Generac 004721-0, 004722-0, 004723-0, 004724-0, 004725-0 User Manual

Owner’s Manual

Liquid-cooled, Prepackaged

Standby Generators

Model Numbers

004721-0, 004722-0,

004723-0, 004724-0,

004725-0, 004725-1,

004725-2, 004725-3,

004726-0

! Not intended for use in critical life support applications. !

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT

INSTALLATION!!

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

This manual should remain with the unit.

INTRODUCTION

Thank you for purchasing this model of the standby generator set product line by Generac Power Systems.

Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest Generac Authorized Service Dealer for starting, operating and servicing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

DANGER

After this heading, read instructions that, if not strictly complied with, will result in personal injury or property damage.

After this heading, read instructions that, if not strictly complied with, may result in personal injury or property damage.

After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

NOTE:

After this heading, read explanatory statements that require special emphasis.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents.

Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows:

This symbol points out important safety informa-

!tion that, if not followed, could endanger personal safety and/or property of others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

The operator is responsible for proper and safe use of the equipment. Generac strongly recommends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. Generac also strongly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by a Generac Authorized Service Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum. See a Generac Authorized Service Dealer for service aids and accessories.

Operating instructions presented in this manual assume that the standby electric system has been installed by a Generac Authorized Service Dealer or other competent, qualified contractor. Installation of this equipment is not a “do-it-yourself” project.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, contact a Generac Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all of servicing needs.

When contacting a Generac Authorized Service Dealer about parts and service, always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit.

AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest GENERAC AUTHORIZED

SERVICE DEALER, please call this number:

1-800-333-1322

OR

Locate us on the web at:

www.generac.com

Generac® Power Systems, Inc.

Table of Contents

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

INTRODUCTION ..................................		IFC
SAFETY RULES ......................................		2
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 ..................................	4
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 ..........	10
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

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	Automatic Operation ..................................	13
3.5	Weekly Exercise Cycle..................................	13
3.6	Engine Heater..............................................	14
Section 4 — MAINTENANCE ..............		14

4.1Maintenance Performed by Authorized

Service Facilities..........................................	14
4.2 Cooling System............................................	15

4.3Overload Protection for Engine DC

Electrical System ........................................	15
4.4 Checking Fluid Levels ................................	15

4.5Maintenance Owner/Operator

	Can Perform ................................................		15
4.6	Miscellaneous Maintenance ........................		17
4.7	Scheduled Maintenance ..............................		19
Section 5 — TROUBLESHOOTING......			22
5.1	Troubleshooting Points................................		22
Section 6		— NOTES............................	23
Section 7		— INSTALLATION
		DIAGRAM ......................	25
Section 8		— ELECTRICAL DATA ........	26
Section 9		— EXPLODED VIEWS AND
		PARTS LISTS ................	30
Section 10 — WARRANTY .................			48

Generac® Power Systems, Inc. 1

IMPORTANT SAFETY INSTRUCTIONS

Guardian Liquid-cooled 15 kW, 20 kW and 25 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.

!

!

! WARNING: !

The engine exhaust from this product contains chemicals known to the state

of California to cause cancer, birth defects or other reproductive harm.

!	WARNING:	!
	This product contains or emits chemicals
	known to the state of California to cause
cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

Generac cannot possibly anticipate every possible cirumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If using a procedure, work method or operating technique that Generac does not specifically recommend, satisfy yourself that it is safe for others. Also make sure the procedure, work method or operating technique chosen 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 maintain 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.

Parts of the generator are rotating and/or hot

!during operation. Exercise care near running generators.

! GENERAL HAZARDS !

•For safety reasons, Generac recommends that this equipment be installed, serviced and repaired by a Generac Authorized Service Dealer or other competent, 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 generator is installed, operated and serviced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations.

•The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided. Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people, animals, etc., will not be harmed. This exhaust system must be installed properly, in strict compliance with applicable codes and standards.

•Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

•Adequate, unobstructed flow of cooling and ventilating 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.

•Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous.

•When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.

2 Generac® Power Systems, Inc.

IMPORTANT SAFETY INSTRUCTIONS

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

•Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts.

•Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.

•Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

ELECTRICAL HAZARDS

•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 well as the standby generator. Avoid contact with bare wires, terminals, connections, etc., on the generator as well as the transfer switch, if applicable. Ensure all appropriate 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.

•The National Electrical Code (NEC), Article 250 requires the frame and external electrically conductive 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 condition 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 electrical current (ampacity) to which they will be subjected.

•Before installing or servicing this (and related) equipment, 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.

•Generators installed with an automatic transfer switch will crank and start automatically 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, 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.

•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 nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

•Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

FIRE HAZARDS

•Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. Consult the local fire department for any questions pertaining to fire extinguishers.

EXPLOSION HAZARDS

•Properly ventilate any room or building housing the generator to prevent build-up of explosive gas.

•Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

•Generac generator sets may operate using one of several types of fuels. All fuel types are potentially FLAMMABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the 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. 3

Section 1 - General Information

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

1.1GENERATOR

This equipment is a liquid-cooled, engine-driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been facto- ry-installed in a weather resistant, all metal enclosure and is intended for outdoor installation only. Use this generator as a source of electrical power for the operation of 120 and/or 240 volts, single phase loads.

These models are available. They are rated as follows:

Models 0047210 and 0047220: Provides 15,000 watts (15 kW) of single phase power.

Models 0047230 and 0047240: Provides 20,000 watts (20 kW) of single phase power.

Models 0047250, 0047251, 0047252, 0047253, and 0047260: Provides 25,000 watts (25 kW) of single phase power.

If this generator is used to power electrical

!load circuits normally powered by a utility power source, it is required by code to install a transfer switch. The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating (NEC 701). Failure to isolate an electrical system by such means results in damage to the generator and may also result in injury or even death to utility power workers due to backfeed of electrical energy.

1.3AUTOMATIC SYSTEM OPERATION

When this generator, along with its transfer switch, has been installed and interconnected, a circuit board in the generator panel constantly monitors utility power source voltage. Should that voltage drop below a preset value, and remain at such a low state for a preset amount of time, the generator cranks and starts. After the generator starts, the transfer switch transfers load circuits so the generator can power them.

When utility source voltage has been restored, the switch re-transfers back to the utility source voltage and the generator then shuts down.

Please reference the transfer switch manual for specific information.

1.4GENERATOR 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 120 volts AC, 60 Hertz. When the two windings are connected in series, a 240 volts, 60 Hertz AC output results. Typically the two “hot” leads in the circuit are Wires No. 11 and 44. The “Neutral” leads are the junction of Wires 22 and 33.

Figure 1.1 - Generator AC Connection System

1.2TRANSFER SWITCH

This generator system may include a matched automatic transfer switch which is intended to be used in conjunction with the Guardian generator. It is supplied in either a NEMA 1 enclosure (15 kW model 004721, 20 kW models 004723) or a NEMA 3R enclosure (25 kW models 004725). 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:

•Install the transfer switch on a firm, sturdy supporting structure.

•To prevent switch distortion, level the switch if necessary. This can be done by placing washers between the switch enclosure and the mounting surface.

•Never install the switch where water or any corrosive substance might drip onto the enclosure.

•Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and corrosive vapors.

•Failure to utilize a Generac/Guardian transfer switch with this generator will void the warranty.

4 Generac® Power Systems, Inc.

1.5MAIN 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 at the top of page 5.

1.6GENERATOR FUEL SYSTEM

The generator has been factory tested and adjusted using a natural gas fuel system. If propane (LP requirements) gas is preferred, contact an authorized service dealer. Refer to Secion 1.12.

Section 1 - General Information

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

Figure 1.2 - Main Circuit Breaker

Model	Rating	Phase	Actual Current	C/B Rating*	% over rating	Circuit Breaker
004721/004722	15,000	1	62.5	70	112%	70A BQ2
004723/004724	20,000	1	83.3	90	108%	90A BQ2
004725/004726	25,000	1	104.2	125	120%	125A BQ2
			* Amp Rating of CB structured under model.

Recommended fuels should have a Btu content of at least 1,000 Btus per cubic foot for natural gas and at least 2,520 Btus per cubic foot for LP gas. Ask the fuel supplier for the Btu content of the fuel being used.

Fuel pressure for both natural gas and liquid propane set ups should be 11 inches to 14 inches of water column (0.6 psi) at all load ranges.

NOTE:

A seperate gas line and regulator may be needed to assure proper gas pressure (11-14”) to the generator. Low gas pressure can cause hard starting and could affect engine durability.

Gaseous fuels such as natural and LP

!(propane) gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explosion. 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.

1.7ENGINE PROTECTIVE DEVICES

The engine has several safety switches which cause the engine to automatically shut down under the following conditions: low oil pressure, high coolant temperature, engine overspeed, low coolant level or overcrank (Figure 1.3).

Figure 1.3 - Engine Protective Devices

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 and the engine shuts down automatically (Figure 1.4).

Figure 1.4 - Low Oil Pressure Switch

1.7.2 HIGH COOLANT TEMPERATURE SWITCH

This normally open (N.O.), thermostatic switch has sensing tip which is immersed in captive coolant. Should coolant temperature exceed about 230°F (110°C), the switch contacts close, which causes the engine to shut down automatically (Figure 1.5).

Figure 1.5- High Coolant Temperature Switch

1.7.3 LOW COOLANT LEVEL 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 automatically shuts down (Figure 1.6 on page 6).

Generac® Power Systems, Inc. 5

Section 1 — General Information

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

Figure 1.6 - Low Coolant Level Sensor	• LED 2 is YELLOW. This LED is on when the circuit
	board battery charger is on. This LED will cycle on
	and off with the battery charger, 4.85 hours on the
	4.85 hours off.

• LED 3 is GREEN. This LED will flash when the circuit board has load voltage available to it. This LED will function when voltage is available across T1 and T2.

1.7.6 OVERCRANK SHUTDOWN

After 90 seconds of crank-rest cycles, this function ends cranking if the engine fails to start in that 90-second span.

1.7.4 OVERSPEED SHUTDOWN

The Pre-pack circuit board on liquid cooled units receives AC frequency (rpm) signals directly from the stator AC power windings, via sensing leads S15 and S16. Should AC frequency exceed about 72 Hz, circuit board action will automatically shutdown the engine (Figure 1.7).

*Rated power of generator is subject to and limited by such factors as ambient temperature, altitude, engine condition, and other factors. Engine power will decrease about 3.5% for each 1000 feet above sea level and will decrease an additional 1% for each 10°F above 60°F. Maximum output power of the generator is limited by maximum engine power.

Figure 1.7 - Control Module Assembly

Circuit Board

M14

J2

E

M15

9R6

9CR1

CR8

R70

R71

R72

U13

U14

PRE-PACKAGED STANDBY

U15

U17

A

C17

M3

5M1M8

R54

Q7

R1

C1

C18

77R

R75

R76

R84

U1

Q14

C12

M10

C21

R68

R60

17

C25

U16

C22

U5

U4 LED3

SW1

R2

R3

BR1

U12

C3

C24

R56

CR1

Q9

C5

C2

U2

R12

C4

Q1

U6

C

R20 CR2

R6 R21

R52 R36

CR37

K4

R14

R15

R13

R17 R16

R18

CR38

R22

CR12

9R1

R31

R30

R7

U7

CR3

R40

R41

9R3 R35

R38

CR20

R37

CR36

CR15

CR14

CR13

R23

R24

R5

R4

R8

R51

R74

R48

U3

U18

R11 R10

CR7

U19

Q4

CR21

R82

R67

K2

R50

Q5

Q12

C23

R27

9R2

R33

CR18

R32

CR17

U10

U9

C19

U8

Q2

CR40

CR34

Q3

9CR2

CR24

C20

K3

R78

Q11

C8

CR16

R25

R26

C15

Q15

R85

R86

LED2

C10

C9

C11

R62

U20

Q16

1

C14

C16

C7

J1

K1

R63

LED1

M9

CR33

CR35

R66

R81

R53

R57

9R5

CR32

R61

CR30

R65

R47

R46

R44

R42

R43

R87

R88

R83

M2

Q13

Q6

9R

M4

CR41

R55

C13

CUT R83

2002 GENERAC POWER SYSTEMS, ASSY #076009A

FOR 50HZ

1.7.5 PCB OPERATION LED’S

•LED 1 is RED. The LED is on when utility sensing is NOT available to the circuit board. This LED will function only when the Auto/Off/Manual switch is set in the Auto position.

1.7.6 DC FUSE

This clearly labeled fuse is located on the front panel of the control system. It protects the panel wiring and components from damaging overload. Always remove this fuse before commencing work on the generator. The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rating. Generac normally uses an AGC fuse rated at 15 amps (part number 022676).

1.8UNPACKING

1.8.1 UNPACKING PRECAUTIONS

Handle shipping cartons and crates with care. Use care to avoid damage from dropping, bumping, collision, etc. Store and unpack cartons with the proper side up, as noted on the shipping carton.

1.8.2 INSPECTION

After unpacking, carefully inspect the generator for any damage that may have occurred during shipment. If loss or damage is noted at the time of delivery, have the person(s) making delivery note all damage on the freight bill or affix their signature under the consignor’s memo of loss or damage.

1.9LIFTING 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.

6 Generac® Power Systems, Inc.

Section 1 — General Information

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

1.10 SPECIFICATIONS

1.10.1 GENERATOR SPECIFICATIONS

		Single-Phase
	Model	004725		004723	004721
		004726		004724	004722
	Rated Max. Cont.	25		20	15
	AC Power Output (kW)
	Rated voltage (volts)		120/240
	No. of Rotor Poles		2		4
	Driven Speed of Rotor	3600		3600	1800
	Rotor Excitation System	Direct excited brush type
	Type of Stator			4 Wire
	Rotor/Stator Insulation			Class F

NOTE:

Fuel consumption is given at rated maximum continuous power output when using natural gas rated at 1000 Btu per cubic foot and LP gas rated 2520 Btu per cubic foot. Actual fuel consumption obtained may vary depending on such variables as applied load, ambient temperature, engine conditions and other environmental factors.

Fuel pressure for both natural gas and liquid propane set ups should be 11 inches to 14 inches of water column (0.6 psi) at all load ranges.

NOTE:

A seperate gas line and regulator may be needed to assure proper gas pressure (11-14”) to the generator. Low gas pressure can cause hard starting and could affect engine durability.

1.10.2 ENGINE SPECIFICATIONS

Make..............................................................................	Mitsubishi
Displacement ..............................................	92 inches3 (1.5 liters)
Cylinder Arrangement......................................................	4, in-line
Valve Arrangement................................................	Overhead Cam
Firing Order........................................................................	1-3-4-2
Number of Main Bearings............................................................	5
Compression Ratio ..............................................................	9 to 1
No. of Teeth on Flywheel ........................................................	104
Ignition Timing
at 1800 rpm ..................................................	35 degrees BTDC
at 3600 rpm ..................................................	43 degrees BTDC
Spark Plug Gap ..................................................	0.020-0.025 inch
Recommended Spark Plugs
Champion ....................................................................	RN11YC4
Oil Pressure....................................................................	30-50 psi
Crankcase Oil Capacity........................	3.0 U.S. quarts (2.8 liters)
Recommended Engine Oil........................................	SAE 15W-40
Type of Cooling System ..................	Pressurized, closed recovery
Cooling Fan ..............................................................	Pusher Type
Cooling System Capacity ......................	2 U.S. gallons (7.6 liters)
Recommended Coolant............................	Use a 50-50 mixture of
	ethylene glycol base.

1.11 FUEL CONSUMPTION

25 kW Models

Using Natural Gas	........................................441 cu. ft. per hour
Using LP Gas..............................	175 cubic ft.(4.8 gal.) per hour
20 kW Models
Using Natural Gas ........................................	359 cu. ft. per hour
Using LP Gas ............................	143 cubic ft. (4.0 gal.) per hour
15 kW Models
Using Natural Gas ........................................	277 cu. ft. per hour
Using LP Gas..............................	110 cubic ft.(3.1 gal.) per hour

1.12RECONFIGURING THE FUEL SYSTEM

NOTE:

All models are configured for natural gas from the factory.

To reconfigure the fuel system from NG to LP, follow these steps:

1.Turn the main gas supply off.

2.Remove the carburetor fuel hose from the outlet port (Port 1) of the demand regulator (Figure 1.8).

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	FUEL HOSE
	PLUG	BRASS HOSE	BRASS HOSE	PLUG
		FITTING	FITTING
		OUT	OUT
		PORT 1	PORT 2
		HOUSING	HOUSING
			PORTS
		PORTS

NG FUEL SYSTEM

LP FUEL SYSTEM

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Section 2 — Installation

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

NOTE:

1.16 BEFORE INSTALLATION

Port 1 is for NG only and Port 2 is for LP vapor only. No provision for simultaneous fuels has been made.

DANGER

Serious injury or damage may occur if not con-

!figured properly. Please consult an authorized Generac Service Dealer with any questions.

1.13 TORQUE SPECIFICATIONS

Cylinder Head ............................................	15 (+ 90° + 90°) ft.lb.
Intake Manifold ................................................................	13 ft.lb.
Exhaust Manifold..............................................................	13 ft.lb.

1.14 ENGINE OIL RECOMMENDATIONS

The unit has been filled with 15W-40 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:

	Temperature			Oil Grade (Recommended)
	Above 80° F (27° C)			SAE 30W or 15W-40
	32° to 80° F (-1° to 27° C)			SAE 20W-20 or 15W-40
	Below 32° F (0° C)			SAE 10W or 15W-40

Any attempt to crank or start the engine before

!it has been properly serviced with the recommended oil may result in an engine failure.

1.15 COOLANT RECOMMENDATIONS

Use a mixture of half low silicate ethylene glycol base anti-freeze and deionized water. Cooling system capacity is about 8 U.S. quarts (7.6 liters). Use only deionized water and only low silicate anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture.

Do not use any chromate base rust inhibitor

!with ethylene glycol base anti-freeze or chromiumhydroxide (“green slime”) forms and will cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high silicate anti-freeze boosters or additives will also cause overheating. Generac Power Systems also recommends that any soluble oil inhibitor is NOT used for this equipment.

8 Generac® Power Systems, Inc.

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 the installation manual (Part No. 079699).

The generator’s rated wattage/amperage capacity must be adequate to handle all electrical loads that the unit will power. The critical (essential) loads may need to be grouped together and wired into a separate “emergency” distribution panel.

This generator can be installed in conjunction with a standard Generac “GTS” type transfer switch, if desired.

The standard transfer switch has no sensing or controlling circuit boards. Instead, the generator control console houses a “Printed Circuit Board Assembly”, which controls all phases of operation, including engine start up and load transfer.

2.1STANDBY GENERATOR INSTALLATION

DANGER

Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch, so as to isolate the electric system from the utility distribution system when the generator is operating. Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy.

If an open bottom is used, the engine-genera- tor is to be installed over non-combustible

materials and should be located such that combustible materials are not capable of accumulating under the generator set.

Only qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system. The installation must comply strictly with all codes, standards and regulations pertaining to the installation.

This genset must be installed on a level surface. The base frame must be level within 1/2 inch all around.

After the system has been installed, do nothing

!that might render the installation in noncompliance with such codes, standards and regulations.

Section 2 — Installation

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

NOTE:

For more information about the installation of a standby system, order Engine-Generator Standby Electric Power Systems Installer’s Guide and Reference Manual (part #046622) from a Generac Authorized Service Dealer.

2.1.1 NFPA STANDARDS

The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection Association (NFPA), Batterymarch Park, Quincy, MA 02269:

•NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS TURBINES.

•Install the generator on high ground where water levels will not rise and endanger it.

•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.

•Install the generator as close as possible to the fuel supply, to reduce the length of piping. HOWEVER, REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE.

•NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES.

•NFPA No. 220, STANDARD TYPES OF BUILDING CONSTRUCTION

•NFPA No. 68, GUIDE FOR EXPLOSION VENTING

•NFPA No. 70, NATIONAL ELECTRICAL CODE.

•NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE.

•NFPA No. 10, INSTALLATION, MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS.

2.3GENERATOR MOUNTING AND

SUPPORT

Retain the generator compartment to a concrete slab with 1/4-inch masonry type anchor bolts. Be sure the bolts are long enough to retain the compartment. The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides. See Section 7, Installation Diagram.

2.1.2 OTHER PUBLISHED STANDARDS

In addition to NFPA standards, the following information pertaining to the installation and use of standby electric systems is available:

•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 MAINTENANCE 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 SYSTEMS, available from the American National Standard Institute, 1430 Broadway, New York, N.Y. 10018.

2.4BASIC 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 transfer switch is required by electrical code and serves the following functions:

•Permits 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 drifting, consider using a windbreak to protect the unit.

Generac® Power Systems, Inc. 9

Section 2 — Installation

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

NOTE:

Generac recommends the use of a Generac Power Systems “GTS” type transfer switch in conjunction with this generator.

2.5EMERGENCY 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 critical loads, within the wattage/amperage capacity, during utility power outages, consider using the emergency circuit isolation method.

Critical electrical loads are grouped together and wired into a separate “Emergency Distribution Panel.” Load circuits powered by that panel are within the wattage/amperage capacity of the generator set. When this method is used, it is difficult to overload the generator. The transfer switch must meet the following requirements:

•It must have an ampere rating equal to, or greater than, the total amperage rating of the emergency distribution panel circuit.

•Have it installed between the building’s main distribution panel and the emergency distribution panel.

2.6TOTAL 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 generator to be overloaded when this isolation method is employed. The following apply to the transfer switch in this type of system.

•Ampere rating of the transfer switch must be equal to, or greater than, the ampere rating of the normal incoming utility service.

•The transfer switch is installed between the utility service entrance and the building distribution panel.

2.7GROUNDING THE GENERATOR

The National Electrical Code requires the frame and external electrically conductive parts of this equipment 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 generator mounting base. Consult a qualified electrician for grounding requirements in the area. Grounding procedures must meet local regulations.

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 condition in the generator or in connected electrical devices. In addition, grounding helps dissipate static electricity that often builds up in ungrounded devices.

Figure 2.2 – Generator Grounding Lug (typical)

2.8GENERATOR AC NEUTRAL

CONNECTIONS

Generac Power Systems 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.

2.9TRANSFER SWITCH START SIGNAL

CONNECTIONS

If the generator is to be installed with an automatic transfer switch, such as a Generac GTS-type switch, it is necessary to connect the two-wire start control system.

Connect the two-wire start signal from the automatic transfer switch to the automatic start connection, which is located in the right hand corner 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.

10 Generac® Power Systems, Inc.

Section 2 — Installation

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

2.10 BATTERY INSTALLATION

DANGER

Standby generators installed with automatic

! transfer switches will crank and start automatically 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 the NORMAL source voltage at the transfer switch is correct and the system is ready to be put into operation.

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.

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.

Do not dispose of the battery in a fire. The bat-

tery 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.

•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.

Lead acid batteries present a risk of fire because they generate hydrogen gas. The following procedure are to be followed:

•DO NOT SMOKE when near batteries,

•DO NOT cause flame or spark in battery area, and

•Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

For recommended batteries, see “Specifications.” All batteries must be at 100 percent state-of-charge before they are installed on the generator.

When using maintenance-free batteries, it is not necessary 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 batteries are correctly connected and terminals are tight. Observe battery polarity when connecting batteries to the generator set.

NOTE:

Damage will result if the battery connections are made in reverse.

2.11 PREPARATION BEFORE START-UP

The instructions in this section assume that the standby generator has been properly installed, serviced, 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) equipment.

2.10.1 VENTED BATTERIES

The electrolyte is a dilute sulfuric acid that is

!harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed:

•Wear full eye protection and protective clothing,

•Where electrolyte contacts the skin, wash it off immediately with water,

•Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention, and

2.11.1 PRIOR TO INITIAL START-UP

Prior to initially starting the generator, it must

!be properly prepared for use. Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure.

Before starting the generator for the first time, the installer must complete the following procedures. For follow-up maintenance information and/or service intervals, please refer to Section 4, “Maintenance.”

Generac® Power Systems, Inc. 11

Section 3 — Operation

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

2.11.2 TRANSFER SWITCH

If this generator is used to supply power to any electrical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (For additional information, see the applicable transfer switch manual for this unit.) The transfer switch, as well as the generator and other standby components, must be properly located and mounted in strict compliance with applicable codes, standards and regulations.

2.11.3 FUEL SYSTEM

Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and

(b) is properly purged and leak tested according to code. No fuel leakage is permitted. See “Specifications” (Section 1.10) for more information.

2.11.4 GENERATOR SET LUBRICATION

Check the engine crankcase oil level before operating and add oil to the proper level – the dipstick “FULL” mark. Never operate the engine with the oil level below the dipstick “ADD” mark. See “Specifications” (Section 1.10) and “Engine Oil Recommendations” (Section 1.14).

NOTE:

This engine is shipped from the manufacturer with 15W-40 oil. This oil should be changed after 30 hours of operation.

2.11.5 ENGINE COOLANT

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).

2.11.6 BELT TENSION

Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of approximately 22 pounds (10 kg), applied midway between pulleys, deflects the belt about 3/8- to 5/8- inch (10 to 16 mm).

2.11.7 ELECTRICAL SYSTEM

Make sure the generator is properly connected to an approved earth ground and/or ground rod.

3.1USING A STANDARD “GTS”

TRANSFER SWITCH

When required, the pre-packaged standby generator can be installed with a standard Generac “GTS” type engineered automatic transfer switch.

When a GTS type transfer switch is used, it controls automatic operation and automatic transfer as follows:

•Solid state circuits in the transfer switch monitor utility power source voltage.

•When utility source voltage drops below a pre-set level, transfer switch action closes the circuit. The engine then cranks and starts as controlled by the pre-packaged generator’s Control Module circuit board.

•After the engine starts and when the generator AC output voltage and frequency have reached a pre-set value, transfer switch circuits signal the transfer switch main contacts to actuate to the “STANDBY” power source side. Generator AC output then powers load circuits.

•When the utility power source voltage is restored above a pre-set level, transfer switch solid state circuits signal the switch main contacts to move back to their utility power source side.

•Following re-transfer back to the utility power source side, transfer switch circuit board action opens the circuit. Engine then shuts down.

NOTE:

If the generator is installed in conjunction with a standard GTS type transfer switch, refer to the applicable transfer switch manual for exact operating parameters and timing sequences.

3.2CONTROL CONSOLE

COMPONENTS

The components of a liquid-cooled generator control console (Figure 3.1) are as follows:

Figure 3.1 - Liquid-Cooled Generator Panel

	FUSE	FAULT
HOUR METER	15-A	INDICATOR
	AGC
AUTO
		SET
OFF		EXERCISE
		TIME
		ON
MANUAL

Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use.

Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear of any moving generator set components.

12 Generac® Power Systems, Inc.

Section 3 - Operation

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

3.2.1 HOURMETER

Indicates time the engine-generator has operated, in hours and tenths of hours. Use the hourmeter along with the periodic maintenance schedule for the generator set.

3.2.2 AUTO/OFF/MANUAL SWITCH

Use this three-position switch as follows:

•Set the switch to AUTO for fully automatic operation. See “Automatic Operation”, Section 3.4.

•Set switch to MANUAL position to crank and start the generator engine.

•Set switch to OFF position to shut down an operating engine. With OFF selected, operation will not be possible.

DANGER

With switch set to AUTO, engine can crank

!and start suddenly without warning. Such automatic start up normally occurs when utility source voltage drops below a pre-set level. To prevent possible injury that might be caused by such sudden starts, set AUTO/OFF/MANUAL switch to OFF before working on or around the unit. Then, place a "DO NOT OPERATE" tag on control console.

3.2.3 FAULT INDICATOR LAMP

The lamp goes ON when one or more of the following engine faults occurs and when engine shuts down.

•	Low oil pressure	•	Overcrank
•	High coolant temperature	•	Overspeed

•Low coolant level

3.2.4 15 AMP FUSE

The 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 replacement of the fuse is necessary, use only an identical 15-amp fuse. (Type AGC, part number 022676).

3.2.5 7.5 AMP INLINE FUSE

This inline fuse is connected in the 15A line that runs between the Auto/Off/Manual switch and position 10 of the 76009A PCB. This fuse protects the start, fuel, field boost, and transfer outputs from the PCB and will open if there is excessive current draw on any one of these outputs.

NOTE:

This fuse will not remove the positive (+) battery input power from the PCB when it opens. This means the exercise timer will not be reset. If this fuse does open, carefully check the wiring to the start, fuel, field boost and transfer outputs before replacing the fuse.

3.2.6 SET EXERCISE TIME SWITCH

This switch allows for programming the generator to start and exercise automatically. See “Weekly Exercise Cycle” (Section 3.5).

3.3MANUAL TRANSFER AND

START-UP

To transfer electrical loads to the STANDBY (GENERATOR) power source side and start the engine manually, refer to the Owner’s Manual of the particular transfer switch.

3.4AUTOMATIC OPERATION

To set the system for fully automatic operation, proceed as follows:

•Check that load circuits are connected to the utility power supply.

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

•Set the generator main circuit breaker to its ON or CLOSED position.

3.5WEEKLY EXERCISE CYCLE

The generator will start and exercise once every seven days. During this weekly exercise, the unit runs for about 20 minutes and shuts down. Transfer of loads to generator output does not occur during the exercise.

To select day and time for exercising, proceed as follows:

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

•Set generator main circuit breaker to OFF or OPEN.

•Locate the rocker switch on the control panel identified with the words “Set Exercise Time” (Figure 3.2).

•Push “Set Exercise Time” switch to ON position for 20 to 30 seconds and then release. Switch will spring back into its original position when released.

•Wait 30 seconds before setting the AUTO/OFF/ MANUAL switch to AUTO position.

Generac® Power Systems, Inc. 13

Section 4 — Maintenance

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

If the AUTO/OFF/MANUAL switch is switched

!too soon, the engine may start. If engine does start, it will shut down automatically in about two (2) minutes.

•Set the generator main circuit breaker to its ON or CLOSED position.

Refer to applicable wiring diagram(s) and electrical schematic(s) at back of manual for wiring connections. Customer supplies a 120V 15A Utility fed circuit for the block heater.

4.1MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES

•Generator is now programmed to start and exercise every seven days thereafter, on day and time of day the switch was actuated.

•Place a sign on the generator control panel and the transfer switch, indicating the day and time the generator will be exercising.

NOTE:

If battery terminals are disconnected, the exercise timer needs to be reset for correct automatic exercise operation.

Figure 3.2 - “Set Exercise” Switch

3.6ENGINE HEATER

This standby generator comes equipped with a block heater (Figure 3.3), similar to the block heaters used in automotive applications. The block heater is wired to a grounded plug.

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.

B. ONCE EVERY SIX MONTHS

1.Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature).

C. ONCE ANNUALLY

1.Test engine governor. Adjust or repair, if needed. 2.Clean, inspect generator.

3.Flush cooling system.

D. FIRST 100 OPERATING HOURS

1.Change engine oil and oil filter. (After initial change, service engine oil and filter at 150 operating hours or six 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.)

E. EVERY 500 OPERATING HOURS

1.Service air cleaner. 2.Check starter.

3.Check engine DC alternator.

Figure 3.3 - Engine Block Heater	F. EVERY 800 OPERATING HOURS
	1.Retorque cylinder head. (See Torque Specs,
	Section 1.13.)
	2.Retorque intake and exhaust manifold. (See
	Torque Specs, Section 1.13.)
	3.Check engine compression.
	4.Check valve clearance.

14 Generac® Power Systems, Inc.