at 1800 rpm Spark Plug Gap 1 01mm 0 040 in Recommended Spark Plugs iPaper I RC12LC4 Oil Pressure 30 80 psi Crankcase Oil Capacity 4 0 U S quarts 3 8 liters Recommended Engine Oil s SAE 15W 40 Type of Cooling System Pressurized closed recovery
65. pable persons to install operate or main tain this equipment A 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 Parts of the generator are rotating and or hot during operation Exercise care near running gen erators A GENERAL HAZARDS A For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by an authorized service dealer or other competent qualified electrician or installation techni cian who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations 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 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
66. r al types of fuels All fuel types are potentially FLAM MABLE 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 immediately 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 detectors accordingly Section 1 General Information GENERAL 40kW Liquid cooled Generators INFORMATION 1 1 GENERATOR This equipment is a liquid cooled engine driven gen erator set The generator is designed to supply elec trical power that operates critical electrical loads during utility power failure The unit has been facto ry installed in a weather resistant all metal enclosure and is intended for outdoor installation only Use this generator as a source of electrical power for the oper ation of 120 and or 240VAC single phase loads WARNING amp If this generator is used to power electrical load circuits normally powered by a utility power source it is required by code to install a trans fer switch The transfer switch must effectively isolate the electric system from the utility distri bution sys
67. r cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury 4 6 5 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 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer A Dd A Storage
68. r 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 wiring for loose connections corrosion and damage Correct as necessary 10 Check the engine accessory drive belts for wear weather cracking and damage Replace as necessary 11 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 12 Test the engine and transfer switch safety devices Correct and or adjust as necessary 21 Section 4 Maintenance MAINTENANCE 40kW Liquid cooled Generators 2 0 13 14 15 16 17 18 19 20 21 Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task mended Comp to be done Comp to be done Comp Required to be Date 3months Date Semi Date to be done monthly Initials Break in Initials annually Initials Annually 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 Start and exercise the unit at full rated load use a load bank if the site load is not enough for at
69. r will still start and run in manual mode or automatically start and run if UTILITY is lost while in AUTO mode but it will not perform a weekly exercise cycle If a failure occurs while running in this mode the five red LEDs will stop flashing the individual fault LED will turn on and the engine will shut down Once the AUTO OFF MANUAL switch has been switch to OFF the individual fault LED will turn OFF and the five red LEDs will begin flashing to show exercise has still not been set Figure 3 2 Set Exercise Time Switch RUSE FUSE 4A 15A CHARGER Sj AUTO OFF OFF ON SET MANUAL EXERCISE yvy TIME 15 MAINTENANCE S o 4 1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE DEALERS EVERY THREE MONTHS 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 ONCE EVERY SIX MONTHS Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY Test engine governor Adjust or repair if needed Clean inspect generator Flush cooling system FIRST 100 OPERATING HOURS Change engine oil and oil filter After initial change service engine oil and filter at 150 oper ating hours or 6 months whichever comes first 2 Retorque cylinder head See Torque Specs Section 1 13 3 Retorque intake and exhaust manifold
70. re Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch 1 Defective AUTO OFF MANUAL switch 2 Open disconnected wire 15A between oA AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open NOTE CORRECTION 1 2 DnA N NOOR WD Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replace fuse Replenish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Clean or replace as needed Unclog fuel line Clean regap or replace plugs Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Setto GENERATOR position Contact an authorized service dealer Auto reset Wait 5 min and attempt restart Under normal operating conditions if repair of generator set or replaceme
71. recommended below 460 feet 140m 461 to 730 feet 223m No 12 AWG 1 161 to 1 850 feet 565m 2 9 2 ATS If the generator is to be installed with an engineered automatic transfer switch such as a GTS type switch it is necessary to connect the two wire start control system Connect the two wire start signal from the automatic transfer switch to the automatic start connection which is located in the middle on the bottom inside the control 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 See Section 3 1 for further explanation NOTE It will be necessary to provide a UTILITY supply to the integral battery charger This battery charger is located in the engine generator control panel Locate the six position terminal strip in the con trol panel Connect a 240 VAC UTILITY supplied source to terminals labeled N1 and N2 The 240 VAC circuit should be protected by a 15A maxi mum rated circuit breaker INSTALLATION he Section 2 Installation 40kW Liquid cooled Generators 2 10 BATTERY INSTALLATION A A Standby generators installed with automatic transfer switches will crank and start automati cally 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
72. ric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following proce dures are to be observed e Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thor oughly and immediately with water and seek med ical attention and 11 INSTALLATION P Section 2 Installation 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 bicarbon ate 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 The fol lowing procedure are to be followed DO NOT SMOKE when near batteries DO NOT cause flame or spark in battery area and Discharge static electricity from body before touch ing batteries by first touching a grounded metal surface Servicing of batteries is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries The recommended battery is Group 27 12V nega tive ground 700 CCA 90 AH minimum capacity All b
73. ry including death or property damage WARNING amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution Ak After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety informa A tion that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard A This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate th
74. s 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 electri cal overload If the fuse needs to be replaced use only an identical 4 amp replacement fuse type AG NOTE This fuse will not remove the battery input power from the PCB when it opens This means the exercise timer will not be reset 3 2 5 SET EXERCISE TIME SWITCH This switch allows programming the generator to start and exercise automatically See Weekly Exercise Cycle 3 2 6 SYSTEM READY LED The System Ready LED green has two main pro poses First the LED will be ON when the AUTO OFF MANUAL switch is in the AUTO position UTILITY is present and there are no system alarms This ON state indicates the system is fully ready for automatic operation The system ready LED will be OFF when the switch is in the MANUAL or OFF positions The system ready LED is also used to indicate the presence of UTILITY sensing at the PCB when the switch is either in the AUTO or MANUAL modes The LED will flash at the rate of 1 2 second on 1 2 sec ond off if the UTILITY sensing level is below the transfer back threshold This secondary function is only available with dip switch two in the OFF position engineered transfer switch application 3 3 MANUAL TRANSFER AND START UP To transfer electrical loads to the Standby EMER GENCY power source side an
75. sonnel 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 gas and cause an explosion Such an explosion can shatter the battery 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 A 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 WARNING amp 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 A 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 2 10 1 VENTED BATTERIES caution A The electrolyte is a dilute sulfu
76. st 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 A ELECTRICAL HAZARDS All generators covered by this manual produce dan gerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dan gerous voltages to the transfer switch as well as the standby generator Avoid contact with bare wires ter minals connections etc on the generator as well as the transfer switch if applicable Ensure all appropri ate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard 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 Article 250 requires the frame and external electrically conduc tive parts of the generator to be connected to an approved earth ground and or grounding rods This grounding will help prevent dangerous electrical shock th
77. tem when the generator is operating NEC 701 Failure to isolate an electrical system by such means results in damage to the genera tor and may also result in injury or even death to utility power workers due to backfeed of electrical energy 1 2 TRANSFER SWITCH This generator system includes a matched 200 amp automatic transfer switch which is intended to be used in conjunction with the generator It is supplied in a NEMA 3R enclosure The NEMA 3R enclosure is weather resistant and can be used indoors or out doors Follow these rules A Install the transfer switch a firm sturdy sup porting structure To prevent switch distortion level the switch if nec essary This can be done by placing washers between the switch enclosure and the mounting surface Never install the switch where water any sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors 1 5 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 cranks and starts After the generator starts the transfer switch transfers load circuits so the generator can po
78. u This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC BOX 297 WHITEWATER WI 53190 e Revision 02 01 05 Part No OF4942 Revision D 07 14 05 Printed in U S A
79. ution panel and the emergency distribution panel 2 6 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 gener ator 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 equal the ampere rating of the normal incoming utility service The transfer switch is installed between the utility service entrance and the building distribution 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 10 2 1 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 For that purpose a GROUND LUG Figure 2 2 is provided on the gener ator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations A DIG A 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 electrical shock in the event of a ground fault condi
80. wer them When utility source voltage has been restored the switch re transfers back to the UTILITY source volt age and the generator then shuts down Please reference the transfer switch manual for spe cific information 1 4 GENERATOR AC CONNECTION SYSTEMS The generator was shipped from the factory with its stator AC output leads connected in a single phase three wire generator AC connection system Figure 1 1 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 120VAC 60 Hertz When the two windings are con nected in series a 240VAC 60 Hertz AC output results Typically the two HOT leads in the circuit are wires 11 and 44 The NEUTRAL leads are the junc tion of Wires 22 and 33 The NEUTRAL is not grounded Figure 1 1 Generator AC Connection System 240 VOLTS CIRCUIT BREAKER 1 5 MAIN CIRCUIT BREAKER The generator s main circuit breaker is included with the unit as shipped from the factory The breaker for this unit is described in Figure 1 2 Figure 1 2 Main Circuit Breaker Model Rating Phase Actual Current C B Rating Circuit Breaker 004992 2 37 000 NG 1 1542 200 200A QN2 40 000 LP 1 166 7 200 200A QN2 Amp Rating of C B structured under model 1 6 GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using a natural gas fuel system If propane LP gas is neces sary refer to Secti
81. y exceed about 72 Hertz for three seconds or 75 Hertz instantaneously the engine shuts down and the overspeed LED turns on Should AC frequency exceed about 72 Hertz circuit board action will automatically shutdown the engine Figure 1 7 Figure 1 7 Printed Circuit Board Assembly gt 2 J2 mint elle Je F Lu III _ mat ele n d A 20 30 8804 on si Nc 1 75 RPM SENSOR 1055 If the engine control board does not receive a proper rpm signal from the starter during cranking or run ning it shuts down the engine on rpm sensor loss and flash the overspeed LED 1 7 6 OVERCRANK SHUTDOWN The engine control board uses a cyclic cranking process when attempting to start the engine The first crank cycle is a 15 second crank followed by a seven second rest This is followed by five more crank cycles each with a seven second crank followed by a seven second rest If the engine fails to start after all six attempts the start attempt is stopped and the overcrank LED turned on Section 1 General Information 1 77 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

Guardian Technologies 004992-2 Portable Generator User Manual

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