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Guardian Technologies 004988-4 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: 004988-4 27kW NG, 30kW LP V apor[...]

  • Page 2

    2 I NTRODUCTION Thank you for purchasing this model of the standby generator set. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ - ten. However , the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any [...]

  • Page 3

    T able of Cont ents Liquid-cooled 30 kW Generators 1 INTRODUCTION ............................................... IFC SAFETY RULES .................................................... 2 Section 1 — GENERAL INFORMA TION ............. 4 1.1 Generator .............................................................. 4 1.2 Transfer Switch ..............[...]

  • Page 4

    2 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 [...]

  • Page 5

    3 • Inspect the generator regularly , and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. • Before performing any maintenance on the generator , disconnect its battery cables to prevent accidental start -up. Disconnect the cable from the battery post indicated by a NEGA TIVE, NEG or (–) first[...]

  • Page 6

    4 1.1 GEN ER A T OR This equipment is a liquid- cooled, engine - driven generator set. The generator is designed to supply electrical 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 [...]

  • Page 7

    5 1.6 GEN ER A T OR F U EL SYST E M 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. F uel pressure for an LP vapor[...]

  • Page 8

    6 Figure 1.6 - Low Coolant Level Sensor 1.7 .4 OVERSPEED SHUTDOWN The engine control board receives AC frequency sig - nals from an engine run winding in the alternator . Should AC frequency exceed about 72 Hertz for three seconds or 75 Hertz instantaniously , the engine shuts down and the overspeed LED turns on. Should AC frequency exceed about 72[...]

  • 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 ECIF ICA TIONS Make ........................................................................................................F ord Displacement .................................................................................... 3.0 liters Cylinder Arrangement ......[...]

  • Page 10

    8 1.1 3 T ORQUE SP ECIF ICA TIONS Cylinder Head ............................................ 15 (+ 90° + 90°) ft.lb . Intake Manif old ................................................................ 13 ft.lb. Exhaust Manifold ............................................................. 13 ft.lb. 1.1 4 ENGI N E OI L R E C OM M END A TIONS The un[...]

  • Page 11

    9 • NFP A No. 37, ST A TIONARY COMBUSTION ENGINES AND GAS TURBINES. • NFP A No. 76A , ESSENTIAL ELECTRICAL SYSTEMS FOR HEAL TH CARE F ACILITIES. • NFP A No. 220, ST ANDARD TYPES OF BUILDING CONSTRUCTION • NFP A No. 68, GUIDE FOR EXPLOSION VENTING • NFP A No. 70, NA TIONAL ELECTRICAL CODE. • NFP A No. 30, FLAMMABLE AND COMBUSTIBLE LIQUID[...]

  • Page 12

    10 2.5 EM ERGENCY CI RCUIT ISOLA TION M E THOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator . If the generator can only power criti- cal loads, within it ’s wattage/amperage capacity , dur - ing utility power outages, use the emergency circuit isolation method. Critical e[...]

  • Page 13

    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- T YP E A TS If the generator is to be installed wi[...]

  • Page 14

    12 2.1 1.1 P RIOR 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 failur e. Before starting the[...]

  • Page 15

    13 MANU AL — The control board will start and run the generator whenever the switch is in the manual position. AUT O — 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 immediat[...]

  • Page 16

    14 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 A UTO or MANU AL 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 ba[...]

  • Page 17

    15 3.7 WEEKL Y EXERCISE CY CLE 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 ch[...]

  • Page 18

    16 4.3 O VER L O AD P RO TE CTION FOR ENGI N E DC ELE CTR ICAL SYSTE M Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via a 15 amp fuse. These overcurrent protection devices will open if the circuit is overloaded.  If a circuit br eaker ope[...]

  • Page 19

    17 4.5.8 CH ECK F AN B EL T • Inspect fan belts every three months. Replace any damaged, deteriorated, worn or otherwise defec- tive belt. • Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 inch. Adjust belt tension as required. 4.5.9 I NSP E CT ENGI NE GO VER NOR V isually inspect electron[...]

  • Page 20

    18 4.5.1 2 SP AR K P L UG S 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 che[...]

  • Page 21

    19 D ANGER  Storage batteries give off explosive hydr ogen 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 [...]

  • Page 22

    20 Section 4 — Maintenance Liquid-cooled 30 kW Generators 4.7 S CH EDU LED MAI NTENANCE The following is a recommended maintenance schedule for small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased [...]

  • Page 23

    21 Section 4 — Maintenance Liquid-cooled 30 kW Generators Maintenance Level 1 Level 2 Level 3 Le vel 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/ Initials) Break-in Initials) annually/ Initials) [...]

  • Page 24

    22 Section 4 — Maintenance Liquid-cooled 30 kW Generators Maintenance Level 1 Level 2 Level 3 Le vel 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/ Initials) Break-in Initials) annually/ Initials) [...]

  • Page 25

    23 Section 5 — T roubleshooting Liquid-cooled 30 kW Generators TROU B LE SHOO TI NG POI NT S P ROBLEM CAUSE CORR E CTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defectiv e 2. Tighten, clean or replace battery cables. battery cables as necessar y . 3. Defectiv e starter contactor. 3. Replace contactor .[...]

  • Page 26

    24 Section 6 - Notes Liquid-cooled 30 kW Generators[...]

  • Page 27

    25 Section 7 — Installation Diagram Liquid-cooled 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

    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 - G ND2 - GO V - F S - LE G END :[...]

  • Page 30

    28 Section 8 - Electrical Data Liquid-cooled 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 T OR BATTERY C HAR G E R DIODE [ FIELD BOOST ] CIRC[...]

  • Page 31

    29 Section 8 - Electrical Data Liquid-cooled 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 ) DRIVER ELE C . GO VERN OR SO LEN O ID F U E L ELE C . GO [...]

  • Page 32

    MOUNTING BA S E CONT ACT OR WIRE HARNE SS 7 5 6 16 ENGINE FOO T 2 4 3 41 40 16 7 6 5 35 9 13 17 12 8 18 16 43 BLOCK ENGINE 30 TO 44 35 34 39 36 33 44 42 22 20 32 38 18 31 20 21 TO S T ARTER S T ARTER BOL T TO BLOCK ENGINE 18 TO 11 1 12 10 14 REAR BEARING 13 15 37 14 CARRIER 3 4 16 2 30 Section 9 - Exploded Views and P arts Liquid-cooled 30 kW Gener[...]

  • Page 33

    ITEM P ART NO . QTY . DESCRIPTION 1 0E5822 1 BA S EFRAME, WELDMENT 3.0L FORD 2 052860 4 NUT FLANGED HEX M12-1.75 3 052251 4 D AMPENER VIBRA TION 40 BLUE 4 052257 4 S P ACER .49 X .62 X 1.87 PWDR/ZNC 5 052252 4 D AMPENER VIBRA TION 6 052259 4 W A S HER FLA T M12 7 052891 4 S CREW HHC M12-1.75 X 80 G8.8 8 0536210213 1 A SS Y GRND WIRE 11"/3/8 &a[...]

  • Page 34

    32 3 7 S TATE S F O AM I S O N FAR S IDE S TATE S F O AM I S O N NEAR S IDE 17 L AT C H DETAIL 3 0 3 1 3 4 38 2 3 2 3 4 27 4 3 1 8 40 4 7 "B " 11 S EE LAT C H DETAIL 25 5 2 9 6 4 9 4 8 5 TO "A" T YPI C AL O F R OO F PANEL THAT R E Q UIRE INSULATION. S E CU RE A S S H O WN. 4 4 4 9 3 5 R ADIAT OR SU PP O R T 33 25 47 7 4 4 9 4 3 [...]

  • Page 35

    33 ITEM P ART NO . QTY . DESCRIPTION 1 0E8411 1 INT AKE DUCT H S B 2 0E8042 1 DUCT DI S CHARGE RH FRONT 3 0E8041 1 DUCT DI S CHARGE LH FRONT 4 0C2454 62 S CREW TH-FRM M6-1 X 16 N W A Z/J S 5 0E8402 1 BAFFLE REAR BOTT OM 6 0E7808 1 PO S T CORNER LH REAR 7 0E7809 1 PO S T CORNER RH REAR 8 0E8387 1 BAFFLE REAR T OP 9 0E6986 2 DOOR COMP ARTMENT S IDE 1[...]

  • Page 36

    34 Section 9 - Exploded Views and P arts Liquid-cooled 30 kW Generators Control Panel — Drawing No. 0E7 11 8-K[...]

  • Page 37

    35 ITEM P ART NO. QTY . DESCRIPTION 1 0E7195 1 CONTROL BO X H S B 2 0E7196 1 CO VER FRONT P ANEL H S B 3 0E7197 1 CO VER T OP P ANEL H S B 4 0E7193 1 DECAL W ARNING S H S B 5 0E7194 1 DECAL CONTROL S H S B 6 0E4494 1 S WITCH ROC DPDT ON-OFF-ON 7 082573 1 S WITCH ROCKER DP S T 125V S PD 8 032300 2 HOLDER FU S E 9 022676 1 FU S E 15A X AGC15 10 06768[...]

  • Page 38

    11 65 17 57 24 61 60 30 25 58 35 39 36 WIRE GROUND 39 32 31 35 79 24 50 54 53 43 2 42 38 61 53 51 14 55 60 25 85 57 58 87 69 36 & REPLACE REMO VE 35 39 86 68 66 67 32 16 18 19 80 48 47 42 41 44 45 31 30 81 88 84 42 78 49 21 49 46 20 47 47 46 4 43 64 38 42 63 1 26 42 15 47 43 81 2 38 42 28 34 REAR UPPER BAFFLE 40 42 36 5 6 7 35 37 89 36 43 3 8 3[...]

  • Page 39

    ITEM P ART NO. QTY . DESCRIPTION 1 0E6201 1 ENGINE 3.0L FORD (FD) (MAKE) 2 0E8824 2 S T AMPING ENG FOOT 3.0L FORD 3 0E8963 1 PULLEY CRANK S HAFT 3.0L FORD RD 4 0E9020 1 BRACKET DC AL T 3.0L FORD 5 0A1232 1 D .C. AL TERNA TOR A SS Y 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

    38 27 FRAME 11 10 9 12 3 8 9 26 25 "A" 20 21 TO WA T ER 12 4 PUMP 6 15 17 7 13 1 15 3 5 24 22 23 2 24 12 31 28 32 12 T O "A" 18 14 HOU S ING THERMO S TAT TO 29 12 33 35 30 ENGINE 12 TO Section 9 - Exploded Views and P arts Liquid-cooled 30 kW Generators Radiator — Drawing No. 0F6848-B[...]

  • Page 41

    39 ITEM P ART NO . QTY . DESCRIPTION 1 0E9947 1 RADIA T OR R-IN,L-OUT 658X489X49 2 0E6340 1 VENTURI 3.0L FORD H S B 3 0E8531 2 S IDE S UPPORT RADIA TOR H S B 4 0E6398 1 TUBE LOWER RAD 3.0L FORD H S B 5 0F6630 1 HO S E RADIA TOR UPPER 6 080713 1 BRACKET COOLANT T ANK 7 076749 1 T ANK COOLANT RECOVER Y 8 049814 4 S CREW HHC M10-1.5 X 25 G8.8 9 022131[...]

  • Page 42

    40 28 "B" 31 10 16 4 2 17 5 9 1 7 6 29 32 30 11 29 13 15 8 3 12 6 13 AIR TO CLEANER 34 33 29 14 T O "B" 19 26 27 18 43 41 40 21 28 20 26 25 42 39 Section 9 - Exploded Views and P arts Liquid-cooled 30 kW Generators Fuel Syst em — Drawing No. 0F6849-A[...]

  • Page 43

    41 ITEM P ART NO . QTY . DESCRIPTION 1 * --------- 1 WELDMENT MOUNTING BA S E 2 075580 1 FLANGE FUEL INLET 3 0E7691 1 A SS Y REGULA TOR 3.0L NG OR LPV 4 039253 2 S CREW HHC M8-1.25 X 20 G8.8 5 022145 2 W A S HER FLA T 5/16 ZINC 6 022129 4 W A S HER LOCK M8-5/16 7 045771 2 NUT HEX M8-1.25 G8 YEL CHR 8 042907 2 S CREW HHC M8-1.25 X 16 G8.8 9 0C2454 2[...]

  • Page 44

    42 3 LOCKTIGHT LOCKTIGHT 7 15 17 8 7 6 18 4 16 LEAD S 5 2 9 13 21 19 20 14 10 11 12 30 1 31 Section 9 - Exploded Views and P arts Liquid-cooled 30 kW Generators Alternator — Drawing No. 0F5 092-B[...]

  • Page 45

    43 ITEM P ART NO . QTY . DESCRIPTION 1 0F1659A 1 RO TOR 390 15KW 1P DIRECT H S B (2.5L FORD) 0F1657A 1 ROT OR 390 20KW 1P DIRECT H S B (2.5L FORD) 0F1655A 1 ROT OR 390 25KW 1P DIRECT H S B (2.5L FORD) 0F5073A 1 ROT OR 390__30AD1 H S B TECUM 0E7413A 1 RTR 390 40KW 1P DIRECT H S B 2 0F1660A 1 S TR 390 15AD H S B (382MM LONG) (2.5L FORD) 0F1658A 1 S T[...]

  • Page 46

    ITEM P ART NO. QTY . DESCRIPTION 1 0F0738 1 MUFFLER 7"X9"-(2)2"IN/2.5"OUT 2 0F6258 1 PIPE MUFFLER OUT 3 044149 2 GA S KET EXHA U S T RING 4 0F1008 1 EXHA U S T PIPE LH 3.0L H S B 5 0F1009 1 EXHA U S T PIPE RH 3.0L H S B 6 039288 1 S CREW HHC M8-1.25 X 55 G8.8 7 0E5914 1 BRACKET MUFFLER 3.0L FORD H S B 8 0E8726 2 S TRAP MUFFLER 9[...]

  • Page 47

    45 ITEM P ART NO . QTY . DESCRIPTION 1 0E5193 1 PLA TE AIR CLEANER AD APTER 2 0E0519A 1 ADAPTER CARB URETOR W/PVC CONN 3 049226 4 W A S HER LOCK M5 4 049815 4 S CREW HHC M5-0.8 X 16 G8.8 5 0C8127 1 ELEMENT AIR CLEANER 6 022127 1 NUT HEX 1/4-20 S TEEL 7 062974 1 S TUD TH 1/4-20 X 4-1/2 G2 ZNC 8 0A5547 1 CO VER - AIR CLEANER 9 037561 1 NUT WING 1/4-2[...]

  • Page 48

    Part No. 0F6866 Revision 0 (07/26/05) Printed in U.S.A. Section 1 0 – W arranty Liquid-cooled 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, Generac P ower Systems, In[...]