Generac Power Systems 004988-2 Owner's Manual

Liquid-cooled, prepackaged standby generator.
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Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number: 004988-2
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

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   Summary of Contents for Generac Power Systems 004988-2

  • Page 1

    Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number: 004988-2 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: Electrical Hazards, Fire Hazards, Explosion Hazards

    • 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

    If a transfer switch is not included, one may be pur- chased separately from a Generac Authorized Dealer. Model Rating 004988-2 27,000 NG 30,000 LP Generac ® Power Systems, Inc.

  • 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

    Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.4 to 0.5 Single-phase psi) at all load ranges. 004988-2 1.12 RECONFIGURING THE FUEL 27 (NG), 30 (LP) 120/240 1800 All models are configured for natural gas from the factory.

  • 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

    • NFPA STATIONARY ENGINES AND GAS TURBINES. • NFPA No. 76A, ESSENTIAL ELECTRICAL SYS- TEMS FOR HEALTH CARE FACILITIES. • NFPA No. 220, STANDARD TYPES OF BUILDING CONSTRUCTION • NFPA No. 68, GUIDE FOR EXPLOSION VENTING • NFPA No. 70, NATIONAL ELECTRICAL CODE. •...

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

    Section 2 — Installation Guardian Liquid-cooled 27 kW and 30 kW Generators 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.

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

    Control system interconnections consist of N1 and N2, and leads 23 and 194. Control system intercon- nection leads must be run in a conduit that is sepa- rate from the AC power lead. Recommended wire gauge sizes for this wiring depends on the length of the wire, as recommended below: MAXIMUM WIRE LENGTH RECOMMENDED WIRE...

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

    Section 3 — Operation Guardian Liquid-cooled 27 kW and 30 kW Generators 2.11.1 PRIOR TO INITIAL START-UP Prior to initially starting the generator, it must be properly prepared for use. Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure.

  • Page 15: Control Console Components

    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...

  • Page 16: Manual Transfer And Startup, Engine Governor Adjustments, Retransfer And Shutdown, Automatic Operation, Weekly Exercise Cycle

    Section 3 — Operation Guardian Liquid-cooled 27 kW and 30 kW Generators 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.

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

    2. Press and hold the “Set Exercise” switch for three seconds, then release. At this time all five red LEDs will flash for approxi- mately 10 seconds, then the engine will start and run for it’s 12 minute exercise period, then shut down. The generator will now start and run each week at the same time.

  • Page 18: Checking Fluid Levels, Maintenance Owner/operator Can Perform

    Section 4 — Maintenance Guardian Liquid-cooled 27 kW and 30 kW Generators 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. • Remove oil dipstick and wipe dry with a clean, lint-free cloth.

  • Page 19: Oil Filter

    DANGER 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.

  • Page 20: Miscellaneous Maintenance

    Section 4 — Maintenance Guardian Liquid-cooled 27 kW and 30 kW Generators Figure 4.4 – Setting the Spark Plug Gap SET PLUG GAP AT 1.06-1.16 mm (0.042-0.046 inch) 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.

  • Page 21

    Do not use any jumper cables or booster bat- tery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging. Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables.

  • Page 22: Scheduled Maintenance

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

  • Page 23

    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. 3. Check the engine coolant level. Adjust as necessary. 4.

  • Page 24

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

  • Page 25: Section 5 — Troubleshooting

    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. Section 5 — Troubleshooting Guardian Liquid-cooled 27 kW and 30 kW Generators CAUSE 1.

  • Page 26: Section 6 — Notes

    Section 6 - Notes Guardian Liquid-cooled 27 kW and 30 kW Generators 24 Generac ® Power Systems, Inc.

  • Page 27

    Section 7 — Installation Diagram Guardian Liquid-cooled 27 kW and 30 kW Generators Installation Diagram — Drawing No. 0E8695 Generac ® Power Systems, Inc. 25...

  • Page 28: Section 8 — Electrical Data

    Section 8 - Electrical Data Guardian Liquid-cooled 27 kW and 30 kW Generators Wiring Diagram — Engine — Drawing No. 0E6199-F NOTE: SIZE (AWG) ALL WIRES ARE 18 AWG 300 VOLT UL LISTED UNLESS OTHERWISE NOTED AS SHOWN: TRANSFER SWITCH CUSTOMER CONNECTION LEGEND: AVR -...

  • Page 29

    PCB J2 PCB J1 LEGEND: ALT - D.C. CHARGE ALTERNATOR BAT - 12VDC BATTERY C1 - CONNECTOR 1 (ENGINE) CC - STARTER CONTACTOR DEG - DRIVER ELEC. GOVERNOR FS - FUEL SOLENOID GND1- GROUND (SENSING/LOW AMP) GND2- GROUND (POWER/HIGH AMP) GOV - ELEC.

  • Page 30

    Section 8 - Electrical Data Guardian Liquid-cooled 27 kW and 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-B LEGEND: AR - ALTERNATOR ROTOR AS - ALTERNATOR STATOR AVR - AUTOMATIC VOLTAGE REGULATOR BA - BRUSH ASSEMLY (GENERATOR) B/C - BATTERY CHARGER BCW -...

  • Page 31

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

  • Page 32

    Section 9 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Mounting Base — Drawing No. 0E6266-E 30 Generac ® Power Systems, Inc.

  • Page 33

    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 34

    Section 9 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Compartment — Drawing No. 0E8333-D 32 Generac ® Power Systems, Inc.

  • Page 35

    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 36

    Section 9 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Control Panel — Drawing No. 0E7118-K 34 Generac ® Power Systems, Inc.

  • Page 37

    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 38

    Section 9 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Engine — Drawing No. 0E8170-N GROUND WIRE 36 Generac ® Power Systems, Inc. BAFFLE REAR UPPER...

  • Page 39

    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 40

    Section 9 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Radiator — Drawing No. 0E8528-B 38 Generac ® Power Systems, Inc.

  • Page 41

    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 9 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Radiator —...

  • Page 42

    Section 9 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Fuel System — Drawing No. 0E8190-C 40 Generac ® Power Systems, Inc.

  • Page 43

    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 44

    Section 9 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Alternator — Drawing No. 0F5092-A 42 Generac ® Power Systems, Inc.

  • Page 45

    ITEM PART NO. QTY. 0F1659A 0F1657A 0F1655A 0F5073A 0E7413A 0F1660A 0F1658A 0F1656A 0F5074A 0E7412A 0E5706 0E5048 0E5048B 0E5048A 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 0C3993 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F ROTOR REPLACEMENT PARTS 047248 070892 Section 9 - Exploded Views and Parts...

  • Page 46

    Section 9 - Exploded Views and Parts Guardian Liquid-cooled 27 kW and 30 kW Generators Muffler — Drawing No. 0E6479-E 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 47

    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 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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