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Generac Power Systems 004988-2 manual

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Table of contents for the manual

  • Page 1

    Owner’ s Man ual ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!! This manual should remain with the unit. Liquid-cooled, Prepac kaged Standb y Generator s Model Number: 004988-2[...]

  • Page 2

    Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the standby generator set product line by Generac P ower Systems. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ- ten. However , the manufacturer reserves the[...]

  • Page 3

    T able of Contents Guardian Liquid-cooled 2 7 kW and 30 kW Generators Generac ® Pow er Systems, Inc. 1 INTRODUCTION ................................................ IFC SAFETY RULES .................................................... 2 Section 1 — GENERAL INFORMA TION ............4 1.1 Generator .................................................[...]

  • Page 4

    2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The genera- tor can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many acci- dents are caused by failing t[...]

  • Page 5

    Generac ® Pow er Systems, Inc. 3 • Inspect the generator regularly , and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. • Before performing any maintenance on the generator , disconnect its battery cables to prevent accidental start -up. Disconnect the cable from the battery post indicated by[...]

  • Page 6

    4 Generac ® Pow er Systems, Inc. 1.1 GEN ER A T OR This equipment is a liquid- cooled, engine - driven gen- erator set. The generator is designed to supply elec- trical power that operates critical electrical loads during utility power failure. The unit has been facto- ry-installed in a weather resistant, all metal enclosure and is intended for ou[...]

  • Page 7

    Generac ® Pow er Systems, Inc. 5 1.6 GEN ER A T OR F U EL SY S TEM 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 . F uel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges[...]

  • Page 8

    6 Generac ® Pow er Systems, Inc. Figure 1.6 - Low Coolant Level Sensor 1.7 .4 O VERSPEED SH UTDOWN 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. Sh[...]

  • Page 9

    1.1 0 SP ECIF ICA TIONS 1.1 0.1 GEN ER A T OR SP ECIF ICA TIONS 1.1 0.2 ENGI N E SP E CI F ICA TIONS Make ........................................................................................................Ford Displacement ....................................................................................3.0 liters Cylinder Arrangement ......[...]

  • Page 10

    8 Generac ® Pow er Systems, Inc. 1.1 3 T ORQU E SP ECIF ICA TIONS Cylinder Head ............................................15 (+ 90° + 90°) ft.lb . Intake Manif old ................................................................13 ft.lb. Exhaust Manif old..............................................................13 ft.lb . 1.1 4 ENGI N E OI[...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 • NFP A No. 37, ST A TIONARY COMBUSTION ENGINES AND GAS TURBINES. • NFP A No. 76A , ESSENTIAL ELECTRICAL SYS- TEMS FOR HEAL TH CARE F ACILITIES. • NFP A No. 220, ST AND ARD TYPES OF BUILDING CONSTRUCTION • NFP A No. 68, GUIDE FOR EXPLOSION VENTING • NFP A No. 70, NA TIONAL ELECTRICAL CODE. • NFP A No. 3[...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. 2.5 EM ERGENCY CI RCU IT IS OL A TION M E THOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator . If the generator is powering only crit- ical loads, within the wattage/amperage capacity , dur- ing utility power outages, consider using the eme[...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 Control system interconnections consist of N1 and N2, and leads 23 and 194. Control system intercon- nection leads must be run in a conduit that is sepa- rate from the AC power lead. Recommended wire gauge sizes for this wiring depends on the length of the wire, as recommended below: 2.9.2 GT S- TYP E A TS If the [...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. 2.1 1.1 P R IOR T O I N ITIAL S T ART -U P Prior to initially starting the generator , it must be properly pr epared for use. Any attempt to crank or start the engine before it has been properly serviced with the r ecommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine [...]

  • Page 15

    Generac ® Pow er Systems, Inc. 13 AUTO — The control board will monitor the two-wire start circuit. When a two -wire start is issued the con- trol board will immediately start and run the genera- tor . Whe the two -wire start is removed the control board will immediately stop the generator . NOTE: If the generator is installed in conjunction wit[...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. 3.3 MAN U AL TR ANSF ER AN D S T ART -U P T o transfer electrical loads to the Standby (EMER- GENCY) power source side and start the engine man- ually , refer to the Owner’s Manual of the particular transfer switch. 3.4 ENGI N E G OVERNOR ADJ US TM ENTS Engine speed governing is also controlled by the engine con[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 2. Press and hold the “Set Exercise” switch for three seconds, then release. At this time all five red LEDs will flash for approxi- mately 10 seconds, then the engine will start and run for it ’s 12 minute exercise period, then shut down. The generator will now start and run each week at the same time. If DC[...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. 4.4 CH E CKI NG F L U I D LEVEL S 4.4.1 CH E CK ENGI NE OI L 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 [...]

  • Page 19

    Generac ® Pow er Systems, Inc. 17 Do not attempt to adjust the governor . Only qualified service facilities should adjust the governor . Excessively high operating speeds are dangerous and incr ease 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. Co[...]

  • Page 20

    18 Generac ® Pow er Systems, Inc. Figure 4.4 – Setting the Spark Plug Gap 4.5.1 3 COOLANT CHANGE Every year , have Authorized Service F acility drain, flush and refill the cooling system. See SPECIFICA- TIONS (Section 1.10) for cooling system recommen- dations. 4.6 M IS CELL AN EOUS MAINTENANCE 4.6.1 CLEAN ING TH E GEN ER A T OR Keep the generat[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 Do not use any jumper cables or booster bat- tery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for r echarging. Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANU[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Guardian Liquid-cooled 2 7 kW and 30 kW Generators 4.7 S CH EDU LED MAI NTENANCE F ollowing is a recommended maintenance schedule for Generac small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an ave[...]

  • Page 23

    Generac ® Pow er Systems, Inc. 21 Section 4 — Maintenance Guardian Liquid-cooled 2 7 kW and 30 kW Generators Maintenance Level 1 Level 2 Le vel 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask 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- monthl[...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Guardian Liquid-cooled 2 7 kW and 30 kW Generators Maintenance Level 1 Level 2 Le vel 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask 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/[...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 Section 5 — T roubleshooting Guardian Liquid-cooled 2 7 kW and 30 kW Generators TROU B LE SHOO TI NG POI NTS P ROBLEM CAUSE CORR E CTION Engine won’t crank. 1. 15 amp fuse b lown. 1. Replace fuse. 2. Loose or corroded or def ective 2. Tighten, clean or replace batter y cables . batter y cables as necessary . 3[...]

  • Page 26

    24 Generac ® Pow er Systems, Inc. Section 6 - Notes Guardian Liquid-cooled 2 7 kW and 30 kW Generators[...]

  • Page 27

    Generac ® Pow er Systems, Inc. 25 Section 7 — Installation Diagram Guardian Liquid-cooled 2 7 kW and 30 kW Generators Installation Diagram — Drawing No. 0E8695[...]

  • Page 28

    BRUSH ASSEMLY ( GENERATOR ) A U T O MATI C V O LTA G E RE GU LAT OR BULKHEAD CONNECTOR 1 ( ENGINE ) CIRCUIT BREAKER ( EXCITATION ) FUSE, BAT. POWER ( 15A AGC TYPE ) CIRCUIT BREAKER ( OUTPUT ) DIODE [ FIELD BOOST ] BATTERY C HAR G E R B C 1 - F1 - D1 - C B2 - C B1 - AVR - BA - B /C - LE G END : NE U TRAL BL OCK TERMINAL BL OC K 1 TRANSFORMER 1 ( 56 [...]

  • Page 29

    Generac ® Pow er Systems, Inc. 27 LEGEND [ CONT. ]: J -2 - L OS - S M - J B - WL S - H C T - J -1 - IM - I C - ELE C . GO VERN O R A C T U AT OR GROUND ( SENSING/LOW AMP ) GROUND ( POWER/HIGH AMP ) D. C . C HAR G E ALTERNAT OR S TARTER CO NTA C T OR CONNECTOR 1 ( ENGINE ) DRIVER ELE C . GO VERN OR F U EL SO LEN O I D 12VD C BATTER Y DE G - G ND1 -[...]

  • Page 30

    28 Generac ® Pow er Systems, Inc. Section 8 - Electrical Data Guardian Liquid-cooled 2 7 kW and 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-B A U T O MATI C V O LTA G E RE GU LAT OR BRUSH ASSEMLY ( GENERATOR ) CIRCUIT BREAKER ( EXCITATION ) DI S PLA C ED PHA S E EX C ITATI ON DPE - ALTERNAT O R S TAT OR ALTERNAT O R R O[...]

  • Page 31

    Generac ® Pow er Systems, Inc. 29 Section 8 - Electrical Data Guardian Liquid-cooled 2 7 kW and 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-B SC - I C - IM - L OS - S M - WL S - LEGEND [ CONT. ]: CONNECTOR (C1) SWITCH , HIGH COOLANT TEM P C RANKIN G CO NTA C T OR D. C . C HAR G E ALTERNAT OR CONNECTOR 1 ( ENGINE ) DRIVE[...]

  • Page 32

    CONTACTOR WIRE H ARNE SS 7 5 6 16 E N G INE FOO T 2 4 3 41 40 16 7 6 5 35 9 13 17 12 8 18 16 43 BLOCK E N G INE 30 TO 44 35 3 4 3 36 33 44 42 22 20 3 2 38 18 31 20 TO S TARTER S TARTER BO LT TO B L OC K E N G INE 18 TO 11 1 12 10 14 R EAR BEARIN G 13 15 3 7 14 C ARRIER 3 4 16 2 30 Generac ® Pow er Systems, Inc. Section 9 - Exploded Views and P art[...]

  • Page 33

    ITEM P ART NO . QTY . DESCRIPTION 1 0E5822 1 BASEFRAME, WELDMENT 3.0L FORD 2 052860 4 NUT FLANGED HEX M12-1.75 3 052251 4 DAMPENER VIBRA TION 40 BLUE 4 052257 4 SP ACER .49 X .62 X 1.87 PWDR/ZNC 5 052252 4 DAMPENER VIBRA TION 6 052259 4 W ASHER FLA T M12 7 052891 4 SCREW HHC M12-1.75 X 80 G8.8 8 0536210213 1 ASSY GRNDWIRE 11"/3/8 & 5/16 LU[...]

  • Page 34

    32 Generac ® Pow er Systems, Inc. S TATE S F O AM I S O N FAR S IDE 3 7 1 7 L AT C H DETAIL 30 3 1 3 4 38 2 3 2 3 4 27 43 18 41 4 "B " 7 D ETAIL S EE LAT C H 11 25 5 2 9 6 53 5 4 5 S E CU RE A S S H O WN. R E Q UIRE INSULATION. T YPI C AL O F R OO F PANEL THAT TO "A" 4 53 4 35 SU PP O R T R ADIAT OR 33 44 55 5 5 53 4 36 4 18 4 [...]

  • Page 35

    Generac ® Pow er Systems, Inc. 33 ITEM P ART NO . QTY . DESCRIPTION 1 0E8411 1 INT AKE DUCT HSB 2 0E8042 1 DUCT DISCHARGE RH FRONT 3 0E8041 1 DUCT DISCHARGE LH FRONT 4 0C2454 62 SCREW TH-FRM M6-1 X 16 N W A Z/JS 5 0E8402 1 BAFFLE REAR BOTT OM 6 0E7808 1 POST CORNER LH REAR 7 0E7809 1 POST CORNER RH REAR 8 0E8387 1 BAFFLE REAR T OP 9 0E6986 2 DOOR [...]

  • Page 36

    34 Generac ® Pow er Systems, Inc. Section 9 - Exploded Views and P arts Guardian Liquid-cooled 2 7 kW and 30 kW Generators Control Panel — Drawing No. 0E7 11 8-K[...]

  • Page 37

    Generac ® Pow er Systems, Inc. 35 ITEM P ART NO . QTY . DESCRIPTION 1 0E7195 1 CONTROL BO X HSB 2 0E7196 1 CO VER FR ONT P ANEL HSB 3 0E7197 1 CO VER TOP P ANEL HSB 4 0E7193 1 DECAL W ARNINGS HSB 5 0E7194 1 DECAL CONTROLS HSB 6 0E4494 1 SWITCH ROC DPDT ON-OFF-ON 7 082573 1 SWITCH R OCKER DPST 125V SPD 8 032300 2 HOLDER FUSE 9 022676 1 FUSE 15A X A[...]

  • Page 38

    38 11 85 6 17 57 24 61 60 30 66 68 2 5 58 35 39 36 WIRE GROUND 39 32 64 63 65 31 35 2 42 51 24 55 2 5 60 86 58 57 16 1 8 1 9 4 8 4 8 42 41 44 4 5 30 81 42 7 8 4 9 49 4 6 47 47 4 4 3 42 1 2 6 42 47 81 2 38 42 69 2 8 REAR U PPE R BAFFLE 4 0 36 5 6 7 35 37 1 5 36 3 8 14 8 12 2 9 7 3 10 82 33 36 3 4 35 2 84 27 Section 9 - Exploded Views and P arts Guar[...]

  • Page 39

    ITEM P ART NO . QTY . DESCRIPTION 1 0E6202 1 ENGINE 3.0L FORD (RD) (MAKE) 2 0E8824 2 ST AMPING ENG FOO T 3.0L FORD 3 0E8963 1 PULLEY CRANKSHAFT 3.0L FORD RD 4 0E9020 1 BRA CKET DC AL T 3.0L FORD 5 0A1232 1 D .C. AL TERNA T OR ASSY 6 0A7801B 1 PULLEY POL Y -V 82 OD . 7 0A5610 1 BRA CKET AL TERNA T OR 8 0E6308 1 PULLEY W A TERPUMP 3.0L FORD (RD) 9 **[...]

  • Page 40

    E N G INE 5 "A " 12 FRAME 10 9 11 8 9 3 21 27 PU MP TO WATER 4 12 17 6 15 7 1 15 20 3 22 24 24 TO 2 12 TO "A" 18 13 14 12 Section 9 - Exploded Views and P arts Guardian Liquid-cooled 2 7 kW and 30 kW Generators Radiator — Drawing No. 0E852 8-B 38 Generac ® Pow er Systems, Inc.[...]

  • Page 41

    ITEM P ART NO . QTY . DESCRIPTION 1 0E9947 1 RADIA T OR R-IN,L-OUT 658X489X49 2 0E6340 1 VENTURI 3.0L FORD HSB 3 0E8531 2 SIDE SUPPORT RADIA T OR HSB 4 0E6398 1 TUBE LOWER RAD 3.0L FORD HSB 5 0E6397 1 HOSE UPPER RAD 3.0LFORD HSB 6 080713 1 BRACKET COOLANT T ANK 7 076749 1 T ANK COOLANT RECO VER Y 8 049814 4 SCREW HHC M10-1.5 X 25 G8.8 9 022131 8 W [...]

  • Page 42

    40 Generac ® Pow er Systems, Inc. 28 "B " 3 1 10 16 4 2 17 5 9 1 7 6 29 3 2 30 11 29 15 8 3 6 3 33 29 14 TO "B" 26 2 7 18 43 41 40 21 28 26 39 Section 9 - Exploded Views and P arts Guardian Liquid-cooled 2 7 kW and 30 kW Generators Fuel Syst em — Drawing No. 0E8 1 90-C[...]

  • Page 43

    Generac ® Pow er Systems, Inc. 41 ITEM P ART NO . QTY . DESCRIPTION 1 * --------- 1 WELDMENT MOUNTING BASE 2 075580 1 FLANGE FUEL INLET 3 0E7691 1 ASSY REGULA T OR 3.0L NG OR LPV 4 039253 2 SCREW HHC M8-1.25 X 20 G8.8 5 022145 2 W ASHER FLA T 5/16 ZINC 6 022129 4 W ASHER LOCK M8-5/16 7 045771 2 NUT HEX M8-1.25 G8 YEL CHR 8 042907 2 SCREW HHC M8-1.[...]

  • Page 44

    42 Generac ® Pow er Systems, Inc. 3 LOC KTI G HT LOC KTI G HT 7 1 5 17 8 7 6 18 4 16 L EAD S 5 2 9 13 21 19 20 14 10 11 1 2 30 1 3 1 Section 9 - Exploded Views and P arts Guardian Liquid-cooled 2 7 kW and 30 kW Generators Alternator — Drawing No. 0F5 092-A[...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 1 0F1659A 1 RO T OR 390 15KW 1P DIRECT HSB (2.5L FORD) 0F1657A 1 RO T OR 390 20KW 1P DIRECT HSB (2.5L FORD) 0F1655A 1 RO T OR 390 25KW 1P DIRECT HSB (2.5L FORD) 0F5073A 1 RO T OR 390__30AD1 HSB TECUM 0E7413A 1 RTR 390 40KW 1P DIRECT HSB 2 0F1660A 1 STR 390 15AD HSB (382MM LONG) (2[...]

  • Page 46

    ITEM P ART NO . QTY . DESCRIPTION 1 0E6134 1 MUFFLER, 3.0L FORD 2 0E6464 2 EXHA UST ELBO W 3.0L FORD HSB 3 0E6465 1 EXHA UST PIPE LH 3.0L FORD HSB 4 0E6465A 1 EXHA UST PIPE RH 3.0L FORD HSB 5 0E5914 1 BRA CKET MUFFLER 3.0L FORD HSB 6 060366 1 MUFFLR STRAP 6IN DIA 7 027837 1 SCREW RHM 1/4-20 X 2-1/4 8 036797 4 BOL T U 5/16-18 X 2.25 9 039253 2 SCREW[...]

  • Page 47

    Generac ® Pow er Systems, Inc. 45 ITEM P ART NO . QTY . DESCRIPTION 1 0E5193 1 PLA TE AIR CLEANER AD APTER 2 0E8200 1 TUBE AIR INT AKE 3.0L FORD 3 0E8201 1 BRA CKET AIR INT AKE 3.0L FORD 4 036434 1 BOL T U 5/16-18 X 2.09 5 0E0519A 1 AD APTER CARBURET OR W/PVC CONN 6 0C8127 1 ELEMENT AIR CLEANER 7 0A5547 1 CO VER - AIR CLEANER 8 062974 1 STUD TH 1/[...]

  • Page 48

    Part No. 0F5095 Revision B (05/05/05) Printed in U.S.A. Section 1 0 – W arranty Guardian Liquid-cooled 2 7 kW and 30 kW Generators GENERA C PO WER SYSTEMS "TWO YEAR" LIMITED W ARRANTY FOR GU ARDIAN ® "PREP A CKA GED EMERGENCY A UT OMA TIC ST ANDBY GENERA T ORS" F or a period of two years from the date of original sale, Genera[...]