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Generac Power Systems 004992-0, 004992-1, 37kW NG, 40kW LP User Manual

Generac Power Systems 004992-0, 004992-1, 37kW NG, 40kW LP
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Owner’s Manual
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
This manual should remain with the unit.
Liquid-cooled, Prepackaged
Standby Generators
Model Nos. 004992-0
004992-1
37kW NG, 40kW LP

Table of Contents

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Generac Power Systems 004992-0, 004992-1, 37kW NG, 40kW LP Specifications

General IconGeneral
Model Number004992-0, 004992-1
Power Output (NG)37 kW
Power Output (LP)40 kW
Voltage120/240 V
Frequency60 Hz
Fuel TypeNatural Gas (NG), Liquid Propane (LP)
Sound Level67 dBA at 23 ft (7 m)
Dimensions (L x W x H)48 x 25 x 29 inches
Phase1-Phase

Summary

Safety Rules

Introduction

Welcome and thank you for purchasing this Guardian standby generator product line.

Important Safety Instructions

Key safety guidelines for operating and maintaining the generator, to be posted in hazard areas.

General Hazards

Overview of general safety risks associated with the generator, installation, and operation.

Electrical Hazards

Details specific risks and precautions related to electrical shock and safe handling practices.

Fire Hazards

Information on fire risks and preventative measures, including extinguisher use.

Explosion Hazards

Guidance on preventing explosive gas buildup and related risks from fuel.

Section 1 - General Information

1.1 Generator

Description of the liquid-cooled, engine-driven generator set and its purpose.

1.2 Transfer Switch

Information on the matched 200 amp automatic transfer switch and its installation requirements.

1.3 Automatic System Operation

Explanation of how the generator and transfer switch work together for automatic power supply.

1.4 Generator AC Connection Systems

Details on the single-phase, three-wire generator AC connection system.

1.5 Main Circuit Breaker

Information about the generator's main circuit breaker as shipped from the factory.

1.6 Generator Fuel System

Specifications and considerations for natural gas and LP vapor fuel systems.

1.7 Engine Protective Devices

Overview of safety switches that automatically shut down the engine under fault conditions.

1.7.1 Low Oil Pressure Switch

Details on the low oil pressure safety switch function and its effect.

1.7.2 High Coolant Temperature Switch

Explanation of the high coolant temperature safety switch and its activation.

1.7.3 Low Coolant Level Switch

Information on the low coolant level sensor and its function to prevent overheating.

1.7.4 Overspeed Shutdown

How the engine overspeed shutdown mechanism operates based on AC frequency.

1.7.5 RPM Sensor Loss

Function of the RPM sensor loss shutdown feature and its indicator.

1.7.6 Overcrank Shutdown

Details on the engine's overcrank shutdown sequence after multiple failed start attempts.

1.7.7 Low Battery

Explanation of the low battery alarm and its effect on starting and operation.

1.7.8 Alarm Reset

Procedure for resetting engine alarms and restarting the unit using the AUTO/OFF/MANUAL switch.

1.7.9 DC Fuse

Location and function of DC fuses protecting the control console wiring and components.

1.8 Unpacking

Instructions and precautions for unpacking the generator set to avoid damage.

1.9 Lifting the Generator

Safety warnings and considerations for lifting the generator due to its weight.

1.10 Specifications

Technical specifications for both the generator and engine.

1.11 Fuel Consumption

Fuel consumption rates for natural gas and LP vapor at various load percentages.

1.12 Reconfiguring the Fuel System

Steps to convert the generator's fuel system from natural gas to LP vapor.

1.13 Torque Specifications

Specified torque values for various engine bolts like cylinder head and manifold.

1.14 Engine Oil Recommendations

Recommended engine oil types and viscosity based on ambient temperature.

1.15 Coolant Recommendations

Guidelines for engine coolant mixture, capacity, and types of antifreeze.

1.16 Before Installation

Pre-installation checks for generator and transfer switch ratings and load capacity.

Section 2 - Installation

2.1 Standby Generator Installation

General requirements and safety precautions for standby generator installation.

2.1.1 NFPA Standards

List of relevant NFPA standards for standby electric systems installation.

2.1.2 Other Published Standards

List of other relevant standards and codes for installation.

2.2 Generator Location

Guidelines for selecting an appropriate location for the generator set.

2.3 Generator Mounting and Support

Instructions for mounting and supporting the generator securely.

2.4 Basic Standby Electric System

Schematic and explanation of a basic standby electric system setup.

2.5 Emergency Circuit Isolation Method

Method to prevent generator overloading by isolating critical loads.

2.6 Total Circuit Isolation Method

Method for powering all electrical loads, potential for generator overload.

2.7 Grounding the Generator

Procedures and safety precautions for grounding the generator frame.

2.8 Generator AC Neutral Connections

Information on Generac's ungrounded AC neutral and connection requirements.

2.9 Transfer Switch Signal Connections

How to connect control wires for pre-packaged and GTS-type transfer switches.

2.10 Battery Installation

Safety precautions and instructions for installing the generator's battery.

2.11 Preparation Before Start-Up

Procedures to follow before the initial start-up of the generator.

2.11.1 Prior to Initial Start-Up

Important pre-start checks for fluids and preparation.

2.11.2 Transfer Switch

Requirements for installing a transfer switch as per the National Electrical Code.

2.11.3 Fuel System

Checks for correct fuel supply pressure, purging, and leak testing.

2.11.4 Generator Set Lubrication

Checking engine oil level before operation and adding oil if needed.

2.11.5 Engine Coolant

Procedures for filling the engine cooling system with the recommended coolant.

2.11.6 Belt Tension

Checking engine fan belt tension and condition before service.

2.11.7 Electrical System

Ensuring the generator is properly connected to an earth ground.

Section 3 - Operation

3.1 Using an Engineered "GTS" Transfer Switch

How to use the generator with a Generac "GTS" type automatic transfer switch.

3.2 Control Console Components

Identification and function of components on the generator's control console.

3.2.1 Auto/Off/Manual Switch

Operation of the three-position AUTO/OFF/MANUAL switch.

3.2.2 Fault Indicator LEDs

Explanation of fault indicator LEDs and the conditions they represent.

3.2.3 15 Amp Fuse

Function of the 15 Amp fuse protecting the DC control circuit.

3.2.4 4.0 Amp Inline Fuse

Function of the 4.0 Amp fuse protecting the battery charger.

3.2.5 Set Exercise Time Switch

How to program the generator for automatic starting and exercising.

3.2.6 System Ready LED

Purpose and indication of the System Ready LED on the control panel.

3.3 Manual Transfer and Start-Up

Steps for manually transferring electrical loads and starting the engine.

3.4 Engine Governor Adjustments

Procedure for adjusting engine speed governor settings if necessary.

3.5 Retransfer and Shutdown

Steps for transferring loads back to utility power and shutting down the generator.

3.6 Automatic Operation

Instructions for setting the system to operate fully automatically.

3.7 Weekly Exercise Cycle

How to set and perform the weekly generator exercise cycle.

Section 4 - Maintenance

4.1 Maintenance Performed by Authorized Service Dealers

Recommended maintenance tasks to be performed by authorized service dealers.

4.2 Cooling System

Importance of keeping air intake and outlet openings clear for proper cooling.

4.3 Overload Protection for Engine DC Electrical System

Explanation of how overcurrent protection devices prevent electrical system overload.

4.4 Checking Fluid Levels

Procedures for checking essential fluid levels like engine oil, battery fluid, and coolant.

4.4.1 Check Engine Oil

Steps for checking engine oil level using the dipstick.

4.4.2 Battery Fluid

Weekly checks for battery electrolyte fluid level and adding distilled water.

4.4.3 Engine Coolant

Checking the engine coolant level in the recovery bottle.

4.5 Maintenance Owner/Operator Can Perform

Routine maintenance tasks that the owner or operator can perform.

4.5.1 Check Engine Oil Level

Refer to "Checking Fluid Levels" in Section 4.4 for oil checks.

4.5.2 Check Battery

Checking battery fluid level, cables for condition, tightness, and corrosion.

4.5.3 Exercise System

Instructions for manually starting and running the generator weekly if not automated.

4.5.4 Inspect Cooling System

Monthly inspection of cooling system hoses, clamps, and for leaks.

4.5.5 Check Engine Coolant Level

Refer to "Checking Fluid Levels" in Section 4.4 for coolant checks.

4.5.6 Perform Visual Inspection

Monthly visual inspection for damage, leaks, loose fasteners, or corrosion.

4.5.7 Inspect Exhaust System

Three-month inspection of exhaust system pipes, mufflers, clamps, etc.

4.5.8 Check Fan Belt

Three-month inspection of fan belts for damage and checking belt tension.

4.5.9 Inspect Engine Governor

Visual inspection of the electronic governor; adjustment by qualified personnel only.

4.5.10 Changing Engine Oil

Procedure for draining warm engine oil and replacing the oil filter.

4.5.11 Changing the Engine Air Cleaner

Steps for replacing the engine air filter.

4.5.12 Spark Plugs

Instructions for cleaning, checking, and adjusting spark plug gaps.

4.5.13 Coolant Change

Annual coolant system drain, flush, and refill by an authorized dealer.

4.6 Miscellaneous Maintenance

General maintenance tasks for the generator's cleanliness and upkeep.

4.6.1 Cleaning the Generator

Keeping the generator clean and dry to maintain insulation resistance.

4.6.2 Battery

Precautions for handling batteries and avoiding hazards like explosion or chemical burns.

4.6.3 Battery Maintenance

Inspection of battery posts, cables, and fluid levels.

4.6.4 Battery Replacement

Information on the correct battery type and number for replacement.

Section 4.7 Scheduled Maintenance

Section 5 - Troubleshooting

Section 6 - Electrical Data

Wiring Diagram – Engine

Engine wiring diagram showing connections and components.

Section 7 - Exploded Views and Parts

Mounting Base

Exploded view and parts list for the generator's mounting base.

Enclosure

Exploded view and parts list for the generator enclosure components.

Control Panel

Exploded view and parts list for the generator's control panel assembly.

Engine

Exploded view and parts list for the engine components.

Radiator

Exploded view and parts list for the generator's radiator assembly.

Fuel System

Exploded view and parts list for the generator's fuel system components.

Alternator

Exploded view and parts list for the generator's alternator assembly.

Section 8 - Installation Diagram

Section 9 - Notes

Section 10 - Warranty

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