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

...
Owner’s Manual
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT
INSTALLATION!!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
Not intended for use in critical life support applications.
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Standby Generators
Model Numbers
004721-0, 004722-0, 004723-0, 004724-0, 004725-0, 004725-1, 004725-2, 004725-3,
004726-0
Generac®Power Systems, Inc.

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:
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 informa­tion 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
DANGER
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Table of Contents

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 1
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
4.1 Maintenance Performed by Authorized
Service Facilities ..........................................14
4.2 Cooling System............................................15
4.3 Overload Protection for Engine DC
Electrical System ........................................15
4.4 Checking Fluid Levels ................................15
4.5 Maintenance Owner/Operator
Can Perform................................................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
2 Generac®Power Systems, Inc.
Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The 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.
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.
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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.
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SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.
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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.
WARNING:
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DANGER
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Generac®Power Systems, Inc. 3
• Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts.
• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by 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.
ELE
CTRICAL 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.
F
IRE 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.
IMPORTANT SAFETY INSTRUCTIONS
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
4 Generac®Power Systems, Inc.
1.1 GENERATOR
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 facto­ry-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 sin-
gle 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.
1.2 TRANSFER 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.
1.3 AUTOMATIC 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.
1.4 GENERATOR AC CONNECTION SYSTEMS
The generator was shipped from the factory with its stator AC output leads connected in a single-phase, three-wire generator AC connection system (Figure
1.1). The stator assembly in this system consists of a
pair of stationary windings, with two leads brought out of each winding. Each single winding can supply 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
1.5 MAIN CIRCUIT BREAKER
The generator’s main circuit breaker is included with the unit as shipped from the factory. The breaker for each unit is described in Figure 1.2 at the top of page
5.
1.6 GENERATOR 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
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Generac®Power Systems, Inc. 5
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.
1.7 ENGINE 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).
Section 1 - General Information
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
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.
Figure 1.2 - Main Circuit Breaker
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6 Generac®Power Systems, Inc.
Figure 1.6 - Low Coolant Level Sensor
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
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.
• 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.
1.7.6 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).
1.8 UNPACKING
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.
1.9 LIFTING THE GENERATOR
When lifting or hoisting equipment is used, be careful not to touch overhead power lines. The generators weight of more than 900 pounds requires proper tools, equipment, and qualified personnel to be used in all phases of handling and unpacking.
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17 1
A
CU
83
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U1
U12
U2
U14
U13
U3
U5
U8
U15
U10
U16
U17
U9
U4
U7
C
C 3
C
2
C
3
C
4
C
5
CR16
C
0
C
1
C
4
C
0
C
2
C
6
C
9
CR1
CR7
C
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C 8
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C23
C24
C1
C3
C19
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C21
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R 6
R 6
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R2
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R 7
R 8
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R 3
R 4
R 5
R 6
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R 0
R 1
R 2
R 3
R 5
R 6
R 7
R 8
R
9
R 0
R 1
R 2
R 3
R 4
R 6
R 7
R 0
R 1
R 2
R 3
56
R 7
R
9
60
R 1
R 2
R 3
R 5
R 7
68
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9
R 0
R 1
R 2
R 4
R 5
R 6
R77
R 8
SW1
R 4
R 0
R 5
R 1
R
9
CR37
J2
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M5
Q13
U6
Q7
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CR41
U18
U19
R 3
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C14
C15
C16
C7
C10
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C18
C12
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R 4
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Q14
Q16
R 8
R 4
R 5
R 6
R 7
R 8
Q15
Section 1 — General Information
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
R1
R
6
7
7
7
1
1
R2
R3
2
1
5
5
PRE-PACKAGED STANDB
R1
3
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2002 GENERAC POWER SYSTEMS, ASSY #076009
1.10 SPECIFICATIONS
1.10.1 GENERATOR SPECIFICATIONS
1.10.2 ENGINE SPECIFICATIONS
Make..............................................................................Mitsubishi
Displacement ..............................................92 inches
3
(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
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.
1.12 RECONFIGURING 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
Section 1 — General Information
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 7
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
Port 2
LP FUEL SYSTEM
PLUG
Port 1
NG FUEL SYSTEM
FUEL HOSE
BRASS HOSE FITTING
PORT 1
HOUSING PORTS
FUEL HOSE
BRASS HOSE FITTING
OUT
OUT PORT 2
HOUSING PORTS
PLUG
8 Generac®Power Systems, Inc.
NOTE:
Port 1 is for NG only and Port 2 is for LP vapor only. No provision for simultaneous fuels has been made.
Serious injury or damage may occur if not con­figured 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:
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.
1.16 BEFORE INSTALLATION
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.
2.1 STANDBY GENERATOR INSTALLATION
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-genera­tor 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.
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Section 2 — Installation

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
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
DANGER
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DANGER
Generac®Power Systems, Inc. 9
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.
• 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.
2.1.2 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.
2.2 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.
• 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.
2.3 GENERATOR 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.
2.4 BASIC STANDBY ELECTRIC
SYSTEM
Figure 2.1 shows a schematic diagram of a basic standby electric system. Both the UTILITY power supply and the STANDBY (generator) output are con­nected to an approved transfer switch. The 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
Section 2 — Installation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
10 Generac®Power Systems, Inc.
NOTE:
Generac recommends the use of a Generac Power Systems “GTS” type transfer switch in conjunc­tion with this generator.
2.5 EMERGENCY CIRCUIT ISOLATION METHOD
This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator. If the generator is powering only 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 dis-
tribution panel and the emergency distribution panel.
2.6 TOTAL CIRCUIT ISOLATION METHOD
When a generator capable of powering all electrical loads in the circuit is to be installed, use the “Total Circuit Isolation Method.” It is possible for the 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.
2.7 GROUNDING 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.
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)
2.8 GENERATOR 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.
2.9 TRANSFER 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.
Section 2 — Installation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
DANGER
Generac®Power Systems, Inc. 11
2.10 BATTERY INSTALLATION
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 bat­tery is capable of exploding.
Do not open or mutilate the battery. Released electrolyte can be toxic and harmful to the skin and eyes.
The battery represents a risk of high short cir­cuit current. When working on the battery, always remove watches, rings or other metal objects, and only use tools that have insulated handles.
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
• 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.
2.11.1 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.”
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Section 2 — Installation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
DANGER
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12 Generac®Power Systems, Inc.
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 5/8­inch (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.
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.
3.1 USING 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.
3.2 CONTROL CONSOLE
COMPONENTS
The components of a liquid-cooled generator control console (Figure 3.1) are as follows:
Figure 3.1 - Liquid-Cooled Generator Panel

Section 3 — Operation

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
HOUR METER
AUTO
MANUAL
OFF
FUSE
15-A AGC
FAULT
INDICATOR
SET EXERCISE TIME
ON
Generac®Power Systems, Inc. 13
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.
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).
3.3 MANUAL 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.
3.4 AUTOMATIC 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.
3.5 WEEKLY 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 iden-
tified 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.
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Section 3 - Operation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
DANGER
14 Generac®Power Systems, Inc.
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.
• 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
3.6 ENGINE 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.
Figure 3.3 - Engine Block Heater
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.
4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES
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.
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.

Section 4 — Maintenance

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