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Generac Power Systems 004988-1 Portable Generator User Manual

1. 30 degrees BTDC Spark MD uuu namin aan X 0 035 0 045 inch Recommended Spark Plugs Motor GIANT resene AG SF 32PGM OIl PrESSUTG Ll l 40 50 psi Crankcase Oil Capacity 5 0 U S quarts 4 7 liters Recommended Engine Oil sess SAE 5W 20 Type of Cooling System Pressurized closed recovery Cooling PA usse dein Pusher Cooling System Capacity 3 0 U S gallons 11 4 liters Recommended Coolant Use a 50 50 mixture of ethylene glycol base and de ionized water 1 11 FUEL CONSUMPTION Natural Gas of Load 25 50 75 100 m hr 3 1 5 9 8 5 11 0 110 3 209 0 299 5 387 0 LP Vapor of Load 25 50 75 100 m3 hr 1 3 24 3 5 4 5 ft hr 45 6 86 4 123 8 160 0 NOTE Fuel consumption is given at rated maximum con tinuous power output when using natural gas rated at 1000 Btu per cubic foot LP gas is rated at 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient temperature engine condi tions and other environmental factors Section 1 General Information Guardian Liquid cooled 27 kW and 30 kW Generators GENERAL INFORMATION Fuel pressure for a natural gas set up should be
2. 10 Section 10 WARRANTY Back Cover 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Transfer Switch Start Signal Connections 10 2 JO Battery Installatlofi 22 a sre 11 2 11 Preparation Before Start Up 11 Generac Power Systems Inc 1 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Guardian Liquid cooled 27 kW and 30 kW Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe A A A WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING A A 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 circumstance that might involve a hazard The warnings in this man ual and on tags and decals affixed to the uni
3. Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury 4 6 3 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 6 The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer Dia A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery A Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painte
4. GUARDIAN by Generac Power Systems Inc Owner s Manual Liquid cooled Prepackaged Standby Generators Model Number 004988 1 TER This manual should remain with the unit caution ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION INTRODUCTION Thank you for purchasing this model of the standby generator set product line by Generac Power Systems Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ ten However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest Generac Authorized Service Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert person nel to special instructions about a particular service or operation that may be hazardous if performed incor rectly or carelessly Observe them carefully Their defi nitions are as follows A After this heading read instructions that if not strictly complied with will result in personal injury or property damage wanNiNG 4 After this heading
5. 1 2 1 1 1 DESCRIPTION MUFFLER 3 0L FORD EXHAUST ELBOW 3 0L FORD HSB EXHAUST PIPE LH 3 0L FORD HSB EXHAUST PIPE RH 3 0L FORD HSB BRACKET MUFFLER 3 0L FORD HSB MUFFLR STRAP 6IN DIA SCREW RHM 1 4 20 X 2 1 4 BOLT U 5 16 18 X 2 25 SCREW HHC 8 1 25 X 20 G8 8 WASHER FLAT 5 16 M8 ZINC 42 Generac Power Systems Inc ITEM 11 12 13 17 18 19 20 22 PART NO 022129 045771 002454 044149 0E0170A 085917 0D2611 081265 022259 no TO MANIFOLD DESCRIPTION WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR SCREW TH FRM 6 1 16 N WA ZIJS GASKET EXHAUST RING EXHAUST BLANKET 3 0L FORD HSB WASHER LOCK 3 8 SS SCREW HHC 3 8 16 X 1 3 4 SS MOUNTING FLANGE NUT HEX 5 16 18 STEEL ITEM or O N PART NO 0E5193 0 8200 0 8201 036434 0E0519A 0C8127 0A5547 062974 022127 037561 DESCRIPTION PLATE AIR CLEANER ADAPTER TUBE AIR INTAKE 3 0L FORD BRACKET AIR INTAKE 3 0L FORD BOLT U 5 16 18 X 2 09 ADAPTER CARBURETOR W PVC CONN ELEMENT AIR CLEANER COVER AIR CLEANER STUD TH 1 4 20 X 4 1 2 G2 ZNC NUT HEX 1 4 20 STEEL NUT WING 1 4 20 NYLK Section 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Air Cleaner Drawing No OE8189 PART NO QTY 049226 091526 052619 051713 051716 022131 046526 051755 022145 022129 022259
6. CLAMP VINYL 5 X 406 Z WASHER SHAKEPROOF EXT 5 16 STL SPACER FLEXPLATE HSB NOT SHOWN USED TO HOLD OIL DRAIN ASSEMBLY NOT SHOWN Generac Power Systems Inc 35 ae Section 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators KO Radiator Drawing No 0 8528 TO WATER AY 5 CCAS MADAM 36 Generac Power Systems Inc ITEM CONDOR N PART NO 0E9947 0E6340 0E8531 0E6398 0E6397 080713 076749 049814 022131 046526 045772 035685 0 8562 058443 002454 048031C 029032 046627 069811 065852 0 2111 052250 035461 0C7649 069860C QTY cO P P gt Section 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Radiator Drawing No 0E8528 B DESCRIPTION RADIATOR R IN L OUT 658X489X49 VENTURI 3 0L FORD HSB SIDE SUPPORT RADIATOR HSB TUBE LOWER RAD 3 0L FORD HSB HOSE UPPER RAD 3 0LFORD HSB BRACKET COOLANT TANK TANK COOLANT RECOVERY SCREW HHC M10 1 5 X 25 G8 8 WASHER FLAT 3 8 M10 ZINC WASHER LOCK M10 NUT HEX M10 1 5 G8 YEL CHR CLAMP HOSE 28 1 32 2 25 FAN GUARD HSB SCREW CRIMPTITE 1 4 20 X 5 8 SCREW TH FRM M6 1 X 16 NWA Z JS CLAMP HOSE BAND 1 4 HOSE 9 32 ID 30 LG CAP RADIATOR CAP HEX 1 4 NPT BRASS SPRING CLIP HOLDER 37 62 SCREW SWAGE
7. Set the generator s main circuit breaker to its OFF or OPEN position Let the generator engine run at no load for a few minutes to stabilize internal unit temperatures On the generator console set the AUTO OFF MANUAL switch to OFF Wait for engine to come to a complete stop For transfer to UTILITY position refer to the Owner s Manual of the particular transfer switch Turn on the UTILITY power supply to the transfer switch using whatever means provided such as utility main line circuit breaker The utility power source now powers the loads 3 6 AUTOMATIC OPERATION To set the system for fully automatic operation pro ceed as follows Check that load circuits are connected to the utility power supply 14 Generac Power Systems Inc DIP SWITCH Set the AUTO OFF MANUAL switch to its AUTO position Set the generator main circuit breaker to its ON or CLOSED position 5 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 Ex
8. 9747 0 6703 0 6667 0 5048 035579 0 8584 083896 084929 055597 077996 057823 056739 047411 022097 022473 042907 040976 022129 022145 045771 051756 049821 059980 005417 046526 _ RROD i Fo OTP REF 17 DESCRIPTION ENGINE 3 0L FORD RD MAKE STAMPING ENG FOOT 3 0L FORD PULLEY CRANKSHAFT 3 0L FORD RD BRACKET DC ALT 3 0L FORD D C ALTERNATOR ASSY PULLEY POLY V 82 OD BRACKET ALTERNATOR PULLEY WATERPUMP 3 0L FORD RD HARN IGNITION 3 0L FORD NOT SHOWN FAN BELT 3 0L FORD CLUTCH COOLING FAN FORD FAN 18 7 BLADE STEEL ECS SENSOR HI COOLANT SHUTDOWN ASSY WATER LEVEL SENSOR C E PL STARTER 12 VOLT COVER FLYWHEEL ACCESS 3 0L HSB ENGINE ADAPTER 3L FORD FLEXPLATE 3 0L FORD BUSHING REDUCER 1 4 TO 1 8 SWITCH OIL PRESSURE 10PSI 2POL WASHER LOCK 1 4 M6 SS WASHER FLAT 1 4 SS SCREW HHC M12 1 75 X 85 G8 8 CAP HOSE CLAMP HOSE 10 56 1 06 RELAY SOLENOID 12VDC PNL MNT SCREW HHC M6 1 0 X 16 68 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW HHC M8 1 25 X 16 G8 8 SCREW SHC M8 1 25 X 20 G12 9 WASHER LOCK M8 5 16 WASHER FLAT 5 16 M8 ZINC NUT HEX M8 1 25 G8 YEL CHR SCREW HHC M10 1 5 X 20 G8 8 SCREW SHC M8 1 25 X 30 G12 9 SCREW HHC M10 1 5 X 25 G10 9 SCREW HHC 10 1 0 X 25 G10 9 WASHER LOCK M10 Section 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Eng
9. 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 e Guardian generators that utilize non Guardian Generac replacement parts e Guardian generators utilizing non Guardian Generac automatic transfer switches e Repairs performed by individuals other than Guardian Generac authorized dealers e Any Guardian generators used as rental or trailer mounted applications e 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 e Ste
10. rm nO nO pp qea 00 DESCRIPTION WASHER LOCK M5 SCREW PPHM M5 0 8 X 12 ZNC SCREW HHC M5 0 8 X 20 G8 8 WASHER FLAT M5 NUT HEX M5 0 8 G8 YEL CHR WASHER FLAT 3 8 M10 WASHER FLAT M10 SCREW HHC M10 1 5 X 16 G8 8 WASHER FLAT 5 16 M8 ZINC WASHER LOCK 8 5 16 NUT HEX 5 16 18 STEEL Generac Power Systems Inc 43 NOTES Section 9 Notes Guardian Liquid cooled 27 kW and 30 kW Generators 44 Generac Power Systems Inc Section 9 Notes NOTES Guardian Liquid cooled 27 kW and 30 kW Generators Generac Power Systems Inc 45 Section 10 Warranty WARRANTY Guardian Liquid cooled 27 kW and 30 kW 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
11. 0 1 ES E 765 2 GOV E 766 3 1 771 4 44 2 767 766 5 us ELIT 2t e 5 NIC LLL 70 8 6 766 BE NEN 771 9 768 10 767 11 769 12 LEGEND CONT D C CHARGE ALTERNATOR IC IGNITION COIL CONNECTOR 1 ENGINE M IGNTION MODULE ON DISTRIBUTOR CRANKING CONTACTOR LOS SWITCH LOW OIL PRESSURE DRIVER ELEC GOVERNOR SC STARTER MOTOR SOLENOID FUEL SM STARTER MOTOR ELEC GOVERNOR ACTUATOR WLS SENSOR COOLANT LEVEL SWITCH HIGH COOLANT TEMP Generac Power Systems Inc 27 n Section 8 Exploded Views and Parts LISTS 0 Guardian Liquid cooled 27 kW and 30 kW Generators KO Mounting Base Drawing No 0 6266 REAR BEARING CARRIER HARNESS WIRE STARTER CONTACTOR TO ee Generac Power Systems Inc ITEM PART NO QTY 1 0 5822 1 2 052860 4 3 052251 4 4 052257 4 5 052252 4 6 052259 4 7 052891 4 8 0536210213 1 9 074906 1 10 047411 1 11 055414 1 12 026850 2 13 022097 1 14 022473 2 15 049813 1 16 0A1694 4 17 052213 1 18 025507 3 20 027482 2 21 022129 1 22 045771 1 23 051756 1 24 046526 1 25 022131 1 26 055934M 1 30 077483 REF 058665 REF 31 038804D 1 32 038805AA 1 33 021991 1 34 049814 1 35 046526 2 36 022131 1 37 075763 1 38 050331 1 39 050331A 1 40 0A4010 2 41 052858 2 42 061902 1 43 059473 1 44 049820 2 NOT SHOWN USED TO HOLD DOWN I N 32 Secti
12. 046357 0D3719B 057073 0E7283 0E3628 0E3664 0 7539 cl cl VAY cl cl cl REF REF REF REF DESCRIPTION CONTROL BOX HSB COVER FRONT PANEL HSB COVER TOP PANEL HSB DECAL WARNINGS HSB DECAL CONTROLS HSB SWITCH ROC DPDT ON OFF ON SWITCH ROCKER DPST 125V SPD HOLDER FUSE FUSE 15A X AGC15 FUSE 4A SLO BLO GLASS FITTING CONDUIT 90D 3 8 DECAL DANGER HIGH VOLTAGE TRANSFRMR 16V 6VA TRANSFORMER 16V 56VA PCB SUPPORT SNAP IN 1 4 ASSY PCB HSB CONTROLLER 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 SW BLOCK TERM 20A 6 X 6 X 1100V DECAL CUSTOMER CNNCTN E1 E3 N JUNCTION BLOCK 3 8 16 CB 0150A2P240V S QN2 LL CB 0200A2P240V S QN2 LL BASE QN CIRCUIT BREAKER DECAL TB1 HSB CONTROL PANEL Section 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Control Panel Drawing No 0E7118 G ITEMS INCLUDED AS PART OF I N 39 PART NO QTY 0D4698 0E7252 001229 001127 0A1441B 0E7128 0E7358 074908 005141 0C2699 0C2323 022155 0C2265 022264 020911 066849 022152 023897 051716 090388 042568 022097 022473 0441140187 070370 0
13. DC Electrical Sy cu 15 1 10 SSPCCWICAlIONS kasahuayan 7 4 4 Checking Fluid Levels 15 1 11 Fuel Consumption 7 4 5 Maintenance Owner Operator 1 12 Reconfiguring the Fuel System uu cn c 16 1 13 Torque Specifications oor rte 8 AG Miscellaneous euren mu 17 1 14 Engine Oil Recommendations 9 4 7 Scheduled Maintenance 19 1 15 Coolant Recommendalions 8 Section 5 TROUBLESHOOTING 22 1 16 Before Installation 8 Section 2 INSTALLATION 8 Section 6 INTALLATION DIAGRAM 23 2 1 Standby Generator Installation 8 Section 7 ELECTRICAL DATA 24 2 2 Generator LOCAU ON 9 2 3 Generator Mounting and Support 9 Section 8 EXPLODED VIEWS AND 2 4 Basic Standby Electric System 9 PARIS TI Pity 95 Emergency Circuit Isolation Method 9 Section 9 NOTES 44 2 6 Total Circuit Isolation Method
14. Figure 2 2 Generator Grounding Lug typical GROUNDING LUG DI A Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against electrical shock in the event of a ground fault condi tion in the generator or in connected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded devices 10 Generac Power Systems Inc 2 8 GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED 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 2 9 TRANSFER SWITCH SIGNAL CONNECTIONS 2 9 1 PRE PACKAGED ATS If the generator is to be installed with a pre packaged transfer switch it is necessary to connect the control wires to the generator and set position two of the four position dip switch to OFF Setting switch two to OFF allows the control PCB to perform the ATS control functions Control system interconnections consist of 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
15. INTAKE ADAPTER 3 0L FORD BOSCH GASKET BOSCH 32 ACTUATOR BOSCH 32 GOVERNOR HOSE 1 5 ID X 2 LG 2084 SCREW SHC M6 1 0 X 18 G12 9 WASHER LOCK M6 1 4 SCREW HHC M6 1 0 X 50 G8 8 CLAMP HOSE 428 1 32 2 25 CLAMP HOSE 10 56 1 06 HOSE 3 8 ID SINGLE BRAID 305mm 12 LONG HOSE 3 8 ID SINGLE BRAID 432mm 17 LONG VALVE PCV GROMMET ROCKER COVER 3 0LFORD BARBED EL 90 3 8 X 3 8 PLST CLAMP VINYL 75 X 343 7 SCREW HHC M6 1 0 X 16 G8 8 WASHER LOCK 6 1 4 WASHER FLAT 1 4 M6 ZINC ASSY THROTTLE 27MM PARTS qea 00 Generac Power Systems Inc 39 n Section 8 Exploded Views and Parts LISTS O Guardian Liquid cooled 27 kW and 30 kW Generators 0 Alternator Drawing 0 8660 Generac Power Systems Inc ITEM ROTOR REPLACEMENT PARTS 30 31 PART NO 0F1659A 0F1657A 0F1655A 0E5093A 0E7413A OF1660A OF 1658A OF 1656A 0 5094 0 7412 0 5706 0 5048 0 5048 0 5048 0 6668 0 6076 046526 051755 04576100 04576100BF 043123 051779 0E7587 023365 092980 057192 0 2602 042558 0 2601 022264 038150 077043 077043 047248 070892 QTY LK L L REF REF REF ARAB p p RAR RRO Section 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Alternator Drawing No 0E8660 B DESCRIPTION ROTOR 390 15KW 1P DIRECT HSB 2 5L FORD ROTOR 390 20KW 1P DIRECT H
16. 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 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 0L HSB Al ROOF PANEL 1 Al DOOR PANEL Al CORNER POST PANEL 1 Al CORNER POST PANEL 2 Al SUPPORT LH PANEL Al SUPPORT RH PANEL Al ROOF PANEL 2 Al BRACE PANEL WASHER SELF LOCKING DOME ALL ITEMS NOTATED WITH Al ARE COMPONENTS OF 0E8441 age LISTS Generac Power Systems Inc 31 LISTS PARTS Section 8 Exploded Views and Parts 2 Guardian Liquid cooled 27 kW 30 kW Generators Control Panel Drawing No 0E7118 G DETAIL 1 RECTIFIER ASSEMBLY SCALE OVER CRANK O RATED TRANSFER SWITCH IN ATION RESERVE CONNECTER TRICE UN COMMUTATEUR DE AU CODE CANADIEN DE 8 b CAUTION RISK OF ELECTRICAL SHO
17. distance of at least three inches on all sides See Section 6 for generator major dimensions 2 4 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic diagram of a basic standby electric system Both the UTILITY power supply and the STANDBY GENERATOR output are connected to an approved transfer switch The trans fer 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 Figure 2 1 Basic Standby Electric System MAIN LINE CIRCUIT BREAKER UTILITY POWER SUPPLY TO LOAD CIRCUITS STANDBY GENERATOR OUTPUT MAIN LINE CIRCUIT BREAKER 2 5 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage amperage capacity of the generator If the generator is powering only crit ical loads within the wattage amperage capacity dur ing utility power outages consider using the emer gency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are with in the wattage amperage capacity of the generator set When this me
18. five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges 1 12 RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for natural gas from the factory 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 Remove the brass hose fitting from the outlet port Port 1 of the demand regulator Remove pipe plug from Port 2 Install brass hose fitting into Port 2 Install pipe plug into Port 1 Connect carburetor gas hose to brass fitting Tighten all clamps and plugs Make sure fuel supply is of the proper pressure and type for configuration 10 Reverse the procedure to convert back to natural gas Figure 1 8 Reconfigure the Fuel System Port 1 Port 2 FUEL HOSE FUEL HOSE Ss BRASS HOSE BRASS HOSE PLUG FITTING FITTIN X1 LN OUT i OUT a HOUSING Q 0 FN 2 e C ERN S r G FUEL SYSTEM LP FUEL SYSTEM NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for du
19. hazardous and possibly fatal electrical shock Connecting this unit to an electrical system normally supplied by an electric utility shall be by means ofa 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 Generators installed with an automatic transfer switch will crank and start automatically when NOR MAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automat ic start up and possible injury to personnel disable the generator s automatic start circuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and on the transfer switch In case of accident caused by electric shock immedi ately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity
20. kW Generators 1 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 Battery voltage is NOT monitored during the crank cycle 1 7 8 ALARM RESET If the engine control board shuts down the generator for any of the above reasons the engine remains stopped until the alarm is cleared by placing the AUTO OFF MANUAL switch into the OFF position 1 79 DC FUSES 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 18 UNPACKING 1 8 1 UNPACKING PRECAUTIONS Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping colli sion etc Store and unpack cartons with the proper side up as noted on the shipping carton 1
21. lead Recommended wire gauge sizes for this wiring depends on the length of the wire as recommended below 461 to 730 feet 223m 731 to 1 160 feet 354m 1 161 to 1 850 feet 565m 2 9 2 QGTS TYPE ATS If the generator is to be installed with an automatic transfer switch such as an engineered 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 Guardian Liquid cooled 27 kW and 30 kW Generators 2 10 BATTERY INSTALLATION DIG A Standby generators installed with automatic transfer switches will crank and start automati cally when NORMAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel do not connect battery cables until certain that normal source voltage at the transfer switch is correct and the system is ready to be placed into operation Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The
22. 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 second off if the utility sensing level is below the transfer back threshold This secondary function is only available with dip switch two in the OFF position standard ATS appli cation 5 5 MANUAL TRANSFER AND 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 3 4 ENGINE GOVERNOR ADJUSTMENTS Engine speed governing is also controlled by the engine control board Connector J2 on the engine control board interfaces with a governor driver mod ule and the Bosch throttle body The engine governor has been set by the factory during final testing of the generator and in most cases should not be adjusted If however adjustments are necessary or a new engine control board is installed in the generator the following procedure should be followed Figure 3 2 1 Set all three potentiometers pots fully counter clockwise 2 Under no load condition increase the GAIN pot as much as possible without causing 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 appl
23. read instructions that if not strictly complied with may result in personal injury or property damage caution amp After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety informa A tion that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard Generac Power Systems Inc The operator is responsible for proper and safe use of the equipment Generac strongly recommends that the operator read this Owner s Manual and thor oughly understand all instructions before using this equipment Generac also strongly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the op
24. resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris 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 units 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 l
25. 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 80 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 Generac 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 kno
26. uU d a m Dif Ex d jT rrr rr 4 RIO 010 Ieo E L a rv K 2 und He R40 R44 06 R57 R58 R59 y AR AA A BEE i n 14 f f T T rr a afe f j m ms M 2552 1 fal Lab su 715711769 513 k I L e l e e e 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 76 OVERCRANK SHUTDOWN The engine control board uses a cyclic cranking process when attempting to start the engine The first crank cycle is a 15 second crank followed by a seven second rest This is followed by five more crank cycles each with a seven second crank followed by a seven second rest If the engine fails to start after all six attempts the start attempt is stopped and the overcrank LED s illuminated 6 Generac Power Systems Inc Section 1 General Information Guardian Liquid cooled 27 kW and 30
27. up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via a 15 amp fuse These overcurrent protection devices will open if the circuit is overloaded caution amp If a circuit breaker opens or a fuse element A melts find the cause of the overload before resetting the circuit breaker or replacing the fuse 4 4 CHECKING FLUID LEVELS 4 4 1 CHECK ENGINE OIL Check engine crankcase oil level Figure 4 1 at least every 20 hours of operation or prior to use Section 4 Maintenance Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Section 1 14 for recom mended oils Figure 4 1 Dipstick and Oil Fill Cap Dp LIN o SE Ze 4 42 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 Generac Power Systems Inc 15 OPERATION Section 4 Maintenance J gt Guardian Liquid cooled 27 kW and 30 kW Generators 4 4 3 ENGINE COOLANT Check coolant lev
28. 10 32 X 5 16 Z YC TAPE FOAM 1 X 1 27 LG BARBED STR 1 4 NPT X 3 8 CLAMP HOSE 38 87 HOSE OIL DRAIN ASSY 21 age LISTS Generac Power Systems Inc 37 dg As Section 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators KO Fuel System Drawing No 0E8190 B DS 38 Generac Power Systems Inc SHOWN IN OTHER VIEW NOT SHOWN USED TO HOLD 31 IN PLACE PART NO 075580 0E7691 039253 022145 022129 045771 042907 002454 026307 0E1056 0 6584 057823 059194 044117 0D1509 050279 0E6123 0E6586 0E4395 057753B 047487 022097 051751 035685 057823 047290 047290 0A4121 0 6609 049099 055934 047411 022097 022473 0 9295 q PO HS HS Section 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Fuel System Drawing No 0E8190 B DESCRIPTION WELDMENT MOUNTING BASE FLANGE FUEL INLET ASSY REGULATOR 3 0L NG OR LPV 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 10 56 1 06 HOSE 5 8 ID LPG amp NG 20 LG BARBED STR 3 8 NPT X 5 8 DECAL INLET PRESSURE DECAL FUEL INLET NG
29. 2 U S quarts 11 4 liters Use only de ionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolant mixture When adding coolant always add the recommended 50 50 mixture caution amp A Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chromi umhydroxide green slime forms and will cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating It is also recommend that any soluble oil inhibitor is NOT USED for this equipment 1 16 BEFORE INSTALLATION Before installing this equipment check the ratings of both the generator and the transfer switch Read Emergency Isolation Method and Total Circuit Isolation Method in Sections 2 6 and 2 6 s Generac Power Systems Inc Guardian Liquid cooled 27 kW and 30 kW Generators The generators 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 This generator can be installed in conjunction with an engineered Generac GTS type transfer switch if necessary The standard transfer switch has
30. 23762 055444 030468 049939 022158 022985 038750 0 2115 002454 REF 1 1 m O Oo m m GO no GLAU BR PARTS qea 00 DESCRIPTION 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 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 DT 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 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 SCREW THF M6 1 X 16 NWA Z JS Generac Power Systems Inc 33 LISTS Section 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators KO Engine Drawing No 0E8170 J BAFFLE REAR UPPER 34 Generac Power Systems Inc ITEM PART NO QTY 0 6202 0 8824 0 8963 0 9020 0 1232 0 7801 0A5610 0E6308 0E7804 0E6310 0E7996 0 8006 035606 0 0561 0
31. 3 SLNIOd NOILOJNNOO I Ej SSION EM x S31d 1 8211626 NILNNOW AWVas 0 1 V3aVv dA anls 1 61 21 S3 IUH DNILNNOW dAL L ETETv6Z TTJ82 23 Generac Power Systems Inc Section 7 Electrical Data Guardian Liquid cooled 27 kW and 30 kW Generators ELECTRICAL DATA Ed Wiring Diagram Engine Drawing No 0E6199 E NOTE SIZE AWG ALL WIRES ARE 18 AWG 300 VOLT UL LISTED UNLESS OTHERWISE NOTED AS SHOWN 13A 239 2 5 0 um ce x 552252 vor 23 23 TRANSFER SWITCH 66 66 CUSTOMER CONNECTION LEGEND CONT LEGEND FUSE BIC 4A AGC TYPE AVR AUTOMATIC VOLTAGE REGULATOR ICT INTERCONNECT TERMINAL BLOCK BA BRUSH ASSEMLY GENERATOR NB NEUTRAL BLOCK BIC BATTERY CHARGER RLi RELAY I BC1 BULKHEAD CONNECTOR 1 ENGINE SWi AUTO OFF MANUAL SWITCH CBi CIRCUIT BREAKER OUTPUT SW2 SET EXERCISER SWITCH CB2 CIRCUIT BREAKER EXCITATION TBi TERMINAL BLOCK 1 Di DIODE FIELD BOOST TRI TRANSFORMER 1 56 VA 240 16 VAC Fl FUSE BAT POWER 15 AGC TYPE TR TRANSFORMER 2 6 VA 240 16 VAC 24 Generac Power Systems Inc Section 7 Electrical Data Guardian Liquid cooled 27 kW and 30 kW Generators ELECTRICAL Wiring Diagram Engine Drawing No 0E6199 E 2 NOTE SIZE AWG DEG I 1 767 ALL WIR
32. 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 their signature under the consignor s memo of loss or damage 1 9 LIFTING THE GENERATOR warninc amp A When lifting or hoisting equipment is used be careful not to touch overhead power lines The generators weight of more than 900 pounds requires proper tools equipment and qualified personnel to be used in all phases of handling and unpacking 1 10 SPECIFICATIONS 1 10 1 GENERATOR SPECIFICATIONS Single phase Model 4988 1 Rated Max Cont 27 NG 30 LP AC Power Output kW Rated voltage volts 120 240 No of Rotor Poles 4 Driven Speed of Rotor 1800 Rotor Excitation System Direct excited brush type Type of Stator 4 Wire Rotor Stator Insulation Class F H 1 10 2 ENGINE SPECIFICATIONS MAKE sun Ford M M T 3 0 liters Cylinder Arrangement V 6 Valve Arrangement eene Overhead Valve gione e 1 4 2 5 3 6 Number of Main Bearings sse 4 Compression Ratio sse 9 3 to 1 No of Teeth on Flywheel sess 164 Ignition Timing at 1600 rpm
33. AC AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 OR Locate us on the web at WWW generac com Table of Contents a CONTENTS Guardian Liquid cooled 27 kW and 30 kW Generators INTRODUCTION uu U uu sQ IFC Section 3 OPERATION 12 3 1 Using a Standard GTS Transfer Switch 12 SAFETY RULES 2 89 u E ss pn u 12 Section 1 GENERAL INFORMATION 4 3 3 Manual Transfer and Startup 13 1 1 x 4 3 4 Engine Governor Adjustments n n 13 1 2 4 3 5 Retransfer and Shutdown 14 1 3 Automatic System Operation 4 3 6 Automatic Operation 14 1 4 Generator AC Connection Systems 4 3 7 Weekly Exercise Cycle 14 Lo Circuit Breaker 25 4 Section 4 MAINTENANCE 15 1 0 Generator Puel Syste 5 4 1 Maintenance Performed by Authorized 1 7 Engine Protective Devices 5 Service Facilities 15 6 4 2 COOLING System 15 1 9 Lifting the Generator a aaa 6 4 3 Overload Protection for Engine
34. C REPLACEMENT PARTS Part Name Generac s Part Number Oil Filter 0E7180 Radiator Cap 046627 Air Cleaner 068127 Spark Plug 0E7079 Section 4 Maintenance Guardian Liquid cooled 27 kW and 30 kW Generators MAINTENANCE 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 the unit hour meter or calendar time whichever occurs first from the previous maintenance interval to deter mine 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 or following each 10 hours of operation of the unit and 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
35. CK DO NOT REMOVE COVER NO USER SERVICEABLE PARTS INSIDE REFER Z O D lt O SERVICING WARNING THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR OUTDOOR INSTALLATION ONLYI TME SWITCH IN ON POSITION FOR THREE SECONDS XERCISER IUAL SWITCH TO AUTO POSITION AND RELEASE SEE OWNER S MANUAL FOR COMLETE DETAILS THE EXERCISER IS NOW SET ALL FIVE RED LED S WLL FLASH FOR 10 SECOND E UNIT eae ID SHUTOQWN SERVICING TO QUALIFIED SERMCE PERSONNEL L ECTRICITE PREMIERE PARTIE IE CAN AUTOMATICALLY START AT ANYTIME WTHOUT NOTICE TO AVOID PERSONAL INJURY REMOVE FUSE ON FOR STAND BY SER GENERATOR TO SUITABL ACCORDANCE WITH CANADIAN ELECTRICAL CODE PART CONTROL PANEL AND NEGATIVE BATTERY CABLE PRIOR TO ATTENTION POUR L ALIMEN LA SORTIE DE LA GENER CAUBRE APPROPRIE CONF ENGINI fao er ene SEE DETAIL 1 KE DEUTSCH 999999 DR NS Hazardous voltage can cau severe injury or death AVR BEHIND COVER AWARNING rvice personnel 16 Er PANEL MOUNT e DETAIL 32 Generac Power Systems Inc ITEM CONDOR N 17 18 19 20 21 22 24 25 27 28 29 30 31 32 33 PART NO QTY 0E7195 0E7196 0E7197 0E7193 0E7194 0E4494 082573 032300 022676 067682B 060015 054199 0C2657 099076 040213 0 9668 0 4905 067680 0 6875 0 6881 065139 0 5142 0 3161 054450 005070 0 2514 0 9457 0 7539
36. ES ARE 18 AWG 300 0 1 gt 765 VOLT UL LISTED UNLESS 765 2 q E OTHERWISE NOTED AS SHOWN B AN 4 766 44 4 5 768 766 5 wi ics 7 NC 767 7 8 14 771 9 1 768 10 p 767 11 769 12 4 23 GOV 5 224 471 3 6 0 767 2 765 3 8 239 770 4 mam fe 10 15E 766 11 85 LL 12 14A 14 66 14 IM C1 QO Ct 4 0 _ 449 x d n 14 5 13 0 6 14A D 7 15A Pe zi 11 225 2 LEGEND LEGEND CONT ALT D C CHARGE ALTERNATOR _ HIGH COOLANT TEMP SWITCH 12VDC BATTERY ie IGNITION COIL 66 01 CONNECTOR 1 ENGINE M IGNITION MODULE ON DISTRIBUTOR CC STARTER CONTACTOR J 1 JUNCTION1 ON PCB DEG DRIVER ELEC GOVERNOR J 2 JUNCTION 2 ON PCB FS FUELSOLENOID JB JUNCTION BLOCK RUN POWER GNDi GROUND SENSING LOW AMP LOS LOW OIL PRESSURE SWITCH GND2 GROUND POWER HIGH AMP SM STARTER MOTOR GOV ELEC GOVERNOR ACTUATOR WLS COOLANT LEVEL SWITCH Generac Power Systems Inc 25 ELECTRICAL DATA Electrical Schematic Engine Drawing No 0E6200 A LEGEND AR AS AVR BA BIC BCW CB1 CB2 01 DPE Section 7 Electrical Data Guardian Liquid cooled 27 kW and 30 kW Generators ALTERNATOR ROTOR ALTERNATOR STATOR AUTOMATIC VOLTAGE REGULATOR BR
37. ION SECURE AS SHOWN Lu Q oc 02 lt i O O gt gt lt lt O O LL LL N N u1 lt lt N N C UN N 77772 LATCH DETAIL Generac Power Systems Inc ITEM CONDOR N PART NO 0E8411 0E8042 0E8041 002454 0E8402 0E7808 0E7809 0E8387 0 6986 0 7795 089961 0 2115 0 8404 0D2538A 0D2538 043116 022097 022473 0E7570 0E7571 070015 0 7662 0D2537A 0D2537 0D2023 0E7869 0 8001 0 8060 0E8406 0D3037A 007781 0E7794 0 8052 003037 0 8007 0 8008 0 6989 0 8055 026850 0912970063 0912970064 049813 0 8665 002023 0 8441 0 7829 0 7829 0 7829 0 7829 0 78295 0 7829 0 7829 0 78290 078115 P OC NO Po PO A N PO VN PP HS HS HS PO PO O Section 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Compartment Drawing No 0E8333 D DESCRIPTION INTAKE DUCT HSB DUCT DISCHARGE RH FRONT DUCT DISCHARGE LH FRONT SCREW TH FRM M6 1 X 16 N WA Z JS BAFFLE REAR BOTTOM POST CORNER LH REAR POST CORNER RH REAR BAFFLE REAR TOP DOOR COMPARTMENT SIDE SUPPORT R H SIDE FOAM STRIP 3 4 WIDE X 3 16 THK 40 LG WASHER NYLON 257 BRACKET STIFFENER RH FRONT HINGE LIFT OFF TYPE B
38. OCATION Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air always is available Consider these factors Install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing consider using a windbreak to protect the 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 Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow five feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install the generator as close as possible to the transfer switch This reduces the length of wiring and conduit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REG ULATE THE DISTANCE INSTALLATION Section 2 Installation 2 5 GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a concrete slab with 1 4 inch masonry type anchor bolts Be sure the bolts are long enough to retain the compartment The slab should be at least six inches thick and should extend beyond the enclosure to a
39. Reset the spark plug gap or replace the spark plugs as necessary See Section 6 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and com mercial solvent Do not blast the spark plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Service Schedule Section 6 for recommended inspection MAINTENANCE 5 Section 4 Maintenance 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 5 0 6 mm 0 020 0 025 inch by carefully bending the ground electrode Figure 4 4 Figure 4 4 Setting the Spark Plug Gap SET PLUG GAP AT 0 5 0 6 mm 0 020 0 025 inch lt em 4 5 13 COOLANT CHANGE Every year have Authorized Service Facility drain flush and refill the cooling system See SPECIFICA TIONS Section 1 10 for cooling system recommen dations 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 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 enc
40. S Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY Test engine governor Adjust or repair if needed Clean inspect generator Flush cooling system FIRST 100 OPERATING HOURS Change engine oil and oil filter After initial change service engine oil and filter at 150 oper ating hours or 6 months whichever comes first 2 Retorque cylinder head See Torque Specs Section 1 13 3 Retorque intake and exhaust manifold See Torque Specs Section 1 13 EVERY 500 OPERATING HOURS Service air cleaner Check starter 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 W aakonr gt TO Sr 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 wanNiNG amp The exhaust system parts from this product get its 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 MAINTENANCE 2 0 4 5 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start
41. SB 2 5L FORD ROTOR 390 25KW 1P DIRECT HSB 2 5L FORD ROTOR 390 30KW 1P DIRECT HSB 3 0L FORD amp 2 5L FORD ROTOR 390 40KW 1 DIRECT HSB 3 9L CHRYSLER STR 390 15AD HSB 382MM LONG 2 5L FORD STR 390 20AD HSB 382MM LONG 2 5L FORD STR 390 25AD HSB 382MM LONG 2 5L FORD STR 390 35AD1 HSB 382MM LONG 3 0L FORD amp 2 5L FORD STR 390 40AD HSB 433MM LONG 3 9L CHRYSLER REAR BEARING CARRIER 390 DRCT FLEXPLATE 3 0L FORD FLEXPLATE 3 9L HSB FLEXPLATE 2 5L FORD FLYWHEEL ASSY 3 0L HSB LG GEAR REVCOR FAN 10 75 X 2 W PRESS DIS WASHER LOCK M10 SCREW HHC 10 1 5 X 16 G8 8 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD amp 2 5L FORD STUD M14 2 0 X 540 G5 ZINC 3 9L CHRYSLER WASHER LOCK M14 NUT HEX M14 2 0 G8 YEL CHR ASSY BRUSH HOLDER 390 HSB WASHER SHAKEPROOF INT 8 SCREW PPHM 4 0 7 X 25 SCREW SHC M10 1 5 X 30 G12 9 WASHER FLAT 688 ID X 3 25 OD KEY SQ 3 8 X 1 STEEL SCREW HHC M16 2 0 X 45 G8 8 WASHER LOCK 8 4 WASHER FLAT 8 ZINC CONDUIT FLEX 1 1 4 30 LG 3 0L FORD amp 3 9L CHRYSLER CONDUIT FLEX 1 1 4 18 LG 2 5L FORD BALL BEARING 45 MM SLIP RING MACHINED LISTS age Generac Power Systems Inc 41 PARTS ITEM ork O N O 9 10 LISTS PART NO 0E6134 0E6464 0 6465 0 6465 0 5914 060366 027837 036797 039253 022145 Section 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Muffler Drawing No 0E6479 D QTY
42. TOR position Contact an Authorized Generac facility Auto reset Wait 5 min and attempt restart INSTALLATION Section 6 Installation Diagram Guardian Liquid cooled 27 kW and 30 kW Generators 0 8695 Installation Diagram Drawing No QQ3AUWdS TANVd 553999 gt MAIA 341 ININdLOO4 3599 L ETI9J8SGI S3HONI Wu SLINA 2NIONADISS SD HLGIM 11933AD 301 994 14 6 NUILO3NNUO 1303 3594 CS ee1oss 7 MDdVA 411 MU SYD TWANLYN T9FlP 0 11 VIVO LHOISAM 3491 3v 13 NI 1304 TIVI3I 3294 13094 7091905 2106 9 9 AITA 31DN 335 LON 33S p LHBI3H 119 4 11 01 13110U 3143308 131100 LSNVHXS 1331S 8 6 NIVad ldNvr AOdVA d 1 S95 IWANLVN 13 INI SNOTLOSNNOD 451 445 3NIDN3 41 11 4 ma 335 ONTLNAOW d 1 IAA 125 4 412 sDDa IV3H33 AU 7721 681 L Z 1 1908 6 111c0 e3 v3s8 LINDAIO 3NI INIVW 6 1194 Ze 49 gt HVO6 AO 92 89 HVGZ ASHLIA 31 0 229 TIIM 71 8 8 X 6 vae X S SNDISN3NIG 3015 AVAL AN3LIIVG WALSAS GNNOSD 3 11993 LTDA 2 4 15 SS I3NVd TOYLNOD NI G3GIADNd 1391 31DN32 NV L Z S 8 SvI i S 211 5 BN3JSNV3I 50931 0901 2v N0
43. USH ASSEMLY GENERATOR BATTERY CHARGER BATTERY CAHRGE WINDING CIRCUIT BREAKER OUTPUT CIRCUIT BREAKER EXCITATION DIODE FIELD BOOST DISPLACED PHASE EXCITATION TRANSFER SWITCH CUSTOMER CONNECTION CONNECTION 120 240V 1 PHASE ee Generac Power Systems Inc LEGEND CONT FI F2 ICT NB SW1 SW2 TRI 183 178 FUSE POWER 15 AGC TYPE FUSE BIC 4A AGC TYPE TERMINAL BLOCK INTERCONNECT NEUTRAL BLOCK RELAY 1 SWITCH AUTO OFF MANUAL SWITCH SET EXERCISER TRANSFORMER 1 56 VA 240 16 VAC TRANSFORMER 2 6 VA 240 16 VAC IN OFF POSITION 66 23 1 x 4 _ 6 8 Ez 10 11 12 66 Jt 14 66 2 2 0 3 0 LEGEND 4 0 ALT C5 5 1 C1 c 6 MA 2 7 15 HI A ti 8 15E DEG 9 1 FS 12 2 ES 86 86 1J1 2 15A 1 3 23 J1 4 224 1 5 0 J1 6 J7 239 J1 8 1 8 15E J1 10 85 Jti 14A J1 12 225 J1 13 Section 7 Electrical Data Guardian Liquid cooled 27 kW and 30 kW Generators Electrical Schematic Engine Drawing No 0E6200 A LOS 0 166 13 so 5 ELECTRICAL DATA WLS HCT 12V BATTERY li x o BLACK RED a 449 DE F uw 100 J2 1 767 Jo J2 2 765 46 J2 3 F 769 56 J2 4 766 6 12 6 0 4057 DEG J2 8 14
44. al fuel has been made A Serious injury or damage may occur if not con figured properly Please consult an authorized Generac Service Dealer with any questions Generac Power Systems Inc 7 INSTALLATION Section 2 Installation 1 13 TORQUE SPECIFICATIONS Cylinder 15 90 90 ft lb Intake Manifold eern n 13 ft lb Exhaust Manifold eene 13 1 14 ENGINE OIL RECOMMENDATIONS The unit has been filled with 5W 20 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE SE Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Temperature Above 80 F 27 C Oil Grade Recommended SAE 5W 20 SAE 5W 20 SAE 5W 20 32 to 80 F 1 to 27 C Below 32 F 0 C NOTE Synthetic oil is highly recommended in any element with temperatures above 90 F or below 30 F caution amp Any attempt to crank or start the engine before A it has been properly serviced with the recom mended oil may result in an engine failure 1 15 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and half de ionized water Cooling system capacity is about 1
45. an who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations Installation operation servicing and repair of this and related equipment must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the gener ator is installed operated and serviced in accordance with the manufacturer s instructions and recommen dations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in 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 unobstr
46. ary 20 Perform a 5 minute no load operational run of the unit looking for any post service oroblems 21 Return the unit to standby setup for operation when required MAINTENANCE 2 0 Section 4 Maintenance Guardian Liquid cooled 27 kW and 30 kW Generators Level 1 Level 2 Level 3 Level 4 Recom Task Required Task Required Task Task mended Comp be done Comp Ito be done Comp Required Comp to be done Date 3months Date Date tobedone Date monthly Initials Break in Initials annually Initials Annually Initials 10 hrs 50 hrs 100 hrs Generac Power Systems Inc 21 TROUBLESHOOTING Section 5 Troubleshooting Guardian Liquid cooled 27 kW and 30 kW Generators TROUBLESHOOTING POINTS CAUSE PROBLEM Engine won t crank Engine cranks but won t start Engine starts hard runs rough Engine starts then shuts down AUTO OFF MANUAL Switch at OFF engine continues to run No AC output from generator 1 2 oO NOOR 15 amp fuse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery 4 amp fuse blown Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Flame arrestor air cleaner plugged or damaged Plugged
47. be used indoors or outdoors Follow these rules A Install the transfer switch on a firm sturdy sup porting structure To prevent switch distortion level the switch if nec essary This can be done by placing washers between the switch enclosure and the mounting surface Never install the switch where water 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 If a transfer switch is not included one may be pur chased separately from a Generac Authorized Dealer Section 1 General Information Guardian Liquid cooled 27 kW and 30 kW Generators 1 5 AUTOMATIC SYSTEM OPERATION When this generator along with a transfer switch has been installed and interconnected a circuit board in the generator panel constantly monitors UTILITY power source voltage Should that voltage drop below a preset value and remain at such a low state for 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 When UTILITY source voltage has been restored the switch re transfers back to the UTILITY source volt age and the generator then shuts down Please reference the transfer switch manual for spe cific information 1 4 GENERATOR AC CONNECTION SYSTEMS The generator was shipped from the factory
48. d 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 18 Generac Power Systems Inc Guardian Liquid cooled 27 kW and 30 kW Generators A 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 bicarbonate 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 A Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging warninc amp A Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the UTILITY power supply is turned off or sparking may occur at the battery posts as the cables are attached and cause an explosion 4 6 4 BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 26 26R 525 0 deg F 600 0 deg F NOTE The BCI number should be located directly on the battery PERIODI
49. e it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information and or service intervals please refer to Section 4 Maintenance 2 11 2 TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems for additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with applicable codes standards and regulations 2 11 3 FUEL SYSTEM Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and b is properly purged and leak tested according to code No fuel leakage is permitted See Specifications Section 1 10 for more information Generac Power Systems Inc 11 OPERATION Section 3 Operation J gt Guardian Liquid cooled 27 kW and 30 kW Generators 2 11 4 GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to
50. e number and type of battery The recommended batteries are Group 26 12V negative ground 525 CCA 75 AH min imum capacity or Group 27F 12V negative ground 600 CCA 90 AH minimum capacity All batteries must be at 100 percent state of charge before they are installed on the generator INSTALLATION Section 2 Installation When using maintenance free batteries it is not nec essary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in Section 4 Maintenance A negative ground system is used Battery connections are shown on the wiring diagrams Make sure all batter ies are correctly connected and terminals are tight Observe battery polarity when connecting batteries to the generator set NOTE Damage will result if the battery connections are made in reverse 2 11 PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed serv iced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules on Pages 2 and 3 as well as all other safety information in this manual before attempting to operate this and related equip ment 2 11 1 PRIOR TO INITIAL START UP caution amp A Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine befor
51. ed standards booklets pertain ing to standby electric systems are available form the National Fire Protection Association NFPA Batterymarch Park Quincy MA 02269 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES No 76A ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES Guardian Liquid cooled 27 kW and 30 kW Generators 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 NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 2 1 2 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following infor mation pertaining to the installation and use of standby electric systems is available 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 452 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 2 GENERATOR L
52. el 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 e Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts e 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 e 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 e Damage related to rodent and or insect infestation e Products that are modified or altered in a manner not authorized by Generac in writing e 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 e Failure due to misapplication e Telephone cellular phone facsimile internet access or other communication expenses e 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 troubleshoo
53. el in coolant recovery bottle See Specifications Section 1 10 Add recommended coolant mixture as necessary Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radiator filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact an authorized Generac Service Dealer Inspect cooling system and coolant recovery system for leaks 4 5 MAINTENANCE OWNER OPERATOR CAN PERFORM 45 1 CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels in Section 4 4 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 otart the generator engine at least once every seven days and let it run at least 20 minutes See Section 3 6 Weekly Exercise Cycle 4 5 4 INSPECT COOLING SYSTEM Inspect engine cooling system at least once each month Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness 4 5 5 CHECK ENGINE COOLANT LEVEL oee Checking Fluid Levels in Section 4 4 4 5 6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvio
54. erator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Authorized Service Dealer Normal maintenance serv ice and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See the Generac Authorized Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by a Generac Authorized Service Dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs contact a Generac Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting a Generac Authorized Service Dealer about parts and service always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit AUTHORIZED SERVICE DEALER LOCATION To locate the nearest GENER
55. ercise 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 its 12 minute exercise period then shut down The generator will now start and run each week at the same time If DC power to the control board is lost the weekly exercise setting will be lost This is indicated by all five red LEDs continually flashing In this state the 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 If a failure occurs while running in this mode the five red LEDs will stop flashing the individual fault LED will turn on and the engine will shut down Once the AUTO OFF MANUAL switch has been switch to OFF the individual fault LED will turn OFF and the five red LEDs will begin flashing to show exercise has still not been set Figure 3 2 Set Exercise Switch FUSE FUSE ae 15A CHARGER gt AUTO OFF e ON EXERCISE MANUAL Ns TIME S 2 Guardian Liquid cooled 27 kW and 30 kW Generators 4 1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES EVERY THREE MONTHS Check battery state of charge and condition Inspect and test fuel system Check transfer switch Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTH
56. ery electrolyte level if accessible Adjust as necessary f fe cables and charger for loose connections corrosion and proper operation Correct as necessary Check the unit wiring for loose connections corrosion and damage Correct as necessary accessory drive belts for wear weather cracking and damage Replace as necessary Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary Test the engine and transfer switch safety devices Correct and or adjust as necessary eo Generac Power Systems Inc Task Comp Date Initials Maintenance Tasks 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 necess
57. es 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 waRNING amp A Gaseous fuels such as natural and LP propane gas are highly explosive Even the slightest spark can ignite such fuels and cause an explo sion No leakage of fuel is permitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas 1 7 ENGINE PROTECTIVE DEVICES The engine has several safety switches which cause the engine to automatically shut down under the fol lowing conditions low oil pressure high coolant tem perature engine overspeed low coolant level or over crank Figure 1 3 Figure 1 3 Engine Protective Devices LOW COOLANT LEVEL SWITCH PRESURE SWITCH COOLANT TEMPERATURE SWITCH 1 71 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below about 8 10 psi 55 68 kPa the switch contacts close the engine shuts down automatically and the low oil pressure LED is turned ON Figure 1 4 Section 1 General Information Guardian Liquid cooled 27 kW and 30 kW Generators NOTE The Low Oil Pressure High Coolant Temperature and Low Coolant Level are not monitored for the first 10 second
58. fuel line Defective spark plugs Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch 1 Defective AUTO OFF MANUAL switch Open disconnected wire 15A between AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open ee Generac Power Systems Inc CORRECTION 1 2 NOOR Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replace fuse Replenish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Clean or replace as needed Unclog fuel line Clean regap or replace plugs Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERA
59. g engine faults occurs and when engine shuts down Low Oil Pressure Overcrank Low Battery Overspeed RPM Sensor Loss High Coolant Temperature Low Coolant Level oee Section 1 7 for further explanation of engine pro tection functions 5 2 5 15 AMP FUSE Fuse protects the control console s DC control circuit against electrical overload If the fuse has melted open because of an overload engine cranking and startup cannot occur If the fuse needs to be replaced use only an identical 15 amp replacement fuse Type AGC 3 2 4 4 0 AMP INLINE FUSE This fuse protects the battery charger against electri cal overload If the fuse needs to be replaced use only an identical 4 amp replacement fuse type AG NOTE This fuse will not remove the battery input power from the PCB when it opens This means the exercise timer will not be reset 3 2 5 SET EXERCISE TIME SWITCH This switch allows programming the generator to start and exercise automatically See Weekly Exercise Cycle 3 2 6 SYSTEM READY LED The System Ready LED green has two main pro poses First the LED will be ON when the AUTO OFF MANUAL switch is in the AUTO position utility is present and there are no system alarms This ON state indicates the system is fully ready for automatic operation The system ready LED will be OFF when the switch is in the MANUAL or OFF positions The system ready LED is also used to indicate the
60. h manual for exact oper ating parameters and timing sequences 3 2 CONTROL CONSOLE COMPONENTS The components of a home standby generator control console Figure 3 1 are as follows 5 2 1 AUTO OFF MANUAL SWITCH Use this three position switch as follows Set the switch to AUTO for fully automatic opera tion See Automatic Operation Section 3 5 Set switch to MANUAL position to crank and start the generator engine Set switch to OFF position to shut down an oper ating engine With OFF selected operation will not be possible A With switch set to AUTO engine can crank and start suddenly without warning Such automat ic start up normally occurs when utility source voltage drops below a pre set level To prevent possible injury that might be caused by such sudden starts set AUTO OFF MANUAL switch to OFF before working on or around the unit Then place a DO NOT OPERATE tag on con trol console OPERATION Section 3 Operation Guardian Liquid cooled 27 kW and 30 kW Generators 1 gt Figure 3 1 Home Standby Generator Panel EXECISER 1 PLA 2 HOLI pR THREE sECSNDS M E AND TAILS THE FOR 10 SECONDS THEN THE UNIT WILL START RUN THROUGH THE EXERCISE CYCLE AND SHUTDOWN SWITCH MANUAL AUTO OFF MANUAL FUSE SWITCH BATTERY 15A FUSE CHARGER MAIN POWER 5 2 2 FAULT INDICATOR LED This LED goes ON when one or more of the followin
61. ications 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 Generac Power Systems Inc 13 OPERATION Section 3 Operation J gt Guardian Liquid cooled 27 kW and 30 kW Generators 6 Adjust differential pot to make the recovery to load changes even faster and minimize load change undershoot and overshoot If it is set too high it may introduce oscillations at some load It can be set to zero full CCW if a small amount causes oscillations at some load Figure 3 2 Engine Governor Adjustment 6 R57 R58 R59 mini F 2 nn F 900 30 894 DIFFERENTIAL STA B LITY POSITION 1 POSITION 2 PUNUSED 50 60 HZ GTS ATS Select ON 50HZ ON GTS GTS ATS OFF ATS standard mode sien Hz OFF 60 HZ 5 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 follows Verify that UTILITY power supply voltage to the transfer switch has been positively turned OFF using whatever means provided such as utility main line circuit breaker
62. ighter than air and LP gas is heavier than air install leak detectors accordingly Generac Power Systems Inc 3 GENERAL INFORMATION 1 1 GENERATOR This equipment is a liquid cooled engine driven gen erator set The generator is designed to supply elec trical power that operates critical electrical loads during utility power failure The unit has been facto ry installed in a weather resistant all metal enclosure and is intended for outdoor installation only Use this generator as a source of electrical power for the oper ation of 120 and or 240VAC single phase loads warnings amp If this generator is used to power electrical load circuits normally powered by a UTILITY power source it is required by code to install a trans fer switch The transfer switch must effectively isolate the electric system from the utility distri bution system when the generator is operating NEC 701 Failure to isolate an electrical system by such means results in damage to the genera tor and may also result in injury or even death to utility power workers due to backfeed of electrical energy 1 2 TRANSFER SWITCH This generator system may include a matched auto matic transfer switch which is intended to be used in conjunction with the Generac generator It is supplied in either a NEMA 1 enclosure or a NEMA 3R enclo sure The NEMA 1 enclosure is intended for indoor use only The NEMA 3R enclosure is weather proof and can
63. ine Drawing No 0E8170 J 76 77 78 79 80 PART NO QTY 022131 059982 098780 051769 049808 051430 045773 0E6203C 0E6679 049226 091526 093278 0 6517 0 7163 0 5527 0E7202 085296 0E6203D 057772 057765 061696 069860C 057822 069811 026925 065852 0A2111 057073 066849 022152 0E7880 0 7880 0 7880 055934 027482 0 8940 Ppp a O n BRONDMY O n G 1 1 1 PARTS qea 00 DESCRIPTION WASHER FLAT 3 8 10 ZINC SCREW SHC M12 1 75 X 45 G10 9 SCREW HHC M12 1 75 X 65 G8 8 WASHER LOCK M12 WASHER FLAT M12 WASHER SHAKEPROOF INT 1 2 NUT HEX M12 1 75 G8 YEL CHR COIL IGNITION 3 0L FORD BRACKET IGN COIL 3 0L FORD WASHER LOCK 5 SCREW PPHM M5 0 8 X 12 ZNC SCREW HHTT M5 0 8 X 25 BP HARNESS ENGINE 3 0L FORD HSB NOT SHOWN GASKET EXHAUST 3 0L FORD MANIFOLD EXHAUST 3 0L FORD HEAT SHIELD 260 X 80 HOT SCREW HHC 1 4 20 X 1 2 SS WIRE SET 3 0L FORD NOT SHOWN WASHER NYLON 565 ADAPTER M14 1 50 X 3 8 NPT BARBED EL 90 3 8 NPT X 1 2 HOSE OIL DRAIN ASSY 21 CLAMP HOSE 8 53 1 00 CAP HEX 1 4NPT BRASS PLUG STD PIPE 3 8 STEEL SQ HD SPRING CLIP HOLDER 37 62 SCREW SWAGE 10 32 X 5 16 Z YC JUNCTION BLOCK 3 8 16 SCREW HHTT M5 0 8 X 16 WASHER LOCK 10 CLIP SPARK PLUG 3P SCREW MOUNT NOT SHOWN CLIP SPARK PLUG 2P SCREW MOUNT NOT SHOWN CLIP SPARK PLUG 3P FREEHANG NOT SHOWN
64. losure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer That deal er will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying 4 6 2 BATTERY All lead acid storage batteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine Generac Power Systems Inc 17 MAINTENANCE Section 4 Maintenance DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery
65. nerator Avoid contact with bare wires ter minals connections etc on the generator as well as the transfer switch if applicable Ensure all appropri ate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT If people must stand on metal or concrete while installing operating servicing adjusting or repairing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC Article 250 requires the frame and external electrically conduc tive parts of the generator to be connected to an approved earth ground and or grounding rods This rounding 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
66. ngine is still warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 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 Turn OIL FILTER Figure 4 2 counterclockwise and remove Dispose of old filter 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVERTIGHTEN 6 Remove OIL FILL CAP 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 caution 4 A After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK Guardian Liquid cooled 27 kW and 30 kW Generators 7 Start engine and check for oil leaks Figure 4 2 Filter ls 7 UA OIL FILTER 4 5 11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 059402 remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 4 3 Figure 4 3 Engine Air Cleaner AIR CLEANER 0 See the Service Schedule Section 6 for air cleaner maintenance 4 5 12 SPARK PLUGS
67. no sensing or con trolling circuit boards Instead the generator control console houses a Printed Circuit Board Assembly which controls all phases of operation including engine start up and load transfer 2 1 STANDBY GENERATOR INSTALLATION DX A A Connecting this generator to an electrical sys tem normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the electric system from the utility distri bution system when the generator is operating Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy A open bottom is used the engine genera f 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 amp After the system has been installed do nothing A that might render the installation in noncompli ance with such codes standards and regula tions 2 1 1 NFPA STANDARDS The following publish
68. on 8 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Mounting Base Drawing No 0E6266 E DESCRIPTION BASEFRAME WELDMENT 3 0L FORD 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 GRNDWIRE 11 3 8 amp 5 16 LUG 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 1 4 ZINC NUT HEX M6 1 0 G8 YEL CHR 1 1 2 BUTTON PLUG SCREW HHC 10 1 25 X 20 G8 8 WASHER SHAKEPROOF EXT 7 16 STL WASHER SHAKEPROOF EXT 5 16 STL WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR SCREW 10 1 5 X 20 G8 8 WASHER LOCK M10 WASHER FLAT 3 8 M10 ZINC CLAMP VINYL 75 X 343 Z BATT 12VDC 75 26 BATT 12VDC 90 AH 27F CABLE BATT RED 4 X 20 00 CABLE BATT BLK 4 X 30 EARTH STRAP SCREW HHC M10 1 5 X 25 G8 8 WASHER LOCK M10 WASHER FLAT 3 8 ZINC BOOT BATTERY CABLE BATTERY POST COVER BACLK BATTERY POST COVER RED SCREW HHC 8 1 25 X 60 G8 8 FT NUT TOP LOCK FL M8 1 25 HOLD DOWN BATTERY HOLD DOWN BATTERY NUT HEX LOCK M8 1 25 NY INS PARTS LISTS OG Generac Power Systems Inc 29 LISTS PARTS Section 8 Exploded Views and Parts Sg 2 Guardian Liquid cooled 27 kW and 30 kW Generators Compartment Drawing No 0E8333 D SEE LATCH TYPICAL OF ROOF PANEL THAT REQUIRE INSULAT
69. s of engine run time 1 7 2 HIGH COOLANT TEMPERATURE SWITCH This normally open N O thermostatic switch has sensing tip which is immersed in captive coolant should coolant temperature exceed about 230 F 110 C the switch contacts close This causes the engine to shut down automatically and turns on the high coolant temperature low coolant level LED Figure 1 5 Figure 1 5 High Coolant Temperature Switch 1 73 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 Generac Power Systems Inc 5 1 74 OVERSPEED SHUTDOWN 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 instantaniously the engine shuts down and the overspeed LED turns on Should AC frequency exceed about 72 Hertz circuit board action will automatically shutdown the engine Figure 1 7 Figure 1 7 Printed Circuit Board Assembly NE N NC Shane m
70. slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery A Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water A 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 bicarbonate 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 warninc amp Do not dispose of the battery in a fire The battery is capable of exploding Do not open or mutilate the battery Released A electrolyte can be toxic and harmful to the skin and eyes A The battery represents a risk of high short circuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles When replacing batteries use the sam
71. t are there fore 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 utilized does not render the generator unsafe DIG A A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to install operate or main tain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator rotating and or hot during operation Exercise care near running gen erators 2 Generac Power Systems Inc 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 A GENERAL HAZARDS For safety reasons Generac recommends that this equipment be installed serviced and repaired by a Generac Authorized Service Dealer or other compe tent qualified electrician or installation technici
72. the GTS is responsible for utility sensing weekly exercising and load transferring Position two of the four position dip switch is used to turn over this control to the GTS Pos2 ON GTS Application The control board will NOT monitor utility The control board will NOT perform a weekly exer cise The five red LEDs will not flash in this mode The control board will NOT activate the transfer output 12 Generac Power Systems Inc The control board WILL monitor all engine condi tions and shut down on all the faults listed in this document Pos2 OFF ATS Application The control board will perform all of the automat ic features listed in this document The two wire start connections should NOT be used GTS Mode Operation When in GTS mode the control board will respond as follows based on the AUTO OFF MANUAL switch position OFF The generator will not start and run in this position MANUAL The control board will start and run the generator whenever the switch is in the manual posi tion AUTO The control board will monitor the two wire start circuit When a two wire start is issued the con trol board will immediately start and run the genera tor Whe the two wire start is removed the control board will immediately stop the generator NOTE If the generator is installed in conjunction with a standard GTS type transfer switch refer to the applicable transfer switc
73. the proper level the dipstick FULL mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications Section 1 10 and Engine Oil Recommendations Section 1 14 NOTE This engine is shipped from the manufacturer with 5W 20 oil This oil should be changed after 30 hours of operation 2 11 5 ENGINE COOLANT Have the engine 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 7 ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground and or ground rod Make sure the generator battery is fully charged prop erly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components 3 1 USING A STANDARD GTS TRANSFER SWITCH When required the pre packaged standby generator can be installed with a standard Generac GTS type automatic transfer switch In this application
74. thod is used it is difficult to overload the generator The transfer switch must meet the fol lowing requirements Generac Power Systems Inc s INSTALLATION Section 2 Installation Guardian Liquid cooled 27 kW and 30 kW Generators 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 2 6 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed use the Total Circuit Isolation Method It is possible for the gener ator to be overloaded when this isolation method is employed The following apply to the transfer switch in this type of system Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service The transfer switch is installed between the utility service entrance and the building distribution panel 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
75. ting where no manufacturing defect is found e 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 e 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 297 WHITEWATER WI53190 Revision 10 01 04 Part No OF2006 Revision A 10 15 04 Printed in U S A
76. ucted flow of cooling and ventilat ing air is critical to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator Keep the area around the generator clean and unclut tered Remove any materials that could become haz ardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Guardian Liquid cooled 27 kW and 30 kW Generators Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts Before performing any maintenance on the generator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable 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 A ELECTRICAL HAZARDS All generators covered by this manual produce dan gerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dan gerous voltages to the transfer switch as well as the standby ge
77. us 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 16 Generac Power Systems Inc 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 5 8 inch Adjust belt tension as required 4 5 9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor A Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incorrect frequency and or voltage Only quali fied service technicians should adjust the gov erned speed 4 5 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized serv ice facilities for engine oil and filter change frequen cies Drain the oil while the e
78. with its stator AC output leads connected in a single phase three wire generator AC connection system Figure 1 1 The stator assembly in this system consists of a pair of stationary windings with two leads brought out of each winding Each single winding can supply 120VAC 60 Hertz When the two windings are con nected in series a 240VAC 60 Hertz AC output results Typically the two HOT leads in the circuit are wires 11 and 44 The NEUTRAL leads are the junc tion of Wires 22 and 33 The NEUTRAL is not grounded Figure 1 1 Generator AC Connection System 240 VOLTS CIRCUIT BREAKER 1 5 CIRCUIT BREAKER The generator s main circuit breaker is included with the unit as shipped from the factory The breaker for each unit is described in Figure 1 2 Figure 1 2 Main Circuit Breaker Model Rating Phase Actual Current C B Rating Circuit Breaker 004948 0 27 000 NG 1 112 5 150 150A QN2 30 000 LP 1 125 0 150 150A QN2 Amp Rating of C B structured under model e Generac Power Systems Inc 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 contact an authorized service dealer Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load rang
79. wledge to accomplish and should be performed only by an authorized Generac 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 Generac Service Dealer Generac Power Systems Inc 19 gt Section 4 Maintenance MAINTENANCE Guardian Liquid cooled 27 kW and 30 kW Generators 2 0 10 Check the engine 11 12 Disable the unit from Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task mended Comp done Comp be done Comp Required to be done Date 3months Date Date be done monthly Initials Break in Initials annually Initials Annually operating per the first page warning Check the engine oil level Adjust as necessary Check the engine coolant level Adjust as necessary Check the engine coolant thermal protection level Correct as necessary Check the natural gas delivery system on gas engine driven units Tighten connections as necessary Check the air inlets and fel f necessary Check the batt

Generac Power Systems 004988-1 Portable Generator User Manual

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