Generac Power Systems Portable Generator 004992 0 004992 1 User Manual

Owner’s Manual

Liquid-cooled, Prepackaged

Standby Generators

Model Nos. 004992-0

004992-1

37kW NG, 40kW LP

This manual should remain with the unit.

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

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Table of Contents

Guardian 40kW Liquid-cooled Generators

INTRODUCTION................................................IFC

SAFETY RULES....................................................2

Section 3 — OPERATION ................................13

3.1 Using an Engineered “GTS” Transfer Switch ......13

3.2 Control Console Components..............................13

3.3 Manual Transfer and Startup..............................14

3.4 Engine Governor Adjustments ............................14

3.5 Retransfer and Shutdown....................................15

3.6 Automatic Operation ..........................................15

3.7 Weekly Exercise Cycle..........................................15

Section 4 — MAINTENANCE ..........................16

Section 1 — GENERAL INFORMATION ............4

1.1 Generator..............................................................4

1.2 Transfer Switch ....................................................4

1.3 Automatic System Operation ................................4

1.4 Generator AC Connection Systems........................4

1.5 Main Circuit Breaker ............................................4

1.6 Generator Fuel System..........................................5

1.7 Engine Protective Devices......................................5

1.8 Unpacking ............................................................6

1.9 Lifting the Generator ............................................6

1.10 Specifications ........................................................7

1.11 Fuel Consumption ................................................7

1.12 Reconfiguring the Fuel System ..............................7

1.13 Torque Specifications............................................8

1.14 Engine Oil Recommendations ..............................8

1.15 Coolant Recommendations....................................8

1.16 Before Installation ................................................8

Section 2 — INSTALLATION ............................8

2.1 Standby Generator Installation ............................8

2.2 Generator Location................................................9

2.3 Generator Mounting and Support ........................9

2.4 Basic Standby Electric System..............................9

2.5 Emergency Circuit Isolation Method....................10

2.6 Total Circuit Isolation Method ............................10

2.7 Grounding the Generator ....................................10

2.8 Generator AC Neutral Connections......................10

2.9 Transfer Switch Start Signal Connections ..........10

2.10 Battery Installation..............................................11

2.11 Preparation Before Start-Up................................12

4.1 Maintenance Performed by Authorized

Service Facilities..................................................16

4.2 Cooling System....................................................16

4.3 Overload Protection for Engine DC

Electrical System ................................................16

4.4 Checking Fluid Levels ........................................16

4.5 Maintenance Owner/Operator

Can Perform........................................................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 — NOTES ........................................44

Section 10 — WARRANTY .................Back Cover

Generac Power Systems, Inc.

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IMPORTANT SAFETY INSTRUCTIONS

Guardian 40kW Liquid-cooled Generators

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe

operation be copied and posted in potential hazard areas. Safety should be stressed to all

operators, potential operators, and service and repair technicians for this equipment.

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be

followed during installation and maintenance of the generator and batteries.

GENERAL HAZARDS

WARNING:

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

• For safety reasons, Generac recommends that this

equipment be installed, serviced and repaired by an

authorized service dealer or other competent, quali-

fied electrician or installation technician who is famil-

iar 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 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.

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.

Generac cannot anticipate every possible circum-

stance 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 Generac does not

specifically recommend, ensure that it is safe for others.

Also make sure the procedure, work method or operat-

ing technique chosen does not render the generator

unsafe.

DANGER

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 capable persons to install, operate or main-

tain this equipment.

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.

• 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.

Parts of the generator are rotating and/or hot

during operation. Exercise care near running gen-

erators.

Generac Power Systems, Inc.

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IMPORTANT SAFETY INSTRUCTIONS

Guardian 40kW Liquid-cooled Generators

• Inspect the generator regularly, and promptly repair • Generators installed with an automatic transfer

or replace all worn, damaged or defective parts using

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 Operate” tag on the generator control

panel and on the transfer switch.

only factory-approved parts.

• Before performing any maintenance on the generator,

disconnect its battery cables to prevent accidental

start-up. Disconnect the cable from the battery post

indicated by a NEGATIVE, NEG or (–) first.

Reconnect that cable last.

• Never use the generator or any of its parts as a step.

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.

• 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.

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.

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

• 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 that 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.

• 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.

• Generac generator sets may operate using one of sev-

eral 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.

Generac Power Systems, Inc.

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Section 1 - General Information

Guardian 40kW Liquid-cooled Generators

1.1 GENERATOR

1.3 AUTOMATIC SYSTEM OPERATION

When this generator, along with a transfer switch, has

been installed and interconnected, a circuit board in

the generator panel constantly monitors UTILITY

power source voltage. Should that voltage drop below

a preset value, and remain at such a low state for a

preset amount of time, the generator cranks and

starts. After the generator starts, the transfer switch

transfers load circuits so the generator can power

them.

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.

When utility source voltage has been restored, the

switch re-transfers back to the UTILITY source volt-

age and the generator then shuts down.

If this generator is used to power electrical

load circuits normally powered by a utility

power source, it is required by code to install

Please reference the transfer switch manual for spe-

cific information.

a transfer switch. The transfer switch must

effectively isolate the electric system from the

utility distribution system when the generator

is operating (NEC 701). Failure to isolate an

electrical system by such means results in

damage to the generator and may also result

in injury or even death to utility power work-

ers due to backfeed of electrical energy.

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.

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:

• Install the transfer switch on a firm, sturdy sup-

porting structure.

Figure 1.1 - Generator AC Connection System

• 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 or any corro-

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 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

004992-0

Rating

37,000 NG

40,000 LP

Phase

Actual Current

154.2

C/B Rating*

Circuit Breaker

200A QN2

200

166.7

200A QN2

* Amp Rating of C/B structured under model.

Generac Power Systems, Inc.

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Section 1 - General Information

Guardian 40kW Liquid-cooled Generators

NOTE:

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 Section 1.12 for conversion.

The Low Oil Pressure, High Coolant Temperature

and Low Coolant Level are not monitored for the

first 10 seconds of engine run time.

Fuel pressure for a natural gas set up should be five

inches to 14 inches of water column (0.18 to 0.5

psi) at all load ranges.

Figure 1.4 - Low Oil Pressure Switch

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.

Gaseous fuels such as natural and LP

(propane) gas are highly explosive. Even the

slightest spark can ignite such fuels and cause

1.7.2 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).

‹

an explosion. 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 1.5- High Coolant Temperature Switch

Figure 1.3 - Engine Protective Devices

Low Oil Pressure Switch

High Coolant

Temperature Switch

Low Coolant

Level Sensor

1.7.3 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).

1.7.1 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 engine

shuts down automatically, and the low oil pressure

LED is turned ON (Figure 1.4).

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Section 1 — General Information

Guardian 40kW Liquid-cooled Generators

Figure 1.6 - Low Coolant Level Sensor

1.7.7 LOW BATTERY

‹

The engine control board continually monitors the

battery voltage and turns on the low battery LED if

the battery voltage falls below 11.0 VDC for one

minute. Low battery voltage is a non-latching alarm,

which will automatically clear if the battery voltage

rises above 11.0 VDC.

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.

1.7.4 OVERSPEED SHUTDOWN

‹

Battery voltage is NOT monitored during the crank

cycle.

The engine control board receives AC frequency sig-

nals from an engine run winding in the alternator.

Should AC frequency 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).

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.

1.7.9 DC FUSE

‹

Figure 1.7 - Printed Circuit Board Assembly

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).

R44

LED1

C27

C26

D10

C21

1.8 UNPACKING

C30

1.8.1 UNPACKING PRECAUTIONS

Handle shipping cartons and crates with care. Use

care to avoid damage from dropping, bumping, colli-

sion, etc..

‹

RL1

RL2

R48

D17

R49

D19

R E V 9 0 6 E 0 4 B #

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 loss or damage.

‹

1.7.5 RPM SENSOR LOSS

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

‹

1.9 LIFTING THE GENERATOR

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.

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.

If the engine fails to start after all six attempts, the

start attempt is stopped and the overcrank LED

turned on.

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Section 1 — General Information

Guardian 40kW Liquid-cooled Generators

Fuel pressure for a natural gas set up should be five

inches to 14 inches of water column (0.18 to 0.5

psi) at all load ranges.

1.10 SPECIFICATIONS

1.10.1 GENERATOR SPECIFICATIONS

‹

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.

Single-phase

Model

Rated Max. Cont.

4992-0

37 (NG), 40 (LP)

AC Power Output (kW)

Rated voltage (volts)

No. of Rotor Poles

Driven Speed of Rotor

Rotor Excitation System

Type of Stator

1.12 RECONFIGURING THE FUEL

120/240

1800

SYSTEM

Fuel pressure for both natural gas and liquid

propane set ups should be 11 inches to 14 inches of

water column (0.4 to 0.5 psi) at all load ranges.

Direct excited brush type

4 Wire

Rotor/Stator Insulation

Class F/H

NOTE:

1.10.2 ENGINE SPECIFICATIONS

‹

All models are configured for natural gas from the

factory.

Make..................................................................................................Chrysler

Displacement ....................................................................................3.9 liters

Cylinder Arrangement ..............................................................................V-6

Valve Arrangement................................................................Overhead Valve

Firing Order ..................................................................................1-6-5-4-3-2

Number of Main Bearings ............................................................................4

Compression Ratio ............................................................................9.1 to 1

No. of Teeth on Flywheel ..........................................................................164

Ignition Timing at 1800 rpm ..............................................30 degrees BTDC

Spark Plug Gap................................................................1.01mm (0.040 in.)

Recommended Spark Plugs

Champion......................................................................................RC12LC4

Oil Pressure ....................................................................................30-80 psi

Crankcase Oil Capacity ........................................4.0 U.S. quarts (3.8 liters)

Recommended Engine Oil ........................................................SAE 15W-40

Type of Cooling System ..................................Pressurized, closed recovery

Cooling Fan ................................................................................Pusher Type

Cooling System Capacity ..................................5.0 U.S. gallons (19.3 liters)

To reconfigure the fuel system from NG to LP vapor,

follow 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).

3. Remove the brass hose fitting from the outlet port

(Port 1) of the demand regulator.

4. Remove pipe plug from Port 2.

5. Install brass hose fitting into Port 2.

6. Install pipe plug into Port 1.

7. Connect carburetor gas hose to brass fitting.

8. Tighten all clamps and plugs.

9. Make sure fuel supply is of the proper pressure

and type for configuration.

10. Reverse the procedure to convert back to natural

Recommended Coolant ............................................Use a 50-50 mixture of

gas.

ethylene glycol base

and de-ionized water.

Figure 1.8 — Reconfigure the Fuel System

Port 1

Port 2

1.11 FUEL CONSUMPTION

FUEL HOSE

Natural Gas:

BRASS HOSE

FITTING

BRASS HOSE

FITTING

% of Load

25%

4.1

50%

7.7

75%

11.0

100%

14.2

PLUG

OUT

PORT 1

OUT

PORT 2

m /hr

HOUSING

PORTS

HOUSING

PORTS

ft /hr

143.1

271.1

388.5

502.0

LP Vapor:

% of Load

25%

1.7

50%

3.3

75%

4.7

100%

6.0

m /hr

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.

NG FUEL SYSTEM

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.

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Section 2 — Installation

Guardian 40kW Liquid-cooled Generators

DANGER

Serious injury or damage may occur if not

configured properly. Please consult an author-

ized service dealer with any questions.

Do not use any chromate base rust inhibitor

with ethylene glycol base anti-freeze or

chromiumhydroxide (“green slime”) forms and

will cause overheating. Engines that have

been operated with a chromate base rust

inhibitor must be chemically cleaned before

adding ethylene glycol base anti-freeze. Using

any high silicate anti-freeze boosters or addi-

tives will also cause overheating. It is also rec-

ommend that any soluble oil inhibitor is NOT

USED for this equipment.

1.13 TORQUE SPECIFICATIONS

Tighten the bolts from the middle out, in a criss-

cross pattern.

Cylinder Head ....................................50 ft.lb./105 ft.lb./105 ft.lb.

Intake Manifold ....................................48 in.lb./84 in.lb./84 in.lb.

Exhaust Manifold..............................................................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, SF.” 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:

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.

Temperature

Above 80° F (27° C)

32° to 80° F (-1° to 27° C)

Below 32° F (0° C)

Oil Grade (Recommended)

SAE 15W-40

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.

NOTE:

Synthetic oil is highly recommended in any ele-

ment with temperatures above 90° F or below 30°

2.1 STANDBY GENERATOR

INSTALLATION

Any attempt to crank or start the engine

DANGER

before it has been properly serviced with the

recommended oil may result in an engine fail-

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

and may also result in injury or death to utility

workers due to backfeed of electrical energy.

ure.

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.

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.

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Section 2 — Installation

Guardian 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:

After the system has been installed, do nothing

that might render the installation in noncompli-

ance with such codes, standards and regula-

tions.

• Install the unit where air inlet and outlet openings

will not become obstructed by leaves, grass, snow,

etc. If prevailing winds will cause blowing or drift-

ing, consider using a windbreak to protect the unit.

• Install the generator on high ground where water

levels will not rise and endanger it.

• This genset must be installed on a level surface.

The base frame must be level within 1/2 inch all

around.

2.1.1 NFPA 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:

• 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.

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

LIQUIDS CODE.

• 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.

• NFPA No. 10, INSTALLATION, MAINTENANCE AND

2.3 GENERATOR MOUNTING AND

USE OF PORTABLE FIRE EXTINGUISHERS.

SUPPORT

2.1.2 OTHER PUBLISHED STANDARDS

‹

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.

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.

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 circuits 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.

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Section 2 — Installation

Guardian 40kW Liquid-cooled Generators

Figure 2.1 – Basic Standby Electric System

2.7 GROUNDING THE GENERATOR

The National Electrical Code requires the frame and

external electrically conductive parts of this 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.

DANGER

Do not connect the ground wire to any pipe

that carries a flammable or explosive substance

– FIRE or an EXPLOSION may result.

2.5 EMERGENCY CIRCUIT ISOLATION

Proper grounding helps protect personnel against

electrical shock in the event of a ground fault condi-

tion in the generator or in connected electrical

devices. In addition, grounding helps dissipate static

electricity that often builds up in ungrounded

devices.

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.

Figure 2.2 – Generator Grounding Lug (typical)

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-

tribution panel and the emergency distribution

panel.

GROUNDING

LUG

2.6 TOTAL CIRCUIT ISOLATION

METHOD

2.8 GENERATOR AC NEUTRAL

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.

CONNECTIONS

Generac uses an UNGROUNDED AC neutral.

Grounding is recommended only at the main service

entrance. If the neutral wire is grounded and one of

the phase loads becomes grounded, the excessive

current opens the load circuit breaker or collapses

the generator field. The actual result depends on the

electrical characteristics of the particular installed

generator.

• 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.

Failure to connect the generator neutral prop-

erly will result in unbalanced line-to-neutral

voltages. Resulting high voltages will cause

equipment damage.

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Section 2 — Installation

Guardian 40kW Liquid-cooled Generators

2.9 TRANSFER SWITCH SIGNAL

CONNECTIONS

2.10 BATTERY INSTALLATION

DANGER

Standby generators installed with automatic

transfer switches will crank and start automati-

‹

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.

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 personnel, do not connect battery

cables until certain that normal source voltage

at the transfer switch is correct and the system

is ready to be placed into operation.

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 recommended below:

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.

MAXIMUM WIRE LENGTH

RECOMMENDED WIRE

SIZE

460 feet (140m)

No. 18 AWG.

No. 16 AWG.

No. 14 AWG.

No. 12 AWG.

461 to 730 feet (223m)

731 to 1,160 feet (354m)

1,161 to 1,850 feet (565m)

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.

‹

2.9.2 GTS-TYPE ATS

If the generator is to be installed with an engineered

automatic transfer switch, such as a Generac 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.)

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.

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.

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.

2.10.1 VENTED BATTERIES

‹

The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive. The following proce-

dures are to be observed:

• 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

Generac Power Systems, Inc. 11

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Section 2 — Installation

Guardian 40kW Liquid-cooled Generators

Before starting the generator for the first time, the

installer must complete the following procedures. For

follow-up maintenance information and/or service

intervals, please refer to Section 4, “Maintenance.”

• 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.

‹

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.

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.

‹

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.

The recommended battery is Group 27F, 12V nega-

tive ground, 700 CCA/90 AH minimum capacity. All

batteries 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.

‹

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:

Damage will result if the battery connections are

This engine is shipped from the manufacturer

with 5W-20 oil. This oil should be changed after

30 hours of operation.

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.

‹

2.11.5 ENGINE COOLANT

Have the engine cooling 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).

2.11.1 PRIOR TO INITIAL START-UP

‹

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,

‹

2.11.7 ELECTRICAL SYSTEM

Make sure the generator is properly connected to an

approved earth ground and/or ground rod.

fuel, etc.) may result in an engine failure.

12 Generac Power Systems, Inc.

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Section 3 - Operation

Guardian 40kW Liquid-cooled Generators

Make sure the generator battery is fully charged, prop-

erly installed and interconnected, and ready for use.

3.2 CONTROL CONSOLE

COMPONENTS

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.

The components of a home standby generator control

console (Figure 3.1) are as follows:

Figure 3.1 - Home Standby Generator Panel

3.1 USING AN ENGINEERED “GTS”

TRANSFER SWITCH

LED INDICATORS:

FLASHING GREEN LED

NO UTILITY SENSE

When required, the pre-packaged standby generator

can be installed with an engineered Generac “GTS”

type automatic transfer switch.

FLASHING RED LED'S

EXERCISER NOT SET

(IN AUTO MODE ONLY) SOLID GREEN LED

RED LED'S INDIVIDUAL FAULT

SYSTEM READY, UTILITY POWER ON

(SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS)

OVER CRANK

RED LED

In this application, the GTS is responsible for utility

sensing, weekly exercising, and load transferring.

AUTO

OFF

SET

EXECISER

TIME

SET

EXERCISE

TIME

MANUAL

GREEN LED

TO SET EXERCISER TIME

1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.

Position two of the four-position dip switch is used to

turn over this control to the GTS.

0E7194

SWITCH

Pos2 ON — GTS Application

AUTO/OFF/MANUAL

SWITCH

• 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.)

4A FUSE

BATTERY

CHARGER

15A FUSE

MAIN

POWER

• The control board will NOT activate the transfer

3.2.1 AUTO/OFF/MANUAL SWITCH

‹

output.

• The control board WILL monitor all engine condi-

tions and shut down on all the faults listed in this

document.

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.

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

DANGER

When in GTS mode, the control board will respond

as follows based on the AUTO/OFF/MANUAL switch

position.

With switch set to AUTO, engine can crank

and start suddenly without warning. Such

automatic start up normally occurs when utili-

ty 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 a “DO NOT

OPERATE” tag on control console.

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.

3.2.2 FAULT INDICATOR LEDS

These LEDs turn ON when one of the following

engine faults occurs and the engine shuts down.

‹

• Low Oil Pressure

• Overcrank

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.

• Low Battery

• Overspeed/RPM Sensor Loss

• High Coolant Temperature/Low Coolant Level

See Section 1.7 for further explanation of engine pro-

tection functions.

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Section 3 — Operation

Guardian 40kW Liquid-cooled Generators

3.2.3 15 AMP FUSE

‹

3.4 ENGINE GOVERNOR

Fuse protects the control console’s DC control circuit

against electrical overload. If the fuse has melted

open because of an overload, engine cranking and

startup cannot occur. If the fuse needs to be replaced,

use only an identical 15-amp replacement fuse. (Type

AGC)

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.

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).

‹

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.

NOTE:

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).

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.”

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.

3.2.6 SYSTEM READY LED

‹

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.

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.

Figure 3.2 — Engine Governor Adjustment

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.

R44

LED1

C27

C26

D10

C21

This secondary function is only available with dip

switch two in the OFF position (engineered transfer

switch application).

C30

RL1

RL2

R48

D17

3.3 MANUAL TRANSFER AND

R49

START-UP

To transfer electrical loads to the Standby (EMER-

GENCY) power source side and start the engine man-

ually, refer to the Owner’s Manual of the particular

transfer switch.

D19

DIP SWITCH

DIFFERENTIAL

STABILITY

POSITION 1

50/60 HZ

POSITION 2

GTS/ATS Select

ON = GTS

UNUSED

ON = 50 HZ

GTS/ATS

OFF = ATS (standard mode)

OFF = 60 HZ

50/60 HZ

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Section 3 - Operation

Guardian 40kW Liquid-cooled Generators

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

generator 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.

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).

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.

• 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.

Figure 3.2 - “Set Exercise Time” Switch

• 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, using whatever means provided (such as a

utility main line circuit breaker). The utility power

source now powers the loads.

FUSE

BAT.

CHARGER

15A

MAIN

3.6 AUTOMATIC OPERATION

To set the system for fully automatic operation, pro-

ceed as follows:

AUTO

OFF

• Check that load circuits are connected to the

utility power supply.

• Set the AUTO/OFF/MANUAL switch to its AUTO

position.

• Set the generator main circuit breaker to its ON or

Closed position.

SET

EXERCISE

TIME

MANUAL

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.

At this time all five red LEDs will flash for approxi-

mately 10 seconds, then the engine will start and run

for it’s 12 minute exercise period, then shut down.

The generator will now start and run each week at the

same time.

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Section 4 — Maintenance

Guardian 40kW Liquid-cooled Generators

4.1 MAINTENANCE PERFORMED BY

AUTHORIZED SERVICE DEALERS

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.

A. EVERY THREE MONTHS

1. Check battery state of charge and condition.

2. Inspect and test fuel system.

3. Check transfer switch.

4. Inspect exhaust system.

5. Check engine ignition system.

6. Check fan belts.

If a circuit breaker opens or a fuse element

melts, find the cause of the overload before

resetting the circuit breaker or replacing the

B. ONCE EVERY SIX MONTHS

1. Test Engine Safety Devices (low oil pressure, low

coolant level, high coolant temperature).

fuse.

4.4 CHECKING FLUID LEVELS

C. ONCE ANNUALLY

1. Test engine governor. Adjust or repair, if needed.

2. Clean, inspect generator.

4.4.1 CHECK ENGINE OIL

Check engine crankcase oil level (Figure 4.1) month-

ly, or prior to use.

‹

3. Flush cooling system.

• Remove oil dipstick and wipe dry with a clean,

lint-free cloth.

D. FIRST 100 OPERATING HOURS

• 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.

1. 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. (See

Torque Specs, Section 1.13.)

Figure 4.1 - Oil Dipstick and Oil Fill Cap

E. EVERY 500 OPERATING HOURS

1. Service air cleaner.

2. Check starter.

Oil Dipstick

Oil Fill

3. Check engine DC alternator.

4.2 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.

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.)

Oil Filter

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.

The exhaust system parts from this product get

extremely hot and remain hot after shutdown.

High grass, weeds, brush, leaves, etc. must

remain clear of the exhaust. Such materials may

ignite and burn from the heat of the exhaust

system.

4.4.3 ENGINE COOLANT

‹

Check coolant level in coolant recovery bottle. See

Specifications, Section 1.10.

16 Generac Power Systems, Inc.

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Section 4 — Maintenance

Guardian 40kW Liquid-cooled Generators

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap to make

sure the coolant recovery system is functioning

properly. Coolant should be at bottom of radiator

filler neck. If coolant level is low, inspect gasket in

radiator pressure cap. Replace cap, if necessary.

To have pressure cap tested, contact an authorized

service dealer. Inspect cooling system and coolant

recovery system for leaks.

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. Adjust belt tension as required.

‹

4.5.9 INSPECT ENGINE GOVERNOR

‹

Visually inspect electronic governor.

4.5 MAINTENANCE OWNER/

OPERATOR CAN PERFORM

DANGER

4.5.1 CHECK ENGINE OIL LEVEL

‹

DANGER: Do not attempt to adjust the gover-

nor. Only qualified service dealers should

adjust the governor. Excessively high operat-

Refer to “Checking Fluid Levels” in Section 4.4.

ing 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 short-

en engine life. Correct rated frequency and

voltage are supplied only at the proper gov-

erned speed. Some connected electrical load

devices may be damaged by incorrect fre-

quency and/or voltage. Only qualified service

technicians should adjust the governed speed.

4.5.2 CHECK BATTERY

• Check battery 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.

‹

4.5.3 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”.

4.5.10 CHANGING ENGINE OIL

Refer to maintenance performed by authorized service

dealers for engine oil and filter change frequencies.

‹

4.5.4 INSPECT COOLING SYSTEM

• Inspect engine cooling system at least once each

month.

‹

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:

• Check hoses for damage, deterioration, leaks, etc.

Correct any discrepancies found.

• Check hose clamps for tightness.

1. Remove OIL DRAIN HOSE from its retaining clip.

2. Loosen and remove OIL 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.

4.5.5 CHECK ENGINE COOLANT LEVEL

See “Checking Fluid Levels” in Section 4.4.

‹

4. Turn OIL FILTER (Figure 4.2) counterclockwise

4.5.6 PERFORM VISUAL INSPECTION

‹

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. Add recommended oil (see

SPECIFICATIONS). DO NOT FILL ABOVE THE

DIPSTICK “FULL” MARK. Crankcase oil capacity

is 4.0 U.S. quarts (3.8 liters).

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.

After refilling the crankcase with oil, always

check oil level on dipstick. NEVER OPERATE

ENGINE WITH OIL BELOW THE DIPSTICK

“ADD” MARK.

Generac Power Systems, Inc. 17

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Section 4 — Maintenance

Guardian 40kW Liquid-cooled Generators

7. Start engine and check for oil leaks.

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.

Figure 4.2 - Oil Filter

4.6 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.

Oil Filter

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.

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.

Once each year, have the generator cleaned and

inspected by an authorized service dealer. That deal-

er will use dry, low pressure air to clean internal

windings. Parts inside the control console should be

cleaned and inspected at this time as well.

See the “Service Schedule,” Section 6, for air cleaner

maintenance.

Finally, have the insulation resistance of stator and

rotor windings checked. If insulation resistances are

excessively low, the generator may require drying.

4.5.12 SPARK PLUGS

‹

Reset the spark plug gap or replace the spark plugs

as necessary. See Section 6.

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:

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).

• DO NOT use jumper 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.

Figure 4.3 – Setting the Spark Plug Gap

SET PLUG GAP AT 1.01 mm

(0.040 inch)

• 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.

18 Generac Power Systems, Inc.

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Section 4 — Maintenance

Guardian 40kW Liquid-cooled Generators

4.6.3 BATTERY MAINTENANCE

4.6.4 BATTERY REPLACEMENT

‹

The battery should be inspected per the “Service

Schedule,” Section 6. The following procedure

should be followed for inspection:

When replacing batteries, use the same number and

the type of battery that follows:

BCI Group No.

CCA

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.

27F

700 @ 0 deg. F

NOTE:

The BCI number should be located directly

on the battery.

PERIODIC REPLACEMENT PARTS

Part Name

Generac’s Part Number

DANGER

Oil Filter

# 0E7415

# 046627

# 0A4637

Radiator Cap

Air Cleaner

Spark Plug

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.

Champion # RC12LC4

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.

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.

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,

or sparking may occur at the battery posts as

the cables are attached and cause an explosion.

Generac Power Systems, Inc. 19

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Section 4 — Maintenance

Guardian 40kW Liquid-cooled Generators

4.7 SCHEDULED MAINTENANCE

Following is a recommended maintenance schedule for Generac small standby and residential generator sets. The

established intervals in the schedule are the maximum recommended when the unit is used in an average service

application. They will need to be decreased (performed more frequently) if the unit is used in a severe application.

Use calendar time from the previous maintenance interval to determine the next required maintenance 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, 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 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 Generac Power Systems, Inc.

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Section 4 — Maintenance

Guardian 40kW Liquid-cooled Generators

Maintenance

Tasks

Level 1

Recom-

mended

Level 2

Required

Level 3

Required

Level 4

Task

Comp.

Comp. to be done Comp. to be done Comp.

Required

to be done (Date-

monthly Initials)

3 months/

Break-in

(Date-

Initials)

Semi-

annually

(Date-

Initials)

to be done (Date-

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 air inlets and

outlets for debris. Clean as

necessary.

7. Check the battery

electrolyte level if

accessible. Adjust as

necessary.

8. Check the battery posts,

cables, and charger for

loose connections,

corrosion, and proper

operation. Correct as

necessary.

9. Check the unit 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.

Generac Power Systems, Inc. 21

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Section 4 — Maintenance

Guardian 40kW Liquid-cooled Generators

Maintenance

Tasks

Level 1

Recom-

mended

Level 2

Required

Level 3

Required

Level 4

Task

Comp.

Comp. to be done Comp. to be done Comp.

Required

to be done (Date-

monthly Initials)

3 months/

Break-in

(Date-

Initials)

Semi-

annually

(Date-

Initials)

to be done (Date-

Annually Initials)

13. Initiate an automatic start

and transfer of the unit to

site load and exercise it for

at least 1 hour looking for

leaks, loose connections

or components, and

abnormal operating

conditions. Correct as

necessary.

14. Start and exercise the unit

at full rated load (use a

load bank if the site load is

not enough) for at least 2

hours looking for leaks,

loose connections or

components, and abnormal

operating conditions.

Correct as necessary.

15. Change the engine oil.

16. Replace the engine oil

filter(s).

17. Replace the engine air

filter(s).

18. Replace the engine fuel

filter(s) on diesel engine

driven units and re-prime

the fuel system.

19. Check the engine spark

plugs on gas engine driven

units. Clean and re-gap or

replace as necessary.

20. Perform a 5 minute no-load

operational run of the unit

looking for any post service

problems.

21. Return the unit to standby

setup for operation when

required.

22 Generac Power Systems, Inc.

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Section 5 — Troubleshooting

Guardian 40kW Liquid-cooled Generators

TROUBLESHOOTING POINTS

PROBLEM

CAUSE

CORRECTION

Engine won’t crank.

1. 15 amp fuse blown.

1. Replace fuse.

2. Loose or corroded or defective

battery cables.

2. Tighten, clean or replace

battery cables as necessary.

3. Defective starter contactor.

4. Defective starter motor.

5. Dead or Defective Battery.

6. 4 amp fuse blown.

3. Replace contactor.

4. Replace starter motor.

5. Remove, change or replace battery.

6. Replace fuse.

Engine cranks, but won't start

1. Out of fuel.

2. Fuel solenoid (FS) is defective

3. Open Wire #14 from Engine Control

circuit board.

1. Replenish fuel.

2. Replace solenoid.

3. Reconnect wire.

4. Spark plugs defective.

4. Clean, regap or replace plugs.

1. Clean or replace as needed.

Engine starts hard, runs rough.

Engine starts, then shuts down.

1. Flame arrestor (air cleaner) plugged or

damaged.

2. Plugged fuel line.

3. Defective spark plugs.

2. Unclog fuel line.

3. Clean, regap or replace plugs.

1. Engine oil level is low.

2. Engine is overheated.

3. Defective Low Oil Pressure Switch

4. Defective Coolant Temperature Switch

5. Defective Control Module circuit board.

6. Coolant Level is Low.

1. Check oil and add oil as needed.

2. Check cooling system for leaks.

3. Replace switch.

4. Replace switch.

5. Replace board.

6. Repair leak - Add coolant.

7. Replace Switch.

7. Defective Low Coolant Level Switch

AUTO/OFF/MANUAL Switch at,

OFF engine continues to run

1. Defective AUTO/OFF/MANUAL switch

1. Replace switch.

2. Reconnect/close wire.

2. Open/disconnected wire #15A between

AUTO/OFF/MANUAL switch and Control

Module circuit board.

3. Defective Control Module circuit board

3. Replace board.

No AC output from generator.

1. Check main line circuit breaker.

2. Check circuit breaker & fuses.

3. Transfer switch set to NORMAL position

4. Generator internal failure.

1. Reset to ON or CLOSED.

2. Reset and replace, if necessary.

3. Set to GENERATOR position.

4. Contact an authorized service dealer.

5. Thermal circuit breaker open.

5. Auto-reset - Wait 5 min. and

attempt restart.

NOTE:

Under normal operating conditions, if repair of generator set or replacement 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.

Generac Power Systems, Inc. 23

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Section 6 - Electrical Data

Guardian 40kW Liquid-cooled Generators

Wiring Diagram — Engine — Drawing No. 0E8115-A

24 Generac Power Systems, Inc.

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Section 6 - Electrical Data

Guardian 40kW Liquid-cooled Generators

Wiring Diagram — Engine — Drawing No. 0E8115-A

Generac Power Systems, Inc. 25

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Section 6 - Electrical Data

Guardian 40kW Liquid-cooled Generators

Electrical Schematic — Engine — Drawing No. 0E8116-A

26 Generac Power Systems, Inc.

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Section 6 - Electrical Data

Guardian 40kW Liquid-cooled Generators

Electrical Schematic — Engine — Drawing No. 0E8116-A

Generac Power Systems, Inc. 27

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Mounting Base — Drawing No. 0E8084-A

28 Generac Power Systems, Inc.

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Mounting Base — Drawing No. 0E8084-A

ITEM

PART NO.

QTY.

DESCRIPTION

0E7331

052860

052251

052257

052252

052259

052891

0536210214

074906

047411

055414

026850

022097

022473

049813

0A1694

025507

0E7359

027482

022129

045771

051756

046526

022131

055934M

049820

059473

061902

058665

038804D

038805J

021991

036833

022237

022131

075763

050331

050331A

0A4010

052858

065852

045764

REF.

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 M6-1.0 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 M6-1/4

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 M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

SCREW HHC 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 M8-1.25 NY INS

HOLD DOWN BATTERY

BATT 12VDC 90-AH 27F

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

23*

24*

25*

26*

WASHER FLAT 3/8 ZINC

BOOT BATTERY CABLE

BATTERY POST COVWER (BLACK)

BATTERY POST COVWER (RED)

SCREW HHC M8-1.25 X 60 G8.8 FT

NUT TOP LOCK FL M8-1.25

SPRING CLIP HOLDER .37-.62

SCREW HHTT M4-0.7 X 8 BP

*NOT SHOWN-USED TO HOLD DOWN I/N 32.

Generac Power Systems, Inc. 29

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Enclosure — Drawing No. 0E8439-E

30 Generac Power Systems, Inc.

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Enclosure — Drawing No. 0E8439-E

ITEM

PART NO.

QTY.

DESCRIPTION

0E8411

0E8042

0E8041

0C2454

0E7807

0E7808

0E7809

0E8387

0E6986

0E7795

089961

0A2115

0E8404

0D2538A

0D2538

043116

022097

022473

0E7570

0E7571

070015

0E7662

0D2537A

0D2537

0D2023

0E7869

0E8001

0E8060

0E7966

0D3037A

0C7781

0E7794

0E8052

0D3037

0E8007

0E8008

0E7992

0E8055

026850

0912970063

0912970064

049813

0E8665

0D2023

0E8442

0E7829A

0E7829B

0E7829P

0E7829R

0E7829S

0E7829T

0E7829N

078115

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

SCREW HHC M6-1.0 X 12 G8.8

WASHER LOCK M6-1/4

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/GAS SPRING MNT 3.0L FRD

BRACE FRONT TOP

LATCH 1/4 TURN NONLOCKING

PAWL DOOR HSB

50 *

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 GRD WIRE 99HSB

ASSEMBLY BASE-DOOR GROUND WIRE

NUT HEX M6 X 1.0 G8 YEL CHR

BRACKET STIFFENER LH FRONT

TRIM VINYL SELF GRIPPING (165.5"LG)

KIT INSULATION 3.9L HSB

AI ROOF PANEL 1

AI DOOR PANEL

AI CORNER POST PANEL 1

AI CORNER POST PANEL 2

AI SUPPORT LH PANEL

AI SUPPORT RH PANEL

AI ROOF PANEL 2

WASHER SELF LOCKING DOME

* ALL ITEMS NOTATED WITH "AI" ARE COMPONENTS OF 0E8442

Generac Power Systems, Inc. 31

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Control Panel — Drawing No. 0E7118-G

32 Generac Power Systems, Inc.

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Control Panel — Drawing No. 0E7118-G

ITEM PART NO. QTY.

DESCRIPTION

ITEM PART NO. QTY.

DESCRIPTION

0E7195

0E7196

0E7197

0E7193

0E7194

0E4494

082573

032300

022676

067682B

060015

054199

0C2657

099076

040213

0E9668

0E4905

CONTROL BOX HSB

0D4698 *

0E7252

0C1229

REF.

BLOCK TERM 20A 6 X 3 X 1100V

BRACKET CB 221.5 X 102

DECAL WARNING ELECTRICAL

SHOCK

DECAL AVR COVER

COVER PLATE, AVR

HARNESS CNTRL PNL 3.0L FORD

(NOT SHOWN)

SCREW PPPH HI-LO #4-24 X 3/8

SCREW HHTT M5-0.8 X 10 BP

CONN DEUTSCH GASKET 8/12 POS

SCREW PHTT #6-32 X 3/8 ZYC

SCREW PHTT #6-32 X 5/8 ZYC

WASHER LOCK #6

SCREW PHTT M4-0.7 X 12 ZYC

WASHER LOCK #8-M4

SCREW PPHM M5-0.8 X 30 ZINC

SCREW HHTT M5-0.8 X 16

WASHER LOCK #10

WASHER FLAT #10 ZINC

NUT HEX M5-0.8 G8 YEL CHR

SCREW HHTT M6-1.0 X 12 ZINC

SCREW HHC M6-1.0 X 20 G8.8

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

WIRE ASSY 3" X (2) 3/16" TABS

WASHER MICA .203

WASHER SHAKEPROOF EXT #10

STL

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

0C1127

0A1441B

0E7128

FUSE 15A X AGC15

0E7358

074908

0C5141

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 3.9L

ASSY PCB HSB CONTRLR 3.0L

FORD

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

BLOCK TERM 20A 6 X 6 X 1100V

DECAL CUSTOMER CNNCTN E1 E3

0C2699

0C2323

022155

0C2265

022264

020911

066849

022152

023897

051716

090388

042568

022097

022473

0441140187

070370

023762

067680

REF.

0E6875A

0E6881 *

0C5139 *

0E5142 *

0E3161

054450

0D5070A

0E2514

0A9457

0E7539

055444

030468

049939

022158

022985

038750

0A2115

0C2454

HEATSINK

WASHER STEP NYLON .20

RECTIFIER MSC 12A 600V 1N1206R

NUT HEX #10-32 STEEL

WASHER FLAT #6 ZINC

SCREW HHC M6-1.0 X 30 G8.8

WASHER NYLON .257

046357 *

0D3719B

REF.

057073

0E7283

0E3628

0E3664

0E7539A

JUNCTION BLOCK 3/8-16

CB 0150A2P240V S QN2 LL

CB 0200A2P240V S QN2 LL

BASE QN CIRCUIT BREAKER

DECAL TB1 HSB CONTROL PANEL

SCREW THF M6-1 X 16 N WA Z/JS

* ITEMS INCLUDED AS PART OF I/N 39

Generac Power Systems, Inc. 33

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Engine — Drawing No. 0E8121-D

34 Generac Power Systems, Inc.

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Engine — Drawing No. 0E8121-D

ITEM PART NO. QTY.

DESCRIPTION

ITEM PART NO. QTY.

DESCRIPTION

0E5048A

0E7477

FLEXPLATE 3.9L HSB

MACHINING, 3.9L ENGINE

ADAPTOR

050873A

031919

PLUG PIPE 1/4 CSK W/ VIBRA SL

PLUG STD PIPE 3/8 COUNTER-

SUNK

0E6703

0E8336

0E7841

0E7254

REF

COVER, FLYWHEEL ACCESS

REWORK, 3.9L CHRYSLER ENGINE

GASKET, THERMOSTAT ADAPTOR

MACH, THERM ADAPTOR 3.9L

CHRY

BRACKET, IGNITION COIL

COIL IGNITION 3.9L CHRYSLER

SCREW HHC M6-1.0 X 16 G8.8

BOLT, AUTO TRANS CRANKSHAFT

BRACKET, ALTERNATOR

FAN SPACER, ENGINE COOLING

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

SCREW HHC M6-1.0 X 35 G8.8 BLK

NUT HEX M6 X 1.0 G8 YEL CHR

SCREW HHC 3/8-16 X 1 G8

WASHER FLAT 3/8-M10 ZINC

WASHER LOCK 3/8

022145

030795

051756

046526

0A1232A

0A7801B

045772

022403

0E7950

0E7951

0E8445

0E7415

042568

061652

031578

082120

023645

0E9974

0D3488A

0E7954

0E8309

029187

032712

054455

0E8606

0E8642

0E8597

WASHER FLAT 5/16-M8 ZINC

SCREW HHC 5/16-18 X 1 G5

SCREW HHC M10-1.5 X 20 G8.8

WASHER LOCK M10

ASSEMBLY, D.C. ALTERNATOR

PULLEY POLY-V 82 OD.

NUT HEX M10-1.5 G8 YEL CHR

SCREW HHC 5/16-18 X 2 G5

TUBE, DIPSTICK 3.9L CHRYSLER

DIPSTICK OIL LEVEL 3.9L CRYSLR

BRACKET, DIPSTICK TUBE

OIL FILTER, 3.9L CHRYSLER

SCREW HHC M6-1.0 X 20 G8.8

SCREW HHC M10-1.5 X 85 G8.8

SCREW HHC 3/8-16 X 1-1/2 G8

SPACER .41 X .75 X .39 ST/ZNC

SCREW SHC 3/8-16 X 1.25 G8.8 Z

CAP VINYL 3/8"ID X 1"DP BLK

BELT SERPENTINE 70"

CABLE IGN COIL 3.9L CHRYSLER

ASSY, IGNITION MODULE 3.9L

SPACER .19 X .31 X .50 PL

SCREW HHTT #10-32 X 1.75 CZ

ADP OIL DRN 1/2-20

SCREW PPH TAPPING #4 X 3/8"LG

ASSEMBLY, RESISTOR

HARNESS, 3.9L CHRYSLER ENGINE

(NOT SHOWN)

0E7956

0E7953

047411

0E8591

0E7921

0E7749

022097

022473

049721

049813

036833

022131

022237

0E9747

022129

049821

057073

052677

066849

056739

0D2244M

087599

0E0992B

STARTER, 12 VOLT

WASHER LOCK M8-5/16

SCREW SHC M8-1.25 X 30 G12.9

JUNCTION BLOCK 3/8-16

WASHER NYLON .50 X .87 X .06

SCREW HHTT M5-0.8 X 16

RELAY SOLENOID 12VDC PNL MNT

ASSY MAGPICKUP(3/8-24 MALE)

PLUG PLASTIC 3/8 NPT

REF

PLUG EXPANSION 21/32" O.D.

(WATER PUMP) (QTY 1)

0E8755

HARNESS, IGNITION 3.9L CHRY

(NOT SHOWN)

PLATE, FLEX DISK SPACER

SCREW SHC M10-1.5 X 25 G12.9

CAP VINYL 1/4"ID X 1"DP BLK

HEAT SHEILD, L/H SIDE

SCREW THF M6-1X16 N WA Z/JS

BARBED EL 90 3/8 NPT X 3/8

HOSE OIL DRAIN ASSY 21"

HOSE CLAMP BAND 5/8"

0E0992A

REF

PLUG EXPANSION 14.1 O.D.

(INJCTOR HOLE) (QTY 6)

COOLING FAN 10-BLADE (KYSAIR)

CLUTCH, COOLING FAN

TENSIONER W/BRACKET

PULLEY CRANKSHAFT 3.9L

CRYSLR

ASSY,WATER LEVEL SENSOR C/E

SENSOR HI COOLANT SHUTDOWN

PLUG STD PIPE 1/8 SOCKET HEAD

SWITCH,OIL PRESSURE, 10PSI,

2POL

0E8731

052647

0E9975

0F1444A

0C2454

043790

069860C

048031J

0F1444

REF

0E7754

0E7854

0E7855

0E7952

0E0561

035606

061012

0A8584

HEAT SHIELD, R/H SIDE

Generac Power Systems, Inc. 35

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Radiator — Drawing No. 0E8102-E

36 Generac Power Systems, Inc.

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Radiator — Drawing No. 0E8102-E

ITEM

PART NO.

QTY.

DESCRIPTION

0D7825A

0D7174C

0E7640

0E7924

0F2853

0D8252

0D8251

0E0726

076749

035685

069860C

058443

0C2454

052250

048031C

029032

0A2111

0E7640A

035461

065852

051756

022131

046526

045772

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 (27"LG)

CLAMP HOSE BAND 1/4

HOSE 9/32 ID (30" LG)

SCREW SWAGE 10-32 X 5/16 Z/YC

RADIATOR SUPPORT R/H SIDE

BARBED STR 1/4NPT X 3/8

SPRING CLIP HOLDER .37-.62

SCREW HHC M10-1.5 X 20 G8.8

WASHER FLAT 3/8-M10 ZINC

WASHER LOCK M10

NUT HEX M10-1.5 G8 YEL CHR

Generac Power Systems, Inc. 37

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Fuel System — Drawing No. 0E8122-F

38 Generac Power Systems, Inc.

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Fuel System — Drawing No. 0E8122-F

ITEM

PART NO.

QTY.

DESCRIPTION

033212

075580

0E8365

039253

022145

022129

045771

042907

0C2454

026307

0E1056

0E6584

057822

059194

064945

0D1509

050279

0E7839

0E6586

0E4394

040105

0E6382B

0F2119

0E6376B

042561

057822

0E7929

0A4637

0E6406

0E7702

0A4632A

037561

046580

0E8286

044118

049815

049226

051713

022097

057796

057795A

052223

061012

0E9295

0F3994

SCREW HHC 5/16-18 X 1-1/4 G5

FLANGE FUEL INLET

ASSY REG. 3.9L N/G-LPV 1800RPM

SCREW HHC M8-1.25 X 20 G8.8

WASHER FLAT 5/16 ZINC

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

SCREW HHC M8-1.25 X 16 G8.8

SCREW TH-FRM M6-1 X 16 N WA Z/JS

ELBOW 90D STREET 3/4

FUEL HOSE ASSY NAT.GAS/L.P.V.

BRACKET REGULATOR 3.0L FORD HSB

CLAMP HOSE #8 .53-1.00

HOSE 5/8 ID LPG & NG (36" LG)

GASKET CARB ADAPTOR

DECAL INLET PRESSURE

DECAL FUEL INLET NG

MACHINING, CARBURETOR ADAPTOR

GASKET BOSCH 32 & 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

CLAMP HOSE #8 .53-1.00

BASE AIR CLEANER PLATE

FILTER AIR 11.5" CA326

HOLDER VENTURI

HOLD DOWN AIR CLEANER

PLATE AIR CLEANER TOP

NUT WING 1/4-20 NYLK

SCREW SHC M6-1.0 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 G8.8

WASHER LOCK M5

WASHER FLAT M5

WASHER LOCK M6-1/4

GROMMET

BARBED EL 90 3/4 PLASTIC

HOSE 1/2 ID SAE-30R2 FUEL/OIL

PLUG STD PIPE 1/8 SOCKET HEAD

ASSY THROTTLE 28MM

PCV VALVE 2.5L FORD

Generac Power Systems, Inc. 39

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Alternator — Drawing No. 0E5146-B

40 Generac Power Systems, Inc.

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Alternator — Drawing No. 0E5146-B

ITEM

PART NO.

QTY.

DESCRIPTION

0E5093A

0E7413A

0E5094A

0E7412A

0E5706

0E5048

0E5048A

0E6668

0E6076

046526

REF

ROTOR 390 30KW 1P DIRECT HSB

ROTOR 390 40KW 1P DIRECT HSB

STR-390--35AD1 HSB (382MM LONG)(3.0LFORD)

STR-390--40AD HSB (433MM LONG)(3.9L CHRYSLER)

REAR BEARING CARRIER 390/DRCT

FLEXPLATE 3.0L FORD

FLEXPLATE 3.9L HSB

FLYWHEEL ASSY 3.0L HSB LG GEAR

REVCOR FAN 10.75 X 2 W/PRESS DIS

WASHER LOCK M10

SCREW HHC M10-1.5 X 16 G8.8

STUD M14-2.0 X 490 G5 ZINC (3.0L FORD)

STUD M14-2.0 X 540 G5 ZINC (3.9L CHRYSLER)

WASHER LOCK M14

051755

04576100BK

04576100BF

043123

051779

0E7587

023365

092980

052625

0A2602

042558

0A2601

0E7226

045757

NUT HEX M14-2.0 G8 YEL CHR

ASSY BRUSH HOLDER 390/HSB

WASHER SHAKEPROOF INT #8

SCREW PPHM M4-0.7 X 25

SCREW SHC M10-1.5 X 35 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

GUARD STATOR 390

SCREW HHC M6-1.0 X 25 G8.8

NUT TOP LOCK FL M6-1.0

052857

051715

038150

077043F

NUT HEX M4-0.7 G8 YEL CHR

WASHER FLAT #8 ZINC

CONDUIT FLEX 1-1/4" (30" LG)

ROTOR REPLACEMENT PARTS

047248

070892

BALL BEARING-45 MM

SLIP RING -MACHINED-

Generac Power Systems, Inc. 41

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Section 7 - Exploded Views and Parts

Guardian 40kW Liquid-cooled Generators

Muffler — Drawing No. 0E8068-E

COMPARTMENT

TO EXHAUST

MANIFOLD

TO EXHAUST

MANIFOLD

ITEM PART NO. QTY.

DESCRIPTION

ITEM PART NO. QTY.

DESCRIPTION

0E8616

MUFFLER 7" X 9" X 21" 2.5" IN &

OUT

25*

052860

052891

0E8816

051769

0E0170

049808

024114

080762

0E8726

039288

0F0170A

082361

NUT TOP LOCK FL M12-1.75

SCREW HHC M12-1.75 X 80 G8.8

EXHAUST FLANGE 2" PIPE

WASHER LOCK M12

EXHAUST BLANKET 705MM

WASHER FLAT M12

NUT HEX 5/16-24 STEEL

BOLT U 3/8-16 X 2.62

STRAP MUFFLER

0F1081

0F1087

0E8026

0E5914

WYE, PIPE 3.9L CHRYSLER

PIPE R/H SIDE 3.9L CHRYSLER

PIPE L/H EXHAUST MANIFOLD

BRACKET MUFFLER 3.0L FORD

HSB

0E8702

0E8727

036797

039253

022145

022129

045771

0C2454

PIPE MUFFLER INLET

PIPE MUFFLER OUT

BOLT U 5/16-18 X 2.25

SCREW HHC M8-1.25 X 20 G8.8

WASHER FLAT 5/16-M8 ZINC

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

SCREW TH-FRM M6-1 X 16 N WA

Z/JS

REF

SCREW HHC M8-1.25 X 55 G8.8

EXHAUST BLANKET 875MM

INSULATION-EXAUST (3.33" LG)

*NOT SHOWN-USED FOR ITEM #2

42 Generac Power Systems, Inc.

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Section 8 — Installation Diagram

Guardian 40kW Liquid-cooled Generators

Installation Diagram — Drawing No. 0E8422-A

Generac Power Systems, Inc. 43

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Section 9 - Notes

Guardian 40kW Liquid-cooled Generators

44 Generac Power Systems, Inc.

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Section 9 - Notes

Guardian 40kW Liquid-cooled Generators

Generac Power Systems, Inc. 45

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Section 10 – Warranty

Guardian 40kW Liquid-cooled Generators

GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN®

"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"

For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator

will be free from defects in material and workmanship for the items and period set forth below. Generac 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 genera-

tors 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 transfer switches.

• Repairs performed by individuals other than Guardian/Generac authorized dealers.

• Any Guardian generators used as rental or trailer mounted applications.

• Air-cooled 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 or indirect damages caused by defects in materials or workmanship, or any delay in repair or replace-

ment 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 you.

This warranty gives you specific legal rights. You also have other rights from state to state.

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 • WHITEWATER, WI 53190

Revision (10/01/04)

Part No. 0E8359

Revision F (01/24/05)

Printed in U.S.A.

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