Download Print this page

Generac Power Systems 004988-4 Owner's Manual

Liquid-cooled, prepackaged standby generator.
Hide thumbs

Advertisement

Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number: 004988-4
27kW NG, 30kW LP Vapor
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

Advertisement

   Related Manuals for Generac Power Systems 004988-4

   Summary of Contents for Generac Power Systems 004988-4

  • Page 1

    Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number: 004988-4 27kW NG, 30kW LP Vapor 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. 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.

  • 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...

  • Page 4: Safety Rules

    IMPORTANT SAFETY INSTRUCTIONS Liquid-cooled 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. ...

  • 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 an Authorized Dealer. Model Rating 004988-4 27,000 NG 30,000 LP 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.

  • 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 Liquid-cooled 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

    Fuel pressure for an LP vapor set up should be 11 Single-phase inches to 14 inches of water column (0.4 to 0.5 psi) at all load ranges. 004988-4 27 (NG), 30 (LP) 1.12 RECONFIGURING THE FUEL 120/240 1800...

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

    Section 2 — Installation Liquid-cooled 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 76A, ESSENTIAL SYSTEMS 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 Liquid-cooled 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 can only power criti- cal loads, within it’s wattage/amperage capacity, dur- ing utility power outages, use the emergency 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

    Section 3 — Operation Liquid-cooled 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

    MANUAL — The control board will start and run the generator whenever the switch is in the manual position. AUTO — The control board will monitor the two- wire start circuit. When a two-wire start is issued the control board will immediately start and run the gen- erator.

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

    Section 3 — Operation Liquid-cooled 30 kW Generators 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 presence of utility sensing at the PCB when the switch is either in the AUTO or MANUAL modes.

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

    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.

  • Page 18: Overload Protection For Engine Dc Electrical System, Checking Fluid Levels, Maintenance Owner/operator Can Perform

    Section 4 — Maintenance Liquid-cooled 30 kW Generators OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via a 15 amp fuse.

  • Page 19: Oil Filter

    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.

  • Page 20: Miscellaneous Maintenance

    Section 4 — Maintenance Liquid-cooled 30 kW Generators 4.5.12 SPARK PLUGS 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 commercial solvent.

  • Page 21

    DANGER  Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charg- ing. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shat- ter the battery and cause blindness or other injury.

  • Page 22: Scheduled Maintenance

    Section 4 — Maintenance Liquid-cooled 30 kW Generators SCHEDULED MAINTENANCE The following is a recommended maintenance schedule for 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 Liquid-cooled 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 abnormal operating...

  • 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 Liquid-cooled 30 kW Generators CAUSE 1.

  • Page 26: Section 6 — Notes

    Section 6 - Notes Liquid-cooled 30 kW Generators...

  • Page 27

    Section 7 — Installation Diagram Liquid-cooled 30 kW Generators Installation Diagram — Drawing No. 0E8695...

  • Page 28: Section 8 — Electrical Data

    Section 8 - Electrical Data Liquid-cooled 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 - AUTOMATIC VOLTAGE REGULATOR BA - BRUSH ASSEMLY (GENERATOR)

  • 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 Liquid-cooled 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 - BATTERY CHARGE WINDING CB1 -...

  • Page 31

    Liquid-cooled 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-B J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J2-1 J1-7 J2-2 J1-8 J1-9 J2-3 J2-4 J1-10 J1-11 J2-5 J2-6 J1-12 J1-13 J2-7 J2-8 J1-14 LEGEND: ALT - D.C. CHARGE ALTERNATOR C1 - CONNECTOR 1 (ENGINE) CC -...

  • Page 32

    Section 9 - Exploded Views and Parts Liquid-cooled 30 kW Generators Mounting Base — Drawing No. 0E6266-F...

  • 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 Liquid-cooled 30 kW Generators Enclosure — Drawing No. 0F1142-B...

  • Page 35

    ITEM PART NO. QTY. 0E8411 0E8042 0E8041 0C2454 0E8402 0E7808 0E7809 0E8387 0E6986 0F5552 089961 0A2115 0E8404 0D2538A 0D2538 078115 022097 022473 0E7570 0E7571 070015 0E7662 0D2537A 0D2537 0D2023 0E7869 0E8001 0F5551 0E8406 0D3037A 0C7781 0E7794 0E8052 0D3037 0E8007 0E8008 0F1130 0E8055 026850...

  • Page 36

    Section 9 - Exploded Views and Parts Liquid-cooled 30 kW Generators Control Panel — Drawing No. 0E7118-K...

  • 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 Liquid-cooled 30 kW Generators Engine — Drawing No. 0F6836-B...

  • Page 39

    ITEM PART NO. QTY. DESCRIPTION 0E6201 ENGINE 3.0L FORD (FD) (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 Liquid-cooled 30 kW Generators Radiator — Drawing No. 0F6848-B...

  • Page 41

    ITEM PART NO. QTY. 0E9947 0E6340 0E8531 0E6398 0F6630 080713 076749 049814 022131 046526 045772 035685 0E8562 058443 0C2454 048031C 029032 046627 069811 065852 0A2111 052250 035461 0C7649 069860C 0F6746 0F6631 0F6657 055934N 092079 022097 047411 Section 9 - Exploded Views and Parts Liquid-cooled 30 kW Generators Radiator —...

  • Page 42

    Section 9 - Exploded Views and Parts Liquid-cooled 30 kW Generators Fuel System — Drawing No. 0F6849-A...

  • 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 0C7649 047290 047290 0A4121 0E6609 049099 35 ** 055934M 36 ** 047411 37 ** 022097...

  • Page 44

    Section 9 - Exploded Views and Parts Liquid-cooled 30 kW Generators Alternator — Drawing No. 0F5092-B...

  • 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 092980 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 Liquid-cooled 30 kW Generators Exhaust — Drawing No. 0F0968-B ITEM PART NO. QTY. DESCRIPTION 0F0738 MUFFLER 7"X9"-(2)2"IN/2.5"OUT 0F6258 PIPE MUFFLER OUT 044149 GASKET EXHAUST RING 0F1008 EXHAUST PIPE LH 3.0L HSB 0F1009 EXHAUST PIPE RH 3.0L HSB 039288 SCREW HHC M8-1.25 X 55 G8.8 0E5914...

  • Page 47

    ITEM PART NO. QTY. 0E5193 0E0519A 049226 049815 0C8127 022127 062974 0A5547 037561 Section 9 - Exploded Views and Parts Liquid-cooled 30 kW Generators Air Cleaner — Drawing No. 0F6850-A DESCRIPTION PLATE AIR CLEANER ADAPTER ADAPTER CARBURETOR W/PVC CONN WASHER LOCK M5 SCREW HHC M5-0.8 X 16 G8.8 ELEMENT AIR CLEANER NUT HEX 1/4-20 STEEL...

  • 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.

Comments to this Manuals

Symbols: 0
Latest comments: