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Generac Power Systems 004988-2 User's Manual

1. 15 4 3 Overload Protection for Engine DC Electrical System 15 4 4 Checking Fluid Levels 16 4 5 Maintenance Owner Operator Can Perform 16 4 6 Miscellaneous Maintenance 18 4 7 Scheduled Maintenance 20 Section 5 TROUBLESHOOTING 23 Section 6 NOTES 24 Section 7 INTALLATION DIAGRAM 25 Section 8 ELECTRICAL DATA 26 Section 9 EXPLODED VIEWS AND PARTS LISTS 30 Section 10 WARRANTY Back Cover 2 Generac Power Systems Inc 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 unit are there fore not all inclusive If using a procedure work method or o
2. DANGER GROUNDING LUG Section 2 Installation Guardian Liquid cooled 27 kW and 30 kW Generators Generac Power Systems Inc 11 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 2 9 2 GTS 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 2 10 BATTERY INSTALLATION 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 p
3. 14A 15E 15A 0 0A 0 0 12 BULKHEAD CONNECTOR BC1 5 9 10 11 6 8 7 2 4 3 1 23 66 5 11 6 33 22 2 44 4 1 55 66 4 239 IN OFF POSITION 3 6 SHOWN 2 1 5 4 1 2a 2 1 1 3 2 2 87 85 86 30 Generac Power Systems Inc 29 Section 8 Electrical Data Guardian Liquid cooled 27 kW and 30 kW Generators Electrical Schematic Engine Drawing No 0E6200 B SC IC IM LOS SM WLS LEGEND CONT CONNECTOR C1 SWITCH HIGH COOLANT TEMP CRANKING CONTACTOR D C CHARGE ALTERNATOR CONNECTOR 1 ENGINE DRIVER ELEC GOVERNOR SOLENOID FUEL ELEC GOVERNOR ACTUATOR HCT GOV LEGEND C1 ALT DEG CC FS CONTACTOR STARTER MOTOR IGNITION MODULE ON DISTRIBUTOR SWITCH LOW OIL PRESSURE SENSOR COOLANT LEVEL IGNITION COIL STARTER MOTOR 14A 13 14 15E 224 225 15A 239 11 12 10 7 9 8 4 6 5 2 1 3 0A 0 0 0 23 66 PCB GOV 14A 225 85 66 4 6 5 1 3 2 J1 12 J1 13 J1 11 J1 14 224 239 15E 0 86 15A 23 56 J1 5 J1 7 J1 6 J1 8 J1 9 J1 10 J1 2 J1 3 J1 4 J1 1 J2 5 768 N C 770 766 N C 771 765 767 J2 7 J2 6 J2 8 14 0 767 769 766 765 J2 1 J2 3 J2 2 J2 4 56 16 13 13 85 14 CC FS 86 0 0
4. 21 17 44 Generac Power Systems Inc Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Muffler Drawing No 0E6479 E Generac Power Systems Inc 45 ITEM PART NO QTY DESCRIPTION 1 0E5193 1 PLATE AIR CLEANER ADAPTER 2 0E8200 1 TUBE AIR INTAKE 3 0L FORD 3 0E8201 1 BRACKET AIR INTAKE 3 0L FORD 4 036434 1 BOLT U 5 16 18 X 2 09 5 0E0519A 1 ADAPTER CARBURETOR W PVC CONN 6 0C8127 1 ELEMENT AIR CLEANER 7 0A5547 1 COVER AIR CLEANER 8 062974 1 STUD TH 1 4 20 X 4 1 2 G2 ZNC 9 022127 1 NUT HEX 1 4 20 STEEL 10 037561 1 NUT WING 1 4 20 NYLK ITEM PART NO QTY DESCRIPTION 11 049226 8 WASHER LOCK M5 12 049815 4 SCREW HHC M5 0 8 X 16 G8 8 13 052619 4 SCREW HHC M5 0 8 X 20 G8 8 14 051713 4 WASHER FLAT M5 15 051716 4 NUT HEX M5 0 8 G8 YEL CHR 16 022131 2 WASHER FLAT 3 8 M10 17 046526 2 WASHER FLAT M10 18 051755 2 SCREW HHC M10 1 5 X 16 G8 8 19 022145 2 WASHER FLAT 5 16 M8 ZINC 20 022129 2 WASHER LOCK M8 5 16 21 022259 2 NUT HEX 5 16 18 STEEL Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Air Cleaner Drawing No 0E8189 A Part No 0F5095 Revision B 05 05 05 Printed in U S A Section 10 Warranty Guardian Liquid cooled 27 kW and 30 kW Generators GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATOR
5. ALT 0 CC 0 LOS 767 768 769 11 10 12 DEG 765 766 765 766 767 770 771 14 0 16 14 SC 7 9 8 4 6 5 2 3 1 IM 449 IC 4 14 0 WLS 12VBATTERY 13 RED SC SM BLACK 0 HCT FRONT 6 2 5 3 6 1 4 CONTACTOR WIRE HARNESS 7 5 6 16 ENGINE FOOT 2 4 3 41 40 16 7 6 5 35 9 13 17 12 8 18 16 43 BLOCK ENGINE 30 TO 44 35 34 3 36 33 44 42 22 20 32 38 18 31 20 TO STARTER STARTER BOLT TO BLOCK ENGINE 18 TO 11 1 12 10 14 REAR BEARING 13 15 37 14 CARRIER 3 4 16 2 30 Generac Power Systems Inc Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Mounting Base Drawing No 0E6266 E ITEM PART NO QTY DESCRIPTION 1 0E5822 1 BASEFRAME WELDMENT 3 0L FORD 2 052860 4 NUT FLANGED HEX M12 1 75 3 052251 4 DAMPENER VIBRATION 40 BLUE 4 052257 4 SPACER 49 X 62 X 1 87 PWDR ZNC 5 052252 4 DAMPENER VIBRATION 6 052259 4 WASHER FLAT M12 7 052891 4 SCREW HHC M12 1 75 X 80 G8 8 8 0536210213 1 ASSY GRNDWIRE 11 3 8 amp 5 16 LUG 9 074906 1 SCREW HHTT M6 1 0 X 20 BP 10 047411 1 SCREW HHC M6 1 0 X 16 BP 11 055414 1 LUG SLDLSS 2 8 X 17 64 CU 12 026850 2 WASHER SHAKEPROOF
6. NOTE It is essential to use the latest version of any stan dard to ensure correct and current information DANGER Section 2 Installation Guardian Liquid cooled 27 kW and 30 kW Generators Temperature Oil Grade Recommended Above 80 F 27 C SAE 5W 20 32 to 80 F 1 to 27 C SAE 5W 20 Below 32 F 0 C SAE 5W 20 Generac Power Systems Inc 9 NFPA No 37 STATIONARY COMBUSTION 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 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 NOTE It is essential to use the latest version of any stan dard to ensure correct and current information 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
7. 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 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 30 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
8. 1 DECAL CUSTOMER CNNCTN 30 057073 1 JUNCTION BLOCK 3 8 16 31 0E7283 1 CB 0150A2P240V S QN2 LL 0E3628 1 CB 0200A2P240V S QN2 LL 32 0E3664 1 BASE QN CIRCUIT BREAKER 33 0E7539A 1 DECAL TB1 HSB CONTROL PANEL 34 0D4698 REF BLOCK TERM 20A 6 X 3 X 1100V 35 0E7252 1 BRACKET CB 221 5 X 102 36 0C1229 1 DECAL WARNING ELECTRICAL SHOCK ITEM PART NO QTY DESCRIPTION 37 0C1127 1 DECAL AVR COVER 38 0A1441B 1 COVER PLATE AVR 39 0E7128 1 HARNESS CNTRL PNL NOT SHOWN 40 0E7358 8 SCREW PPPH HI LO 4 24 X 3 8 41 074908 6 SCREW HHTT M5 0 8 X 10 BP 42 0C5141 1 CONN DEUTSCH GASKET 8 12 POS DT 43 0C2699 11 SCREW PHTT 6 32 X 3 8 ZYC 44 0C2323 4 SCREW PHTT 6 32 X 5 8 ZYC 45 022155 15 WASHER LOCK 6 46 0C2265 4 SCREW PHTT M4 0 7 X 12 ZYC 47 022264 4 WASHER LOCK 8 M4 49 020911 2 SCREW PPHM M5 0 8 X 30 ZINC 50 066849 2 SCREW HHTT M5 0 8 X 16 51 022152 4 WASHER LOCK 10 52 023897 3 WASHER FLAT 10 ZINC 53 051716 2 NUT HEX M5 0 8 G8 YEL CHR 54 090388 2 SCREW HHTT M6 1 0 X 12 ZINC 55 042568 4 SCREW HHC M6 1 0 X 20 G8 8 56 022097 8 WASHER LOCK M6 1 4 57 022473 6 WASHER FLAT 1 4 M6 ZINC 58 0441140187 2 WIRE ASSY 3 X 2 3 16 TABS 59 070370 2 WASHER MICA 203 60 023762 1 WASHER SHAKEPROOF EXT 10 STL 61 055444 1 HEATSINK 62 030468 1 WASHER STEP NYLON 20 63 049939 1 RECTIFIER MSC 12A 600V 1N1206R 64 022158 1 NUT HEX 10 32 STEEL 65 022985 1 WASH
9. 2 32 3 4 27 43 18 41 4 B 7 DETAIL SEE LATCH 11 25 52 9 6 53 54 5 SECURE AS SHOWN REQUIRE INSULATION TYPICAL OF ROOF PANEL THAT TO A 4 53 4 35 SUPPORT RADIATOR 33 44 555 5 53 4 36 4 18 4 26 588 5 4 8 4 A A A A 29 12 13 16 17 52 54 B 20 11 10 15 14 19 2 59 28 4 1 17 16 42 40 9 18 23 57 57 5 41 17 4 26 2 PLCS TO B 10 39 18 STATES FOAM IS ON NEAR SIDE Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Compartment Drawing No 0E8333 D Generac Power Systems Inc 33 ITEM PART NO QTY DESCRIPTION 1 0E8411 1 INTAKE DUCT HSB 2 0E8042 1 DUCT DISCHARGE RH FRONT 3 0E8041 1 DUCT DISCHARGE LH FRONT 4 0C2454 62 SCREW TH FRM M6 1 X 16 N WA Z JS 5 0E8402 1 BAFFLE REAR BOTTOM 6 0E7808 1 POST CORNER LH REAR 7 0E7809 1 POST CORNER RH REAR 8 0E8387 1 BAFFLE REAR TOP 9 0E6986 2 DOOR COMPARTMENT SIDE 10 0E7795 1 SUPPORT R H SIDE 11 089961 2 FOAM STRIP 3 4 WIDE X 3 16 THK 40 LG 12 0A2115 4 WASHER NYLON 257 13 0E8404 1 BRACKET STIFFENER RH FRONT 14 0D2538A 1 HINGE LIFT OFF TYPE B KNUCKLE 15 0D2538 1 HINGE LIFT OFF TYPE B PIN 16 043116 8 SCREW HHC M6 1 0 X 12 G8 8 17 022097 12 WASHER LOCK M6 1 4 18 02
10. 49 045773 3 NUT HEX M12 1 75 G8 YEL CHR 50 0E6203C 1 COIL IGNITION 3 0L FORD 51 0E6679 2 BRACKET IGN COIL 3 0L FORD 53 049226 7 WASHER LOCK M5 54 091526 3 SCREW PPHM M5 0 8 X 12 ZNC 55 093278 4 SCREW HHTT M5 0 8 X 25 BP 56 0E6517 1 HARNESS ENGINE 3 0L FORD HSB NOT SHOWN 57 0E7163 2 GASKET EXHAUST 3 0L FORD 58 0E5527 2 MANIFOLD EXHAUST 3 0L FORD 60 0E7202 2 HEAT SHIELD 260 X 80 HOT 61 085296 6 SCREW HHC 1 4 20 X 1 2 SS 62 0E6203D 1 WIRE SET 3 0L FORD NOT SHOWN 63 057772 1 WASHER NYLON 565 64 057765 1 ADAPTER M14 1 50 X 3 8 NPT 65 043790 1 BARBED EL 90 3 8 NPT X 3 8 66 069860C 1 HOSE OIL DRAIN ASSY 21 67 057822 2 CLAMP HOSE 8 53 1 00 68 069811 1 CAP HEX 1 4 NPT BRASS 69 026925 1 PLUG STD PIPE 3 8 STEEL SQ HD 70 065852 1 SPRING CLIP HOLDER 37 62 71 0A2111 1 SCREW SWAGE 10 32 X 5 16 Z YC 72 057073 1 JUNCTION BLOCK 3 8 16 73 066849 2 SCREW HHTT M5 0 8 X 16 74 022152 2 WASHER LOCK 10 75 0E7880 2 CLIP SPARK PLUG 3P SCREW MOUNT NOT SHOWN 76 0E7880A 4 CLIP SPARK PLUG 2P SCREW MOUNT NOT SHOWN 77 0E7880B 1 CLIP SPARK PLUG 3P FREEHANG NOT SHOWN 78 055934C 1 CLAMP VINYL 5 X 406 Z 79 027482 1 WASHER SHAKEPROOF EXT 5 16 STL 80 0E8940 1 SPACER FLEXPLATE HSB 81 0A7387 2 SCREW HHC M10 1 5 X 40 G10 9 82 022097 4 WASHER LOCK M6 1 4 83 022473 4 WASHER FLAT 1 4 M6 ZINC 84 055934H 2 CLAMP VINYL 62 X 406 Z 85 0F5966 1 REFLECTIVE
11. Defective starter motor 4 Replace starter motor 5 Dead or Defective Battery 5 Remove change or replace battery 6 4 amp fuse blown 6 Replace fuse Engine cranks but won t start 1 Out of fuel 1 Replenish fuel 2 Fuel solenoid FS is defective 2 Replace solenoid 3 Open Wire 14 from Engine Control 3 Reconnect wire circuit board 4 Spark plugs defective 4 Clean regap or replace plugs Engine starts hard runs rough 1 Flame arrestor air cleaner plugged or 1 Clean or replace as needed damaged 2 Plugged fuel line 2 Unclog fuel line 3 Defective spark plugs 3 Clean regap or replace plugs Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defective Low Coolant Level Switch 7 Replace Switch AUTO OFF MANUAL Switch at 1 Defective AUTO OFF MANUAL switch 1 Replace switch OFF engine continues to run 2 Open disconnected wire 15A between 2 Reconnect close wire AUTO OFF MANUAL switch and Control Module circuit board 3 Defective Control Module circuit board 3 Replace board No AC output from generator 1 Check main line circuit breaker 1 Reset
12. FS LEGEND ALT BAT CC C1 JUNCTION 2 ON PCB LOW OIL PRESSURE SWITCH IGNITION MODULE ON DISTRIBUTOR HIGH COOLANT TEMP SWITCH JUNCTION BLOCK RUN POWER COOLANT LEVEL SWITCH JUNCTION 1 ON PCB STARTER MOTOR IGNITION COIL ALT GND1 14 14 14 HCT WLS 4 224 5 16 16 14 23 66 23 66 0 86 0 0 1 7 10 11 12 9 8 4 5 6 2 3 15A 224 225 15E 239 14 14A 0A 13 0 0 11 14 13 12 8 9 10 6 7 85 14A 225 66 C1 239 15E 0 RED 0 14 85 85 0 BLK FS 0A 0 0 16 16 13 GND2 0 0 0 4 16 10 0 0 SM 4 10 16 3 769 PCB J1 2 3 4 1 6 7 8 4 5 15A 86 23 56 768 766 N C 0 14 PCB J2 1 2 767 765 VOLT UL LISTED UNLESS ALL WIRES ARE 18 AWG 300 OTHERWISE NOTED AS SHOWN 13 14 0 56 13 13 10 10 CC NOTE 16 BAT 13 13 16 10 JB 4 10 10 16 16 16 SIZE AWG 1 771 449 14 0 449 14 0 14 16 16 16 16 767 770 N C 765 766 IC IM 4 5 6 2 3 DEG GOV 766 771 769 767 768 765 766 770 767 14 16 765 0 3 9 12 11 10 6 7 8 4 5 1 2 NC 1 1 3 2 1 2 5 6 3 5 4 1 Section 8 Electrical Data Guardian Liquid cooled 27 kW and 30 k
13. such as utility main line circuit breaker 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 a 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 Set the AUTO OFF MANUAL switch to its AUTO position Set the generator main circuit breaker to its ON or CLOSED position 3 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 PCB 0E4906 REV R49 D17 J2
14. 16 0D1509 1 DECAL INLET PRESSURE 17 050279 1 DECAL FUEL INLET NG 18 0E6123 1 INTAKE ADAPTER 3 0L FORD BOSCH 19 0E6586 1 GASKET BOSCH 32 20 0E4395 1 ACTUATOR BOSCH 32 GOVERNOR 21 057753B 1 HOSE 1 5 ID X 2 LG 20R4 25 047487 4 SCREW SHC M6 1 0 X 18 G12 9 26 022097 8 WASHER LOCK M6 1 4 27 051751 4 SCREW HHC M6 1 0 X 50 G8 8 28 035685 2 CLAMP HOSE 28 1 32 2 25 29 057823 4 CLAMP HOSE 10 56 1 06 30 047290 1 HOSE 3 8 ID SINGLE BRAID 305mm 12 LONG 31 047290 1 HOSE 3 8 ID SINGLE BRAID 432mm 17 LONG 32 0A4121 1 VALVE PCV 33 0E6609 1 GROMMET ROCKER COVER 3 0LFORD 34 049099 1 BARBED EL 90 3 8 X 3 8 PLST 35 055934M 1 CLAMP VINYL 75 X 343 Z 36 047411 1 SCREW HHC M6 1 0 X 16 G8 8 37 022097 1 WASHER LOCK M6 1 4 38 O22473 1 WASHER FLAT 1 4 M6 ZINC 39 0E9295A 1 ASSY THROTTLE 27MM 40 0E6382A 1 VENTURI HOLDER W 32MM ACTUATOR 41 0E7121 1 O RING 47 625 ID X 2 38 WIDTH 42 0E6376A 1 VENTURI 27 ID THROTTLE W CHOK 43 0F2119 1 O RING 45 63 ID X 2 62 WIDTH SHOWN IN OTHER VIEW NOT SHOWN USED TO HOLD 31 IN PLACE Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Fuel System Drawing No 0E8190 C 42 Generac Power Systems Inc 3 LOCKTIGHT LOCKTIGHT 7 15 17 8 7 6 18 4 16 LEADS 5 2 9 13 21 19 20 14 10 11 12 30 1 31 Section 9 Exploded View
15. 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 P O BOX 297 WHITEWATER WI 53190 Revision 02 01 05
16. HEAT SHIELD 3 0L FD 86 022985 3 WASHER FLAT 6 ZINC 87 036261 3 RIVET POP 125 X 275 SS NOT SHOWN USED TO HOLD OIL DRAIN ASSEMBLY NOT SHOWN Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Engine Drawing No 0E8170 N Generac Power Systems Inc 37 ENGINE 5 A 12 FRAME 10 9 11 8 9 3 21 27 PUMP TO WATER 4 12 17 6 15 7 1 15 20 3 22 24 24 TO 2 12 TO A 18 13 14 12 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 ITEM PART NO QTY DESCRIPTION 1 0E9947 1 RADIATOR R IN L OUT 658X489X49 2 0E6340 1 VENTURI 3 0L FORD HSB 3 0E8531 2 SIDE SUPPORT RADIATOR HSB 4 0E6398 1 TUBE LOWER RAD 3 0L FORD HSB 5 0E6397 1 HOSE UPPER RAD 3 0LFORD HSB 6 080713 1 BRACKET COOLANT TANK 7 076749 1 TANK COOLANT RECOVERY 8 049814 4 SCREW HHC M10 1 5 X 25 G8 8 9 022131 8 WASHER FLAT 3 8 M10 ZINC 10 046526 4 WASHER LOCK M10 11 045772 4 NUT HEX M10 1 5 G8 YEL CHR 12 035685 4 CLAMP HOSE 28 1 32 2 25 13 0E8562 1 FAN GUARD HSB 14 058443 4 SCREW CRIMPTITE 1 4 20 X 5 8 15 0C2454 9 SCREW TH FRM M6 1 X 16 N WA Z JS 17 048031C 1 CLAMP HOSE BAND 1 4 18 029032 1 HOSE 9 32 ID 30 LG 20 046627 1 CAP RADIATOR 21 069811 1 CAP HEX 1 4 NPT BRASS
17. Motor Craft AG SF 32PGM Oil Pressure 40 50 psi Crankcase Oil Capacity 5 0 U S quarts 4 7 liters Recommended Engine Oil SAE 5W 20 Type of Cooling System Pressurized closed recovery Cooling Fan Pusher Type 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 m3 hr 3 1 5 9 8 5 11 0 ft3 hr 110 3 209 0 299 5 387 0 LP Vapor of Load 25 50 75 100 m3 hr 1 3 2 4 3 5 4 5 ft3 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 Fuel pressure for a natural gas set up should be five inches to 14 inches of water colum
18. 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 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 1 5 MAIN 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 Section 1 General Information Guardian Liquid cooled 27 kW and 30 kW Generators Model Rating Phase Actual Current C B Rating Circuit Breaker 004988 2 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 Figure 1 2 Main Circuit Breaker Generac Power Systems Inc 5 1 6 GENERATOR FUEL SYSTEM The unit has been factory tested and adju
19. 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 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 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 sm
20. 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 knowledge 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 21 Section 4 Maintenance Guardian Liquid cooled 27 kW and 30 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp to be done Comp to be done Comp Required Comp to be done Date 3 months Date Semi Date to be done Date monthly Initials Break in Initials annually Initials Annually Initials 1
21. 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 hazardous and possibly fatal electrical shock Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a 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 fr
22. is turned ON Figure 1 4 Figure 1 4 Low Oil Pressure Switch NOTE The Low Oil Pressure High Coolant Temperature and Low Coolant Level are not monitored for the first 10 seconds 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 7 3 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 LOW OIL PRESURE SWITCH SWITCH COOLANT TEMPERATURE HIGH LOW COOLANT LEVEL SWITCH Section 1 General Information Guardian Liquid cooled 27 kW and 30 kW Generators 6 Generac Power Systems Inc 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 alternat
23. 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 NOTE The BCI number should be located directly on the battery Section 4 Maintenance Guardian Liquid cooled 27 kW and 30 kW Generators BCI Group No CCA 26 26R 525 0 deg F 27 600 0 deg F PERIODIC REPLACEMENT PARTS Part Name Generac s Part Number Oil Filter 0E7180 Radiator Cap 046627 Air Cleaner 0C8127 Spark Plug 0E7079 20 Generac Power Systems Inc Section 4 Maintenance Guardian Liquid cooled 27 kW and 30 kW Generators 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
24. 0 hrs 30 hrs 50 hrs 100 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 Check the engine coolant thermal protection level Correct as necessary 5 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiring for loose connections corrosion and damage Correct as necessary 10 Check the engine accessory drive belts for wear weather cracking and damage Replace as necessary 11 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 12 Test the engine and transfer switch safety devices Correct and or adjust as necessary 22 Generac Power Systems Inc Section 4 Maintenance Guardian Liquid cooled 27 kW and 30 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp to be done Comp to be done Comp Required Comp to be done Date 3 months Date Semi Date to be done Dat
25. 1 BELT SERPENTINE 38 35 11 0E7996 1 CLUTCH COOLING FAN FORD 12 0E8006 1 FAN 18 7 BLADE STEEL ECS 14 035606 1 SENSOR HI COOLANT SHUTDOWN 15 0E0561 1 ASSY WATER LEVEL SENSOR C E PL 16 0E6729 1 STARTER DELCO REMY 12V 17 0E6703 1 COVER FLYWHEEL ACCESS 3 0L HSB 18 0E6667 1 ENGINE ADAPTER 3L FORD 19 0E5048 1 FLEXPLATE 3 0L FORD 20 035579 1 BUSHING REDUCER 1 4 TO 1 8 21 0A8584 1 SWITCH OIL PRESSURE 10PSI 2POL 24 083896 6 WASHER LOCK 1 4 M6 SS 25 084929 6 WASHER FLAT 1 4 SS 26 055597 1 SCREW HHC M12 1 75 X 85 G8 8 27 077996 1 CAP HOSE 28 057823 1 CLAMP HOSE 10 56 1 06 29 056739 1 RELAY SOLENOID 12VDC PNL MNT 30 047411 6 SCREW HHC M6 1 0 X 16 G8 8 31 022097 6 WASHER LOCK M6 1 4 32 022473 6 WASHER FLAT 1 4 M6 ZINC 33 047411 4 SCREW HHC M6 1 0 X 16 G8 8 34 040976 4 SCREW SHC M8 1 25 X 20 G12 9 35 022129 24 WASHER LOCK M8 5 16 36 022145 22 WASHER FLAT 5 16 M8 ZINC 37 045771 1 NUT HEX M8 1 25 G8 YEL CHR 38 051756 6 SCREW HHC M10 1 5 X 20 G8 8 39 049821 16 SCREW SHC M8 1 25 X 30 G12 9 40 059980 4 SCREW HHC M10 1 5 X 25 G10 9 41 0D5417 REF SCREW HHC M10 1 0 X 25 G10 9 42 046526 18 WASHER LOCK M10 43 022131 11 WASHER FLAT 3 8 M10 ZINC 44 059982 4 SCREW SHC M12 1 75 X 45 G10 9 45 098780 2 SCREW HHC M12 1 75 X 65 G8 8 46 051769 3 WASHER LOCK M12 ITEM PART NO QTY DESCRIPTION 47 049808 2 WASHER FLAT M12 48 051430 6 WASHER SHAKEPROOF INT 1 2
26. 22 065852 1 SPRING CLIP HOLDER 37 62 23 0A2111 1 SCREW SWAGE 10 32 X 5 16 Z YC 24 052250 2 TAPE FOAM 1 X 1 27 LG 25 035461 1 BARBED STR 1 4 NPT X 3 8 26 0C7649 1 CLAMP HOSE 38 87 27 069860C 1 HOSE OIL DRAIN ASSY 21 Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Radiator Drawing No 0E8528 B Generac Power Systems Inc 39 40 Generac Power Systems Inc 28 B 31 10 16 4 2 17 5 9 1 7 6 29 32 30 11 29 15 8 3 6 3 33 29 14 TO B 26 27 18 43 41 40 21 28 26 39 Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Fuel System Drawing No 0E8190 C Generac Power Systems Inc 41 ITEM PART NO QTY DESCRIPTION 1 1 WELDMENT MOUNTING BASE 2 075580 1 FLANGE FUEL INLET 3 0E7691 1 ASSY REGULATOR 3 0L NG OR LPV 4 039253 2 SCREW HHC M8 1 25 X 20 G8 8 5 022145 2 WASHER FLAT 5 16 ZINC 6 022129 4 WASHER LOCK M8 5 16 7 045771 2 NUT HEX M8 1 25 G8 YEL CHR 8 042907 2 SCREW HHC M8 1 25 X 16 G8 8 9 0C2454 2 SCREW TH FRM M6 1 X 16 N WA Z JS 10 026307 1 ELBOW 90D STREET 3 4 11 0E1056 1 FUEL HOSE ASSY NAT GAS L P V 12 0E6584 1 BRACKET REGULATOR 3 0L FORD HSB 13 057823 2 CLAMP HOSE 10 56 1 06 14 059194 1 HOSE 5 8 ID LPG amp NG 20 LG 15 044117 1 BARBED STR 3 8 NPT X 5 8
27. 2473 12 WASHER FLAT 1 4 M6 ZINC 19 0E7570 2 GAS SPRING 20 0E7571 4 BALL STUD GAS SPRING MOUNT 21 070015 4 NUT HEX 5 16 18 LOCK 22 0E7662 4 SCREW WING M6 1 00 X 25 23 0D2537A 1 HINGE LIFT OFF TYPE A KNUCKLE 24 0D2537 1 HINGE LIFT OFF TYPE A PIN 25 0D2023 2 TRIM VINYL SELF GRIPPING 91 LG 26 0E7869 2 BRACKET STIFFENING BACK 27 0E8001 1 MUFFLER BOX 28 0E8060 1 ROOF W GAS SPRING MNT 3 0L FRD 29 0E8406 1 BRACE FRONT TOP 30 0D3037A 1 LATCH 1 4 TURN NONLOCKING 31 0C7781 2 PAWL DOOR HSB 32 0E7794 1 SUPPORT LH SIDE 33 0E8052 1 MUFFLER BOX TOP 34 0D3037 1 LATCH QUARTER TURN LOCKING 35 0E8007 1 POST CORNER LH FRONT 36 0E8008 1 POST CORNER RH FRONT 37 0E6989 1 BRACE FRONT BOTTOM 38 0E8055 1 DUCT DISCHARGE MID FRONT 39 026850 4 WASHER SHAKEPROOF EXT 1 4 STL 40 0912970063 2 ASSY GRD WIRE 99HSB 41 0912970064 2 ASSEMBLY BASE DOOR GROUND WIRE 42 049813 2 NUT HEX M6 X 1 0 G8 YEL CHR 43 0E8665 1 BRACKET STIFFENER LH FRONT 44 0D2023 1 TRIM VINYL SELF GRIPPING 165 5 LG 50 0E8441 1 KIT INSULATION 3 0L HSB 51 0E7829A 1 AI ROOF PANEL 1 52 0E7829B 2 AI DOOR PANEL 53 0E7829P 4 AI CORNER POST PANEL 1 54 0E7829R 2 AI CORNER POST PANEL 2 55 0E7829S 1 AI SUPPORT LH PANEL 56 0E7829T 1 AI SUPPORT RH PANEL 57 0E7829N 2 AI ROOF PANEL 2 58 0E7829U 2 AI BRACE PANEL 59 078115 8 WASHER SELF LOCKING DOME ALL ITEMS NOTATED WITH AI ARE COMPONENTS OF 0E8441
28. 4 4 WASHER LOCK 8 M4 20 038150 4 WASHER FLAT 8 ZINC 21 077043F 1 CONDUIT FLEX 1 1 4 30 LG 3 0L FORD amp 3 9L CHRYSLER 077043F 1 CONDUIT FLEX 1 1 4 18 LG 2 5L FORD ROTOR REPLACEMENT PARTS 30 047248 1 BALL BEARING 45 MM 31 070892 1 SLIP RING MACHINED Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Alternator Drawing No 0F5092 A ITEM PART NO QTY DESCRIPTION 1 0E6134 1 MUFFLER 3 0L FORD 2 0E6464 2 EXHAUST ELBOW 3 0L FORD HSB 3 0E6465 1 EXHAUST PIPE LH 3 0L FORD HSB 4 0E6465A 1 EXHAUST PIPE RH 3 0L FORD HSB 5 0E5914 1 BRACKET MUFFLER 3 0L FORD HSB 6 060366 1 MUFFLR STRAP 6IN DIA 7 027837 1 SCREW RHM 1 4 20 X 2 1 4 8 036797 4 BOLT U 5 16 18 X 2 25 9 039253 2 SCREW HHC M8 1 25 X 20 G8 8 10 022145 2 WASHER FLAT 5 16 M8 ZINC ITEM PART NO QTY DESCRIPTION 11 022129 10 WASHER LOCK M8 5 16 12 045771 2 NUT HEX M8 1 25 G8 YEL CHR 13 0C2454 4 SCREW TH FRM M6 1X16 N WA Z JS 17 044149 2 GASKET EXHAUST RING 18 0E0170 2 EXHAUST BLANKET 750MM 19 085917 4 WASHER LOCK 3 8 SS 20 0D2611 4 SCREW HHC 3 8 16 X 1 3 4 SS 21 081265 2 MOUNTING FLANGE 22 022259 8 NUT HEX 5 16 18 STEEL MANIFOLD 2 8 1 13 13 7 6 9 MANIFOLD 18 3 8 20 19 21 17 18 TO COMPARTMENT TO 10 13 8 2 12 10 11 11 13 11 22 8 12 5 4 TO 19 20
29. 6 15 IC 13 13 11 14 13A 15A 239 1b 16 1a 15 1 16 16 15 2a 2b 1 15 VOLT UL LISTED UNLESS ALL WIRES ARE 18 AWG 300 224 OTHERWISE NOTED AS SHOWN 16 14 16 14 225 NOTE OA SIZE AWG BA 66 6 6 6 33 44 22 11 STATOR TR1 178 183 194 178 6 N1 225A 224A 178 178 44 4 5 6 2 55 11 N2 1 N1 N2 23 66 23 66 BC1 11 0 16 16 14 15A 225 224 15E 239 14 14A 0A 13 0 0 55 0 0 44 6 4 1 7 10 11 12 9 8 4 6 5 2 3 2 1 CB2 55 14 16 225 224 TR2 TB1 14 0 0 0 AVR 14 55 0 0 162 2 0 4 4 6 5 4 3 44 6 11 4 162 1 1 2 2 3 8 2 1 3 4 5 6 85 1 1 2 3 6 5 7 4 1 2 2 3 1 CB1 NB F2 RL1 F1 SW1 D1 26 Generac Power Systems Inc Section 8 Electrical Data Guardian Liquid cooled 27 kW and 30 kW Generators Wiring Diagram Engine Drawing No 0E6199 F Generac Power Systems Inc 27 LEGEND CONT J 2 LOS SM JB WLS HCT J 1 IM IC ELEC GOVERNOR ACTUATOR GROUND SENSING LOW AMP GROUND POWER HIGH AMP D C CHARGE ALTERNATOR STARTER CONTACTOR CONNECTOR 1 ENGINE DRIVER ELEC GOVERNOR FUEL SOLENOID 12VDC BATTERY DEG GND1 GND2 GOV
30. C2 C26 U7 C27 R44 Q2 D19 C30 RL1 2 L3 LED1 C4 R25 C9 C21 D10 J1 R48 R1 U1 RL2 1 2 3 4 UNUSED GTS ATS 50 60 HZ POSITION 1 50 60 HZ ON 50 HZ OFF 60 HZ POSITION 2 GTS ATS Select ON GTS OFF ATS standard mode STABILITY DIFFERENTIAL DIP SWITCH 00 Section 3 Operation Guardian Liquid cooled 27 kW and 30 kW Generators Generac Power Systems Inc 15 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 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 Exerci
31. ER FLAT 6 ZINC 66 038750 2 SCREW HHC M6 1 0 X 30 G8 8 67 0A2115 4 WASHER NYLON 257 68 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 69 0F6146 1 HANG TAG 2 WIRE START NOT SHOWN ITEMS INCLUDED AS PART OF I N 39 Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Control Panel Drawing No 0E7118 K 38 11 85 6 17 57 24 61 60 30 66 68 25 58 35 39 36 WIRE GROUND 39 32 64 63 65 31 35 2 42 51 24 55 25 60 86 58 57 16 18 19 48 48 42 41 44 45 30 81 42 78 49 4946 47 47 4 43 42 1 26 42 47 81 2 38 42 69 28 REAR UPPER BAFFLE 40 36 5 6 7 35 37 15 36 3 8 14 8 12 29 73 10 82 33 36 34 35 2 84 27 Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Engine Drawing No 0E8170 N 36 Generac Power Systems Inc ITEM PART NO QTY DESCRIPTION 1 0E6202 1 ENGINE 3 0L FORD RD MAKE 2 0E8824 2 STAMPING ENG FOOT 3 0L FORD 3 0E8963 1 PULLEY CRANKSHAFT 3 0L FORD RD 4 0E9020 1 BRACKET DC ALT 3 0L FORD 5 0A1232 1 D C ALTERNATOR ASSY 6 0A7801B 1 PULLEY POLY V 82 OD 7 0A5610 1 BRACKET ALTERNATOR 8 0E6308 1 PULLEY WATERPUMP 3 0L FORD RD 9 0E7804 1 HARN IGNITION 3 0L FORD NOT SHOWN 10 0D3488F
32. EXT 1 4 STL 13 022097 1 WASHER LOCK M6 1 4 14 022473 2 WASHER FLAT M6 1 4 ZINC 15 049813 1 NUT HEX M6 1 0 G8 YEL CHR 16 0A1694 4 1 1 2 BUTTON PLUG 17 052213 1 SCREW HHC M10 1 25 X 20 G8 8 18 025507 3 WASHER SHAKEPROOF EXT 7 16 STL 20 027482 2 WASHER SHAKEPROOF EXT 5 16 STL 21 022129 1 WASHER LOCK M8 5 16 22 045771 1 NUT HEX M8 1 25 G8 YEL CHR 23 051756 1 SCREW HHC M10 1 5 X 20 G8 8 24 046526 1 WASHER LOCK M10 25 022131 1 WASHER FLAT 3 8 M10 ZINC 26 055934M 1 CLAMP VINYL 75 X 343 Z 30 077483 REF BATT 12VDC 75 AH 26 058665 REF BATT 12VDC 90 AH 27F 31 038804D 1 CABLE BATT RED 4 X 20 00 32 038805AA 1 CABLE BATT BLK 4 X 30 33 021991 1 EARTH STRAP 34 049814 1 SCREW HHC M10 1 5 X 25 G8 8 35 046526 2 WASHER LOCK M10 36 022131 1 WASHER FLAT 3 8 ZINC 37 075763 1 BOOT BATTERY CABLE 38 050331 1 BATTERY POST COVER BACLK 39 050331A 1 BATTERY POST COVER RED 40 0A4010 2 SCREW HHC M8 1 25 X 60 G8 8 FT 41 052858 2 NUT TOP LOCK FL M8 1 25 42 061902 1 HOLD DOWN BATTERY 43 059473 1 HOLD DOWN BATTERY 44 049820 2 NUT HEX LOCK M8 1 25 NY INS NOT SHOWN USED TO HOLD DOWN I N 32 Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Mounting Base Drawing No 0E6266 E Generac Power Systems Inc 31 32 Generac Power Systems Inc STATES FOAM IS ON FAR SIDE 37 17 LATCH DETAIL 30 31 34 38
33. Owner s Manual ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model Number 004988 2 Generac Power Systems Inc 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 After this heading read instructions that if not strictly complied with will result in personal injury or property damage After this heading read instructions that if not strictly complied with may result in personal injury or property damage After this heading read inst
34. PORT 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 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 Section 2 Installation Guardian Liquid cooled 27 kW and 30 kW Generators 10 Generac Power Systems Inc 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 isolatio
35. S 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 This warranty applies only to Generac Guardian prepackaged emergency automatic standby generators 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 Warran
36. Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Compartment Drawing No 0E8333 D 34 Generac Power Systems Inc Section 9 Exploded Views and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Control Panel Drawing No 0E7118 K Generac Power Systems Inc 35 ITEM PART NO QTY DESCRIPTION 1 0E7195 1 CONTROL BOX HSB 2 0E7196 1 COVER FRONT PANEL HSB 3 0E7197 1 COVER TOP PANEL HSB 4 0E7193 1 DECAL WARNINGS HSB 5 0E7194 1 DECAL CONTROLS HSB 6 0E4494 1 SWITCH ROC DPDT ON OFF ON 7 082573 1 SWITCH ROCKER DPST 125V SPD 8 032300 2 HOLDER FUSE 9 022676 1 FUSE 15A X AGC15 10 067682B 1 FUSE 4A SLO BLO GLASS 11 060015 1 FITTING CONDUIT 90D 3 8 12 054199 1 DECAL DANGER HIGH VOLTAGE 13 0C2657 1 TRANSFRMR 16V 6VA 14 099076 1 TRANSFORMER 16V 56VA 15 040213 2 PCB SUPPORT SNAP IN 1 4 16 0E9668 1 ASSY PCB HSB CONTROLLER 17 067680 1 ASSY VOLTAGE REGULATOR 60HZ 18 0E6875A 1 RELAY 12VDC C FORM W DIODE 19 0E6881 REF SOCKET RELAY 20 0C5139 REF CONN DEUTSCH RECEPT GY FLN 21 0C5142 REF CONN DEUTSCH RECEPT WDGE BLKHD 22 0E3161 1 ASSY BOSCH GOV DRIVER 23 054450 1 CIRCT BRK 5 5 X 1 ETA 46 500 P 24 0D5070A 1 ASSY 2A 12V UL BATTERY CHARGER 25 0E2514 1 FITTING CONDUIT STR 1 1 2 26 0A9457 1 DECAL NEUTRAL 27 0E7539 1 DECALCUSTOMER CNNCTN XFER SW 28 046357 REF BLOCK TERM 20A 6 X 6 X 1100V 29 0D3719B
37. 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 See the Service Schedule Section 6 for air cleaner maintenance 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 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 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 1 06 1 16 mm 0 042 0 046 inch by carefully bending the ground elec trode Figure 4 4 OIL FILTER DANGER Section 4 Maintenance Guardian Liquid cooled 27 kW and 30 kW Generators 18 Generac Power Systems Inc Figure 4 4 Setting the Spark Plug Gap 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 po
38. UM WIRE LENGTH RECOMMENDED WIRE SIZE 460 feet 140m No 18 AWG 461 to 730 feet 223m No 16 AWG 731 to 1 160 feet 354m No 14 AWG 1 161 to 1 850 feet 565m No 12 AWG 12 Generac Power Systems Inc 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 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 i
39. W Generators Wiring Diagram Engine Drawing No 0E6199 F 28 Generac Power Systems Inc Section 8 Electrical Data Guardian Liquid cooled 27 kW and 30 kW Generators Electrical Schematic Engine Drawing No 0E6200 B AUTOMATIC VOLTAGE REGULATOR BRUSH ASSEMLY GENERATOR CIRCUIT BREAKER EXCITATION DISPLACED PHASE EXCITATION DPE ALTERNATOR STATOR ALTERNATOR ROTOR BATTERY CHARGER DIODE FIELD BOOST CIRCUIT BREAKER OUTPUT BATTERY CHARGE WINDING AS AR LEGEND AVR BA BCW CB2 CB1 D1 B C TR2 TRANSFORMER 2 6 VA 240 16 VAC FUSE BAT POWER 15A AGC TYPE SWITCH SET EXERCISER SWITCH AUTO OFF MANUAL FUSE B C 4A AGC TYPE TERMINAL BLOCK INTERCONNECT TRANSFORMER 1 56 VA 240 16 VAC NEUTRAL BLOCK LEGEND CONT RL1 SW1 SW2 TR1 NB F2 ICT F1 RELAY1 2 4 3 5 6 TRANSFER SWITCH 5 CUSTOMER CONNECTION 120 240V 1 PHASE CB1 E1 NB 00 DPE AS 2 CONNECTION N2 E3 N1 23 194 183 178 CB2 11 44 162 N1 N2 D1 BCW BA 55 AR 4 6 1 66 14 1 194 178 183 15 ICT N2 225A 183 178 23 194 224A TR1 N1 15 N1 SW1 224 23 225 178 15A 15 TR2 N2 SW2 15E AVR 13A 0A 14 15 15 F1 14 15 14 15 F2 13 13 66 0 0 RL1 14A 239 13 14 224 225
40. ailable 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 engine 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 2 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 Figure 4 2 Oil Filter After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 7 Start engine and check for oil leaks 4 5 11 CHANGING THE ENGINE AIR CLEANER
41. available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 A52 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 LOCATION 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 2 3 GENERATOR MOUNTING AND SUP
42. by Generator Installation 8 2 2 Generator Location 9 2 3 Generator Mounting and Support 9 2 4 Basic Standby Electric System 9 2 5 Emergency Circuit Isolation Method 10 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Transfer Switch Start Signal Connections 10 2 10 Battery Installation 11 2 11 Preparation Before Start Up 11 Section 3 OPERATION 12 3 1 Using a Standard GTS Transfer Switch 12 3 2 Control Console Components 13 3 3 Manual Transfer and Startup 14 3 4 Engine Governor Adjustments 14 3 5 Retransfer and Shutdown 14 3 6 Automatic Operation 14 3 7 Weekly Exercise Cycle 14 Section 4 MAINTENANCE 15 4 1 Maintenance Performed by Authorized Service Facilities 15 4 2 Cooling System
43. e monthly Initials Break in Initials annually Initials Annually Initials 10 hrs 30 hrs 50 hrs 100 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 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 necessary 20 Perform a 5 minute no load operational run of the unit looking for any post service problems 21 Return the unit to standby setup for operation when required Generac Power Systems Inc 23 Section 5 Troubleshooting Guardian Liquid cooled 27 kW and 30 kW Generators TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine won t crank 1 15 amp fuse blown 1 Replace fuse 2 Loose or corroded or defective 2 Tighten clean or replace battery cables battery cables as necessary 3 Defective starter contactor 3 Replace contactor 4
44. e 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 DANGER AUTHORIZED SERVICE DEALER LOCATION To locate the nearest GENERAC AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 OR Locate us on the web at www generac com Table of Contents Guardian Liquid cooled 27 kW and 30 kW Gene
45. east 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 See 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 obvious 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 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 DIPSTICK OIL FILL OIL Section 4 Maintenance Guardian Liquid cooled 27 kW and 30 kW Generators Generac Power Systems Inc 17 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 av
46. ee 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 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 uni
47. ener 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 unobstructed 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
48. he 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 applications Figure 3 2 Engine Governor Adjustment 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 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 3 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 fol lows Verify that UTILITY power supply voltage to the transfer switch has been positively turned OFF using whatever means provided
49. ian Liquid cooled 27 kW and 30 kW Generators Generac Power Systems Inc 7 Single phase Model 004988 2 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 8 Generac Power Systems Inc 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 Use a high quality detergent oil classified For Service CC SD SE SF 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 NOTE Synthetic oil is highly recommended in any element with temperatures above 90 F or below 30 F Any attempt to crank or start the engine before 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
50. ion 1 14 for recom mended oils Figure 4 1 Oil Dipstick and Oil Fill Cap 4 4 2 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 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 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 4 5 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 Start 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 l
51. is about 12 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 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 The generator s 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 no sensing or con trolling circuit boards Instead the generator control console houses a Printed Ci
52. laced 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 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 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 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 Do not dispose of the battery in a fire The battery is capable of exploding Do not open or mutilate the battery Released electrolyte can be toxic and harmful to the skin and eyes The battery represents a risk of high short cir cuit current When working on the battery always remo
53. lectrician for grounding requirements in the area Grounding procedures must meet local regulations Figure 2 2 Generator Grounding Lug typical 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 2 8 GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED AC 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 Failure to connect the generator neutral prop erly will result in unbalanced line to neutral voltages Resulting high voltages will cause equipment damage 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
54. n 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 3 Remove the brass hose fitting from the outlet port Port 1 of the demand regulator 4 Remove pipe plug from Port 2 5 Install brass hose fitting into Port 2 6 Install pipe plug into Port 1 7 Connect carburetor gas hose to brass fitting 8 Tighten all clamps and plugs 9 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 NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made Serious injury or damage may occur if not con figured properly Please consult an authorized Generac Service Dealer with any questions DANGER NG FUEL SYSTEM LP FUEL SYSTEM Port 1 Port 2 FUEL HOSE BRASS HOSE FITTING HOUSING PORTS OUT PORT 2 PLUG FUEL HOSE BRASS HOSE FITTING HOUSING PORTS PLUG OUT PORT 1 Section 1 General Information Guard
55. n 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 method is used it is difficult to overload the generator The transfer switch must meet the fol lowing requirements 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 e
56. oking open flame sparks or any spark producing tools or equipment near the battery 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 the fluid is spilled flush the affected area immediately with clear water 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 DANGER Section 4 Maintenance Guardian Liquid cooled 27 kW and 30 kW Generators SET PLUG GAP AT 1 06 1 16 mm 0 042 0 046 inch Generac Power Systems Inc 19 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 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
57. om leaking exhaust gases fuel leakage oil leakage etc 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 generator 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 grounding 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
58. ong 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 7 9 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 1 8 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 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 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
59. or 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 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 7 6 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 1 7 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 l
60. perating 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 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 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 are rotating and or hot during operation Exercise care near running gen erators 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 technician 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 g
61. personnel to be used in all phases of handling and unpacking PCB 0E4906 REV R49 D17 J2 C2 C26 U7 C27 R44 Q2 D19 C30 RL1 2 L3 LED1 C4 R25 C9 C21 D10 J1 R48 R1 U1 RL2 Section 1 General Information Guardian Liquid cooled 27 kW and 30 kW Generators 1 10 SPECIFICATIONS 1 10 1 GENERATOR SPECIFICATIONS 1 10 2 ENGINE SPECIFICATIONS Make Ford Displacement 3 0 liters Cylinder Arrangement V 6 Valve Arrangement Overhead Valve Firing Order 1 4 2 5 3 6 Number of Main Bearings 4 Compression Ratio 9 3 to 1 No of Teeth on Flywheel 164 Ignition Timing at 1800 rpm 30 degrees BTDC Spark Plug Gap 0 042 0 046 inch Recommended Spark Plugs
62. physically or mentally fatigued DANGER 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 This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING Generac Power Systems Inc 3 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 fr
63. rators Generac Power Systems Inc 1 INTRODUCTION IFC SAFETY RULES 2 Section 1 GENERAL INFORMATION 4 1 1 Generator 4 1 2 Transfer Switch 4 1 3 Automatic System Operation 4 1 4 Generator AC Connection Systems 4 1 5 Main Circuit Breaker 4 1 6 Generator Fuel System 5 1 7 Engine Protective Devices 5 1 8 Unpacking 6 1 9 Lifting the Generator 6 1 10 Specifications 7 1 11 Fuel Consumption 7 1 12 Reconfiguring the Fuel System 7 1 13 Torque Specifications 8 1 14 Engine Oil Recommendations 8 1 15 Coolant Recommendations 8 1 16 Before Installation 8 Section 2 INSTALLATION 8 2 1 Stand
64. rcuit Board Assembly which controls all phases of operation including engine start up and load transfer 2 1 STANDBY GENERATOR INSTALLATION 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 If an open bottom is used the engine genera 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 After the system has been installed do nothing that might render the installation in noncompli ance with such codes standards and regula tions 2 1 1 NFPA STANDARDS The following published standards booklets pertain ing to standby electric systems are available form the National Fire Protection Association NFPA Batterymarch Park Quincy MA 02269
65. re freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses 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 troubleshooting where no manufacturing defect is found 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 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
66. ructions 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 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 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 operator 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 Servic
67. s and Parts Guardian Liquid cooled 27 kW and 30 kW Generators Alternator Drawing No 0F5092 A Generac Power Systems Inc 43 ITEM PART NO QTY DESCRIPTION 1 0F1659A 1 ROTOR 390 15KW 1P DIRECT HSB 2 5L FORD 0F1657A 1 ROTOR 390 20KW 1P DIRECT HSB 2 5L FORD 0F1655A 1 ROTOR 390 25KW 1P DIRECT HSB 2 5L FORD 0F5073A 1 ROTOR 390__30AD1 HSB TECUM 0E7413A 1 RTR 390 40KW 1P DIRECT HSB 2 0F1660A 1 STR 390 15AD HSB 382MM LONG 2 5L FORD 0F1658A 1 STR 390 20AD HSB 382MM LONG 2 5L FORD 0F1656A 1 STR 390 25AD HSB 382MM LONG 2 5L FORD 0F5074A 1 STR 390__30AD1 HSB TECUM 0E7412A 1 STR 390 40AD HSB 433MM LONG 3 0E5706 1 REAR BEARING CARRIER 390 DRCT 4 0E5048 REF FLEXPLATE 3 0L FORD 0E5048B REF FLEXPLATE 2 5L FORD 0E5048A REF FLEXPLATE HSB 3 9L CHRYSLER 5 0E6668 1 FLYWHEEL ASSY 3 0L HSB LG GEAR 6 0E6076 1 REVCOR FAN 10 75 X 2 W PRESS DIS 7 046526 8 WASHER LOCK M10 8 051755 4 SCREW HHC M10 1 5 X 16 G8 8 9 04576100BK 4 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD amp 2 5L FORD 04576100BF 4 STUD M14 2 0 X 540 G5 ZINC 10 043123 4 WASHER LOCK M14 11 051779 4 NUT HEX M14 2 0 G8 YEL CHR 12 0E7587 1 ASSY BRUSH HOLDER 390 HSB 13 023365 1 WASHER SHAKEPROOF INT 8 14 0C3993 4 SCREW HHTT M4 0 7 X 25 BP 15 057192 4 SCREW SHC M10 1 5 X 30 G12 9 16 0A2602 1 WASHER FLAT 688 ID X 3 25 OD 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0A2601 1 SCREW HHC M16 2 0 X 45 G8 8 19 02226
68. s properly purged and leak tested according to code No fuel leakage is permitted See Specifications Section 1 10 for more information 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 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 properly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires
69. se Switch 4 1 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 ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high coolant temperature C ONCE ANNUALLY 1 Test engine governor Adjust or repair if needed 2 Clean inspect generator 3 Flush cooling system D FIRST 100 OPERATING HOURS 1 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 E EVERY 500 OPERATING HOURS 1 Service air cleaner 2 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 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 The exhaust system parts from this product get extremely ho
70. ssible 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 enclosure 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 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
71. sted 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 ranges 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 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 1 7 1 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
72. t s 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 lighter than air and LP gas is heavier than air install leak detectors accordingly IMPORTANT SAFETY INSTRUCTIONS Guardian Liquid cooled 27 kW and 30 kW Generators 4 Generac Power Systems Inc 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 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 po
73. t 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 4 3 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 These overcurrent protection devices will open if the circuit is overloaded If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse E E U S F F S U S E E U S F F U S F U S BAT FUSE CHARGER ON OFF EXERCISE TIME SET 4A MANUAL AUTO OFF FUSE 15A MAIN Section 4 Maintenance Guardian Liquid cooled 27 kW and 30 kW Generators 16 Generac Power Systems Inc 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 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 Sect
74. to ON or CLOSED 2 Check circuit breaker amp fuses 2 Reset and replace if necessary 3 Transfer switch set to NORMAL position 3 Set to GENERATOR position 4 Generator internal failure 4 Contact an Authorized Generac facility 5 Thermal circuit breaker open 5 Auto reset Wait 5 min and attempt restart 24 Generac Power Systems Inc Section 6 Notes Guardian Liquid cooled 27 kW and 30 kW Generators Generac Power Systems Inc 25 Section 7 Installation Diagram Guardian Liquid cooled 27 kW and 30 kW Generators Installation Diagram Drawing No 0E8695 BRUSH ASSEMLY GENERATOR AUTOMATIC VOLTAGE REGULATOR BULKHEAD CONNECTOR 1 ENGINE CIRCUIT BREAKER EXCITATION FUSE BAT POWER 15A AGC TYPE CIRCUIT BREAKER OUTPUT DIODE FIELD BOOST BATTERY CHARGER BC1 F1 D1 CB2 CB1 AVR BA B C LEGEND NEUTRAL BLOCK TERMINAL BLOCK 1 TRANSFORMER 1 56 VA 240 16 VAC TRANSFORMER 2 6 VA 240 16 VAC INTERCONNECT TERMINAL BLOCK FUSE B C 4A AGC TYPE AUTO OFF MANUAL SWITCH SET EXERCISER SWITCH SW1 TB1 TR1 TR2 SW2 LEGEND CONT ICT F2 RL1 NB RELAY1 B C 194 CUSTOMER CONNECTION NEUTRAL 44 NO REMOTE START UTILITY FROM T SW UTILITY FROM T SW C REMOTE START TRANSFER RELAY COIL TRANSFER RELAY COIL TRANSFER SWITCH 15E N2 N1 13A 23 183 178 14 13 13A 0 14 14A 1
75. 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 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 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 Section 3 Operation Guardian Liquid cooled 27 kW and 30 kW Generators Generac Power Systems Inc 13 AUTO The control board will monitor the
76. 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 switch 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 3 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 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 Figure 3 1 Home Standby Generator Panel 3 2 2 FAULT INDICATOR LED This LED goes ON when one or more of the following engine faults occurs and when engine shuts do
77. ty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Guardian generators that utilize non Guardian Generac replacement parts Guardian generators utilizing non Guardian Generac automatic transfer switches Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems Any Guardian generators used as rental or trailer mounted applications 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 Steel 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 Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts 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 Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fi
78. ve watches rings or other metal objects and only use tools that have insulated handles When replacing batteries use the same 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 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 DANGER Section 2 Installation Guardian Liquid cooled 27 kW and 30 kW Generators MAXIM
79. wer 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 be used indoors or outdoors Follow these rules 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 1 3 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 a 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
80. witch 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 E U S U F F E U S U F SEE OWNER S MANUAL FOR COMPLETE LED DETAILS 5 FLASHING RED LED S EXERCISER NOT SET FLASHING GREEN LED NO UTILITY SENSE TO SET EXERCISER TIME 1 PLACE AUTO OFF MANUAL SWITCH TO AUTO POSITION IN AUTO MODE ONLY SOLID GREEN LED SYSTEM READY UTILITY POWER ON OFF EXERCISE TIME ON SET LED INDICATORS RED LED S INDIVIDUAL FAULT MANUAL OFF AUTO 0E7194 OVER CRANK AUTO OFF MANUAL SWITCH 15A FUSE MAIN POWER 4A FUSE BATTERY CHARGER SET EXECISER TIME SWITCH RED LED GREEN LED DANGER Section 3 Operation Guardian Liquid cooled 27 kW and 30 kW Generators 14 Generac Power Systems Inc 3 3 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 T
81. wn Low Oil Pressure Overcrank Low Battery Overspeed RPM Sensor Loss High Coolant Temperature Low Coolant Level See Section 1 7 for further explanation of engine pro tection functions 3 2 3 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 presence of utility sensing at the PCB when the s

Generac Power Systems 004988-2 User's Manual

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