Generac Power Systems Portable Generator 004988 1 User Manual

Owner’s Manual

Liquid-cooled, Prepackaged

Standby Generators

Model Number: 004988-1

This manual should remain with the unit.

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

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Table of Contents

Guardian Liquid-cooled 27 kW and 30 kW Generators

INTRODUCTION................................................IFC

SAFETY RULES....................................................2

Section 3 — OPERATION ................................12

3.1 Using a Standard “GTS” Transfer Switch............12

3.2 Control Console Components..............................12

3.3 Manual Transfer and Startup..............................13

3.4 Engine Governor Adjustments ............................13

3.5 Retransfer and Shutdown....................................14

3.6 Automatic Operation ..........................................14

3.7 Weekly Exercise Cycle..........................................14

Section 4 — MAINTENANCE ..........................15

Section 1 — GENERAL INFORMATION ............4

1.1 Generator..............................................................4

1.2 Transfer Switch ....................................................4

1.3 Automatic System Operation ................................4

1.4 Generator AC Connection Systems........................4

1.5 Main Circuit Breaker ............................................4

1.6 Generator Fuel System..........................................5

1.7 Engine Protective Devices......................................5

1.8 Unpacking ............................................................6

1.9 Lifting the Generator ............................................6

1.10 Specifications ........................................................7

1.11 Fuel Consumption ................................................7

1.12 Reconfiguring the Fuel System ..............................7

1.13 Torque Specifications............................................8

1.14 Engine Oil Recommendations ..............................8

1.15 Coolant Recommendations....................................8

1.16 Before Installation ................................................8

Section 2 — INSTALLATION ............................8

2.1 Standby Generator Installation ............................8

2.2 Generator Location................................................9

2.3 Generator Mounting and Support ........................9

2.4 Basic Standby Electric System..............................9

2.5 Emergency Circuit Isolation Method......................9

2.6 Total Circuit Isolation Method ............................10

2.7 Grounding the Generator ....................................10

2.8 Generator AC Neutral Connections......................10

2.9 Transfer Switch Start Signal Connections ..........10

2.10 Battery Installation..............................................11

2.11 Preparation Before Start-Up................................11

4.1 Maintenance Performed by Authorized

Service Facilities..................................................15

4.2 Cooling System....................................................15

4.3 Overload Protection for Engine DC

Electrical System ................................................15

4.4 Checking Fluid Levels ........................................15

4.5 Maintenance Owner/Operator

Can Perform........................................................16

4.6 Miscellaneous Maintenance ................................17

4.7 Scheduled Maintenance ......................................19

Section 5 — TROUBLESHOOTING ..................22

Section 6 — INTALLATION DIAGRAM ............23

Section 7 — ELECTRICAL DATA ....................24

Section 8 — EXPLODED VIEWS AND

PARTS LISTS ..............................28

Section 9 — NOTES ........................................44

Section 10 — WARRANTY .................Back Cover

Generac Power Systems, Inc.

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IMPORTANT SAFETY INSTRUCTIONS

Guardian Liquid-cooled 27 kW and 30 kW Generators

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe

operation be copied and posted in potential hazard areas. Safety should be stressed to all

operators, potential operators, and service and repair technicians for this equipment.

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be

followed during installation and maintenance of the generator and batteries.

GENERAL HAZARDS

WARNING:

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

• For safety reasons, Generac recommends that this

equipment be installed, serviced and repaired by a

Generac Authorized Service Dealer or other compe-

tent, qualified electrician or installation technician

who is familiar with applicable codes, standards and

regulations. The operator also must comply with all

such codes, standards and regulations.

• Installation, operation, servicing and repair of this

(and related) equipment must always comply with

applicable codes, standards, laws and regulations.

Adhere strictly to local, state and national electrical

and building codes. Comply with regulations the

Occupational Safety and Health Administration

(OSHA) has established. Also, ensure that the gener-

ator is installed, operated and serviced in accordance

with the manufacturer’s instructions and recommen-

dations. Following installation, do nothing that might

render the unit unsafe or in noncompliance with the

aforementioned codes, standards, laws and regula-

tions.

• The engine exhaust fumes contain carbon monoxide

gas, which can be DEADLY. This dangerous gas, if

breathed in sufficient concentrations, can cause

unconsciousness or even death. For that reason, ade-

quate ventilation must be provided. Exhaust gases

must be piped safely away from any building or

enclosure that houses the generator to an area where

people, animals, etc., will not be harmed. This

exhaust system must be installed properly, in strict

compliance with applicable codes and standards.

• Keep hands, feet, clothing, etc., away from drive belts,

fans, and other moving or hot parts. Never remove

any drive belt or fan guard while the unit is operating.

• Adequate, unobstructed flow of cooling and ventilat-

ing air is critical to prevent buildup of explosive gases

and to ensure correct generator operation. Do not

alter the installation or permit even partial blockage

of ventilation provisions, as this can seriously affect

safe operation of the generator.

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 genera-

tor can operate safely, efficiently and reliably only if it is

properly installed, operated and maintained. Many acci-

dents are caused by failing to follow simple and funda-

mental rules or precautions.

Generac cannot anticipate every possible circumstance

that might involve a hazard. The warnings in this man-

ual, and on tags and decals affixed to the unit are, there-

fore, not all-inclusive. If using a procedure, work

method or operating technique that Generac does not

specifically recommend, ensure that it is safe for others.

Also make sure the procedure, work method or operat-

ing technique utilized does not render the generator

unsafe.

DANGER

Despite the safe design of this generator,

operating this equipment imprudently, neglecting

its maintenance or being careless can cause

possible injury or death. Permit only responsible

and capable persons to install, operate or main-

tain this equipment.

Potentially lethal voltages are generated by these

machines. Ensure all steps are taken to render the

machine safe before attempting to work on the

generator.

• 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.

Parts of the generator are rotating and/or hot

during operation. Exercise care near running gen-

erators.

Generac Power Systems, Inc.

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IMPORTANT SAFETY INSTRUCTIONS

Guardian Liquid-cooled 27 kW and 30 kW Generators

• Inspect the generator regularly, and promptly repair • Generators installed with an automatic transfer

or replace all worn, damaged or defective parts using

switch will crank and start automatically when NOR-

MAL (UTILITY) source voltage is removed or is below

an acceptable preset level. To prevent such automat-

ic start-up and possible injury to personnel, disable

the generator’s automatic start circuit (battery cables,

etc.) before working on or around the unit. Then,

place a “Do Not Operate” tag on the generator control

panel and on the transfer switch.

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.

• In case of accident caused by electric shock, immedi-

ately 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.

ELECTRICAL HAZARDS

• All generators covered by this manual produce dan-

gerous electrical voltages and can cause fatal electrical

shock. Utility power delivers extremely high and dan-

gerous voltages to the transfer switch as well as the

standby generator. Avoid contact with bare wires, ter-

minals, connections, etc., on the generator as well as

the transfer switch, if applicable. Ensure all appropri-

ate covers, guards and barriers are in place before

operating the generator. If work must be done around

an operating unit, stand on an insulated, dry surface

to reduce shock hazard.

• Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or

feet are wet. DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

• If people must stand on metal or concrete while

installing, operating, servicing, adjusting or repairing

this equipment, place insulative mats over a dry

wooden platform. Work on the equipment only while

standing on such insulative mats.

FIRE HAZARDS

• Keep a fire extinguisher near the generator at all

times. Do NOT use any carbon tetra-chloride type

extinguisher. Its fumes are toxic, and the liquid can

deteriorate wiring insulation. Keep the extinguisher

properly charged and be familiar with its use. If there

are any questions pertaining to fire extinguishers,

consult the local fire department.

EXPLOSION HAZARDS

• 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 of a

transfer switch so as to isolate the generator electric

system from the electric utility distribution system

when the generator is operating. Failure to isolate the

two electric system power sources from each other by

such means will result in damage to the generator

and may also result in injury or death to utility power

workers due to backfeed of electrical energy.

• Properly ventilate any room or building housing the

generator to prevent build-up of explosive gas.

• Do not smoke around the generator. Wipe up any fuel

or oil spills immediately. Ensure that no combustible

materials are left in the generator compartment, or

on or near the generator, as FIRE or EXPLOSION

may result. Keep the area surrounding the generator

clean and free from debris.

• Generac generator sets may operate using one of sev-

eral types of fuels. All fuel types are potentially FLAM-

MABLE and/or EXPLOSIVE and should be handled

with care. Comply with all laws regulating the storage

and handling of fuels. Inspect the unit’s fuel system

frequently and correct any leaks immediately. Fuel

supply lines must be properly installed, purged and

leak tested according to applicable fuel-gas codes

before placing this equipment into service.

• Diesel fuels are highly FLAMMABLE. Gaseous fluids

such as natural gas and liquid propane (LP) gas are

extremely EXPLOSIVE. Natural gas is lighter than air,

and LP gas is heavier than air; install leak detectors

accordingly.

Generac Power Systems, Inc.

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Section 1 - General Information

Guardian Liquid-cooled 27 kW and 30 kW Generators

1.1 GENERATOR

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.

This equipment is a liquid-cooled, engine-driven gen-

erator set. The generator is designed to supply elec-

trical power that operates critical electrical loads

during utility power failure. The unit has been facto-

ry-installed in a weather resistant, all metal enclosure

and is intended for outdoor installation only. Use this

generator as a source of electrical power for the oper-

ation of 120 and/or 240VAC, single-phase loads.

When UTILITY source voltage has been restored, the

switch re-transfers back to the UTILITY source volt-

age and the generator then shuts down.

If this generator is used to power electrical load

circuits normally powered by a UTILITY power

Please reference the transfer switch manual for spe-

cific information.

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.

1.4 GENERATOR AC CONNECTION

SYSTEMS

The generator was shipped from the factory with its

stator AC output leads connected in a single-phase,

three-wire generator AC connection system (Figure

1.1). The stator assembly in this system consists of a

pair of stationary windings, with two leads brought

out of each winding. Each single winding can supply

120VAC, 60 Hertz. When the two windings are con-

nected in series, a 240VAC, 60 Hertz AC output

results. Typically the two HOT leads in the circuit are

wires 11 and 44. The NEUTRAL leads are the junc-

tion of Wires 22 and 33. The NEUTRAL is not

grounded.

1.2 TRANSFER SWITCH

This generator system may include a matched auto-

matic transfer switch which is intended to be used in

conjunction with the Generac generator. It is supplied

in either a NEMA 1 enclosure or a NEMA 3R enclo-

sure. The NEMA 1 enclosure is intended for indoor

use only. The NEMA 3R enclosure is weather proof

and can be used indoors or outdoors. Follow these

rules:

Figure 1.1 - Generator AC Connection System

• Install the transfer switch on a firm, sturdy sup-

porting structure.

• To prevent switch distortion, level the switch if nec-

essary. This can be done by placing washers

between the switch enclosure and the mounting

surface.

• Never install the switch where water or any corro-

sive substance might drip onto the enclosure.

• Protect the switch at all times against excessive

moisture, dust, dirt, lint, construction grit and cor-

rosive vapors.

If a transfer switch is not included, one may be pur-

chased separately from a Generac Authorized Dealer.

1.5 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

004948-0

Rating

27,000 NG

30,000 LP

Phase

Actual Current

112.5

C/B Rating*

Circuit Breaker

150A QN2

150

125.0

150A QN2

* Amp Rating of C/B structured under model.

Generac Power Systems, Inc.

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Section 1 - General Information

Guardian Liquid-cooled 27 kW and 30 kW Generators

Figure 1.4 - Low Oil Pressure Switch

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.

The Low Oil Pressure, High Coolant Temperature

and Low Coolant Level are not monitored for the

first 10 seconds of engine run time.

1.7.2 HIGH COOLANT TEMPERATURE

SWITCH

‹

Gaseous fuels such as natural and LP (propane)

gas are highly explosive. Even the slightest

spark can ignite such fuels and cause an explo-

sion. No leakage of fuel is permitted. Natural

gas, which is lighter than air, tends to collect in

high areas. LP gas is heavier than air and tends

to settle in low areas.

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).

1.7 ENGINE PROTECTIVE DEVICES

The engine has several safety switches which cause

the engine to automatically shut down under the fol-

lowing conditions: low oil pressure, high coolant tem-

perature, engine overspeed, low coolant level or over-

crank (Figure 1.3).

Figure 1.5- High Coolant Temperature Switch

Figure 1.3 - Engine Protective Devices

LOW COOLANT

LEVEL SWITCH

LOW OIL

PRESURE

SWITCH

1.7.3 LOW COOLANT LEVEL SWITCH

‹

HIGH

COOLANT

TEMPERATURE

SWITCH

Should engine coolant level drop below the level of

the high coolant temperature switch, it is possible for

the engine to overheat without automatic shutdown.

To prevent such overheating without automatic shut

down, the engine has a low coolant level sensor. If the

engine coolant drops too low, the engine automatical-

ly shuts down and turns on the high coolant temper-

ature/low coolant level LED (Figure 1.6 on page 6).

1.7.1 LOW OIL PRESSURE SWITCH

‹

This switch is normally-closed (N.C.) but is held open

by engine oil pressure during engine running. Should

operating oil pressure drop below about 8-10 psi

(55-68 kPa), the switch contacts close, the engine

shuts down automatically, and the low oil pressure

LED is turned ON (Figure 1.4).

Generac Power Systems, Inc.

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Section 1 — General Information

Guardian Liquid-cooled 27 kW and 30 kW Generators

Figure 1.6 - Low Coolant Level Sensor

1.7.7 LOW BATTERY

‹

The engine control board continually monitors the

battery voltage and turns on the low battery LED if

the battery voltage falls below 11.0 VDC for one

minute. Low battery voltage is a non-latching alarm,

which will automatically clear if the battery voltage

rises above 11.0 VDC.

The control system will not attempt to start the

engine if there is a low battery condition, however, if

the engine is already running when the low battery

condition occurs, the engine will continue to run as

long as possible.

Battery voltage is NOT monitored during the crank

cycle.

1.7.4 OVERSPEED SHUTDOWN

‹

1.7.8 ALARM RESET

‹

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).

If the engine control board shuts down the generator

for any of the above reasons, the engine remains

stopped until the alarm is cleared by placing the

AUTO/OFF/MANUAL switch into the OFF position.

1.7.9 DC FUSES

‹

These fuses are located on the front panel of the con-

trol system. They protect the panel wiring and com-

ponents from damaging overload. Always remove the

15 amp main fuse before working on the generator.

The unit will not start or crank if this fuse is blown.

Replace the fuse with one of the same size, type, and

rating (main AGC-15, battery charger AG4).

Figure 1.7 - Printed Circuit Board Assembly

R44

LED1

C27

C26

D10

C21

1.8 UNPACKING

C30

1.8.1 UNPACKING PRECAUTIONS

‹

RL1

RL2

R48

D17

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.

R49

D19

R E V 9 0 . 6 E 0 4 B #

1.8.2 INSPECTION

‹

1.7.5 RPM SENSOR LOSS

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.

If the engine control board does not receive a proper

rpm signal from the starter during cranking or run-

ning, it shuts down the engine on rpm sensor loss

and flash the overspeed LED.

1.7.6 OVERCRANK SHUTDOWN

‹

The engine control board uses a cyclic cranking

process when attempting to start the engine. The first

crank cycle is a 15-second crank followed by a seven-

second rest. This is followed by five more crank

cycles each with a seven-second crank followed by a

seven-second rest.

1.9 LIFTING THE GENERATOR

When lifting or hoisting equipment is used, be

careful not to touch overhead power lines. The

generators weight of more than 900 pounds

requires proper tools, equipment, and qualified

personnel to be used in all phases of handling

and unpacking.

If the engine fails to start after all six attempts, the

start attempt is stopped and the overcrank LED’s

illuminated.

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Section 1 — General Information

Guardian Liquid-cooled 27 kW and 30 kW Generators

Fuel pressure for a natural gas set up should be five

1.10 SPECIFICATIONS

inches to 14 inches of water column (0.18 to 0.5

psi) at all load ranges.

1.10.1 GENERATOR SPECIFICATIONS

‹

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.

Single-phase

Model

4988-1

Rated Max. Cont.

27 (NG), 30 (LP)

1.12 RECONFIGURING THE FUEL

AC Power Output (kW)

Rated voltage (volts)

No. of Rotor Poles

Driven Speed of Rotor

Rotor Excitation System

Type of Stator

SYSTEM

120/240

1800

NOTE:

All models are configured for natural gas from the

factory.

Direct excited brush type

4 Wire

To reconfigure the fuel system from NG to LP vapor,

follow these steps:

Rotor/Stator Insulation

Class F/H

1. Turn the main gas supply off.

1.10.2 ENGINE SPECIFICATIONS

‹

2. Remove the carburetor fuel hose from the outlet

port (Port 1) of the demand regulator (Figure

1.8).

Make........................................................................................................Ford

Displacement ....................................................................................3.0 liters

Cylinder Arrangement ..............................................................................V-6

Valve Arrangement................................................................Overhead Valve

Firing Order ..................................................................................1-4-2-5-3-6

Number of Main Bearings ............................................................................4

Compression Ratio ............................................................................9.3 to 1

No. of Teeth on Flywheel ..........................................................................164

Ignition Timing at 1800 rpm ..............................................30 degrees BTDC

Spark Plug Gap ..................................................................0.035-0.045 inch

Recommended Spark Plugs

Motor Craft ..........................................................................AG, SF 32PGM

Oil Pressure ....................................................................................40-50 psi

Crankcase Oil Capacity ........................................5.0 U.S. quarts (4.7 liters)

Recommended Engine Oil ..........................................................SAE 5W-20

Type of Cooling System ..................................Pressurized, closed recovery

Cooling Fan ................................................................................Pusher Type

Cooling System Capacity ..................................3.0 U.S. gallons (11.4 liters)

3. Remove the brass hose fitting from the outlet port

(Port 1) of the demand regulator.

4. Remove pipe plug from Port 2.

5. Install brass hose fitting into Port 2.

6. Install pipe plug into Port 1.

7. Connect carburetor gas hose to brass fitting.

8. Tighten all clamps and plugs.

9. Make sure fuel supply is of the proper pressure

and type for configuration.

10. Reverse the procedure to convert back to natural

gas.

Figure 1.8 — Reconfigure the Fuel System

Port 1

Port 2

FUEL HOSE

BRASS HOSE

FITTING

BRASS HOSE

FITTING

Recommended Coolant ............................................Use a 50-50 mixture of

PLUG

OUT

PORT 1

OUT

PORT 2

ethylene glycol base

and de-ionized water.

HOUSING

PORTS

HOUSING

PORTS

1.11 FUEL CONSUMPTION

Natural Gas:

% of Load

25%

3.1

50%

5.9

75%

8.5

100%

11.0

m /hr

ft /hr

110.3

209.0

299.5

387.0

LP Vapor:

% of Load

NG FUEL SYSTEM

LP FUEL SYSTEM

25%

1.3

50%

2.4

75%

3.5

100%

4.5

m /hr

NOTE:

ft /hr

45.6

86.4

123.8

160.0

Port 1 is for NG only and Port 2 is for LP vapor

only. No provision for dual fuel has been made.

NOTE:

Fuel consumption is given at rated maximum con-

tinuous power output when using natural gas rated

at 1000 Btu per cubic foot. LP gas is rated at 2520

Btu per cubic foot. Actual fuel consumption

obtained may vary depending on such variables as

applied load, ambient temperature, engine condi-

tions and other environmental factors.

DANGER

Serious injury or damage may occur if not con-

figured properly. Please consult an authorized

Generac Service Dealer with any questions.

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Section 2 — Installation

Guardian Liquid-cooled 27 kW and 30 kW Generators

The generator’s rated wattage/amperage capacity

1.13 TORQUE SPECIFICATIONS

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.

Cylinder Head ............................................15 (+ 90° + 90°) ft.lb.

Intake Manifold ................................................................13 ft.lb.

Exhaust Manifold..............................................................13 ft.lb.

This generator can be installed in conjunction with

an engineered Generac “GTS” type transfer switch, if

necessary.

1.14 ENGINE OIL RECOMMENDATIONS

The unit has been filled with 5W-20 engine oil at the

factory. Use a high-quality detergent oil classified “For

Service CC, SD, SE, SF.” Detergent oils keep the engine

cleaner and reduce carbon deposits. Use oil having the

following SAE viscosity rating, based on the ambient

temperature range anticipated before the next oil

change:

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.

Temperature

Above 80° F (27° C)

32° to 80° F (-1° to 27° C)

Below 32° F (0° C)

Oil Grade (Recommended)

SAE 5W-20

2.1 STANDBY GENERATOR

INSTALLATION

SAE 5W-20

DANGER

NOTE:

Connecting this generator to an electrical sys-

tem normally supplied by an electric utility

shall be by means of a transfer switch, so as to

isolate the electric system from the utility distri-

bution system when the generator is operating.

Failure to isolate the electric system by these

means will result in damage to the generator

and may also result in injury or death to utility

workers due to backfeed of electrical energy.

Synthetic oil is highly recommended in any element

with temperatures above 90° F or below 30° F.

Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.

If an open bottom is used, the engine-genera-

tor is to be installed over non-combustible

materials and should be located such that com-

bustible materials are not capable of accumu-

lating under the generator set.

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.

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.

Do not use any chromate base rust inhibitor

with ethylene glycol base anti-freeze or chromi-

umhydroxide (“green slime”) forms and will

cause overheating. Engines that have been

operated with a chromate base rust inhibitor

must be chemically cleaned before adding eth-

ylene glycol base anti-freeze. Using any high

silicate anti-freeze boosters or additives will

also cause overheating. It is also recommend

that any soluble oil inhibitor is NOT USED for

this equipment.

After the system has been installed, do nothing

that might render the installation in noncompli-

ance with such codes, standards and regula-

tions.

2.1.1 NFPA STANDARDS

‹

The following published standards booklets pertain-

ing to standby electric systems are available form the

National Fire Protection Association (NFPA),

Batterymarch Park, Quincy, MA 02269:

1.16 BEFORE INSTALLATION

• NFPA No. 37, STATIONARY COMBUSTION

ENGINES AND GAS TURBINES.

Before installing this equipment, check the ratings of

both the generator and the transfer switch. Read

“Emergency Isolation Method” and “Total Circuit

Isolation Method” in Sections 2.6 and 2.6.

• NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-

TEMS FOR HEALTH CARE FACILITIES.

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Section 2 — Installation

Guardian Liquid-cooled 27 kW and 30 kW Generators

• NFPA No. 220, STANDARD TYPES OF BUILDING

2.3 GENERATOR MOUNTING AND

CONSTRUCTION

SUPPORT

• NFPA No. 68, GUIDE FOR EXPLOSION VENTING

• NFPA No. 70, NATIONAL ELECTRICAL CODE.

• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE

LIQUIDS CODE.

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.

• NFPA No. 10, INSTALLATION, MAINTENANCE AND

USE OF PORTABLE FIRE EXTINGUISHERS.

2.1.2 OTHER PUBLISHED STANDARDS

‹

In addition to NFPA standards, the following infor-

mation pertaining to the installation and use of

standby electric systems is available:

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:

• Article X, NATIONAL BUILDING CODE, available

from the American Insurance Association, 85 John

Street, New York, N.Y. 10038.

• AGRICULTURAL WIRING HANDBOOK, obtainable

from the Food and Energy Council, 909 University

Avenue, Columbia, MO, 65201.

• ASAE EP-364.2, INSTALLATION AND MAINTE-

NANCE OF FARM STANDBY ELECTRIC POWER,

available from the American Society of Agricultural

Engineers, 2950 Niles Road, St. Joseph, MI 49085.

• A52.1, AMERICAN NATIONAL STANDARD FOR

CHIMNEYS, FIREPLACES AND VENTING SYS-

TEMS, available from the American National

Standard Institute, 1430 Broadway, New York, N.Y.

10018.

• Allows the LOAD circuits to be connected to only

one power supply at a time.

• Prevents electrical backfeed between the generator

and the UTILITY power circuits.

Notice that both the STANDBY and the UTILITY

power supplies to the transfer switch are protected

against overload by a main line circuit breaker.

Figure 2.1 – Basic Standby Electric System

2.2 GENERATOR LOCATION

Install the generator set, in its protective enclosure

outdoors, where adequate cooling and ventilating air

always is available. Consider these factors:

• Install the unit where air inlet and outlet openings

will not become obstructed by leaves, grass, snow,

etc. If prevailing winds will cause blowing or drift-

ing, consider using a windbreak to protect the unit.

• Install the generator on high ground where water

levels will not rise and endanger it.

• This genset must be installed on a level surface.

The base frame must be level within 1/2 inch all

around.

• Allow sufficient room on all sides of the generator

for maintenance and servicing. A good rule is to

allow five feet of space on all sides.

• Where strong prevailing winds blow from one

direction, face the generator air inlet openings into

the prevailing winds.

• Install the generator as close as possible to the

transfer switch. This reduces the length of wiring

and conduit.

2.5 EMERGENCY CIRCUIT ISOLATION

METHOD

This prevents overloading the generator by keeping

electrical loads below the wattage/amperage capacity

of the generator. If the generator is powering only crit-

ical loads, within the wattage/amperage capacity, dur-

ing utility power outages, consider using the emer-

gency circuit isolation method.

Critical electrical loads are grouped together and

wired into a separate “Emergency Distribution

Panel.” Load circuits powered by that panel are with-

in the wattage/amperage capacity of the generator set.

When this method is used, it is difficult to overload

the generator. The transfer switch must meet the fol-

• Install the generator as close as possible to the fuel

supply, to reduce the length of piping. HOWEVER,

REMEMBER THAT LAWS OR CODES MAY REG-

ULATE THE DISTANCE.

lowing requirements:

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Section 2 — Installation

Guardian Liquid-cooled 27 kW and 30 kW Generators

• It must have an ampere rating equal to the total

2.8 GENERATOR AC NEUTRAL

amperage rating of the emergency distribution

panel circuit.

CONNECTIONS

Generac uses an UNGROUNDED AC neutral.

Grounding is recommended only at the main service

entrance. If the neutral wire is grounded and one of

the phase loads becomes grounded, the excessive

current opens the load circuit breaker or collapses

the generator field. The actual result depends on the

electrical characteristics of the particular installed

generator.

• Have it installed between the building’s main dis-

tribution panel and the emergency distribution

panel.

2.6 TOTAL CIRCUIT ISOLATION

METHOD

When a generator capable of powering all electrical

loads in the circuit is to be installed, use the “Total

Circuit Isolation Method.” It is possible for the gener-

ator to be overloaded when this isolation method is

employed. The following apply to the transfer switch

in this type of system.

2.9 TRANSFER SWITCH SIGNAL

CONNECTIONS

‹

• Ampere rating of the transfer switch must equal

the ampere rating of the normal incoming utility

service.

• The transfer switch is installed between the utility

service entrance and the building distribution

panel.

2.9.1 PRE-PACKAGED ATS

If the generator is to be installed with a pre-packaged

transfer switch, it is necessary to connect the control

wires to the generator and set position two of the

four-position dip switch to OFF.

Setting switch two to OFF allows the control PCB to

perform the ATS control functions.

2.7 GROUNDING THE GENERATOR

The National Electrical Code requires the frame and

external electrically conductive parts of this equip-

ment to be properly connected to an approved earth

ground and/or grounding rods. For that purpose, a

GROUND LUG (Figure 2.2) is provided on the gener-

ator mounting base. Consult a qualified electrician

for grounding requirements in the area. Grounding

procedures must meet local regulations.

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

460 feet (140m)

No. 18 AWG.

No. 16 AWG.

No. 14 AWG.

No. 12 AWG.

Figure 2.2 – Generator Grounding Lug (typical)

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 Generac GTS-

type switch, it is necessary to connect the two-wire

start control system.

GROUNDING

LUG

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.)

DANGER

Do not connect the ground wire to any pipe

that carries a flammable or explosive substance

– FIRE or an EXPLOSION may result.

Proper grounding helps protect personnel against

electrical shock in the event of a ground fault condi-

tion in the generator or in connected electrical

devices. In addition, grounding helps dissipate static

electricity that often builds up in ungrounded

devices.

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Section 2 — Installation

Guardian Liquid-cooled 27 kW and 30 kW Generators

When using maintenance-free batteries, it is not nec-

2.10 BATTERY INSTALLATION

DANGER

essary to check the specific gravity or electrolyte level.

Have these procedures performed at the intervals

specified in Section 4, “Maintenance.” A negative

ground system is used. Battery connections are

shown on the wiring diagrams. Make sure all batter-

ies are correctly connected and terminals are tight.

Observe battery polarity when connecting batteries to

the generator set.

Standby generators installed with automatic

transfer switches will crank and start automati-

cally when NORMAL (UTILITY) source voltage is

removed or is below an acceptable preset level.

To prevent such automatic start-up and possible

injury to personnel, do not connect battery

cables until certain that normal source voltage

at the transfer switch is correct and the system

is ready to be placed into operation.

NOTE:

Damage will result if the battery connections are

made in reverse.

Storage batteries give off explosive hydrogen

gas. This gas can form an explosive mixture

around the battery for several hours after

charging. The slightest spark can ignite the gas

and cause an explosion. Such an explosion can

shatter the battery and cause blindness or

other injury. Any area that houses a storage

battery must be properly ventilated. Do not

allow smoking, open flame, sparks or any spark

producing tools or equipment near the battery.

2.11 PREPARATION BEFORE START-UP

The instructions in this section assume that the

standby generator has been properly installed, serv-

iced, tested, adjusted and otherwise prepared for use

by a competent, qualified installation contractor. Be

sure to read the “Safety Rules” on Pages 2 and 3, as

well as all other safety information in this manual,

before attempting to operate this (and related) equip-

ment.

Battery electrolyte fluid is an extremely caustic

sulfuric acid solution that can cause severe

2.11.1 PRIOR TO INITIAL START-UP

‹

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.

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.

Spilled electrolyte is to be washed down with

an acid neutralizing agent. A common practice

is to use a solution of one pound (500 grams)

bicarbonate of soda to one gallon (4 liters) of

water. The bicarbonate of soda solution is to be

added until the evidence of reaction (foaming)

has ceased. The resulting liquid is to be flushed

with water and the area dried.

Before starting the generator for the first time, the

installer must complete the following procedures. For

follow-up maintenance information and/or service

intervals, please refer to Section 4, “Maintenance.”

‹

2.11.2 TRANSFER SWITCH

If this generator is used to supply power to any elec-

trical system normally powered by an electric utility,

the National Electrical Code requires that a transfer

switch be installed. The transfer switch prevents elec-

trical backfeed between two different electrical sys-

tems (for additional information, see the applicable

transfer switch manual for this unit). The transfer

switch, as well as the generator and other standby

components, must be properly located and mounted

in strict compliance with applicable codes, standards

and regulations.

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 min-

imum capacity, or Group 27F, 12V negative ground

600 CCA/90 AH minimum capacity. All batteries

must be at 100 percent state-of-charge before they

are installed on the generator.

‹

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.

Generac Power Systems, Inc. 11

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Section 3 — Operation

Guardian Liquid-cooled 27 kW and 30 kW Generators

• The control board WILL monitor all engine condi-

‹

2.11.4 GENERATOR SET LUBRICATION

tions and shut down on all the faults listed in this

document.

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).

Pos2 OFF — ATS Application

• The control board will perform all of the automat-

ic features listed in this document.

• The two-wire start connections should NOT be used.

NOTE:

GTS Mode Operation

When in GTS mode, the control board will respond

as follows based on the AUTO/OFF/MANUAL switch

position.

This engine is shipped from the manufacturer

with 5W-20 oil. This oil should be changed after

30 hours of operation.

OFF — The generator will not start and run in this

‹

2.11.5 ENGINE COOLANT

position.

Have the engine cooling system properly filled with

the recommended coolant mixture. Check the system

for leaks and other problems. See “Specifications”

(Section 1.10) and “Coolant” (Section 1.15).

MANUAL — The control board will start and run the

generator whenever the switch is in the manual posi-

tion.

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.

‹

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).

NOTE:

If the generator is installed in conjunction with a

standard GTS type transfer switch, refer to the

applicable transfer switch manual for exact oper-

ating parameters and timing sequences.

‹

2.11.7 ELECTRICAL SYSTEM

Make sure the generator is properly connected to an

approved earth ground and/or ground rod.

3.2 CONTROL CONSOLE

COMPONENTS

Make sure the generator battery is fully charged, prop-

erly installed and interconnected, and ready for use.

The components of a home standby generator control

console (Figure 3.1) are as follows:

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.

3.2.1 AUTO/OFF/MANUAL SWITCH

‹

Use this three-position switch as follows:

• Set the switch to AUTO for fully automatic opera-

tion. See “Automatic Operation” (Section 3.5).

• Set switch to MANUAL position to crank and start

the generator engine.

• Set switch to OFF position to shut down an oper-

ating engine. With OFF selected, operation will not

be possible.

3.1 USING A STANDARD “GTS”

TRANSFER SWITCH

When required, the pre-packaged standby generator

can be installed with a standard Generac “GTS” type

automatic transfer switch.

In this application, the GTS is responsible for utility

sensing, weekly exercising, and load transferring.

DANGER

Position two of the four-position dip switch is used to

turn over this control to the GTS.

With switch set to AUTO, engine can crank and

start suddenly without warning. Such automat-

Pos2 ON — GTS Application

ic start up normally occurs when utility source

voltage drops below a pre-set level. To prevent

possible injury that might be caused by such

sudden starts, set AUTO/OFF/MANUAL switch

to OFF before working on or around the unit.

Then, place a “DO NOT OPERATE” tag on con-

trol console.

• The control board will NOT monitor utility.

• The control board will NOT perform a weekly exer-

cise. (The five red LEDs will not flash in this

mode.)

• The control board will NOT activate the transfer

output.

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Section 3 - Operation

Guardian Liquid-cooled 27 kW and 30 kW Generators

Figure 3.1 - Home Standby Generator Panel

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.

LED INDICATORS:

FLASHING GREEN LED

NO UTILITY SENSE

EXERCISER NOT SET

FLASHING RED LED'S

(IN AUTO MODE ONLY) SOLID GREEN LED

RED LED'S INDIVIDUAL FAULT

SYSTEM READY, UTILITY POWER ON

(SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS)

OVER CRANK

RED LED

AUTO

OFF

The system ready LED will be OFF when the switch

is in the MANUAL or OFF positions.

SET

EXECISER

TIME

SET

EXERCISE

TIME

MANUAL

GREEN LED

TO SET EXERCISER TIME

1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.

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.

0E7194

SWITCH

AUTO/OFF/MANUAL

SWITCH

4A FUSE

BATTERY

CHARGER

15A FUSE

This secondary function is only available with dip

switch two in the OFF position (standard ATS appli-

cation).

MAIN

POWER

3.2.2 FAULT INDICATOR LED

This LED goes ON when one or more of the following

engine faults occurs and when engine shuts down.

‹

3.3 MANUAL TRANSFER AND

START-UP

To transfer electrical loads to the Standby (EMER-

GENCY) power source side and start the engine man-

ually, refer to the Owner’s Manual of the particular

transfer switch.

• Low Oil Pressure

• Overcrank

• Low Battery

• Overspeed/RPM Sensor Loss

• High Coolant Temperature/Low Coolant Level

See Section 1.7 for further explanation of engine pro-

tection functions.

3.4 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 governor

has been set by the factory during final testing of the

generator and, in most cases, should not be adjusted.

3.2.3 15 AMP FUSE

‹

Fuse protects the control console’s DC control circuit

against electrical overload. If the fuse has melted

open because of an overload, engine cranking and

startup cannot occur. If the fuse needs to be replaced,

use only an identical 15-amp replacement fuse. (Type

AGC)

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.

3.2.4 4.0 AMP INLINE FUSE

‹

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).

This fuse protects the battery charger against electri-

cal overload. If the fuse needs to be replaced, use only

an identical 4 amp replacement fuse (type AG).

NOTE:

This fuse will not remove the + battery input

power from the PCB when it opens. This means

the exercise timer will not be reset.

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.

3.2.5 SET EXERCISE TIME SWITCH

This switch allows programming the generator to

start and exercise automatically. “See Weekly

Exercise Cycle.”

‹

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Section 3 — Operation

Guardian Liquid-cooled 27 kW and 30 kW Generators

6. Adjust differential pot to make the recovery to

• Set the AUTO/OFF/MANUAL switch to its AUTO

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.

position.

• Set the generator main circuit breaker to its ON or

CLOSED position.

3.7 WEEKLY EXERCISE CYCLE

The engine control board will start and run the gen-

erator once every seven days for approximately 12

minutes. If utility should fail during this exercise

period, the engine control board will transfer the load

to the generator output and continue to run until util-

ity returns.

Figure 3.2 — Engine Governor Adjustment

R44

LED1

C27

C26

On the day, and at the time of day chosen for the gen-

erator to exercise, set the weekly exercise cycle as fol-

lows:

D10

C21

1. Place the AUTO/OFF/MANUAL switch in the

AUTO position.

C30

2. Press and hold the “Set Exercise” switch for three

seconds, then release.

RL1

RL2

R48

D17

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.

R49

D19

If DC power to the control board is lost, the weekly

exercise setting will be lost. This is indicated by all

five red LEDs continually flashing. In this state the

generator will still start and run in manual mode, or

automatically start and run if UTILITY is lost while in

Auto mode, but it will not perform a weekly exercise

cycle.

DIP SWITCH

DIFFERENTIAL

STABILITY

POSITION 1

50/60 HZ

POSITION 2

GTS/ATS Select

ON = GTS

UNUSED

ON = 50 HZ

GTS/ATS

OFF = ATS (standard mode)

OFF = 60 HZ

50/60 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 follows:

• 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).

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.

• Set the generator’s main circuit breaker to its OFF

or OPEN position.

Figure 3.2 - “Set Exercise” Switch

• Let the generator engine run at no-load for a few

minutes, to stabilize internal unit temperatures.

• On the generator console, set the AUTO/OFF/

MANUAL switch to OFF. Wait for engine to come to

a complete stop.

• For transfer to UTILITY position, refer to the

Owner’s Manual of the particular transfer switch.

• Turn on the UTILITY power supply to the transfer

switch, using whatever means provided (such as a

utility main line circuit breaker). The utility power

source now powers the loads.

FUSE

BAT.

CHARGER

15A

MAIN

AUTO

OFF

3.6 AUTOMATIC OPERATION

To set the system for fully automatic operation, pro-

ceed as follows:

SET

EXERCISE

TIME

MANUAL

• Check that load circuits are connected to the

utility power supply.

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Section 4 — Maintenance

Guardian Liquid-cooled 27 kW and 30 kW Generators

4.1 MAINTENANCE PERFORMED BY

AUTHORIZED SERVICE FACILITIES

4.3 OVERLOAD PROTECTION FOR

ENGINE DC ELECTRICAL SYSTEM

Engine cranking, start up and running are controlled

by a solid state Engine Controller circuit board.

Battery voltage is delivered to that circuit board via a

15 amp fuse. These overcurrent protection devices

will open if the circuit is overloaded.

A. EVERY THREE MONTHS

1. Check battery state of charge and condition.

2. Inspect and test fuel system.

3. Check transfer switch.

4. Inspect exhaust system.

5. Check engine ignition system.

6. Check fan belts.

If a circuit breaker opens or a fuse element

melts, find the cause of the overload before

resetting the circuit breaker or replacing the

fuse.

B. ONCE EVERY SIX MONTHS

1. Test Engine Safety Devices (low oil pressure, low

coolant level, high coolant temperature).

4.4 CHECKING FLUID LEVELS

C. ONCE ANNUALLY

1. Test engine governor. Adjust or repair, if needed.

2. Clean, inspect generator.

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.

‹

3. Flush cooling system.

• Remove oil dipstick and wipe dry with a clean,

lint-free cloth.

D. FIRST 100 OPERATING HOURS

• 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.

1. Change engine oil and oil filter. (After initial

change, service engine oil and filter at 150 oper-

ating hours or 6 months, whichever comes first.)

2. Retorque cylinder head. (See Torque Specs,

Section 1.13.)

3. Retorque intake and exhaust manifold. (See

Torque Specs, Section 1.13.)

Figure 4.1 - Oil Dipstick and Oil Fill Cap

E. EVERY 500 OPERATING HOURS

1. Service air cleaner.

2. Check starter.

3. Check engine DC alternator.

OIL

DIPSTICK

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.

OIL

FILL

Without sufficient cooling and ventilating air flow, the

engine/generator quickly overheats, which causes it

to shut down. (See Section 6 for installation drawings

and vent locations.)

The exhaust system parts from this product get

extremely 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.

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.

Generac Power Systems, Inc. 15

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Section 4 — Maintenance

Guardian Liquid-cooled 27 kW and 30 kW Generators

4.4.3 ENGINE COOLANT

4.5.8 CHECK FAN BELT

‹

Check coolant level in coolant recovery bottle. See

Specifications, Section 1.10.

• 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.

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap to make

sure the coolant recovery system is functioning

properly. Coolant should be at bottom of radiator

filler neck. If coolant level is low, inspect gasket in

radiator pressure cap. Replace cap, if necessary.

To have pressure cap tested, contact an authorized

Generac Service Dealer. Inspect cooling system

and coolant recovery system for leaks.

4.5.9 INSPECT ENGINE GOVERNOR

‹

Visually inspect electronic governor.

DANGER

Do not attempt to adjust the governor. Only

qualified service facilities should adjust the

4.5 MAINTENANCE OWNER/

OPERATOR CAN PERFORM

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

incorrect frequency and/or voltage. Only quali-

fied service technicians should adjust the gov-

erned speed.

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.

4.5.10 CHANGING ENGINE OIL

Refer to maintenance performed by authorized serv-

ice facilities for engine oil and filter change frequen-

cies.

‹

4.5.3 EXERCISE SYSTEM

‹

Start the generator engine at least once every seven

days and let it run at least 20 minutes. See Section

3.6, “Weekly Exercise Cycle”.

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:

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.

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.

4.5.5 CHECK ENGINE COOLANT LEVEL

‹

4. Turn OIL FILTER (Figure 4.2) counterclockwise

See “Checking Fluid Levels” in Section 4.4.

and remove. Dispose of old filter.

5. Apply light coating of new engine oil to seal of new

oil filter. Install FILTER and tighten by hand only.

DO NOT OVERTIGHTEN.

6. Remove OIL FILL CAP. Add recommended oil (see

SPECIFICATIONS). DO NOT FILL ABOVE THE

DIPSTICK “FULL” MARK. Crankcase oil capacity

is 4.0 U.S. quarts (3.8 liters).

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.

After refilling the crankcase with oil, always

check oil level on dipstick. NEVER OPERATE

ENGINE WITH OIL BELOW THE DIPSTICK “ADD”

MARK.

16 Generac Power Systems, Inc.

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Section 4 — Maintenance

Guardian Liquid-cooled 27 kW and 30 kW Generators

7. Start engine and check for oil leaks.

3. Check the spark plug gap using a wire feeler

gauge. Adjust the gap to 0.5-0.6 mm (0.020-0.025

inch) by carefully bending the ground electrode

(Figure 4.4).

Figure 4.2 - Oil Filter

Figure 4.4 – Setting the Spark Plug Gap

SET PLUG GAP AT 0.5-0.6 mm

(0.020-0.025 inch)

OIL FILTER

4.5.11 CHANGING THE ENGINE AIR CLEANER

‹

4.5.13 COOLANT CHANGE

‹

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).

Every year, have Authorized Service Facility drain,

flush and refill the cooling system. See SPECIFICA-

TIONS (Section 1.10) for cooling system recommen-

dations.

Figure 4.3 – Engine Air Cleaner

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 deal-

er will use dry, low pressure air to clean internal

windings. Parts inside the control console should be

cleaned and inspected at this time as well.

See the “Service Schedule,” Section 6, for air cleaner

maintenance.

4.5.12 SPARK PLUGS

‹

Finally, have the insulation resistance of stator and

rotor windings checked. If insulation resistances are

excessively low, the generator may require drying.

Reset the spark plug gap or replace the spark plugs

as necessary. See Section 6.

1. Clean the area around the base of the spark plugs

to keep dirt and debris out of the engine. Clean by

scraping or washing using a wire brush and com-

mercial solvent. Do not blast the spark plugs to

clean.

2. Remove the spark plugs and check the condition.

Replace the spark plugs if worn or if reuse is

questionable. See the “Service Schedule,” Section

6, for recommended inspection.

4.6.2 BATTERY

‹

All lead-acid storage batteries discharge when not in

use. Refer to specific instructions and warnings that

accompany the battery. If such information is not

available, observe the following precautions when

handling a battery:

• DO NOT use jumper cables and a booster battery

to crank or start the generator engine.

Generac Power Systems, Inc. 17

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Section 4 — Maintenance

Guardian Liquid-cooled 27 kW and 30 kW Generators

• DO NOT recharge a weak battery while it is

Spilled electrolyte is to be washed down with

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.

an acid neutralizing agent. A common practice

is to use a solution of one pound (500 grams)

bicarbonate of soda to one gallon (4 liters) of

water. The bicarbonate of soda solution is to be

added until the evidence of reaction (foaming)

has ceased. The resulting liquid is to be flushed

with water and the area dried.

Do not use any jumper cables or booster bat-

tery to crank and start the generator engine. If

the battery has completely discharged, remove

it from the generator for recharging.

• 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.

Be sure the AUTO/OFF/MANUAL switch is set to

the OFF position before connecting the battery

cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as

the battery cables are connected.

4.6.3 BATTERY MAINTENANCE

‹

The battery should be inspected per the “Service

Schedule,” Section 6. The following procedure

should be followed for inspection:

Be sure the UTILITY power supply is turned off,

or sparking may occur at the battery posts as

the cables are attached and cause an explosion.

1. Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries

and, if necessary, fill with DISTILLED WATER

ONLY. DO NOT USE TAP WATER IN BATTERIES.

3. Have the state of charge and condition checked.

This should be done with an automotive-type bat-

tery hydrometer.

4.6.4 BATTERY REPLACEMENT

When replacing batteries, use the same number and

the type of battery that follows:

‹

BCI Group No.

26/26R

CCA

525 @ 0 deg. F

600 @ 0 deg. F

NOTE:

DANGER

The BCI number should be located directly

on the battery.

Storage batteries give off explosive hydrogen

gas. This gas can form an explosive mixture

around the battery for several hours after

charging. The slightest spark can ignite the gas

and cause an explosion. Such an explosion can

shatter the battery and cause blindness or

other injury. Any area that houses a storage

battery must be properly ventilated. Do not

allow smoking, open flame, sparks or any spark

producing tools or equipment near the battery.

PERIODIC REPLACEMENT PARTS

Part Name

Generac’s Part Number

Oil Filter

# 0E7180

# 046627

# 0C8127

# 0E7079

Radiator Cap

Air Cleaner

Spark Plug

Battery electrolyte fluid is an extremely caustic

sulfuric acid solution that can cause severe

burns. Do not permit fluid to contact eyes, skin,

clothing, painted surfaces, etc. Wear protective

goggles, protective clothing and gloves when

handling a battery. If the fluid is spilled, flush

the affected area immediately with clear water.

18 Generac Power Systems, Inc.

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Section 4 — Maintenance

Guardian Liquid-cooled 27 kW and 30 kW Generators

4.7 SCHEDULED MAINTENANCE

Following is a recommended maintenance schedule for Generac small standby and residential generator sets. The

established intervals in the schedule are the maximum recommended when the unit is used in an average service

application. They will need to be decreased (performed more frequently) if the unit is used in a severe application.

Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to deter-

mine the next required maintenance interval.

Service Maintenance Interval Information:

The various service maintenance intervals are designated by interval numbers as follows:

1 An early inspection of the generator set to ensure it is ready to operate when required and to identify any poten-

tial problem areas.

Performed monthly or following each 10 hours of operation of the unit and requires approximately .5 man-

hours per unit to complete.

This inspection may be performed by the end user providing the following safety steps are taken to prevent

the engine from starting automatically without warning:

To prevent injury, perform the following steps in the order indicated before starting any maintenance:

•

Disable the generator set from starting and/or connecting to the load by setting the control panel

AUTO-OFF-MANUAL switch to the “OFF” position.

Remove the control panel fuse.

Turn off the battery charger.

Remove the negative battery cable.

•

The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condi-

tion from burning out sensitive control panel components and circuits.

Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal

operation when required.

2 A break-in service inspection of the generator set to ensure it is ready to operate and carry the load when

required, and to identify any potential problem areas.

Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of

the unit and requires approximately 2.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an authorized Generac Service Dealer.

3 An operational inspection of the generator set to ensure it is ready to operate and carry the load when required,

and to identify any potential problem areas.

Performed semi-annually or following each 50 hours of operation of the unit and requires approximately 1.5

man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an authorized Generac Service Dealer.

4 A mid-level inspection of the generator set to ensure it is ready to operate and carry the load when required,

and to identify any potential problem areas.

Performed annually or following each 100 hours of operation of the unit and requires approximately 4.0

man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an authorized Generac Service Dealer.

Generac Power Systems, Inc. 19

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Section 4 — Maintenance

Guardian Liquid-cooled 27 kW and 30 kW Generators

Maintenance

Tasks

Level 1

Recom-

mended

Level 2

Required

Level 3

Required

Level 4

Task

Comp.

Comp. to be done Comp. to be done Comp.

Required

to be done (Date-

3 months/

Break-in

30 hrs.

(Date-

Initials)

Semi-

annually/

50 hrs.

(Date-

Initials)

to be done (Date-

Annually/ Initials)

100 hrs.

monthly/

10 hrs.

Initials)

1. Disable the unit from

operating per the first page

warning.

2. Check the engine oil level.

Adjust as necessary.

3. Check the engine coolant

level. Adjust as necessary.

4. Check the engine coolant

thermal protection level.

Correct as necessary.

5. Check the natural gas

delivery system on gas

engine driven units.

Tighten connections as

necessary.

6. Check the air inlets and

outlets for debris. Clean as

necessary.

7. Check the battery

electrolyte level if

accessible. Adjust as

necessary.

8. Check the battery posts,

cables, and charger for

loose connections,

corrosion, and proper

operation. Correct as

necessary.

9. Check the unit wiring for

loose connections,

corrosion, and damage.

Correct as necessary.

10. Check the engine

accessory drive belts for

wear, weather cracking,

and damage. Replace as

necessary.

11. Visually inspect the unit

looking for leaks, wear or

damage, loose connections

or components, and

corrosion. Correct as

necessary.

12. Test the engine and

transfer switch safety

devices. Correct and/or

adjust as necessary.

20 Generac Power Systems, Inc.

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Section 4 — Maintenance

Guardian Liquid-cooled 27 kW and 30 kW Generators

Maintenance

Tasks

Level 1

Recom-

mended

Level 2

Required

Level 3

Required

Level 4

Task

Comp.

Comp. to be done Comp. to be done Comp.

Required

to be done (Date-

3 months/

Break-in

30 hrs.

(Date-

Initials)

Semi-

annually/

50 hrs.

(Date-

Initials)

to be done (Date-

Annually/ Initials)

100 hrs.

monthly/

10 hrs.

Initials)

13. Initiate an automatic start

and transfer of the unit to

site load and exercise it for

at least 1 hour looking for

leaks, loose connections

or components, and

abnormal operating

conditions. Correct as

necessary.

14. Start and exercise the unit

at full rated load (use a

load bank if the site load is

not enough) for at least 2

hours looking for leaks,

loose connections or

components, and abnormal

operating conditions.

Correct as necessary.

15. Change the engine oil.

16. Replace the engine oil

filter(s).

17. Replace the engine air

filter(s).

18. Replace the engine fuel

filter(s) on diesel engine

driven units and re-prime

the fuel system.

19. Check the engine spark

plugs on gas engine driven

units. Clean and re-gap or

replace as necessary.

20. Perform a 5 minute no-load

operational run of the unit

looking for any post service

problems.

21. Return the unit to standby

setup for operation when

required.

Generac Power Systems, Inc. 21

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Section 5 — Troubleshooting

Guardian Liquid-cooled 27 kW and 30 kW Generators

TROUBLESHOOTING POINTS

PROBLEM

CAUSE

CORRECTION

Engine won’t crank.

1. 15 amp fuse blown.

1. Replace fuse.

2. Loose or corroded or defective

battery cables.

2. Tighten, clean or replace

battery cables as necessary.

3. Defective starter contactor.

4. Defective starter motor.

5. Dead or Defective Battery.

6. 4 amp fuse blown.

3. Replace contactor.

4. Replace starter motor.

5. Remove, change or replace battery.

6. Replace fuse.

Engine cranks, but won't start

1. Out of fuel.

2. Fuel solenoid (FS) is defective

3. Open Wire #14 from Engine Control

circuit board.

1. Replenish fuel.

2. Replace solenoid.

3. Reconnect wire.

4. Spark plugs defective.

4. Clean, regap or replace plugs.

1. Clean or replace as needed.

Engine starts hard, runs rough.

Engine starts, then shuts down.

1. Flame arrestor (air cleaner) plugged or

damaged.

2. Plugged fuel line.

3. Defective spark plugs.

2. Unclog fuel line.

3. Clean, regap or replace plugs.

1. Engine oil level is low.

2. Engine is overheated.

3. Defective Low Oil Pressure Switch

4. Defective Coolant Temperature Switch

5. Defective Control Module circuit board.

6. Coolant Level is Low.

1. Check oil and add oil as needed.

2. Check cooling system for leaks.

3. Replace switch.

4. Replace switch.

5. Replace board.

6. Repair leak - Add coolant.

7. Replace Switch.

7. Defective Low Coolant Level Switch

AUTO/OFF/MANUAL Switch at,

OFF engine continues to run

1. Defective AUTO/OFF/MANUAL switch

1. Replace switch.

2. Reconnect/close wire.

2. Open/disconnected wire #15A between

AUTO/OFF/MANUAL switch and Control

Module circuit board.

3. Defective Control Module circuit board

3. Replace board.

No AC output from generator.

1. Check main line circuit breaker.

2. Check circuit breaker & fuses.

3. Transfer switch set to NORMAL position

4. Generator internal failure.

1. Reset to ON or CLOSED.

2. Reset and replace, if necessary.

3. Set to GENERATOR position.

4. Contact an Authorized Generac

facility.

5. Thermal circuit breaker open.

5. Auto-reset - Wait 5 min. and

attempt restart.

22 Generac Power Systems, Inc.

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Section 6 — Installation Diagram

Guardian Liquid-cooled 27 kW and 30 kW Generators

Installation Diagram — Drawing No. 0E8695

Generac Power Systems, Inc. 23

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Section 7 - Electrical Data

Guardian Liquid-cooled 27 kW and 30 kW Generators

Wiring Diagram — Engine — Drawing No. 0E6199-E

NOTE:

SIZE (AWG)

CB2

162

ALL WIRES ARE 18 AWG 300

VOLT UL LISTED UNLESS

OTHERWISE NOTED AS SHOWN:

162

AVR

TB1

225

224

TR2

225A

224A

13A

239

15A

TR1

178

BC1

RL1

13A

14A

15A

15E

224

225

239

CB1

STATOR

NEUTRAL

TRANSFER SWITCH

CUSTOMER CONNECTION

LEGEND {CONT.]:

LEGEND:

AVR -

BA -

F2 -

FUSE, B/C (4A AGC TYPE)

AUTOMATIC VOLTAGE REGULATOR

BRUSH ASSEMLY (GENERATOR)

BATTERY CHARGER

ICT -

INTERCONNECT. TERMINAL BLOCK

NEUTRAL BLOCK

NB -

RL1 -

SW1 -

SW2 -

TB1 -

TR1 -

TR2 -

B/C -

RELAY 1

BC1 -

CB1 -

CB2 -

D1 -

BULKHEAD CONNECTOR 1 (ENGINE)

CIRCUIT BREAKER (OUTPUT)

CIRCUIT BREAKER (EXCITATION)

DIODE [FIELD BOOST]

AUTO/OFF/MANUAL SWITCH

SET EXERCISER SWITCH

TERMINAL BLOCK 1

TRANSFORMER 1 (56 VA 240/16 VAC)

TRANSFORMER 2 (6 VA 240/16 VAC)

F1 -

FUSE, BAT. POWER (15A AGC TYPE)

24 Generac Power Systems, Inc.

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Section 7 - Electrical Data

Guardian Liquid-cooled 27 kW and 30 kW Generators

Wiring Diagram — Engine — Drawing No. 0E6199-E

NOTE:

ALL WIRES ARE 18 AWG 300

VOLT UL LISTED UNLESS

OTHERWISE NOTED AS SHOWN:

SIZE (AWG)

PCB J2

DEG

765

767

765

769

766

768

766

765

767

770

771

768

767

769

N/C

PCB J1

15A

BAT

GOV

224

771

767

765

770

N/C

766

239

15E

14A

225

449

GND1

14A

15A

15E

224

225

239

BLK

RED

HCT

WLS

LEGEND:

LEGEND [CONT.]:

ALT -

BAT -

C1 -

D.C. CHARGE ALTERNATOR

12VDC BATTERY

HCT -

IC -

HIGH COOLANT TEMP SWITCH

IGNITION COIL

CONNECTOR 1 (ENGINE)

STARTER CONTACTOR

DRIVER ELEC. GOVERNOR

FUEL SOLENOID

IM -

IGNITION MODULE (ON DISTRIBUTOR)

JUNCTION 1 (ON PCB)

CC -

J-1 -

DEG -

FS -

J-2 -

JUNCTION 2 (ON PCB)

JB -

JUNCTION BLOCK (RUN POWER)

LOW OIL PRESSURE SWITCH

STARTER MOTOR

GND1-

GND2-

GOV -

GROUND (SENSING/LOW AMP)

GROUND (POWER/HIGH AMP)

ELEC. GOVERNOR ACTUATOR

LOS -

SM -

WLS -

COOLANT LEVEL SWITCH

Generac Power Systems, Inc. 25

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Section 7 - Electrical Data

Guardian Liquid-cooled 27 kW and 30 kW Generators

Electrical Schematic — Engine — Drawing No. 0E6200-A

LEGEND:

AR -

AS -

ALTERNATOR ROTOR

LEGEND {CONT.]:

ALTERNATOR STATOR

F1 -

FUSE, BAT. POWER (15A AGC TYPE)

AVR -

BA -

AUTOMATIC VOLTAGE REGULATOR

BRUSH ASSEMLY (GENERATOR)

BATTERY CHARGER

F2 -

FUSE, B/C (4A AGC TYPE)

TERMINAL BLOCK, INTERCONNECT.

NEUTRAL BLOCK

ICT -

NB -

RL1 -

SW1 -

SW2 -

TR1 -

TR2 -

B/C -

BCW -

CB1 -

CB2 -

D1 -

BATTERY CAHRGE WINDING

CIRCUIT BREAKER (OUTPUT)

CIRCUIT BREAKER (EXCITATION)

DIODE [FIELD BOOST]

RELAY 1

SWITCH, AUTO/OFF/MANUAL

SWITCH, SET EXERCISER

TRANSFORMER 1 (56 VA 240/16 VAC)

TRANSFORMER 2 (6 VA 240/16 VAC)

DPE -

DISPLACED PHASE EXCITATION

RL1

14A

BCW

13A

2 3

AVR

224A

224

225

225A

162

CB2

DPE

14A

15A

15E

224

225

239

TR1

TR2

SW2

1a 2a

194

183

178

15A

178

CB1

239

ICT

194

SW1

IN OFF POSITION

SHOWN

183

178

CUSTOMER CONNECTION

120/240V 1-PHASE

TRANSFER SWITCH

CONNECTION

26 Generac Power Systems, Inc.

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Section 7 - Electrical Data

Guardian Liquid-cooled 27 kW and 30 kW Generators

Electrical Schematic — Engine — Drawing No. 0E6200-A

WLS

HCT

LOS

12V BATTERY

) +

(-)

RED

BLACK

ALT

PCB

J1-1

J1-2

J1-3

J1-4

J1-5

J1-6

J1-7

J1-8

J1-9

15A

449

224

5 6

J2-1

J2-2

J2-3

J2-4

J2-5

J2-6

J2-7

J2-8

767

765

769

766

768

239

15E

J1-10

J1-11

J1-12

J1-13

J1-14

14A

225

N/C

DEG

765

766

GOV

771

767

765

770

N/C

766

765

767

770

771

768

767

769

LEGEND:

ALT -

LEGEND [CONT.]:

14A

15A

15E

224

225

239

D.C. CHARGE ALTERNATOR

CONNECTOR 1 (ENGINE)

CRANKING CONTACTOR

DRIVER ELEC. GOVERNOR

SOLENOID FUEL

IC -

IGNITION COIL

C1 -

IM -

IGNITION MODULE (ON DISTRIBUTOR)

SWITCH LOW OIL PRESSURE

CONTACTOR, STARTER MOTOR

STARTER MOTOR

CC -

LOS -

SC -

SM -

WLS -

DEG -

FS -

GOV -

HCT -

ELEC. GOVERNOR ACTUATOR

SWITCH, HIGH COOLANT TEMP

SENSOR, COOLANT LEVEL

Generac Power Systems, Inc. 27

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Mounting Base — Drawing No. 0E6266-E

28 Generac Power Systems, Inc.

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Mounting Base — Drawing No. 0E6266-E

ITEM

PART NO.

QTY.

DESCRIPTION

23 *

24 *

25 *

26 *

0E5822

052860

052251

052257

052252

052259

052891

0536210213

074906

047411

055414

026850

022097

022473

049813

0A1694

052213

025507

027482

022129

045771

051756

046526

022131

055934M

077483

058665

038804D

038805AA

021991

049814

046526

022131

075763

050331

050331A

0A4010

052858

061902

059473

049820

REF.

BASEFRAME, WELDMENT 3.0L FORD

NUT FLANGED HEX M12-1.75

DAMPENER VIBRATION 40 BLUE

SPACER .49 X .62 X 1.87 PWDR/ZNC

DAMPENER VIBRATION

WASHER FLAT M12

SCREW HHC M12-1.75 X 80 G8.8

ASSY GRNDWIRE 11"/3/8 & 5/16 LUG

SCREW HHTT M6-1.0 X 20 BP

SCREW HHC M6-1.0 X 16 BP

LUG SLDLSS #2-#8 X 17/64 CU

WASHER SHAKEPROOF EXT 1/4 STL

WASHER LOCK M6-1/4

WASHER FLAT M6-1/4 ZINC

NUT HEX M6 -1.0 G8 YEL CHR

1-1/2" BUTTON PLUG

SCREW HHC M10-1.25 X 20 G8.8

WASHER SHAKEPROOF EXT 7/16 STL

WASHER SHAKEPROOF EXT 5/16 STL

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

SCREW HHC M10-1.5 X 20 G8.8

WASHER LOCK M10

WASHER FLAT 3/8-M10 ZINC

CLAMP VINYL .75 X .343 Z

BATT 12VDC 75-AH 26

BATT 12VDC 90-AH 27F

CABLE BATT RED #4 X 20.00

CABLE BATT BLK #4 X 30"

EARTH STRAP

SCREW HHC M10-1.5 X 25 G8.8

WASHER LOCK M10

WASHER FLAT 3/8 ZINC

BOOT BATTERY CABLE

BATTERY POST COVER BACLK -

BATTERY POST COVER RED +

SCREW HHC M8-1.25 X 60 G8.8 FT

NUT TOP LOCK FL M8-1.25

HOLD DOWN BATTERY

NUT HEX LOCK M8-1.25 NY INS

* NOT SHOWN-USED TO HOLD DOWN I/N 32

Generac Power Systems, Inc. 29

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Compartment — Drawing No. 0E8333-D

30 Generac Power Systems, Inc.

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Compartment — Drawing No. 0E8333-D

ITEM

PART NO.

QTY.

DESCRIPTION

0E8411

0E8042

0E8041

0C2454

0E8402

0E7808

0E7809

0E8387

0E6986

0E7795

089961

0A2115

0E8404

0D2538A

0D2538

043116

022097

022473

0E7570

0E7571

070015

0E7662

0D2537A

0D2537

0D2023

0E7869

0E8001

0E8060

0E8406

0D3037A

0C7781

0E7794

0E8052

0D3037

0E8007

0E8008

0E6989

0E8055

026850

0912970063

0912970064

049813

0E8665

0D2023

0E8441

0E7829A

0E7829B

0E7829P

0E7829R

0E7829S

0E7829T

0E7829N

0E7829U

078115

INTAKE DUCT HSB

DUCT DISCHARGE RH FRONT

DUCT DISCHARGE LH FRONT

SCREW TH-FRM M6-1 X 16 N WA Z/JS

BAFFLE REAR BOTTOM

POST CORNER LH REAR

POST CORNER RH REAR

BAFFLE REAR TOP

DOOR COMPARTMENT SIDE

SUPPORT, R/H SIDE

FOAM STRIP 3/4" WIDE X 3/16" THK (40" LG)

WASHER NYLON .257

BRACKET STIFFENER RH FRONT

HINGE LIFT OFF TYPE B KNUCKLE

HINGE LIFT OFF TYPE B PIN

SCREW HHC M6-1.0 X 12 G8.8

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

GAS SPRING

BALL STUD GAS SPRING MOUNT

NUT HEX 5/16-18 LOCK

SCREW WING M6-1.00 X 25

HINGE LIFT OFF TYPE A KNUCKLE

HINGE LIFT OFF TYPE A PIN

TRIM VINYL SELF GRIPPING (91" LG)

BRACKET STIFFENING BACK

MUFFLER BOX

ROOF W/GAS SPRING MNT 3.0L FRD

BRACE FRONT TOP

LATCH 1/4 TURN NONLOCKING

PAWL DOOR HSB

50 *

SUPPORT LH SIDE

MUFFLER BOX TOP

LATCH QUARTER TURN LOCKING

POST CORNER LH FRONT

POST CORNER RH FRONT

BRACE FRONT BOTTOM

DUCT DISCHARGE MID FRONT

WASHER SHAKEPROOF EXT 1/4 STL

ASSY GRD WIRE 99HSB

ASSEMBLY BASE-DOOR GROUND WIRE

NUT HEX M6 X 1.0 G8 YEL CHR

BRACKET STIFFENER LH FRONT

TRIM VINYL SELF GRIPPING (165.5"LG)

KIT INSULATION 3.0L HSB

AI ROOF PANEL 1

AI DOOR PANEL

AI CORNER POST PANEL 1

AI CORNER POST PANEL 2

AI SUPPORT LH PANEL

AI SUPPORT RH PANEL

AI ROOF PANEL 2

AI BRACE PANEL

WASHER SELF LOCKING DOME

* ALL ITEMS NOTATED WITH "AI" ARE COMPONENTS OF 0E8441

Generac Power Systems, Inc. 31

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Control Panel — Drawing No. 0E7118-G

32 Generac Power Systems, Inc.

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Control Panel — Drawing No. 0E7118-G

ITEM PART NO. QTY.

DESCRIPTION

ITEM PART NO. QTY.

DESCRIPTION

0E7195

0E7196

0E7197

0E7193

0E7194

0E4494

082573

032300

022676

067682B

060015

054199

0C2657

099076

040213

0E9668

0E4905

CONTROL BOX HSB

0D4698 *

0E7252

0C1229

REF.

BLOCK TERM 20A 6 X 3 X 1100V

BRACKET CB 221.5 X 102

DECAL WARNING ELECTRICAL

SHOCK

DECAL AVR COVER

COVER PLATE, AVR

HARNESS CNTRL PNL 3.0L FORD

(NOT SHOWN)

SCREW PPPH HI-LO #4-24 X 3/8

SCREW HHTT M5-0.8 X 10 BP

CONN DEUTSCH GASKET 8/12 POS

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-M4

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 M6-1.0 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

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

0C1127

0A1441B

0E7128

FUSE 15A X AGC15

0E7358

074908

0C5141

FUSE 4A SLO BLO GLASS

FITTING CONDUIT 90D 3/8"

DECAL DANGER HIGH VOLTAGE

TRANSFRMR 16V 6VA

TRANSFORMER 16V 56VA

PCB SUPPORT SNAP-IN 1/4"

ASSY PCB HSB CONTROLLER 3.9L

ASSY PCB HSB CONTRLR 3.0L

FORD

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

BLOCK TERM 20A 6 X 6 X 1100V

DECAL CUSTOMER CNNCTN E1 E3

0C2699

0C2323

022155

0C2265

022264

020911

066849

022152

023897

051716

090388

042568

022097

022473

0441140187

070370

023762

067680

REF.

0E6875A

0E6881 *

0C5139 *

0E5142 *

0E3161

054450

0D5070A

0E2514

0A9457

0E7539

055444

030468

049939

022158

022985

038750

0A2115

0C2454

HEATSINK

WASHER STEP NYLON .20

RECTIFIER MSC 12A 600V 1N1206R

NUT HEX #10-32 STEEL

WASHER FLAT #6 ZINC

SCREW HHC M6-1.0 X 30 G8.8

WASHER NYLON .257

046357 *

0D3719B

REF.

057073

0E7283

0E3628

0E3664

0E7539A

JUNCTION BLOCK 3/8-16

CB 0150A2P240V S QN2 LL

CB 0200A2P240V S QN2 LL

BASE QN CIRCUIT BREAKER

DECAL TB1 HSB CONTROL PANEL

SCREW THF M6-1 X 16 N WA Z/JS

* ITEMS INCLUDED AS PART OF I/N 39

Generac Power Systems, Inc. 33

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Engine — Drawing No. 0E8170-J

BAFFLE

REAR UPPER

GROUND

WIRE

34 Generac Power Systems, Inc.

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Engine — Drawing No. 0E8170-J

ITEM PART NO. QTY.

DESCRIPTION

ITEM PART NO. QTY.

DESCRIPTION

0E6202

0E8824

0E8963

ENGINE 3.0L FORD (RD) (MAKE)

STAMPING ENG FOOT 3.0L FORD

PULLEY CRANKSHAFT 3.0L FORD

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)

022131

059982

098780

051769

049808

051430

045773

0E6203C

0E6679

049226

091526

093278

0E6517

WASHER FLAT 3/8-M10 ZINC

SCREW SHC M12-1.75 X 45 G10.9

SCREW HHC M12-1.75 X 65 G8.8

WASHER LOCK M12

0E9020

0A1232

0A7801B

0A5610

0E6308

WASHER FLAT M12

WASHER SHAKEPROOF INT 1/2

NUT HEX M12-1.75 G8 YEL CHR

COIL IGNITION 3.0L FORD

BRACKET IGN COIL 3.0L FORD

WASHER LOCK M5

SCREW PPHM M5-0.8 X 12 ZNC

SCREW HHTT M5-0.8 X 25 BP

HARNESS ENGINE 3.0L FORD HSB

(NOT SHOWN)

GASKET EXHAUST 3.0L FORD

MANIFOLD EXHAUST 3.0L FORD

HEAT SHIELD 260 X 80 HOT

SCREW HHC 1/4-20 X 1/2 SS

WIRE SET 3.0L FORD (NOT

SHOWN)

9 **

0E7804

0E6310

0E7996

0E8006

035606

0E0561

FAN BELT 3.0L FORD

CLUTCH COOLING FAN FORD

FAN 18" 7 BLADE STEEL ECS

SENSOR HI COOLANT SHUTDOWN

ASSY WATER LEVEL SENSOR C/E

STARTER 12 VOLT

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-M6 SS

WASHER FLAT 1/4 SS

SCREW HHC M12-1.75 X 85 G8.8

CAP HOSE

0E7163

0E5527

0E7202

085296

0E6203D

0E9747

0E6703

70 *

71 *

057772

057765

061696

069860C

057822

069811

026925

065852

0A2111

057073

066849

022152

0E7880

WASHER NYLON .565

0E6667

0E5048

035579

0A8584

ADAPTER M14-1.50 X 3/8 NPT

BARBED EL 90 3/8 NPT X 1/2

HOSE OIL DRAIN ASSY 21"

CLAMP HOSE #8 .53-1.00

CAP HEX 1/4NPT BRASS

PLUG STD PIPE 3/8 STEEL SQ HD

SPRING CLIP HOLDER .37-.62

SCREW SWAGE 10-32 X 5/16 Z/YC

JUNCTION BLOCK 3/8-16

SCREW HHTT M5-0.8 X 16

WASHER LOCK #10

CLIP SPARK PLUG 3P SCREW

MOUNT (NOT SHOWN)

CLIP SPARK PLUG 2P SCREW

MOUNT (NOT SHOWN)

CLIP SPARK PLUG 3P FREEHANG

(NOT SHOWN)

CLAMP VINYL .5 X .406 Z

WASHER SHAKEPROOF EXT 5/16

STL

083896

084929

055597

077996

057823

056739

047411

022097

022473

042907

040976

022129

022145

045771

051756

049821

059980

0D5417

046526

REF.

CLAMP HOSE #10 .56-1.06

RELAY SOLENOID 12VDC PNL MNT

SCREW HHC M6-1.0 X 16 G8.8

WASHER LOCK M6-1/4

WASHER FLAT 1/4-M6 ZINC

SCREW HHC M8-1.25 X 16 G8.8

SCREW SHC M8-1.25 X 20 G12.9

WASHER LOCK M8-5/16

WASHER FLAT 5/16-M8 ZINC

NUT HEX M8-1.25 G8 YEL CHR

SCREW HHC M10-1.5 X 20 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

0E7880A

0E7880B

055934C

027482

0E8940

SPACER FLEXPLATE HSB

* NOT SHOWN-USED TO HOLD OIL DRAIN ASSEMBLY.

** NOT SHOWN

Generac Power Systems, Inc. 35

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Radiator — Drawing No. 0E8528-B

36 Generac Power Systems, Inc.

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Radiator — Drawing No. 0E8528-B

ITEM

PART NO.

QTY.

DESCRIPTION

0E9947

0E6340

0E8531

0E6398

0E6397

080713

076749

049814

022131

046526

045772

035685

0E8562

058443

0C2454

048031C

029032

046627

069811

065852

0A2111

052250

035461

0C7649

069860C

RADIATOR R-IN,L-OUT 658X489X49

VENTURI 3.0L FORD HSB

SIDE SUPPORT RADIATOR HSB

TUBE LOWER RAD 3.0L FORD HSB

HOSE UPPER RAD 3.0LFORD HSB

BRACKET COOLANT TANK

TANK COOLANT RECOVERY

SCREW HHC M10-1.5 X 25 G8.8

WASHER FLAT 3/8-M10 ZINC

WASHER LOCK M10

NUT HEX M10-1.5 G8 YEL CHR

CLAMP HOSE #28 1.32-2.25

FAN GUARD HSB

SCREW CRIMPTITE 1/4-20 X 5/8

SCREW TH-FRM M6-1 X 16 N WA Z/JS

CLAMP HOSE BAND 1/4

HOSE 9/32 ID (30" LG)

CAP RADIATOR

CAP HEX 1/4 NPT BRASS

SPRING CLIP HOLDER .37-.62

SCREW SWAGE 10-32 X 5/16 Z/YC

TAPE FOAM 1 X 1 (27" LG)

BARBED STR 1/4 NPT X 3/8

CLAMP HOSE .38-.87

HOSE OIL DRAIN ASSY 21"

Generac Power Systems, Inc. 37

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Fuel System — Drawing No. 0E8190-B

38 Generac Power Systems, Inc.

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Fuel System — Drawing No. 0E8190-B

ITEM

PART NO.

QTY.

DESCRIPTION

1 *

---------

WELDMENT MOUNTING BASE

FLANGE FUEL INLET

ASSY REGULATOR 3.0L NG OR LPV

SCREW HHC M8-1.25 X 20 G8.8

WASHER FLAT 5/16 ZINC

075580

0E7691

039253

022145

022129

045771

042907

0C2454

026307

0E1056

0E6584

057823

059194

044117

0D1509

050279

0E6123

0E6586

0E4395

057753B

047487

022097

051751

035685

057823

047290

0A4121

0E6609

049099

055934M

047411

022097

O22473

0E9295A

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

SCREW HHC M8-1.25 X 16 G8.8

SCREW TH-FRM M6-1 X 16 N WA Z/JS

ELBOW 90D STREET 3/4

FUEL HOSE ASSY NAT.GAS/L.P.V.

BRACKET REGULATOR 3.0L FORD HSB

CLAMP HOSE #10 .56 - 1.06

HOSE 5/8 ID LPG & NG (20" LG)

BARBED STR 3/8 NPT X 5/8

DECAL INLET PRESSURE

DECAL FUEL INLET NG

INTAKE ADAPTER 3.0L FORD-BOSCH

GASKET BOSCH 32

ACTUATOR BOSCH 32 GOVERNOR

HOSE 1.5 ID X 2 LG 20R4

SCREW SHC M6-1.0 X 18 G12.9

WASHER LOCK M6-1/4

SCREW HHC M6-1.0 X 50 G8.8

CLAMP HOSE #28 1.32-2.25

CLAMP HOSE #10 .56-1.06

HOSE 3/8 ID SINGLE BRAID (305mm [12"] LONG)

HOSE 3/8 ID SINGLE BRAID (432mm [17"] LONG)

VALVE PCV

GROMMET ROCKER COVER 3.0LFORD

BARBED EL 90 3/8 X 3/8 PLST

CLAMP VINYL .75 X .343 Z

SCREW HHC M6-1.0 X 16 G8.8

WASHER LOCK M6-1/4

35 **

36 **

37 **

38 **

WASHER FLAT 1/4-M6 ZINC

ASSY THROTTLE 27MM

* SHOWN IN OTHER VIEW

** NOT SHOWN-USED TO HOLD #31 IN PLACE

Generac Power Systems, Inc. 39

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Alternator — Drawing No. 0E8660-B

40 Generac Power Systems, Inc.

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Alternator — Drawing No. 0E8660-B

ITEM

PART NO.

QTY.

DESCRIPTION

0F1659A

0F1657A

0F1655A

0E5093A

0E7413A

0F1660A

0F1658A

0F1656A

0E5094A

0E7412A

0E5706

REF

ROTOR 390 15KW 1P DIRECT HSB (2.5L FORD)

ROTOR 390 20KW 1P DIRECT HSB (2.5L FORD)

ROTOR 390 25KW 1P DIRECT HSB (2.5L FORD)

ROTOR 390 30KW 1P DIRECT HSB (3.0L FORD & 2.5L FORD)

ROTOR 390 40KW 1P DIRECT HSB (3.9L CHRYSLER)

STR 390 15AD HSB (382MM LONG)(2.5L FORD)

STR 390 20AD HSB (382MM LONG)(2.5L FORD)

STR 390 25AD HSB (382MM LONG)(2.5L FORD)

STR 390 35AD1 HSB (382MM LONG)(3.0L FORD & 2.5L FORD)

STR 390 40AD HSB (433MM LONG)(3.9L CHRYSLER)

REAR BEARING CARRIER 390/DRCT

FLEXPLATE 3.0L FORD

FLEXPLATE 3.9L HSB

FLEXPLATE 2.5L FORD

FLYWHEEL ASSY 3.0L HSB LG GEAR

REVCOR FAN 10.75 X 2 W/PRESS DIS

WASHER LOCK M10

0E5048

0E5048A

0E5048B

0E6668

0E6076

046526

051755

SCREW HHC M10-1.5 X 16 G8.8

04576100BK

04576100BF

043123

STUD M14-2.0 X 490 G5 ZINC (3.0L FORD & 2.5L FORD)

STUD M14-2.0 X 540 G5 ZINC (3.9L CHRYSLER)

WASHER LOCK M14

051779

0E7587

023365

092980

057192

0A2602

042558

0A2601

022264

038150

077043F

NUT HEX M14-2.0 G8 YEL CHR

ASSY BRUSH HOLDER 390/HSB

WASHER SHAKEPROOF INT #8

SCREW PPHM M4-0.7 X 25

SCREW SHC M10-1.5 X 30 G12.9

WASHER FLAT .688 ID X 3.25 OD

KEY SQ 3/8 X 1 STEEL

SCREW HHC M16-2.0 X 45 G8.8

WASHER LOCK #8-M4

WASHER FLAT #8 ZINC

CONDUIT FLEX 1-1/4" (30" LG - 3.0L FORD & 3.9L CHRYSLER)

CONDUIT FLEX 1-1/4" (18" LG - 2.5L FORD)

ROTOR REPLACEMENT PARTS

047248

070892

BALL BEARING-45 MM

SLIP RING -MACHINED-

Generac Power Systems, Inc. 41

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Muffler — Drawing No. 0E6479-D

COMPARTMENT

MANIFOLD

ITEM PART NO. QTY.

DESCRIPTION

ITEM PART NO. QTY.

DESCRIPTION

0E6134

0E6464

0E6465

0E6465A

0E5914

MUFFLER, 3.0L FORD

022129

045771

0C2454

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 YEL CHR

SCREW TH-FRM M6-1X16 N WA

Z/JS

GASKET EXHAUST RING

EXHAUST BLANKET 3.0L FORD

HSB

WASHER LOCK 3/8 SS

SCREW HHC 3/8-16 X 1-3/4 SS

MOUNTING FLANGE

EXHAUST ELBOW 3.0L FORD HSB

EXHAUST PIPE LH 3.0L FORD HSB

EXHAUST PIPE RH 3.0L FORD HSB

BRACKET MUFFLER 3.0L FORD

HSB

MUFFLR STRAP 6IN DIA

SCREW RHM 1/4-20 X 2-1/4

BOLT U 5/16-18 X 2.25

044149

0E0170A

060366

027837

036797

039253

022145

085917

0D2611

081265

022259

SCREW HHC M8-1.25 X 20 G8.8

WASHER FLAT 5/16-M8 ZINC

NUT HEX 5/16-18 STEEL

42 Generac Power Systems, Inc.

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 27 kW and 30 kW Generators

Air Cleaner — Drawing No. 0E8189

ITEM PART NO. QTY.

DESCRIPTION

ITEM PART NO. QTY.

DESCRIPTION

0E5193

0E8200

0E8201

036434

0E0519A

PLATE AIR CLEANER ADAPTER

TUBE AIR INTAKE 3.0L FORD

BRACKET AIR INTAKE 3.0L FORD

BOLT U 5/16-18 X 2.09

ADAPTER, CARBURETOR W/PVC

CONN

ELEMENT, AIR CLEANER

COVER - AIR CLEANER

STUD TH 1/4-20 X 4-1/2 G2 ZNC

NUT HEX 1/4-20 STEEL

049226

091526

052619

051713

051716

022131

046526

051755

022145

022129

022259

WASHER LOCK M5

SCREW PPHM M5-0.8 X 12 ZNC

SCREW HHC M5-0.8 X 20 G8.8

WASHER FLAT M5

NUT HEX M5-0.8 G8 YEL CHR

WASHER FLAT 3/8-M10

0C8127

0A5547

062974

022127

037561

WASHER FLAT M10

SCREW HHC M10-1.5 X 16 G8.8

WASHER FLAT 5/16-M8 ZINC

WASHER LOCK M8-5/16

NUT HEX 5/16-18 STEEL

NUT WING 1/4-20 NYLK

Generac Power Systems, Inc. 43

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Section 9 - Notes

Guardian Liquid-cooled 27 kW and 30 kW Generators

44 Generac Power Systems, Inc.

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Section 9 - Notes

Guardian Liquid-cooled 27 kW and 30 kW Generators

Generac Power Systems, Inc. 45

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Section 10 – Warranty

Guardian Liquid-cooled 27 kW and 30 kW Generators

GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN®

"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"

For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator

will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or

replace any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is

found to be defective. 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 genera-

tors 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

Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Guardian generators that utilize non-Guardian/Generac replacement parts.

• Guardian generators utilizing non-Guardian/Generac automatic transfer switches.

• Repairs performed by individuals other than Guardian/Generac authorized dealers.

• Any Guardian generators used as rental or trailer mounted applications.

• Air-cooled units used for prime power in place of existing utility power where utility power is present or in place of utility power where

utility power service does not normally exist.

• Costs of normal maintenance, adjustments, installation and start-up.

• Steel enclosures that are rusting due to the improper installation, location in a harsh or saltwater environment or scratched where

integrity of paint applied is compromised.

• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all

mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not

cover repair when normal use has exhausted the life of a part(s) or engine.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,

freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Damage related to rodent and/or insect infestation.

• Products that are modified or altered in a manner not authorized by Generac in writing.

• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replace-

ment of the defective part(s).

• Failure due to misapplication.

• Telephone, cellular phone, facsimile, internet access or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty

period.

• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.

• Rental equipment used while warranty repairs are being performed.

• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)

• Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES

NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not

allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT

SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A

DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential

damages, so the above limitation may not apply to you.

This warranty gives you specific legal rights. You also have other rights from state to state.

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 • WHITEWATER, WI 53190

Revision (10/01/04)

Part No. 0F2006

Revision A (10/15/04)

Printed in U.S.A.

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