Generac Power Systems 04137-0 User Manual
POWER SYSTEMS, INC
Owner’s Manual
SUARDIAry
by GENERAC- POWER SYSTEMS
Liquid-cooied, Prepackaged
Standby Generators
Models:
04136- 0 (8 kW/Singie-phase)
04137- 0 (8 kW/Three-phase)
INTRODUCTION
Thank you for purchasing the Guardian product
line by Generac Power Systems. This model is a
compact, high performance, liquid-cooled, enginedriven generator designed to automatically supply
electrical power to operate critical loads during a
utility power failure.
This unit is factory installed in an all-weather, metal
enclosure that is intended exclusively for outdoor
installation.
» READ THIS MANUAL THOROUGHLY
______________
If you do not understand any portion of this manual,
contact Generac or your nearest Generac/Guardian
Authorized Dealer for starting, operating and servic
ing procedures.
Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert you to
special instruction about a particular operation that
may be hazardous if performed incorrectly or care
lessly. Observe them carefully. Their definitions are
as follorvs;
-AEŒ3 A-
After this heading, you can read instructions that,
if not strictly complied with, wiil result in personal
injury or property damage.
—A WARNING A—
After this heading, you can read instructions that,
if not strictly complied with, may result in persona!
injury or property damage.
------
M CAUTION M
After this heading, you can read instructions that,
if not strictly complied with, could result in damage
to equipment and/or property.
NOTE:
After this heading, you can read explanatory
statements that require special emphasis.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict com
pliance with the special instructions whUe perform
ing the seiwice are essential to preventing accidents.
Four commonlv used safety symbols accompany
tire DANGER. WARNING and CAUTION blocks. The
type of information each indicates is as follows:
This symbol points out important safety informa
A
tion that, if not followed, could endanger persona!
safety and/or property of you and others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
A This symbol points out potential electrical shock
hazard.
Generac® Power Systems, Inc.
-----------
,
The operator is responsible for proper and safe use
of the equipment. We strongly recommend that the
operator read this Owner’s Manual and thoroughly
understand all instructions before using this equip
ment. We also strongly recommend instructing
other users to properly start and operate the unit.
This prepares them if they need to operate the
equipment in an emergency.
# CONTENTS
________________ ______________________
This manual contains pertinent owner’s informa
tion, including warranty, electrical diagrams,
exploded views and lists of repair parts, for the fol
lowing Guardian models;
04136-0 and 04137-0
4 OPERATION AND MAINTENANCE_____________
_
It is the operator's responsibility to perform all safety
checks, to malce sure that all maintenance for sale
operation is performed promptly and to have the
equipment checked periodically by a Generac/
Guardian Authorized Dealer. Normal maintenance
service and replacement of maintenance parts are the
responsibility of the owner/operator and, as such,
are not considered defects in materials or workman
ship within the terms of the warranty. Indirfdual
operating habits and usage contribute to the need for
maintenance service.
Proper maintenance and care of your generator ensure
a ininimumi number of problems and keep operating
expenses at a rnlniaium. See your Generac/Guardian
Autiiorized Dealer for service aids and accessories.
^ HOW TO OBTAIN SERVICE_______________________
V.'Tien your generator requires servicing or repairs,
simply contact a Generac/Guardian Authorized
Dealer for assistance. Sendee technicians are facto
ry-trained and are capable of handling all of your
sendee needs.
WTien contacting a Generac/Guardian Autlrorized
Dealer or tlie factoiy about parts and service,
always supply the complete model number and
serial number of your unit as grfen on its data
decal, which is located on your generator.
Model No. Serial No.
AUTHORIZED
DEALER LOCATION
To locate the GENERAC/GUARDIAN AUTHORIZED
DEALER nearest you, please call this number:
1-800-747-1530
DEALER LOCATION INFORMdTION
CNN BE OBTAINED AT THIS NUMBER.
SAFETY RULES
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
A
operators and potential operators of this equipment. Mm.
important Safety instructions
Guardian Llquid-cooied 8 kW Generators
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
Study these SAf'ETY RULES carefully before
installing, operating or servicing this equipment.
Become familiar with this Oiuner's Manual and with
the unit. The generator can operate safely, effi
ciently and reliably only If it is properly installed,
operated and maintained. Many accidents are
caused by failing to follow simple and fundamental
rules or precautions.
Generac cannot possibly anticipate every possi
ble circumstance that might involve a hazard. The
warnings in this manual, and on tags and decals
afffxed to the unit are, therefore, not all-inclusive. If
you use a procedure, work method or operating
technique Generac does not specificaJly recom
mend, you must satisfy yourself that it is safe for
you and others. You also must make sure the pro
cedure. work method or operating technique that
you choose does not render the generator unsafe.
-A0UE33 A-
Despite the safe design of this ' generator,
A
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
A
these machines. Ensure ai! steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
M GEIMERAL HAZARDS M
For safety reasons, Generac recommends
that the installation, inihal start-up and mainte
nance of this equipment is carried out by a
Generac/Guardian Authorized Dealer.
The engine exhaust fumes contain carbon
monoxicTe, which can be DEADLY. This danger
ous gas, If breathed in sufficient concenhations,
can cause unconsciousness or even death. This
exliaust system must be installed properly, in
strict compliance with applicable codes and stan
dards. Following installation, you must do noth
ing that might render the system unsafe or in
noncompliance with such 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 venti
lating air is critical to comect generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as tliis can
seriously affect safe operation of the generator.
When working on this equipment, remain alert at
all times. Never work on the equipment when you
are physically or mentally fatigued.
Inspect the generator regularly, and repair or
replace all damaged or defective parts irrumedi-
ately. Always use factory-authorized parts.
Turn off the AC power to the batterv' charger
before disconnecting the battery to minimize the
chance of equipment damage.
Before performing any maintenance on the gen
erator, disconnect Its battery cables to prevent
accidental start-up. Disconnect the cable from
tlie battery post indicated by a NEGATIYTD. NEG
or H 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 etdaaust gases, fuel leak
age, oil leakage, etc.
Generac® Power Systems, Jnc.
Table of Contents
Guardian Liquíd-cooied 8 kW Generators
Introduction
Read This Manual Thoroughly
Contents
Operation and Maintenance
....
....................inside Front Cover
.........................
...........................................................
..............................
IFC
IFC
IFC
How, to Obtain Service ....................................IFC
Authorized Dealer Locator Number
Safety Rules
.....
.................................................
..................
.......2
IFC
Section Ì - General Information..................................
1.1 Unpacking/Inspection
1.1.1 Lifting the Generator
1.2
The Generator .................................................4
1.3
Generator AC Connection Systems
Automatic System Operation
1.4
Main Circuit Breaker
1.5
Engine Protective Devices
1.6
....................................
.........................
................
.........................
......................................
..................1...........
1.6.1 Low Oil Pressure Switch....................5
1.6.2
1.6.3
1.6.4
1.6.5
Specifications
1.7
High Coolant
Temperature Switch
..........................
Low Coolant Level Switch ................6
Overspeed Shutdovm
Or’ercrank Shutdown
........................
........................
..................................................
1.7.1 Generator............................................6
1.7.2 Engine ................................................6
Fuel Requirements
1
and Recommendations
.............'..................
1.9 Engine Oil Recommendations.........................7
1.10 The Barterv .....................................................7
2.4 Automatic Transfer Operation
2.5 Sequence of Automatic Operation
.......................
..................
Q
9
2.6 Engine Heater................................................10
2.7 Weeldy Exercise Cycle .................................10
2.8 Optional GTS Transfer Switch .....................10
2.8.1 Using an Optional GTS
Transfer Switch
Section 3 - Maintenance
4
4
4
4
5
5
5
3.1 25-Hour Break-in Period
3.2 25-Hour Checkup
3.3 Checldng the Engine Oil Level
3.4 Changing the Engine Oil and Filter ..............12
3.5 Changing the Engine Air Cleaner
3.6 Вatteiy Maintenance
3.7 Cooling System
............................................
3.8 Overload Protection for
Engine DC Electrical System
................................
..........
.................................12
..............................
..........................................
....................
.................
.....................................
.......................
11
12
12
12
13
13
14
14
3.9 Fuse................................^...............................14
5
6
6
6
3.10 Engine Coolant
3.11 Miscellaneous Maintenance
3.11.1 Cleaning the Generator
3.11.2 Rodent Protection
3.12 Out of Sendee Procedure
3.12.1 Removal From Service
3.12.2 Return to Service
3.13 Service Schedule
..............................................
.........................
....................
.............................
...............................
.....................
.............................
..........................................
14
15
15
15
15
15
15
16
7
Section 4 - Troubleshooting
...........................17
4.1 Troubleshooting Guide.................................17
Section 2 - Operation
2.1 Control Console Components
2.1.1 AC Voltmeter
2.1.2 AC Ammeter
2.1.3 AC Frequency Meter
....
.................................8
.........................
.....................................
.......................................
..........................
2.1.4 DC Voltmeter .....................................8
2.1.5 Hourmeter
2.1.6 Auto/Off/Manual Switch
2.1.7 Fault Indicator Lamp
.........................................
...................
.........................
2.1.8 30-amp Fuse.......................................8
2.1.9 Voltage-phase Selector Switch
2.1.10 Set Exercise Time Switch
2.1.11 Main Circuit Breaker .........................8
2.2 Preparation Before Start-up
............................
2.3 Using the Auto/Off/Manual Switch
2.3.1 “Auto" Position
2.3.2 “Off Position
2.3.3 “Manual" Position
.................................
......................................
..............................
.............
.................
................
Section 5- Electrical Data................................18
S
8
8
Section 6 - Exploded Views and
Parts Lists.....................................................22
S
Section 7 - Installation Drawings
..................
34
S
8
Section 8 - Warranty
......................................
36
8
8
8
8
8
8
9
9
еЗепегас® Power Systems, ¡nc.
/k
ELECTRICAL HAZARDS
Important Safety Instructions
Guardian Liquid-cooled 8 kW Generators
FIRE HAZARDS
SAFETY RULES
All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer
switch as does the standby generator when it is
in operation. Avoid contact with bare wires, ter
minals, connections, etc., while the unit is run
ning, Ensure all appropriate covers, guards and
barriers are in place before operating the genera
tor. If you must work around an operating unit,
stand on an insulated, diy 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 ELECTRICAX
SHOCK my RESULT.
The National Electrical Code (NEC) requires the
frame and emernal electrically conductive parts
of the generator to be connected to an approved
earth ground. Local electrical codes also may
require proper grounding of the generator electri
cal system.
ATter installing this standby electrical system, the
generator may crank and start at any time vdthout warning. Wlien this occurs, load circuits are
transferred to the STANDBY (generator] power
source. To prevent possible injury if such a start
and transfer occur, always set the generator’s
Auto/Off/Manual switch to its OFF position
before working on equipment.
In case of accident caused by electric shock,
immediately 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 noncon
ducting implement, such as a rope or board, to
free the victim from the live conductor. If the vic
tim is unconscious, apply first aid and get imme
diate medical help.
Never wear jewelry when working on this equip
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com
ponents causing injun/.
For fire safety, the generator must be installed
and maintained properly. Installation altvays
must 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 estab
lished. Also, ensure that the generator is
installed in accordance with the manufacturer's
instructions and recommendations. Following
proper installation, do nothing that might alter a
safe installation and render the unit in noncom
pliance mth the aforementioned codes, stan
dards, laws and regulations.
Keep a fire extinguisher near the generator at ail
times. Extinguishers rated JABC" by the National
Fire Protection Association are appropriate for
use on the standby electric system. Keep the
extinguisher properly charged and be familiar
with its use. If you have any question pertaining
to fire extinguishers, consult your local fire
department.
A
EXPLOSION HAZARDS
A
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 tlie generator clean and free from
debris.
Although using diesel fuel is safer than using gaso
line or gaseous fluids, which are are extremely
EXPLOSIVE, diesel stiU. presents the danger of
possible FIRE. Install the fuel supply system
according to applicable fuel-gas codes. Before plac
ing the standby electric system into sertlce, fuel
system lines must be properly purged and lecJt
tested according to applicable code. After installa
tion, you must inspect the fuel system periodically
for leaks. No lealtage is permitted.
Generac® Power Systiems, inc.
GENERAL
INFORMATION
Section 1 — General Information
Guardian Liquid-cooied 8 kW Generators
1,1 UNPACKlNG/iNSPECTiON
After unpacldng, carefully inspect the contents
for damage.
« This standby generator set has been factory
installed in an all-weather, metal enclosure that
is intended exclusively for outdoor installation.
-A WARNING A-
lf this generator is used to power electrical load
A
circuits normally powered by a utility power
source, you are required by code to install a
transfer switch. The transfer switch must effec
tively isolate the electrical system from the util
ity distribution system when the generator is
operating (NEC 701). Failure to isolate an elec
trical system by such means will result in dam
age to the generator and also may result in
injury or death to utility power workers due to
backfeed of electrical energy.
If. any loss or damage is noted at time of delivery,
have the person(s) making the delivery note all
damage on the freight bill or affix his or her signa
ture under the consignor's memo of loss or damage.
If you note loss or damage after delivery, separate
the damaged materials and contact the carrier for
claim procedures.
“Concealed damage” is understood to mean damage
to the contents of a package that is not in evidence
at the time of delivery, but is discovered later.
# 1.1.1 LIFTING THE GENERATOR
-A WARNING A-
When lifting or hoisting equipment is used, be
A
careful not to touch overhead power lines.
The generator's weight of more than 1,500
A
pounds requires proper tools and equipment,
and qualified personnel to be used in all phases
of handling and unpacking.
1.2 THE GENERATOR ..
This liquid-cooled, Guardian generator set is
designed to supply electrical power to operate criti
cal electrical loads during utility power failure. The
unit has a four-pole revolving field (rotor) and uti
lizes long-life brushes and slip rings to deliver exci
tation current to the rotor windings. The rotor is
directly connected to the engine shaft by a highstrength flexible disc. The engine governor holds
the diesel engine and rotor speeds at a constant
factory setting of approximately 1,860 rpm.
Use this generator as a source of electrical power
for tlie operation of 120- and/or 240-volt, singleor three-phase loads; or 120- and/or 208-volt,
three-phase loads.
These models are available, rated as follows;
04136- 0: Provides 8,000 watts (8 kW) of single
phase power.
04137- 0: Provides 8,000 rvatts (8 kVV) of three-
phase power.
1.3 GENER.ATORAC
CONNECTION SYSTEMS
Ttie three-phase generators are shipped from tlie fac
tory with their stator AC output leads connected in a
12-lead low we configuration (Figure 1.1). This tyq)e
of connection system wül supply a 120- and/or 208volt, three-phase output as showm in tire illustration.
If, however, load voltage requires a 120/240-voIt,
single- or three-phase output, the stator's output
leads will need to be reconnected (Figure 1.2). This
task should be performed only by a qualified
Generac/Guardian Authorized Technician. Refer to
the
Guardian Installamn, Start-up and Adjustment
Manual (Part No, 79699) for details.
Figure 1.1 - 12-!ead Low Wye
Generator AC Connection System
E1
Section 1 — Generai Information
Guardian Liquid-cooied 8 kW Generators
GENERAL
INFORMATION
Figure 1.2 - Single- and Three-phase Delta
Generator AC Connection System
Figure 1.3 represents a single-phase, threenvlre
generator AC connection system. The stator assem
bly in this system consists of a pair of stationaiy
windings with Pan leads brought out of each wincl-
ing. Each single nhnding can supply a 120-volt, 60Hertz AC output. When the two windings are con
nected in series, a 240-volt, 60-Hertz AC output
results. Typically, the two "hot” leads in the circuit
are Wires 11 and 44. The neutral leads are the
junction of Wires 22 and 33.
Figure 1.3 - Single-phase
Generator AC Connection System
When utility source voltage has been restored, the
switch transfers back to the utility source voltage,
and the generator then shuts down,
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 as follows:
Mode! Number Circuit Breaker Ratinq
04135-0
04137-0 35A-3P-BQ3
35A-2P-BQ2
1.6 ENGINE PROTECTIVE DEVICES
The engine has several safely switches tliat cause
it to automatically shut down under the following con
ditions: low oil pressure, high coolant temperature,
low coolant level, and engine overspeed or overcrank.
See Figure 1.4 for the location of these devices.
4 1.6.1 LOW Oil PRESSURE SWITCH
This switch is normally closed {N.C.] but is held open
by engine oil pressure during engine running. Should
operating oU pressure drop below apprommately 15
psi, the switch contacts close, and die engine shuts
down automatically.
Figure 1.4 - Engine Protective Devices
________________
Low Oil
Pressure Switch
1.4 , AUTOMATIC SYSTEM OPERATION
Wnen this generator, along with its transfer switch,
has been Installed and interconnected, a circuit
board in the generator panel continuously 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 genera
tor can power them.
4 1.6.2 HIGH COOLANT TEMPERATURE SWITCH
This normally open (N.O.) thermostatic switch has
a sensing tip that is immersed in captive coolant.
Should the coolant temperature exceed approzdmately 124° C (256° F), the switch contacts close,
wTich causes the engine to shut clown automatically.
Generac® Power Systems, !nc.
GENERAL
INFORMATION
Section 1 — General information
Guardian Liquid-cooied 8 kW Generators
» 1.6.3 LOW COOLANT LEVEL SWITCH
Should tlie .engine coolant level drop below tloe level
of’the high coolant temperature switch, it is possible
for the engine to overheat wltlaout automatic shut
down. To prevent such overheating without automat
ic shut down, the engine has a low coolant level sen
sor. If the engine coolant drops too low, the engine
_____________
_
# 1.6.4 0¥ERSPEE0 SHUTDOWN
______________
The DC control circuit board (inside control panel)
senses engine speed from the frequency of the
alternator AC output. Should the alternator output
frequency exceed approximately 72 Hertz (2,160
alternator rpm), circuit board action initiates an
automatic engine shutdown.
automatically shuts down.
# 1.6.5 OVERCRANK SHUTDOWN
After 90 seconds of crank-rest cycles (while in Auto
mode], this function ends cranking if the engine
fails to start in that 90-second span.
1.7 SPECIFICATIONS
♦ 1.7.] GENERATOR
SINGLE-PHASE
Model
Rated Maximum Continuous
AC Power Outnut (kW)*
Rated Voltage (volts)
Rated Ma:d.mum Continuous
Current at ...
»240 Volts, Single-phase (amps)
»240 Volts. Tlcxee-phase (amps)
•208 Volts, Three-phase (amps) NA
Power Factor
Rated AC Frequency
Number of Rotor Poles
Rotor Speed at No Load
Type of Stator
Rotor Excitation Svstem Direct Excited Brush-h/pe Svstem
Rotor and Stator Insulation
'“Rated p)wer of geneiator is subjeci to and limited by such iactom as ambient leinperature, altitude, engine condition and otiier factoi-s. Engine power will deci-ease about 3.5
percent for eacti 1,000 feet above sea le/el; and also will dettrease an additional 1 percent for each 12° C (10° F) above 15.5° C (60° Fj. Maximum output power of the generator is
hmited by maximum engine power.
04136-0
8
120/240
33.3
NA 24,1
1.0
60 Hertz at 1,800 rpm
4
1,860 rpm
'Four-wire
Class “F”
♦ 1.7.2 engine’
Make ............................................................................ISM Diesel
Cylinder Arrangement
Displacement.................................................58.2 inches (954 cc)
Bore ............................................................2.95 inches (75 mm)
Stroke..............................................................2.85 inches (72 mm)
Compression Ratio...............................................................23-to-l
Compression Pressure ar 200 rpm
Standard......................................................................426.7 psi
Minimum Limit..........................................................2S4.5 psi
Combustion Chamber Type ..................................Pre-Combustion
Firing Order
Direction of Rotation ...........................................Counterdodvvise
NumAer of Main Bearings
No. of Teeth on Flywheel..........................................................104
Ground Polariw ................................................................Negative
Oil Filter.......................................Full flow, woth byptass valve
Oil Pressure ....................................................................29-71 psi
Crankcase Oil Capacity
With Filter Change
Whthout Filter Change
Recoznmended .Engine Oil.................See Section 1,9 (Pcige 7)
Type of Cooling System ....Pressurized, closed recovery
...........................................................................
....................................................
...........................................................
...........................
......................
4.0 U.S. quarts (3.8 L)
3.7 U.S. quarts (3.5 L)
3, in-line
1-2-3
Type of Cooling Fan
Cooling System Capacity
Recommended Coolant ..................Use a 50-50 rnimire of low
Type of Fuel System
Recommended Fuel
Fuel Filter......................................................................10 micron
Fuel Injection Pump
Injection Spray Angle
Injection Pressure ...........................................................1,707 psi
4
Fuel Consumption - 60 Hz (gal/h)
25% Load 50%Load 75% Load 100% Load
0.35 0,52 0.63 0.S4
Actual fuel consumption obtained may vary
depending on such variables as applied load, ambi
ent temperature, engine conditions and other
environmental factors.
..........................................................
....................
.............................................................
.............................
...........................................
............................................
S Generac^ Power Svstems, !nc.
THREE-PHASE
04137-0
120/208
NA
27.8
0.8
12-'wire Reconnectable
2.5 U.S. gallons (9.5 L)
silicate, ethylene glycol base
anti.iTeeze and soft water. See
Section 3.10 (Page 14),
See Section 1.8 (Page 7)
NOTE:
__
________________
Pusher
Diesel
Bosch “M” Type
20°-21° BTDC
Section 1 - General Information
Guardian Liquid-cooled 8 kW Generators
GENERAL
INFORMATION
.8 FUEL REQUIREMENTS
AND RECOMMENDATIONS
Г-se clean, fresh No. 2D diesel fuel with minimum
htane number of 40. It also must conform to
merican Society of Testing and Materials (ASTM)
pecifications. The iiiel should be stored in sealed
.3ntainers that have low point drains which permit
Viter to be drained from the fuel periodically. Never
se any dirty or contaminated fuel.
his unit has a 46-gallon fuel tank. When adding
lel, DO NOT overfill the tank. Allow room at the
)p of the tank for fuel expansion.
NOTE:
ppropriate care should be taken in applications
here extremely low ambient temperatures are
ossible to ensure the temperature of the diesel
lel is not allowed to fall below levels where
felling” could occur.
-A WARNING A-
y Although using diesel fuel is safer than using
A gasoline or gaseous fluids, which are are
extremely EXPLOSIVE, diesel stiil presents the
danger of possible FIRE. The fuel supply system
must be installed according to applicable
fuel-gas codes. After installation, you must
inspect the fuel system periodically for leaks.
No leakage is permitted.
9 ENGINE GIL RECOMMENDATIONS
;e a high-quality detergent oil with American
croleum Institute (API) classification “For Service
A’ Detergent oils keep the engine cleaner and
Jiice carbon deposits. Use oil having the follovdng
ciety of Automotive Engineers (SAE) viscosity' rati, based on the ambient temperature range anticLied before the next oil change:
Temperature
Above 70° F (21° C)
3° to 70° F (-7° to 21° C)
Below 20° F (-7° C)
------
M. CAUTION
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.
Oil Grade (Recommended)
SAE 30W
SAE 20W
SÀE 10W or 10W-30
A-
1.10 THE BATTERY
Use a 12-volt, automotive-type storage battery
(Group 26F) rated 75 amp hours or more and capar
bie of a minimum of 530 cold-cranking amps at
'17,8° C (0° F). When using a maintenance-free bat
tery, it is not necessaiy to check the specific gravity
or electrolyte level. Have these procedures per
formed at the intervals specified in the service
schedule. A negative ground system is used. Battery
connections ai'e shown on the wiring diagrams.
Make sure the battery is correctly connected and
terminals are tight. Observe battery polarity when
connecting the battery to the generator set.
NOTE:
Damage will result if the battery connections are
made in reverse.
Your generator is equipped with a battery triclde
charger that is active when ypur unit is set up for
automatic operation. The trickle charge is designed
to help extend the life of your battery by maintain
ing the battery when the unit is not running.
-АСШШЭ A-
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 pro
ducing tools or equipment near the battery.
Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If you spill the fluid, flush
the affected area immediately with clear water.
WARNING
Do not dispose of the battery in a fire. The
A
battery is capable of exploding.
Do not open or mutilate the battery. Released
A
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.
A-
Generac® Power Systems, Inc.
OPERATION
(jo
Section 2 - Operation
Guardian Liquid-cooled 8 kW Generators
2.1 CONTROL CONSOLE COMPONENTS
The components of a liquid-cooled generator con
trol console (Figure 2.1) are as follows:
Figure 2.1 - Control Console
♦ 2.1.1 AC VOLTIVI EIER
The voltmeter displays generator AC output voltage
during operation. Voltage is regulated by a solidstate voltage regulator and is proportional to AC
frequency. Refer to your unit's DATA PLATE for
rated AC voltage.
# 2.1.5 HGURMETER
This indicates the time the engine-generator has
operated, in hours and tenths of hours. Use the
hourmeter along with the periodic maintenance
schedule for your generator set.
» 2.1.6 AUTO/OFF/MANUAL SWITCH
See Section 2.3.
» 2.1.7 FAULT INDICATOR LAMP
This lamp goes ON when one or more of the following
engine faults occurs and when engine shuts down.
<> Low oil pressure « High coolant temperature
® Low coolant level ® Overcrank
» Overspeed
♦ 2.1.8 30-AiVIP FUSE
This fuse protects the contrcd console’s DC control
circuit against electrical overload. If the fuse has
melted open because of an overload, engine crank
ing and start-up cannot occur. Should you need to
replace the fuse, use only an identical 30-amp
replacement fuse.
______________
___________________
4 2.1.2 AC AMMETER
This indicates current draw of connected electrical
loads during operation. DO NOT EXCEED YOUR
UNIT’S RxCTED MAXIMUM CONTINUOUS CUR
RENT. Refer to th,e unit DATA PLATE.
# 2.1.3 AC FREQUENCY METER
This indicates generator AC output frequency in
Hertz (cycles per second). Frequency is proportion
al to engine speed. Units vlth a four-pole rotor sup
ply 60 Hertz at 1,800 rpm. The frequency reading
with no electrical loads connected (no-load condi
tion) should be between 61-6.3 Hertz. With full
rated wattage/amperage load applied to the gener
ator, frequency should not droop below approxi
mately 58 Hertz.
♦ 2.1.4 DC VOLTMETER
The generator is equipped with a belt-driven DC
alternator, which maintains batten/ state of charge
when the engine operates. The control module
assembly also incorporates a triclde charge circuit
that maintains battery state of charge during non
operating periods. Battery voltage should read
approximately 12.5 to 14.5 volts DC. A low battery
voltage indicates the battery is discharging.
» 2.1.9 VOLTAGE-PHASE SELECTOR SWITCH
This switch permits you to select either line-to-llne
or line-to-neutral voltage and amperage readings
on the console AC voltmeter and ammeter.
♦ 2.1.10 SET EXERCISE TIME SWITCH
This switch allows you to program the generator to
start and exercise automatically.
4 2.1.11 MAIN CIRCUIT BREAKER
The generator’s main circuit breaker is included
with the unit as shipped from the factory. See
“Main Circuit Breaker." Section 1.5 (Page 5), for the
appropriate breaker.
______________
___________________
2.2 PREPARATION BEFORE START-UP
Before starting the generator, check that oil,
coolant and fuel levels are correct (see
“Specifications,” Section 1.7, Page 6).
2.3 USING THE AUTO/OFF/MANUAL
SWITCH
♦ 2.3.1 "AUTO" POSITION
vSelecting this switch position activates fully automat
ic system operation. It also allows the unit to start
and exercise the engine every seven days with the set
ting of tire exercise timer (see Section 2.7, Page 10).
Gensrac* Power Systems, ine.
Section 2 ~ Operation
Guardian Liquid-cooled 8 kW Generators
OPERATiON
(pix
^ 2.3.2 "OFF" POSITION
This switch position shuts down the engine. This
position also prevents operation.
# 2.3.3 "MANUAL" POSITION
Set the switch to Manual to crank and start the
engine. Transfer to standby power will not automaticallv occur unless there is a utility failure.
-A WARMING A-
With the switch set to AUTO, the engine may
crank and start at any time without warning.
Such automatic starting normally occurs when
utility power source voltage drops below a pre
set level or during the normal exercise cycle. To
prevent possible Injury that might be caused by
such sudden starts, always set the switch to
OFF and remove the fuse before working on or
around the generator or transfer switch. Then,
place a "Do Not Operate" tag on the generator
panel and on the transfer switch.
2.4
AUTOMATIC TRANSFER
OPERATION
To select automatic operation, do the following:
1. Make sure the transfer switch main contacts
are set to their “Utility" position, i.e., loads con
nected to the utility power source.
2. Be sure tfiat normal utility power source voltage is
available to transfer switch terrninal lugs N1 and
N2. {See the electrical data in the applicable trans
fer switch manual.)
3. Set the generator’s Auto/Otl/Manuai switch to
AUTO.
4. Set the generator's main circuit breaker to Its
ON (or closed) position.
With the preceding steps complete, the generator
will start automatically when utility source voltage
drops below a preset level. After the unit starts,
loads are transferred to the standby power source.
Refer to “Sequence of Automatic Operation.”
Upon restoration of utility source voltage above a
preset level, generator circuit board action signals
the transfer switch to transfer loads back to that
power supply. After retransfer, the engine is sig
nalled to shut down.
The actual sequence of operation is controlled by
sensors and timers on a control logic circuit board",
as follows:
A. Utility Voltage Dropout Sensor
o This sensor monitors utility source voltage.
® If utility source voltage drops below about 60
percent of the nominal supply voltage, the sen
sor energizes a 15-second timer.
® Once the timer has expired, the engine v/ill
crank and start.
B. Engine Warm-up Time Delay
• This mechanism lets the engine warm up for
about 10 seconds before the load is transferred
to a standby source.
C. Standby Voltage Sensor
» This sensor monitors generator .EC output volt
age. 'Wlien the vtytage has reached 50 percent
of the nom.incJ rated voltage, transfer to stand
by can occur.
D. Utiliw Voltage Pickup Sensor
® This sensor monitors utillbv power supply volt
age, When that voltage is restored above SO per
cent of the nominal source volta.ge, a retrcmsfer,
time delay starts timing,
E. Retransfer Time Delay
= This timer runs for about 15 seconds.
® AT end of a 15-second delay, circuit board
acrioii de-energizes transfer relay in the trans
fer switch.
» Retransfer to utility power source tlien occurs.
F. Engine Cool-down Timer
• When the load is transferred back to utility"
power source, tihe engine cool-down timer
starts timing,
• The timer will run for about one minute, and
the generator will then shut down.
2.5 SEQUENCE OF
AUTOMATIC OPERATION
The generator’s control panel houses a control logic
circuit board. This board constantly monitors utllibv* power source voltage. Should tiiat voltage drop
below a preset level, circuit board action will signal
the engine to crank and stmt. .After the engine
starts, the circuit board signals the transfer switch
to activate and connect load circuits to the standby
power supply (load terminal lugs T1/T2 connect to
terminal lugs E1/E2). (See tlie electrical data in tire
applicable transfer switch manual.)
Generac® Power Systems, Inc.
OPERATION
-On
Section 2 - Operation
Guardian Liquid-cooled 8 kW Generators
2.6 ENGINE HEATER
Your Generac standby generator comes equipped
with a block heater (Figure 2.2) that is similar to
the block hea.ters used in automotive applications.
Figure 2.2 - Engine Block Heater
Refer to applicable wring diagram(s) and electrical
schematic(s) at the back of this manual for wiring
connections.
2.7- WEEKLY EXERCISE CYCLE
The generator wll start and exercise once ever/
seven days. During this weekly exercise, the unit
runs for approximately 20 minutes and shuts
dotvn. Transfer of loads to generator oucput does
not occur during the exercise unless power is lost
during the exercise period.
To select the day of the tveek and time of day for
exercising, proceed as follov/s:
« Set the Auto/Off/Manual switch to OFF.
« Set generator's main circuit breaker to its OFF (or
open) position.
» Locate 'the rocker swatch on the control panel
identified wdtli the wnrds “Set Exercise Time”
(Figure 2.3).
» Push “Set Exercise Time” swdtch to the ON posi
tion for 20 to 30 seconds and dien release. The
swdtch will spring back into its original positLo.n
wdien released.
» Wait 30 seconds before setting the Auto/Off/
Manual swdtch to the AUTO position.
NOTE;
The unit -will exercise 20 minutes after it is set.
Example: Set - Noon; Exercise - 12:20 p.m.
-A CAUTION A-
If you switch the Auto/Off/Manual switch too
A
soon, the engine may start. If engine does
start, it will shut down automatically in about
two (2) minutes.
® Set the generator's main circuit breaker to its ON
(or closed) position.
• The generator is now programmed to start and
exercise eveiy seven days thereafter, on the day
and at the time of day the swdtch was activched.
0 Place a sign on tlie generator’s control panel and
on the transfer sv/itch that indicates the day and
time the generator tvill be exercising.
NOTE:
If the battery terminals are disconnected or the
control panel fuse is removed, the exercise
timer needs to be reset for automatic exercise
operation.
Figure 2.3 - "Set Exercise" Switch on Control Panel
MANUAL
2.8 OPTIONAL GTS TRANSFER SWITCH
This generator can be installed in conjunction wdth
a Generac GTS-type automatic transfer switch, if
desired.
The standard ATS-type transfer swdtch has no
sensing or controlling circuit boards. Instead, the
generator control console houses a control module
assembly (CfVLA), which controls all phases of oper
ation, including engine start-up and load transfer.
Section 2 — Operation
Guardian Liquid-cooied 8 kW Generators
OPERATION
6
&
# 2.8.1 USING AN OPTIONAL GTS
_________
When you use a GTS-type transfer swatch, it con
trols automatic operation and automatic transfer
as follows:
• Solid-state circuits in the transfer switch monitor
utility power source voltage.
• When utilitjr source voltage drops below a preset
level, transfer swdtch action closes the engine cir
cuit. The engine then cranks and starts as con
trolled by the generator's control module circuit
board.
* After the engine starts and when the generator
A.C output voltage and frequency have reached a
preset value, transfer switch circuits signal the
transfer switch main contacts to move to the
standby power source side. Generator AC output
then pownrs load circuits.
TRANSFER SWITCH
_______________________
® When the utiliW power source voltage is restored
above a preset level and the return to utility
timer has timed out. the transfer switch solidstate circuits signal the switch main contacts to
move back to their utility power source side.
» The engine cooldown timer stains and times out.
Then, the transfer switch circuit board action
opens the engine run circuit. The engine then
shuts down.
NOTE:
If yonr generator is installed in conjunction
with an optional GTS-type transfer switch, refer
to the applicable transfer switch manual for
exact operating parameters and timing
sequences.
MAINTENANCE
5izz=:0
Section 3 - Maintenance
Guardian Liquid-cooled 8 kW Generators
3.1 25-HOUR BREAK-IN PERIOD
The first 25 hours of operation constitute the breakn period for the standicy generator. Correctly breakng in the generator is essential to mitiiiriize oil connimption and macdmize engine performance. During
he break-in period, observe the ibllowing rules:
. Run the generator at va.rious elecuical loads for
the first 25 hours of operation, to help seat
engine piston rings properly.
For the next 75 operating hours, avoid light
electrical loads.
' During this period, load the unit at 50 percent or
more of its rated capacity (4,000 watts or more).
Repeated light electrical loads during the break-
in period can cause improper seating of engine
piston rings, resulting in blowb\^ and high oil
consumption.
. Check the engine crankcase oil level frequently
during the break-in period. It is normal for oil
consumption to be high during this period.
, xkfter the 25 hour break-in period is completed,
perform the tasks recommended under "25
Hour Checkup.”
.2 25-HOUR CHECKUP
tlloiving the first 25 hours of operation, contact an
tithorized sendee facility for tlie following mainte-
ince. The generator ovmer is responsible for all
targes.
Change the engine crankcase oil and filter.
Check all fluid levels (engine coolant, fuel, bat-
ter\" electrolyte fluid).
Inspect cooling system hoses for deterioration
and leaks, all hose clamps for tightness and
security.
Check fuel system lines for leaks, tightness and
condition.
Check fuel injection timing,
Check/Adjust engine governed speed (frequency).
Inspect engine belts for condition, proper tension.
Check for correct AC voltage output.
Check all generator receptacles and circuit
brealcers for condition and proper operation.
3 CHECKING THE ENGINE
OIL LEVEL
ter the 25-hour break-in period, check the engine oU
'el eveiy" eight hours or operation or at least once
ily before using the generator. For oil capacities, see
oecltications,” Section 1,7 (Page 6). For engine oil rec-
iinendations. see Section 1,9 (Page 7). To check the
gine oil level, proceed as follows (Figure 3.1):
Remove tlae dipstick and rvlpe it dry rvlth a
clean clotli.
S, Generac* Power Systems, !nc.
Install the dipstick cap; then, remove it again.
The oil level should be at the dipstick “Full”
mark. If necessary, add oil to the “Full” mark
only. DO NOT FILL ABOVE THE “FULL” MARK.
3.
Install the dipstick.
CAUTION M.
-A
Never operate the engine with the oil level
below the "Add" mark on the dipstick. Doing
this could damage the engine.
Figure 3.1 - Engine OH Servicing Points
Oil Filler
Cap
--------
3.4 CHANGING THE ENGINE
GIL AND FILTER
See Section 1.9, “Engine Oil Recommendsfoons” (Page
7), for die proper oil grade for your application.
NOTE;
The engine oil and filter should be changed after
the 25-hour break-in period. See the “Service
Schedule,” Section 3.13 (Page 16), for subse
quent oil and filter changes.
-A
.Any attempt to crank or start the engine before
A
it has been properly serviced with the recom
mended oil may result in an engine failure.
To change tiie oil and filter, proceed as follows:
Refer to tlie “Sendee Schedule,” Section 3.13 (Page
16), for engine oU and filter change frequencies.
Drain the oil while the eng,ine is still warm from run
ning. This means you should warm up the engine,
shut it down and drain It immediately as follows:
1. Remove tlie oil drain hose from its retaining clip,
located on the generator base frame.
2. Loosen and remove tlie oil drain hose cap, locat
ed on tlie base frame end of tlie hose. Drain tlie
oil completely into a suitable container.
CAUTiON
A-
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