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Guardian Technologies 004988-4 Portable Generator User Manual

1. t ooeoo REE I 1 m x s us e e je T 4 e Ct C29 C22 B e 1 02 elell V3R 806530 999 018 019 1 75 RPM SENSOR LOSS If the engine control board does not receive a proper rpm signal from the starter during cranking or run ning it shuts down the engine on rpm sensor loss and flash the overspeed LED 1 76 OVERCRANK SHUTDOWN The engine control board uses a cyclic cranking pro cess when attempting to start the engine The first crank cycle is a 15 second crank followed by a seven second rest This is followed by five more crank cycles each with a seven second crank followed by a seven second rest If the engine fails to start after all six attempts the start attempt is stopped and the overcrank LED s illuminated 6 Section 1 General Information 1 77 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
2. 1 i 8 ja a e ez El 8 XD T e tua i a HHHIEHHTHH el 2 Iki e i F as ei Im eL e Ci C22 V3R 00030 803 GAIN DIFFERENTIAL STA LITY POSITION1 POSITION 2 PUNUSED 50 60 HZ GTS ATS Select ON 50HZ ON GTS GTS ATS OFF ATS standard mode 50 60 HZ OFF 60 HZ 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 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 UTILIT
3. 24 Section 7 INTALLATION DIAGRAM 25 Section 8 ELECTRICAL DATA 26 Section 9 EXPLODED VIEWS AND PARTS LISTS u 2 30 Section 10 WARRANTY Back Cover SAFETY RULES Liquid cooled 30 kW Generators A IMPORTANT SAFETY INSTRUCTIONS 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 WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The gen erator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fun damental rules or precautions The manufacturer cannot anticipate
4. GUARDIAN by Generac Power Systems Inc Owner s Manual Liquid cooled Prepackaged Standby Generators Model Number 004988 4 27kW NG 30kW LP Vapor AMA mm p an a _ 2 xdi um m p uum n i aem Oe p i a a am a p p p gt gm E P Fd i e a ana ODAN at a a M s p E am 7 p 2 p A at Lu pe p v a s a x m a a _ t a si i m QT we mt lt 7 em m emm p E am il rr rm i i Ps a p i _ P gi g ur d p uno s um n ou ue a ail 3 a P ed an a a um i s es s t 2 E Quit dU uU UE This manual should remain with the unit caution amp ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION INTRODUCTION Thank you for purchasing this model of the standby generator set Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ ten However the manufacturer reserves the right to change alter or otherwise improve
5. 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 0F7000 1 HARN ENGINE 3 0L FORD HSB CAR 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 055596 1 BARBED STR 3 8NPT 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 061012 1 PLUG STD PIPE 1 8 SOCKET HEAD 70 065852 1 SPRING CLIP HOLDER 37 62 n 0A2111 1 SCREW SWAGE 10 32 X 5 16 Z YC 72 057073 1 JUNCTION BLOCK 3 8 16 78 066849 2 SCREW HHTT M5 0 8 X 16 74 022152 2 WASHER LOCK 10 75 0 7880 2 CLIP SPARK PLUG SCREWMOUNT NOT SHOWN 76 0 7880 4 CLIP SPARK PLUG 2 SCREWMOUNT NOT SHOWN 77 0E7880B 1 CLIP SPARK PLUG 3P FREEHANG NOT SHOWN 78 055934 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 0 5966 1 REFLECTIVE HEAT SHIELD 3 0L FD 86 022985 3 WASHER FLAT 6 ZINC 87 036261 3 RIVET POP 125 X 275 SS 88 OF6658 1 COVER EGR 89 0 6809 1 ADAPTER WATER PUMP NOT SHOWN USED TO HOLD OIL DRA
6. The NEUTRAL leads are the junction of Wires 22 and 33 The NEUTRAL is not grounded Figure 1 1 Generator AC Connection System 240 VOLTS CIRCUIT BREAKER 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 Figure 1 2 Main Circuit Breaker Model Rating Phase Actual Current C B Rating Circuit Breaker 004988 4 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 1 6 GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using a natural gas fuel system If propane LP gas is neces sary contact an authorized service dealer Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load 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 waRnNING amp 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 L
7. 1 13 3 Retorque intake and exhaust manifold See Torque Specs Section 1 13 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 Section 4 Maintenance Liquid cooled 30 kW Generators oS 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 warninc amp The exhaust system parts from this product get extremely hot and remain hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system 15 OPERATION Section 4 Maintenance J gt Liquid cooled 30 kW Generators 4 5 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 caution amp If a circuit breaker opens or a fuse element melts find the cause of the overload bef
8. 12 POS DT SCREW PHTT 6 32 X 3 8 ZYC SCREW PHTT 6 32 X 5 8 ZYC WASHER LOCK 6 SCREW PHTT M4 0 7 X 12 ZYC WASHER LOCK 8 4 SCREW PPHM M5 0 8 X 30 ZINC SCREW HHTT M5 0 8 X 16 WASHER LOCK 10 WASHER FLAT 10 ZINC NUT HEX M5 0 8 G8 YEL CHR SCREW HHTT M6 1 0 X 12 ZINC SCREW HHC 6 1 0 X 20 G8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC WIRE ASSY 3 X 2 3 16 TABS WASHER MICA 203 WASHER SHAKEPROOF EXT 10 STL HEATSINK WASHER STEP NYLON 20 RECTIFIER MSC 12A 600V 1N1206R NUT HEX 410 32 STEEL WASHER FLAT 46 ZINC SCREW HHC M6 1 0 X 30 G8 8 WASHER NYLON 257 SCREW THF M6 1 X 16 N WA Z JS HANG TAG 2 WIRE START NOT SHOWN 35 Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators Engine Drawing No 0F6836 B LISTS OG PARTS der a 125 b 36 ITEM PART NO 1 0E6201 2 0E8824 3 0E8963 4 0E9020 5 0A1232 6 0A7801B 7 0 5610 8 0E6308 0 7804 10 0D3488F 11 0E7996 12 0E8006 14 0A6751 15 0E0561 077043H 16 0E6729 17 0E6703 18 0E6667 19 0E5048 20 035579 21 0A8584 24 083896 25 084929 26 055597 27 0F6151 28 057823 29 056739 30 047411 31 022097 32 022473 33 047411 34 040976 35 022129 36 022145 37 045771 38 049814 39 049821 40 059980 41 0D5417 42 046526 43 022131 44 059982 45 098780 46 051769 TY 1 2 ee O5 O DO M CO DESCRIPTION ENGINE 3 0L FORD F
9. 3 8 ID SINGLE BRAID 305mm 22 LONG 31 047290 1 HOSE 3 8 ID SINGLE BRAID 432mm 13 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 022097 1 WASHER LOCK M6 1 4 38 022473 WASHER FLAT 1 4 6 ZINC 39 0 9295 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 gt SHOWN IN OTHER VIEW NOT SHOWN USED TO HOLD 31 IN PLACE 41 Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators KO Alternator Drawing No 0F5092 B LOCKTIGHT gt lt O O ae Section 9 Exploded Views and Parts Qi us Liquid cooled 30 kW Generators Alternator Drawing No 0F5092 B 0 DESCRIPTION 1 0F1659A ROTOR 390 15KW 1P DIRECT HSB 2 5L FORD 1 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
10. 6VA TRANSFORMER 16V 56VA PCB SUPPORT SNAP IN 1 4 ASSY PCB HSB CONTROLLER ASSY VOLTAGE REGULATOR 60HZ RELAY 12VDC C FORM W DIODE SOCKET RELAY CONN DEUTSCH RECEPT GY FLN CONN DEUTSCH RECEPT WDGE BLKHD ASSY BOSCH GOV DRIVER CIRCT BRK 5 5 X 1 ETA 46 500 P ASSY 2A 12V UL BATTERY CHARGER FITTING CONDUIT STR 1 1 2 DECAL NEUTRAL DECALCUSTOMER CNNCTN XFER SW BLOCK TERM 20A 6 X 6 X 1100V DECAL CUSTOMER CNNCTN JUNCTION BLOCK 3 8 16 CB 0150A2P240V S QN2 LL CB 0200A2P240V S QN2 LL BASE QN CIRCUIT BREAKER DECAL TB1 HSB CONTROL PANEL BLOCK TERM 20A 6 X 3 X 1100V BRACKET CB 221 5 X 102 DECAL WARNING ELECTRICAL SHOCK Section 9 Exploded Views and Parts ITEM APART NO 37 0 1127 38 0 1441 39 0E7128 40 0E7358 41 074908 42 0C5141 43 0C2699 44 0C2323 45 022155 46 0C2265 47 022264 49 020911 50 066849 51 022152 52 023897 53 051716 54 090388 55 042568 56 022097 57 022473 58 0441140187 59 070370 60 023762 61 055444 62 030468 63 049939 64 022158 65 022985 66 038750 67 0A2115 68 0C2454 69 0F6146 ITEMS INCLUDED AS PART OF I N 39 Liquid cooled 30 kW Generators Control Panel Drawing No 0E7118 K TY 1 1 1 8 6 1 O P N PARTS qea OG DESCRIPTION DECAL AVR COVER COVER PLATE AVR HARNESS CNTRL PNL NOT SHOWN SCREW PPPH HI LO 4 24 X 3 8 SCREW HHTT M5 0 8 X 10 BP CONN DEUTSCH GASKET 8
11. CONNECTION LEGEND LEGEND F2 FUSE BIC 4A AGC AVR AUTOMATIC VOLTAGE REGULATOR ICT INTERCONNECT TERMINAL BLOCK BA BRUSH ASSEMLY GENERATOR NB NEUTRAL BLOCK BIC BATTERY CHARGER RLi RELAYI BC1 BULKHEAD CONNECTOR 1 ENGINE SWi AUTO OFF MANUAL SWITCH CBi CIRCUIT BREAKER OUTPUT SW2 SET EXERCISER SWITCH CB2 CIRCUIT BREAKER EXCITATION TBi TERMINAL BLOCK 1 Di DIODE FIELD BOOST TR TRANSFORMER 1 56 VA 240 16 VAC F1 FUSE BAT POWER 154 AGC TYPE TR TRANSFORMER 2 6 VA 240 16 VAC Section 8 Electrical Data Liquid cooled 30 kW Generators ELECTRICAL Wiring Diagram Engine Drawing No 0E6199 F DATA KH PCBJ2 NOTE SIZE AWG DEG I 1 767 ALL WIRES ARE 18 AWG 300 1 o 765 VOLT UL LISTED UNLESS 765 2 uw OTHERWISE NOTED AS SHOWN Lee mE 4 766 E 5 768 6 0 7 N C 8 14 zi uu gt CO og 5 224 6 0 8 239 a 10 15E 11 8 12 14 13 225 14 66 0 9 acad Qu EN AE AE RN 7 15 8 15E 9 M 10 224 LEGEND LEGEND CONT ALT D C CHARGE ALTERNATOR HCT HIGH COOLANT TEMP SWITCH BAT 12VDC BATTERY IC IGNITION COIL C1 CONNECTOR 1 ENGINE IM IGNITION MODULE ON DISTRIBUTOR CC STARTER CONTACTOR H JUNCTION 1 ON DEG DRIVER ELEC GOVERNOR J2 JUNCTION 2 ON PCB FS FUEL SOLENOID JB JUNCT
12. HSB SCREW HHC 8 1 25 X 55 G8 8 BRACKET MUFFLER 3 0L FORD HSB STRAP MUFFLER EXHAUST BLANKET 750MM BOLT U 5 16 18 X 2 25 BOLT U 3 8 16 X 2 62 COMPARTMENT MANIFOLD ITEM PART NO DESCRIPTION 0E8816 085917 0D2611 039253 022145 022129 045771 002454 022259 022241 hwo N FBP EXHAUST FLANGE 2 PIPE WASHER LOCK 3 8 SS SCREW HHC 3 8 16 X 1 3 4 SS SCREW HHC M8 1 25 X 20 G8 8 WASHER FLAT 5 16 M8 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR SCREW TH FRM M6 1 X 16 N WA 205 5 16 18 STEEL 3 8 16 STEEL N O Section 9 Exploded Views and Parts Cp Liquid cooled 30 kW Generators Air Cleaner Drawing No 0F6850 A 0 YV Z N Z A A A NN NN NN Z NN NN NB VN NNN NEZ NNNM M gt N 0 5193 1 PLATE AIR CLEANER ADAPTER 0E0519A 1 ADAPTER CARBURETOR W PVC CONN 049226 4 WASHER LOCK M5 049815 4 SCREW HHC M5 0 8 X 16 G8 8 0C8127 1 ELEMENT AIR CLEANER 022127 1 NUT HEX 1 4 20 STEEL 062974 1 STUD TH 1 4 20 X 4 1 2 G2 ZNC 0A5547 1 COVER AIR CLEANER 037561 1 NUT WING 1 4 20 NYLK 45 Section 10 Warranty WARRANTY Liquid cooled 30 kW Generators GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the dat
13. O 2 d ee Task Comp Date Initials Section 5 Troubleshooting Liquid cooled 30 kW Generators TROUBLESHOOTING POINTS CAUSE PROBLEM Engine won t crank Engine cranks but won t start Engine starts hard runs rough Engine starts then shuts down AUTO OFF MANUAL Switch at OFF engine continues to run No AC output from generator 1 2 Co N O O1 15 luse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery 4 amp fuse blown Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Flame arrestor air cleaner plugged or damaged Plugged fuel line Defective spark plugs Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch 1 Defective AUTO OFF MANUAL switch MN Open disconnected wire 15A between AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circ
14. crank and start the generator engine Set switch to OFF position to shut down an operat ing engine With OFF selected operation will not be possible Figure 3 1 Home Standby Generator Panel SET EXECISER TIME SWITCH AUTO OFF MANUAL AA FUSE SWITCH BATTERY 15A FUSE CHARGER MAIN POWER Section 3 Operation OPERATION Liquid cooled 30 kW Generators A Da A With switch set to AUTO engine can crank and start suddenly without warning Such automatic 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 control console 35 2 2 FAULT INDICATOR LED This LED goes ON when one or more of the following engine faults occurs and when engine shuts down Low Oil Pressure Overcrank Low Battery Overspeed RPM Sensor Loss High Coolant Temperature Low Coolant Level oee Section 1 7 for further explanation of engine pro tection functions 5 2 5 15 AMP FUSE Fuse protects the control console s DC control circuit against electrical overload If the fuse has melted open because of an overload engine cranking and startup cannot occur If the fuse needs to be replaced use only an identical 15 amp replacement fuse Type AGC 3 2 4 4 0 AMP INLINE FUSE This fuse protects the battery
15. every possible cir cumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique that the manufac turer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique utilized does not render the generator unsafe A Da A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to install operate or maintain this equipment N 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 dur ing operation Exercise care near running genera tors AN N GENERAL HAZARDS For safety reasons The manufacturer recommends that this equipment be installed serviced and repaired by an Authorized Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regula tions The operator also must comply with all such codes standards and regulations nstallation operation servicing and repair of this and related equipment must always comply with appl
16. fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTER IES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer 11 A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charg ing The slightest spark can ignite the gas and cause an explosion Such an explosion can shat ter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smok ing open flame sparks or any spark producing tools or equipment near the battery Battery electrolyte fluid is extremely tic 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 AN Spilled electrolyte is to be washed down with an acid neutralizing agent 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 AN Do not use any jum
17. lines The generators weight of more than 900 pounds requires proper tools equipment and qualified personnel to be used in all phases of handling and unpacking 1 10 SPECIFICATIONS 1 10 1 GENERATOR SPECIFICATIONS Single phase Model 004988 4 Rated Max Cont A Power Outpu KW Ra O ol acc ol 120 240 27 NG 30 LP No of Rotor Pole 2 Driven Speed of Roto S00 Rotor Excitation System Direct excited brush type pe o ato 4 Wire Rotor Stator Insulation Class F H 1 10 2 ENGINE SPECIFICATIONS ccc u Ford NE o 3 0 liters Cylinder Arrangement l I U nn V 6 Valve Arrangement I I n a Overhead Valve VO 1 4 2 5 3 6 Number of Main Bearings U I I I n 4 Compression Rali NN OO 9 3 to 1 No of Teeth on Flywheel sese 164 Ignition Timing at 1800 30 degrees BTDC Spark PIB uuu u u u uu u u uu uuu u u 0 042 0 046 inch Recommended Spark Plugs Motor Craft u RR AG SF 2 OL SS E E u Lu uuu Lu ua 40 50 psi Crankcase Oil 5 0 U S quarts 4 7 liters Recommended Engine Oil a SAE 5W 20 Type of Cooling System Pressurized closed recovery e Ec T Pusher Type Cool
18. 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 repair ing 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 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 ofa transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating Failure to isolate the two electric system power sources f
19. operation of the generator Keep the area around the generator clean and unclut tered Remove any materials that could become haz ardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts Before performing any maintenance on the generator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS A All generators covered by this manual produce dan gerous electrical voltages and can cause fatal electri cal shock Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the standby generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appro priate 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
20. service application They will need to be decreased performed more frequently if the unit is used in a severe applica tion Use the unit hour meter or calendar time whichever occurs first from the previous maintenance interval to determine the next required maintenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to ensure it is ready to operate when required and to identify any poten tial problem areas Performed monthly or following each 10 hours of operation of the unit and requires approximately 5 man hours per unit to complete This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the control panel AUTO OFF MANUAL switch to the OFF position Remove the control panel 15 and 4A fuses Turn off the battery charger e Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the u
21. the low battery condition occurs the engine will continue to run as long as possible Battery voltage is NOT monitored during the crank cycle 1 78 ALARM RESET If the engine control board shuts down the genera tor 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 warninc A AN When lifting or hoisting equipment is used be careful not to touch overhead power
22. 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 Authorized Service Dealer for start ing 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 incorrectly or carelessly Observe them carefully Their definitions are as follows A Da A After this heading read instructions that if not strictly complied with will result in personal injury or property damage warninc amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution amp After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follow
23. 14 J2 8 14 0 Ss a p 765 GOV 766 3 1 771 D 44 4 2 767 766 5 am 4 770 767 7 66 5 N C L 770 8 8 6 766 771 9 768 10 767 11 769 12 1 0 2 0 3 0 _ 4 0 A LEGEND LEGEND CONT 5 J ALT D C CHARGE ALTERNATOR IC IGNITION COIL O 7 arn Jy C1 CONNECTOR 1 ENGINE M IGNITION MODULE ON DISTRIBUTOR 8 15E CC CRANKING CONTACTOR LOS SWITCH LOW OIL PRESSURE 2 9 DEG DRIVER ELEC GOVERNOR SC CONTACTOR STARTER MOTOR 10 24 FS SOLENOID FUEL SM STARTER MOTOR E GOV ELEC GOVERNOR ACTUATOR WLS SENSOR COOLANT LEVEL HCT SWITCH HIGH COOLANT TEMP Liquid cooled 30 kW Generators Electrical Schematic Engine Drawing No 0E6200 B LOS Section 8 Electrical Data WLS RED a 12V BATTERY B BLACK ELECTRICAL DATA HCT es OE6266 F Section 9 Exploded Views and Parts Liquid cooled 50 kW Generators Mounting Base Drawing No LISTS OG PARTS der 3JSVg ONILNNOW 7 T M2 Pi 7 T ONIuV3a dV3d HOLOVLNOO ie ge OL 2 nog OL 4 N 2 AX NBI 3NION3 9 3NION3 OL 3Q Section 9 Exploded Views and Parts Qi us Liquid cooled 30 kW Generators Mounting Base Drawing No 0 6266 0 PART NO TY DESCRIPTION 1 0E5822 1 BASEFRAME WELD
24. 34N 2 CLAMP VINYL 1 31 X 281 Z 32 092079 2 SCREW HHTT M6 1 0 X 25 BP 33 022097 2 WASHER LOCK M6 1 4 35 047411 2 SCREW HHC M6 1 0 X 16 G8 8 3g As Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators KO Fuel System Drawing No 0 6849 CLEANER TO AIR A N 40 Section 9 Exploded Views and Parts Qi us Liquid cooled 30 kW Generators Fuel System Drawing No 0 6849 0 DESCRIPTION WELDMENT MOUNTING BASE 1 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 0 2454 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 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 08 8 28 035685 2 CLAMP HOSE 28 1 32 2 25 29 0C7649 4 CLAMP HOSE 38 87 30 047290 1 HOSE
25. BEARING CARRIER 390 DRCT 4 0E5048 REF FLEXPLATE 3 0L FORD 0E5048B REF FLEXPLATE 2 5L FORD 0 5048 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 04576100 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 092980 4 SCREW PPHM M4 0 7 X 25 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 022264 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 43 PARTS LISTS OG Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators Exhaust Drawing No 0 0968 MANIFOLD NOOB 10 11 eeu 0F0738 OF6258 044149 OF1008 0F1009 039288 0E5914 0E8726 0E0170 036797 080762 PO PO MUFFLER 7 X9 2 2 IN 2 5 OUT PIPE MUFFLER OUT GASKET EXHAUST RING EXHAUST PIPE LH 3 0L HSB EXHAUST PIPE RH 3 0L
26. BLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES 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 BOX 297 WHITEWATER WI 53190 u Revision 02 01 05 Part No OFGS866 Revision O 07 26 05 Printed in U S A
27. CLUSIVELY FOR OUTDOOR INSTALLATION ONLY SERVICING TO QUALIFIED SERMCE PERSONNEL L ATTENTION POUR L ALIMENTATION DE RESERVE CONNECTER LA SORTE DE LX GENERATRICE IR DE CALIBRE APPROPRIE CONFORMENENT AU CODE CANADIEN DE CONTROL PANEL AND E BATTERY CABLE PRIOR TO vi ALLY IT AT NOTICE TO AVOID PERSONAL INJURY REMOVE FUSE ON 5 FLASHING RED LED S EXERCISER NOT SET ON MODE ONLY SOUD GREEN LED SYSTEM READY UTILITY POWER O LED S INON FAULT FLASHING GREEN LED NO UTILITY SENSE LED INDICATORS plelele 2211212 le AWARNING AVR BEHIND COVER G PANEL MOUNT Gg DETAIL ITEM PART NO 1 0E7195 2 0E7196 3 0E7197 4 0E7193 5 0E7194 6 0E4494 7 082573 8 032300 9 022676 10 067682B 11 060015 12 054199 13 0 2657 14 099076 15 040213 16 0E9668 17 067680 18 0 6875 19 0 6881 20 005139 21 005142 22 0E3161 23 054450 24 0D5070A 25 0E2514 26 0A9457 27 0E7539 28 046357 29 0D3719B 30 057073 31 0E7283 0E3628 32 0E3664 33 0E7539A 34 0D4698 35 0E7252 36 0 1229 N cllc REF REF REF DESCRIPTION CONTROL BOX HSB COVER FRONT PANEL HSB COVER TOP PANEL HSB DECAL WARNINGS HSB DECAL CONTROLS HSB SWITCH ROC DPDT ON OFF ON SWITCH ROCKER DPST 125V SPD HOLDER FUSE FUSE 15A X AGC15 FUSE 4 SLO BLO GLASS FITTING CONDUIT 90D 3 8 DECAL DANGER HIGH VOLTAGE TRANSFRMR 16V
28. D MAKE STAMPING ENG FOOT 3 0L FORD PULLEY CRANKSHAFT 3 0L FORD RD BRACKET DC ALT 3 0L FORD D C ALTERNATOR ASSY PULLEY POLY V 82 OD BRACKET ALTERNATOR PULLEY WATERPUMP 3 0L FORD RD HARN IGNITION 3 0L FORD NOT SHOWN BELT SERPENTINE 38 35 CLUTCH COOLING FAN FORD FAN 18 7 BLADE STEEL ECS SWITCH HI TEMP 245D X 3 8NPT ASSY WATER LEVEL SENSOR C E PL CONDUIT FLEX 25 10 6 LG NOT SHOWN STARTER DELCO REMY 12V COVER FLYWHEEL ACCESS 3 0L HSB ENGINE ADAPTER 3L FORD FLEXPLATE 3 0L FORD BUSHING REDUCER 1 4 TO 1 8 SWITCH OIL PRESSURE 10PSI 2POL WASHER LOCK 1 4 6 SS WASHER FLAT 1 4 SS SCREW HHC M12 1 75 X 85 G8 8 CAP RUBBER CLAMP HOSE 10 56 1 06 RELAY SOLENOID 12VDC PNL MNT SCREW HHC M6 1 0 X 16 68 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW HHC M6 1 0 X 16 G8 8 SCREW SHC M8 1 25 X 20 G12 9 WASHER LOCK 8 5 16 WASHER FLAT 5 16 M8 ZINC NUT HEX M8 1 25 G8 YEL CHR SCREW HHC M10 1 5 X 25 G8 8 SCREW SHC M8 1 25 X 30 G12 9 SCREW HHC M10 1 5 X 25 G10 9 SCREW HHC M10 1 0 X 25 G10 9 WASHER LOCK M10 WASHER FLAT 3 8 M10 ZINC SCREW SHC 12 1 75 X 45 G10 9 SCREW HHC M12 1 75 X 65 G8 8 WASHER LOCK M12 Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators PARTS Ce LISTS Engine Drawing No 0 6836 0 ITEM JA PART NO TY _ DESCRIPTION 47 049808 4 WASHER FLAT M12 48 051430 4 WASHER SHAKEPROOF INT 1 2 49 045773 3 NUT HEX M12 1 75 G8 YEL CHR 50 0E6203C 1 COIL IGNITION 3 0L FORD
29. D STANDARDS In addition to NFPA standards the following informa tion 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 e AGRICULTURAL WIRING HANDBOOK obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 364 2 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 e AD52 1 AMERICAN NATIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYSTEMS 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 open ings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drifting 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 a
30. IN ASSEMBLY NOT SHOWN 37 CHG Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators 0 Radiator Drawing 0 6848 gt LLI O oz WS Pu y e 5 a i as TO WATER 12 AMY 38 Section 9 Exploded Views and Parts Qi us Liquid cooled 30 kW Generators Radiator Drawing No OF6848 B 0 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 6630 1 HOSE RADIATOR UPPER 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 6 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 002454 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 1 4 BRASS 22 065852 1 SPRING 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 28 0F6746 1 TUBE UPPER COOLANT C4 3 0L 29 6631 1 HOSE RADIATOR ENGINE 30 0 6657 2 SUPPORT RADIATOR 31 0559
31. ION BLOCK RUN POWER GND1 GROUND SENSING LOW AMP LOS LOW OIL PRESSURE SWITCH GND2 GROUND POWER HIGH AMP SM STARTER MOTOR GOV ELEC GOVERNOR ACTUATOR WLS COOLANT LEVEL SWITCH 27 ELECTRICAL DATA CUSTOMER CONNECTION LEGEND Section 8 Electrical Data Liquid cooled 30 kW Generators Electrical Schematic Engine Drawing No 0E6200 B AR ALTERNATOR ROTOR AS ALTERNATOR STATOR AVR AUTOMATIC VOLTAGE REGULATOR BA BRUSH ASSEMLY GENERATOR B C BATTERY CHARGER BCW BATTERY CHARGE WINDING 1 CIRCUIT BREAKER OUTPUT CB2 CIRCUIT BREAKER EXCITATION 01 DIODE FIELD BOOST DPE DISPLACED PHASE EXCITATION 00 120 240V 1 PHASE TRANSFER SWITCH CONNECTION 183 178 LEGEND CONT Fi FUSE BAT POWER 15A AGC TYPE F2 FUSE BIC 4A AGC TYPE ICT TERMINAL BLOCK INTERCONNECT NB NEUTRAL BLOCK RLI RELAY1 SWi SWITCH AUTO OFF MANUAL SWo SWITCH SET EXERCISER TR1 TRANSFORMER 1 56 VA 240 16 VAC TR2 TRANSFORMER 2 6 VA 240 16 VAC IN OFF POSITION X 5 224 229 239 E 43 j cO 4 i BULKHEAD CONNECTOR 1 12 15A 4 1 3 dre i 0 2n ww 0 a7 J2 1 767 239 4 1 8 J2 2 765 OA J1 9 J2 3 769 I 3 c 1 J1 10 J2 4 766 6 5 85 1 11 J2 5 sa 768 INI 2 14 1 12 J2 6 0 225 1 13 J2 7 pi DEG 66 J1
32. Isolation Method It is possible for the gen erator 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 util ity 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 gen erator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations 10 Figure 2 2 Generator Grounding Lug typical GROUNDING LUG A DIE A Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against electrical shock in the event of a ground fault condi tion in the generator or in connected electrical devic es In addition grounding helps dissipate static elec tricity that often builds up in ungrounded devices 2 8 GENERATOR AC NEUTRAL CONNECTIONS The manufacturer uses an UNGROUNDED AC neu tral Grounding is recommended only at the main ser
33. MENT 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 EXT 1 4 STL 13 022097 1 WASHER LOCK M6 1 4 14 022473 2 WASHER FLAT 6 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 LOCK FL M8 1 25 42 061902 1 HOLD DOWN BATTERY 43 059473 1 HOLD DOWN BATTERY 44 049820 2
34. N 25 0D2023 3 GASKET CLIP ON SELF GRIPPING 84 LG 26 0E7869 2 BRACKET STIFFENING BACK 27 0E8001 1 MUFFLER BOX 28 5551 1 ROOF W SHOCK MOUNT 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 0 1130 1 BRACE FRONT BOT 3 0L FD STEEL 38 0E8055 1 DUCT DISCHARGE MID FRONT 39 026850 4 WASHER SHAKEPROOF EXT 1 4 STL 40 0912970063 2 ASSY WIRE 14AWG 7 5 0 GRN YEL 41 0912970064 2 ASSY WIRE 14AWG 7 5 0 GRN YEL 42 049813 2 NUT HEX M6 X 1 0 G8 YEL CHR 43 0E8665 1 BRACKET STIFFENER LH FRONT 44 0 78290 2 Al BRACE PANEL 45 0E7829N 2 Al ROOF PANEL 2 46 0E7829T 1 Al SUPPORT RH PANEL 47 0 78295 1 Al SUPPORT LH PANEL 48 0E7829R 2 Al CORNER POST PANEL 2 49 0E7829P 4 Al CORNER POST PANEL 1 50 0E8441 1 KIT INSULATION 3 0L HSB 51 0E7829A 1 Al ROOF PANEL 1 52 0E7829B 2 Al DOOR PANEL 53 043116 8 SCREW HHC M6 1 0 X 12 G8 8 ALL ITEMS NOTATED WITH ARE COMPONENTS OF 0E8441 33 CHG Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators 0 Control Panel Drawing No 0 7118 DETAIL 1 RECTIFIER ASSEMBLY MICA SCALE NONE REMOVE RISK OF ELECTRICAL SHOCK DO NOT COVER NO USER SERVICEABLE PARTS INSIDE REFER UN COMMUTATEUI L ECTRICITE PREMIERE PARTIE THIS EMERGENCY POWER SYSTEM IS DESIGNED EX
35. NUT HEX LOCK M8 1 25 NY INS NOT SHOWN USED TO HOLD DOWN I N 32 31 PARTS LISTS wa LLI e LLI Q oc m cc 2 d 2 lt O O e e gt gt lt lt O O LL LL o o LLI LLI lt lt OO N epi 3e Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators Enclosure Drawing No 0F1142 B SEE LATCH TYPICAL OF ROOF PANEL THAT REQUIRE INSULATION SECURE AS SHOWN LATCH DETAIL Section 9 Exploded Views and Parts Qi us Liquid cooled 30 kW Generators Enclosure Drawing No 0F1142 B 0 DESCRIPTION 1 0E8411 1 INTAKE DUCT HSB 2 0E8042 1 DUCT DISCHARGE RH FRONT 3 0E8041 1 DUCT DISCHARGE LH FRONT 4 002454 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 0F5552 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 078115 8 WASHER SELF LOCKING DOME 17 022097 12 WASHER LOCK M6 1 4 18 022473 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 PI
36. OR 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 otart the generator engine at least once every seven days and let it run at least 20 minutes See Section 3 6 Weekly Exercise Cycle 4 5 4 INSPECT COOLING SYSTEM Inspect engine cooling system at least once each month Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness 4 5 5 CHECK ENGINE COOLANT LEVEL oee Checking Fluid Levels in Section 4 4 4 5 6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for 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 Liquid cooled 30 kW Generators 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 midwa
37. P 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 following conditions low oil pressure high coolant temperature engine overspeed low coolant level or overcrank Figure 1 3 Figure 1 3 Engine Protective Devices TS LOW COOLANT FOWL LEVEL SWITCH PRESURE SWITCH COOLANT TEMPERATURE SWITCH 1 71 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below about 8 10 psi 55 68 kPa the switch contacts close the engine shuts down automatically and the low oil pressure LED is turned ON Figure 1 4 Section 1 General Information Liquid cooled 30 kW Generators 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 72 HIGH COOLANT TEMPERATURE SWITCH This normally open N O thermostatic switch has sensing tip which is immersed in captive coolant should coolant temperature exceed about 230 F 110 C the switch contacts close This causes the engine to shut down automatically and turns on the high coolant temperature low coolant level LED Figure 1 5 Figure 1 5 High Coolant Temperature Switch 1 73 LOW COOLANT LEVEL SWITCH Should engine coolant lev
38. TTERY 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 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 5 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
39. Y 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 DIP SWITCH 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 5 7 WEEKLY EXERCISE CYCLE The engine control board will start and run the gen erator once every seven days for approximately 12 minutes If utility should fail during this exercise period the engine control board will transfer the load to the generator output and continue to run until util ity returns On the day and at the time of day chosen for the generator to exercise set the weekly exercise cycle as follows 1 Place the AUTO OFF MANUAL switch in the AUTO position 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 its 12 minute exercise period then shut down The generator will now start and run each week at the same time If DC power to the control board is lost the weekly exercise setting will be lost This is indicated by all five red LEDs continually flashing In t
40. amp NIV3G lID ldNv DdVA d SVB amp LJANI SNOTLOSNNOO 329IAS3S 3NIDN3 3ONV3V3 9 00d V3H33 AD 1 681 W3iv3isg LInO8IO 3NI NNIVW AddLllV8 Ze 80 HVO6 AO 92 855 HVGZ 3Hl1I3 ALVAOWWOI9V TIIM AVAL 8 8 X S ET11 S vea X G eve SNDISNJAIG J ISNI AVAL A331198 W3lISAS GNNOSD JAIIVO3N LIDA el TANVd 1051 NI G3GIAUSd l9V1S 3LlDW38 ANY HOLIMS ASASNVAL 80937 advO1 304 SINIOd NUILIO3NND2 I SALON C QSAUWSS TANVd SS3999 MAIA ACIS INTddlOO4 3SV8 C T918SST GOIS 493 LdN v NOILISNNOS 1303 7 dDIdVA d i A0 SVD WANLYN L T9v1v0ZTI 2015 3v 13 NI 13043 210S c 31DN 335 Ad3lIlIV8 IAA eI S3 IDH ONILNAOW 5 dAL 1 9349 dN anls L S JG SrI UeJES E VjalV dN Nls L SJZe1 dAL L TTJ82 SO ld t S3 lH AWVa4 L E G 05 G ET 25 Section 8 Electrical Data Liquid cooled 30 kW Generators ELECTRICAL DATA 5 Wiring Diagram Engine Drawing 0E6199 F NOTE SIZE AWG ALL WIRES ARE 18 AWG 300 VOLT UL LISTED UNLESS OTHERWISE NOTED AS SHOWN 13A 239 1 2 p B 0 4 te 8 5 Lm s 15 7 15 8 n 14 9 224 10 Z r 239 12 Z233 kaa 220 r ir E 55 o p4QV OUTPUT TO 23 23 E TRANSFER SWITCH 66 66 a CUSTOMER
41. and the UTILITY power circuits Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker Figure 2 1 Basic Standby Electric System MAIN LINE CIRCUIT BREAKER UTILITY Nam POWER SUPPLY SWITCH TO LOAD CIRCUITS STANDBY eet GENERATOR 697 OUTPUT Buc dm MAIN LINE CIRCUIT BREAKER INSTALLATION Hh Section 2 Installation Liquid cooled 30 kW Generators 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 can only power criti cal loads within its wattage amperage capacity dur ing utility power outages use the emergency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are within the wattage amperage capacity of the generator set The transfer switch must meet the following require ments 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
42. anic 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 e 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 e Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses e Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or 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 BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIA
43. cal 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 operation of 120 and or 240VAC single phase loads wanNiNG amp AN If this generator is used to power electrical load circuits normally powered by a UTILITY power source it is required by code to install a trans fer switch The transfer switch must effectively isolate the electric system from the utility distri bution system when the generator is operating NEC 701 Failure to isolate an electrical system by such means results in damage to the genera tor and may also result in injury or even death to utility power workers due to backfeed of electrical energy 1 2 TRANSFER SWITCH This generator system may include a matched auto matic transfer switch which is intended to be used in conjunction with the generator It is supplied in a NEMA 3R enclosure 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 necessary 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
44. 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 13 OPERATION Section 3 Operation J gt Liquid cooled 30 kW Generators The system ready LED will be OFF when the switch is in the manual or OFF positions The system ready LED is also used to indicate the presence of utility sensing at the PCB when the switch is either in the AUTO or MANUAL modes 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 3 5 MANUAL TRANSFER AND START UP To transfer electrical loads to the Standby EMERGENCY power source side and start the engine manually refer to the Owner s Manual of the particular tran
45. ded 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 Figure 4 4 Setting the Spark Plug Gap SET PLUG GAP AT 1 06 1 16 mm 0 042 0 046 inch pm Comm M N N 4 5 13 COOLANT CHANGE Every year have Authorized Service Facility drain flush and refill the cooling system See SPECIFICATIONS Section 1 10 for cooling system recommendations 4 6 MISCELLANEOUS MAINTENANCE 4 6 1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather 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 dealer 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 18 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 BA
46. e free batteries it is not necessary to check the specific gravity or electrolyte level Have these procedures performed at the inter vals specified in Section 4 Maintenance A nega tive 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 ser viced 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 11 OPERATION Section 3 Operation J gt Liquid cooled 30 kW Generators 2 11 1 PRIOR TO INITIAL START UP caution amp 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 maintena
47. e 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 Warranty Policies Procedures and Flat Rate Man
48. ed 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 ambi ent temperature range anticipated before the next oil change OAO Above oU to 80 1 to 27 Below 32 F 0 C NOTE Synthetic oil is highly recommended in any element with temperatures above 90 F or below 30 caution amp Any attempt to crank or start the engine before it has been properly serviced with the recommend ed oil may result in an engine failure 1 15 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and half de ionized water Cooling system capacity is about 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 caution amp AN Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chro miumhydroxide green slime forms and will cause overheating Engines that have been oper ated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will als
49. el 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 tempera ture low coolant level LED Figure 1 6 on page 6 Liquid cooled 30 kW Generators 1 72 4 OVERSPEED SHUTDOWN The engine control board receives AC frequency sig nals from an engine run winding in the alternator Should AC frequency exceed about 72 Hertz for three seconds or 75 Hertz instantaniously the engine shuts down and the overspeed LED turns on 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 EXER 71mm R44 06 R57 R58 R59 bi a ITTI 91999 L L L L 1 T3 ET 1 aao pee eo F 2 j aa ALILI mim m DU NW a A33 et o Tr LITT r m s TITLUL tility w RE o0 oo x P m owe D i L s LI A 1 eet 00000
50. em 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 A A Standby generators installed with automatic transfer switches will crank and start automati cally when NORMAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel ensure that the 15A and 4A fuses are removed from the control console the AUTO OFF MANUAL switch is set to OFF and the utility supply to the battery charger is removed before removing or connecting battery cables Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charg ing The slightest spark can ignite the gas and cause an explosion Such an explosion can shat ter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smok ing open flame sparks or any spark producing tools or equipment near the battery INSTALLATION LED Section 2 Installation Liquid cooled 30 kW Genera
51. 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 an Authorized Dealer Section 1 General Information 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 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 sup ply 120VAC 60 Hertz When the two windings are connected in series a 240VAC 60 Hertz AC output results Typically the two HOT leads in the circuit are wires 11 and 44
52. his state the generator will still start and run in manual mode or automatically start and run if UTILITY is lost while in Auto mode but it will not perform a weekly exercise cycle If a failure occurs while running in this mode the five red LEDs will stop flashing the individual fault LED will turn on and the engine will shut down Once the AUTO OFF MANUAL switch has been switch to OFF the individual fault LED will turn OFF and the five red LEDs will begin flashing to show exercise has still not been set Figure 3 2 Set Exercise Switch ee FUSE 4A 15A CHARGER sy AUTO OFF OFF ON SET MANUAL EXERCISE TIME 2 MAINTENANCE 2 9 4 1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES EVERY THREE MONTHS Check battery state of charge and condition Inspect and test fuel system Check transfer switch Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY 1 Test engine governor Adjust or repair if needed 2 Clean inspect generator 3 Flush cooling system FIRST 100 OPERATING HOURS 1 Change engine oil and oil filter After initial change service engine oil and filter at 150 operat ing hours or 6 months whichever comes first 2 Retorque cylinder head See Torque Specs Section
53. icable codes standards laws and regulations Adhere strictly to local state and national electri cal and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the genera tor 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 adequate 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 operat ing 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
54. ill 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 generator s control board will perform all of the automatic features listed in this document The two wire start connections should NOT be used GTS Mode Operation When in GTS mode the generator s 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 position AUTO The control board will monitor the two wire start circuit When a two wire start is issued the control board will immediately start and run the gen erator Whe the two wire start is removed the control board will immediately stop the generator NOTE If the generator is installed in conjunction with an engineered 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 6 Set switch to MANUAL position to
55. ing System Capacity 3 0 U S gallons 11 4 liters Recommended Use a 50 50 mixture of ethylene glycol base and de ionized water 1 11 FUEL CONSUMPTION Natural Gas of Load 25 50 15 100 m hr 3 1 59 8 5 11 0 ft9 hr 110 3 209 0 299 5 387 0 LP Vapor of Load 25 50 15 100 m3 hr 13 24 35 4 5 45 6 86 4 123 8 160 0 Fuel consumption is given at rated maximum continuous power output when using natural gas rated at 1000 Btu per cubic foot LP gas is rated at 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient temperature engine condi tions and other environmental factors Section 1 General Information GENERAL Liquid cooled 30 kW Generators INFORMATION 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 1 12 RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for natural gas from the factory To reconfigure the fuel system from NG to LP vapor follow these steps 1 Turn the main gas supply off 2 Remove the carburetor fuel hose from the outlet port Port 1 of the demand regulator Figure 1 8 Remove the b
56. ll 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 INSTALLATION Hh Section 2 Installation Liquid cooled 30 kW Generators 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 REGULATE THE DISTANCE 2 3 GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a concrete slab with 1 4 inch masonry type anchor bolts Be sure the bolts are long enough to retain the compartment The slab should be at least six inches thick and should extend beyond the enclosure to a 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
57. nce information and or service intervals please refer to Section 4 Maintenance 2 11 2 TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems for additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with applicable codes standards and regulations 2 11 3 FUEL SYSTEM Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and b is properly purged and leak tested according to code No fuel leakage is permitted See Specifications Section 1 10 for more information 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
58. nd 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 Section 4 Maintenance MAINTENANCE Figure 4 2 Oil Filter QA lt OIL FILTER caution amp 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 To replace the engine air cleaner part number 059402 remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 4 3 Figure 4 3 Engine Air Cleaner AIR CLEANER See the Service Schedule Section 6 for air cleaner maintenance 17 MAINTENANCE S Section 4 Maintenance Liquid cooled 30 kW Generators 4 5 12 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary See Section 6 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent 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 recommen
59. nit 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 hours of operation after purchase of the unit and requires approximately 2 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer 3 Anoperational 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 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 k
60. nowledge to accomplish and should be performed only by an Authorized Service Dealer eo Section 4 Maintenance Liquid cooled 30 kW Generators MAINTENANCE 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 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 corro
61. ns presented in this manual assume that the standby electric system has been installed by an 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 an Authorized Service Dealer for assistance Service technicians are factory trained and are capa ble of handling all service needs When contacting an Authorized Service Dealer about parts and service always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit AUTHORIZED SERVICE DEALER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 OR Locate us on the web at WWW generac com INTRODUCTION SAFETY RULES Section 1 GENERAL INFORMATION Transfer Switch Automatic System Operation Generator AC Connection Systems Main Circuit Breaker Generator Fuel System Engine Protective Devices Lifting the Generator Specifications Fuel Consumption Reconfiguring the Fuel System Torque Specifications Engine Oil Recommendations Coolant Recommendations m m E E Before Installation Section 2 INSTALLATION standby Generator Installation Generator Location Generator Mounting and Support Basic Standby Elect
62. o cause overheating It is also recommend that any solu ble 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 5 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 GTS type transfer switch if neces sary The standard transfer switch has no sensing or con trolling circuit boards Instead the generator control console houses a Printed Circuit Board Assembly which controls all phases of operation including engine start up and load transfer 2 1 STANDBY GENERATOR INSTALLATION A A AN Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the electric system from the utility distribution 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
63. orate 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 These generator sets may operate using one of several types of fuels All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the units fuel system frequently and correct any leaks imme diately 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 GENERAL a Liquid cooled 30 kW Generators INFORMATION 1 1 GENERATOR This equipment is a liquid cooled engine driven generator set The generator is designed to supply electri
64. ore resetting the circuit breaker or replacing the fuse 4 4 CHECKING FLUID LEVELS 4 4 1 CHECK ENGINE OIL Check engine crankcase oil level Figure 4 1 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Section 1 14 for recom mended oils Figure 4 1 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 16 4 4 5 ENGINE COOLANT Check coolant level in coolant recovery bottle See opecifications 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 Service Dealer Inspect cooling system and coolant recovery system for leaks 4 5 MAINTENANCE OWNER OPERAT
65. per cables or booster battery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging waRNING A AN Ensure that the 15 and 4A fuses are removed from the control console the AUTO OFF MANUAL switch is set to OFF and the utility supply to the battery charger is removed before removing or connecting battery cables If the switch is set to AUTO or MANUAL the genera tor can crank and start as soon as the battery cables are connected Be sure the UTILITY power supply to the battery charger is turned off or sparking may occur at the battery posts as the cables are attached and cause an explosion MAINTENANCE S Section 4 Maintenance Liquid cooled 30 kW Generators 4 6 4 BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows A 600 0 deg F NOTE The BCI number should be located directly on the battery 1 PERIODIC REPLACEMENT PARIS Part Name Part Number Qil Filter 0E7180 046627 Air Cleaner 0C8127 Spark Plug 0E7079 Radia Section 4 Maintenance MAINTENANCE Liquid cooled 30 kW Generators 4 7 SCHEDULED MAINTENANCE The following is a recommended maintenance schedule for small standby and residential generator sets The established intervals in the schedule are the maximum recommended when the unit is used in an average
66. rass hose fitting from the outlet port Port 1 of the demand regulator Remove pipe plug from Port 2 Install brass hose fitting into Port 2 Install pipe plug into Port 1 Connect carburetor gas hose to brass fitting Tighten all clamps and plugs Make sure fuel supply is of the proper pressure and type for configuration 10 Reverse the procedure to convert back to natural gas ad P ILE bas Figure 1 8 Reconfigure the Fuel System Port 1 Port 2 FUEL HOSE FUEL HOSE ft BRASS HOSE BRASS HOSE fI F T aa FITTING a Pus E s OUT OUT E 8 Sj PORT 1 PORT 2 i HOUSING PORTS NG FUEL SYSTEM LP 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 A DIE A Serious injury or damage may occur if not con figured properly Please consult an Authorized Service Dealer with any questions INSTALLATION IL Section 2 Installation Liquid cooled 30 kW Generators 1 13 TORQUE SPECIFICATIONS Cylinder 15 90 90 ft Ib Intake Manifold 13 ft Ib Exhaust Manifold l n 13 ft Ib 1 14 ENGINE OIL RECOMMENDATIONS The unit has been fill
67. ric System Emergency Circuit Isolation Method Total Circuit Isolation Method Grounding the Generator Generator AC Neutral Connections Transfer Switch Start Signal Connections Battery Installation Preparation Before Start Up Table of Contents E OF CONTENTS Liquid cooled 30 kW Generators Section 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 56 Automatic OperatiOn 14 3 7 Weekly Exercise Cycle scicsccsssavensenssciiemananesareiias 15 Section 4 15 4 1 Maintenance Performed by Authorized SETVICE FACES L 15 4 5 a Oy SU 15 4 3 Overload Protection for Engine DC PIC CHICA SV SECM 16 4 4 Checking Fluid Levels 16 4 5 Maintenance Owner Operator sa 16 4 6 Miscellaneous Maintenance 18 4 7 scheduled Maintenance 20 Section 5 TROUBLESHOOTING 23 Section 6
68. rom 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 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Liquid cooled 30 kW Generators 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 automatic start up and possible injury to personnel disable the generator s automatic start circuit disconnect battery cables etc before working on or around the unit Then place a Do Not Operate tag on the gen erator control panel and on the transfer switch In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity 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 deteri
69. s 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 The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly 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 an Authorized Service Dealer Normal maintenance service 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 Authorized Service Dealer for service aids and accessories Operating instructio
70. sfer switch 3 4 ENGINE GOVERNOR ADJUSTMENTS Engine speed governing is also controlled by the engine control board Connector J2 on the engine control board interfaces with a governor driver mod ule and the Bosch throttle body The engine gover nor 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 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 14 Figure 3 2 Engine Governor Adjustment Sse amp
71. sion Correct as necessary 12 Test the engine and transfer switch safety devices Correct and or adjust as necessary Section 4 Maintenance MAINTENANCE Liquid cooled 350 kW Generators 13 14 15 16 17 18 19 20 21 Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task mended Comp to be done Comp Ito be done Comp Required to be done Date 3months Date Semi Date to be done monthly Initials Break in Initials annually Initials Annually 10 hrs 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 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 Change the engine oil Replace the engine oil filter s Replace the engine air filter s Replace the engine fuel filter s on diesel engine driven units and re prime the fuel system Check the engine spark plugs on gas engine driven units Clean and re gap or replace as necessary Perform a 5 minute no load operational run of the unit looking for any post service problems Return the unit to standby setup for operation when required
72. tors Battery electrolyte fluid is an extremely caus tic 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 AN Spilled electrolyte is to be washed down with an acid neutralizing agent 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 wanNiNG 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 circuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles When replacing batteries use the same number and type of battery The recommended batteries are Group 26 12V negative ground 525 CCA 75 AH mini mum capacity or Group 27 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 maintenanc
73. ual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING e Guardian generators that utilize non Guardian Generac replacement parts e Guardian generators utilizing non Guardian Generac automatic transfer switches e Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems e Any Guardian generators used as rental or trailer mounted applications e 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 e Costs of normal maintenance adjustments installation and start up e 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 e Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts e Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine e Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volc
74. uit breaker open TROUBLESHOOTING CORRECTION 1 2 Co N O O1 WP MN Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replace fuse Replenish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Clean or replace as needed Unclog fuel line Clean regap or replace plugs Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Contact an Authorized facility Auto reset Wait 5 min and attempt restart 23 NOTES ea Section 6 Notes Liquid cooled 30 kW Generators INSTALLATION Section 7 Installation Diagram id cooled 30 kW Generators Liqu Installation Diagram Drawing No 0E8695 501 S3HONI wu SlINn ONIGNNOYD 6 1001 CHLGIM TIVadAD imd1DD4 ASVd L G EEJ0S8 501 29211 6 1IND VIVI LHOTSM JIN13 3993 I3NVd IDSLNLOS V V M3IA T 3 DN 338 31DUN 33S LHOISH TIVadAUu L cg 2v 11401 13110U a314d N D LaAILAO LSQhVHX3 Oflld 13318 8
75. used the engine generator is to be installed over non combustible materi als and should be located such that combustible materials are not capable of accumulating 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 caution After the system has been installed do nothing that might render the installation in noncompli ance with such codes standards and regulations 2 1 1 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 NOTE It is essential to use the latest version of any stan dard to ensure correct and current information No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES NFPA No 220 STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No 68 GUIDE FOR EXPLOSION VENTING NFPA No 70 NATIONAL ELECTRICAL CODE NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 2 1 2 OTHER PUBLISHE
76. vice entrance If the neutral wire is grounded and one of the phase loads becomes grounded the exces sive current opens the load circuit breaker or col lapses the generator field The actual result depends on the electrical characteristics of the particular installed generator waRNING amp Failure to connect the generator neutral proper ly will result in unbalanced line to neutral volt ages Resulting high voltages will cause equip ment damage 2 9 TRANSFER SWITCH SIGNAL CONNECTIONS 2 9 1 PRE PACKAGED ATS If the generator is to be installed with a pre packaged non control board based transfer switch it is nec essary to connect the control wires to the generator and set position two of the four position dip switch to OFF Setting switch two to OFF allows the control PCB to perform the ATS control functions Control system interconnections consist of N1 and N2 and leads 23 and 194 Control system intercon nection leads must be run in a conduit that is sepa rate from the AC power lead Recommended wire gauge sizes for this wiring depends on the length of the wire as recommended below MAXIMUM WIRE LENGTH RECOMMENDED WIRE SIZE 461 to 730 feet 223m 731 to 1 160 feet 354m 1 161 to 1 850 feet 565m 2 9 2 GTS TYPE ATS If the generator is to be installed with an automatic transfer switch such as an engineered GTS type switch it is necessary to connect the two wire start control syst
77. with the recommended coolant mixture Check the system for leaks and other problems See Specifications Section 1 10 and Coolant Section 1 15 12 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 to keep them clear of any moving generator set components 3 1 USING AN ENGINEERED GTS TRANSFER SWITCH When required the pre packaged standby generator can be installed with an engineered GTS type auto matic 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 generator s control board will NOT monitor utility The control board will NOT perform a weekly exercise The five red LEDs will not flash in this mode The control board w
78. y between pulleys should deflect about 3 8 to 5 8 inch Adjust belt tension as required 4 5 9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor A DX A AN Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incor rect frequency and or voltage Only qualified service technicians should adjust the governed speed 4 5 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized ser vice 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 ha

Guardian Technologies 004988-4 Portable Generator User Manual

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