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Generac Power Systems 004988-1 Owner's Manual

Generac liquid-cooled, prepackaged standby generator owner's manual.

 
Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number: 004988-1
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

Summary of Contents

  • Page 1

    Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number: 004988-1 This manual should remain with the unit. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

  • Page 2

    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.

  • Page 3: Table Of Contents

    INTRODUCTION ...IFC SAFETY RULES ...2 Section 1 — GENERAL INFORMATION ...4 Generator ...4 Transfer Switch ...4 Automatic System Operation ...4 Generator AC Connection Systems...4 Main Circuit Breaker ...4 Generator Fuel System ...5 Engine Protective Devices ...5 Unpacking ...6 Lifting the Generator ...6 1.10 Specifications ...7 1.11 Fuel Consumption ...7 1.12 Reconfiguring the Fuel System ...7...

  • Page 4: 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 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 –...

  • Page 5

    • 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.

  • Page 6: Section 1 — General Information, Generator, Transfer Switch, Automatic System Operation, Generator Ac Connection Systems

    Section 1 - General Information Guardian Liquid-cooled 27 kW and 30 kW Generators 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.

  • Page 7: Generator Fuel System, Engine Protective Devices

    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.

  • Page 8: Unpacking, Lifting The Generator

    Section 1 — General Information Guardian Liquid-cooled 27 kW and 30 kW Generators Figure 1.6 - Low Coolant Level Sensor 1.7.4 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.

  • Page 9: Specifications, Fuel Consumption, Reconfiguring The Fuel System

    1.10 SPECIFICATIONS 1.10.1 GENERATOR SPECIFICATIONS Model Rated Max. Cont. AC Power Output (kW) Rated voltage (volts) No. of Rotor Poles Driven Speed of Rotor Rotor Excitation System Direct excited brush type Type of Stator Rotor/Stator Insulation 1.10.2 ENGINE SPECIFICATIONS Make...Ford Displacement ...3.0 liters Cylinder Arrangement ...V-6 Valve Arrangement ...Overhead Valve...

  • Page 10: Torque Specifications, Engine Oil Recommendations, Coolant Recommendations, Before Installation, Section 2 — Installation

    Section 2 — Installation Guardian Liquid-cooled 27 kW and 30 kW Generators 1.13 TORQUE SPECIFICATIONS Cylinder Head ...15 (+ 90° + 90°) ft.lb. Intake Manifold ...13 ft.lb. Exhaust Manifold...13 ft.lb. 1.14 ENGINE OIL RECOMMENDATIONS The unit has been filled with 5W-20 engine oil at the factory.

  • Page 11: Generator Location, Generator Mounting And Support, Basic Standby Electric System, Emergency Circuit Isolation Method

    • 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.

  • Page 12: Total Circuit Isolation Method, Grounding The Generator, Generator Ac Neutral Connections

    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.

  • Page 13: Battery Installation, Preparation Before Start-up

    2.10 BATTERY INSTALLATION DANGER 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.

  • Page 14: Section 3 — Operation, Using A Standard "gts" Transfer Switch, Control Console Components

    Section 3 — Operation 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 the proper level – the dipstick “FULL ” mark. Never operate the engine with the oil level below the dipstick “ADD”...

  • Page 15: Manual Transfer And Startup, Engine Governor Adjustments

    Figure 3.1 - Home Standby Generator Panel LED INDICATORS: FLASHING GREEN LED = NO UTILITY SENSE 5 FLASHING RED LED'S = EXERCISER NOT SET (IN AUTO MODE ONLY) SOLID GREEN LED = SYSTEM READY, UTILITY POWER ON RED LED'S = INDIVIDUAL FAULT (SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS) OVER CRANK AUTO...

  • Page 16: Retransfer And Shutdown, Automatic Operation, Weekly Exercise Cycle

    Section 3 — Operation 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.

  • Page 17: Section 4 — Maintenance, Maintenance Performed By Authorized Service Facilities, Cooling System

    MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A. EVERY THREE MONTHS 1. Check battery state of charge and condition. 2. Inspect and test fuel system. 3. Check transfer switch. 4. Inspect exhaust system. 5. Check engine ignition system. 6. Check fan belts. B.

  • Page 18: Maintenance Owner/operator Can Perform

    Section 4 — Maintenance Guardian Liquid-cooled 27 kW and 30 kW Generators 4.4.3 ENGINE COOLANT Check coolant level in coolant recovery bottle. See Specifications, Section 1.10. • Add recommended coolant mixture as necessary. • Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly.

  • Page 19: Miscellaneous Maintenance

    7. Start engine and check for oil leaks. Figure 4.2 - Oil Filter 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).

  • Page 20

    Section 4 — Maintenance Guardian Liquid-cooled 27 kW and 30 kW Generators • 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. •...

  • Page 21: Scheduled Maintenance

    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.

  • Page 22

    Section 4 — Maintenance Guardian Liquid-cooled 27 kW and 30 kW Generators Maintenance Level 1 Tasks Recom- mended to be done monthly/ 10 hrs. 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary.

  • Page 23

    Maintenance Level 1 Tasks Recom- mended to be done monthly/ 10 hrs. 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.

  • Page 24: Section 5 — Troubleshooting

    Section 5 — Troubleshooting Guardian Liquid-cooled 27 kW and 30 kW Generators TROUBLESHOOTING POINTS 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.

  • Page 25

    Section 6 — Installation Diagram Guardian Liquid-cooled 27 kW and 30 kW Generators Installation Diagram — Drawing No. 0E8695 Generac ® Power Systems, Inc. 23...

  • Page 26: Section 7 — Electrical Data

    Section 7 - Electrical Data Guardian Liquid-cooled 27 kW and 30 kW Generators Wiring Diagram — Engine — Drawing No. 0E6199-E NOTE: SIZE (AWG) ALL WIRES ARE 18 AWG 300 VOLT UL LISTED UNLESS OTHERWISE NOTED AS SHOWN: TRANSFER SWITCH CUSTOMER CONNECTION LEGEND: AVR -...

  • Page 27

    PCB J2 PCB J1 Section 7 - Electrical Data Guardian Liquid-cooled 27 kW and 30 kW Generators Wiring Diagram — Engine — Drawing No. 0E6199-E NOTE: SIZE (AWG) ALL WIRES ARE 18 AWG 300 VOLT UL LISTED UNLESS OTHERWISE NOTED AS SHOWN: GND1 LEGEND: ALT -...

  • Page 28

    Section 7 - Electrical Data Guardian Liquid-cooled 27 kW and 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-A LEGEND: AR - AS - AVR - BA - B/C - BCW - CB1 - CB2 - D1 - DPE - TRANSFER SWITCH CUSTOMER CONNECTION...

  • Page 29

    Section 7 - Electrical Data Guardian Liquid-cooled 27 kW and 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-A J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J1-7 J2-1 J2-2 J1-8 J2-3 J1-9 J2-4 J1-10 J1-11 J2-5 J1-12 J2-6 J1-13 J2-7 J1-14 J2-8...

  • Page 30

    Section 8 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Mounting Base — Drawing No. 0E6266-E 28 Generac ® Power Systems, Inc.

  • Page 31

    ITEM PART NO. QTY. 0E5822 052860 052251 052257 052252 052259 052891 0536210213 074906 047411 055414 026850 022097 022473 049813 0A1694 052213 025507 027482 022129 045771 23 * 051756 24 * 046526 25 * 022131 26 * 055934M 077483 REF. 058665 REF.

  • Page 32

    Section 8 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Compartment — Drawing No. 0E8333-D 30 Generac ® Power Systems, Inc.

  • Page 33

    ITEM PART NO. QTY. 0E8411 0E8042 0E8041 0C2454 0E8402 0E7808 0E7809 0E8387 0E6986 0E7795 089961 0A2115 0E8404 0D2538A 0D2538 043116 022097 022473 0E7570 0E7571 070015 0E7662 0D2537A 0D2537 0D2023 0E7869 0E8001 0E8060 0E8406 0D3037A 0C7781 0E7794 0E8052 0D3037 0E8007 0E8008 0E6989 0E8055 026850...

  • Page 34

    Section 8 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Control Panel — Drawing No. 0E7118-G 32 Generac ® Power Systems, Inc.

  • Page 35

    ITEM PART NO. QTY. DESCRIPTION 0E7195 CONTROL BOX HSB 0E7196 COVER FRONT PANEL HSB 0E7197 COVER TOP PANEL HSB 0E7193 DECAL WARNINGS HSB 0E7194 DECAL CONTROLS HSB 0E4494 SWITCH ROC DPDT ON-OFF-ON 082573 SWITCH ROCKER DPST 125V SPD 032300 HOLDER FUSE 022676 FUSE 15A X AGC15 067682B...

  • Page 36

    Section 8 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Engine — Drawing No. 0E8170-J GROUND WIRE 34 Generac ® Power Systems, Inc. BAFFLE REAR UPPER...

  • Page 37

    ITEM PART NO. QTY. DESCRIPTION 0E6202 ENGINE 3.0L FORD (RD) (MAKE) 0E8824 STAMPING ENG FOOT 3.0L FORD 0E8963 PULLEY CRANKSHAFT 3.0L FORD 0E9020 BRACKET DC ALT 3.0L FORD 0A1232 D.C. ALTERNATOR ASSY 0A7801B PULLEY POLY-V 82 OD. 0A5610 BRACKET ALTERNATOR 0E6308 PULLEY WATERPUMP 3.0L FORD (RD)

  • Page 38

    Section 8 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Radiator — Drawing No. 0E8528-B 36 Generac ® Power Systems, Inc.

  • Page 39

    ITEM PART NO. QTY. 0E9947 0E6340 0E8531 0E6398 0E6397 080713 076749 049814 022131 046526 045772 035685 0E8562 058443 0C2454 048031C 029032 046627 069811 065852 0A2111 052250 035461 0C7649 069860C Section 8 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Radiator —...

  • Page 40

    Section 8 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Fuel System — Drawing No. 0E8190-B 38 Generac ® Power Systems, Inc.

  • Page 41

    ITEM PART NO. QTY. --------- 075580 0E7691 039253 022145 022129 045771 042907 0C2454 026307 0E1056 0E6584 057823 059194 044117 0D1509 050279 0E6123 0E6586 0E4395 057753B 047487 022097 051751 035685 057823 047290 047290 0A4121 0E6609 049099 35 ** 055934M 36 ** 047411 37 ** 022097...

  • Page 42

    Section 8 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Alternator — Drawing No. 0E8660-B 40 Generac ® Power Systems, Inc.

  • Page 43

    ITEM PART NO. QTY. 0F1659A 0F1657A 0F1655A 0E5093A 0E7413A 0F1660A 0F1658A 0F1656A 0E5094A 0E7412A 0E5706 0E5048 0E5048A 0E5048B 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 092980 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F ROTOR REPLACEMENT PARTS 047248 070892 Section 8 - Exploded Views and Parts...

  • Page 44

    Section 8 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Muffler — Drawing No. 0E6479-D ITEM PART NO. QTY. DESCRIPTION 0E6134 MUFFLER, 3.0L FORD 0E6464 EXHAUST ELBOW 3.0L FORD HSB 0E6465 EXHAUST PIPE LH 3.0L FORD HSB 0E6465A EXHAUST PIPE RH 3.0L FORD HSB 0E5914...

  • Page 45

    ITEM PART NO. QTY. DESCRIPTION 0E5193 PLATE AIR CLEANER ADAPTER 0E8200 TUBE AIR INTAKE 3.0L FORD 0E8201 BRACKET AIR INTAKE 3.0L FORD 036434 BOLT U 5/16-18 X 2.09 0E0519A ADAPTER, CARBURETOR W/PVC CONN 0C8127 ELEMENT, AIR CLEANER 0A5547 COVER - AIR CLEANER 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC 022127...

  • Page 46: Section 9 — Notes

    Section 9 - Notes Guardian Liquid-cooled 27 kW and 30 kW Generators 44 Generac ® Power Systems, Inc.

  • Page 47

    Section 9 - Notes Guardian Liquid-cooled 27 kW and 30 kW Generators Generac ® Power Systems, Inc. 45...

  • Page 48

    "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.

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