Generac Power Systems 004742-0, 004744-0, 004746-0 Owner's Manual

POWER SYSTEMS, INC.

Owner’s Manual

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

This manual should remain with the unit.

Liquid-cooled, Prepackaged

Standby Generators

Model Numbers

004742-0 004744-0 004746-0

INTRODUCTION

Thank you for purchasing this model of the standby generator set.

Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was 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, the nearest 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. We strongly recommend that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. We also strongly recommend instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.

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 an 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 an Authorized Service Dealer for service aids and accessories.

Operating instructions presented in this manual assume that the standby electric system has been installed by an 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, simply contact an Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs.

When contacting an 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.

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AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest AUTHORIZED SERVICE

DEALER, please call this number:

1-800-333-1322

Locate us on the web at:

www.generac.com

DANGER

Table of Contents

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 ................................................6

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 Retransfer and Shutdown............................13

3.5 Automatic Operation ..................................13

3.6 Weekly Exercise Cycle..................................14

3.7 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................................................16

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

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

Section 5 — TROUBLESHOOTING......22

Section 6 — INTALLATION

DIAGRAM ......................23

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

Section 8 — EXPLODED VIEWS AND

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

Section 9 — NOTES............................47

Section 10 — WARRANTY .................48

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.

The manufacturer cannot anticipate every possible circumstance 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 the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized 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, the manufacturer recommends that this equipment be installed, serviced and repaired by an 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.

Important Safety Instructions

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.

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:

DANGER

• 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.

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. If there are any questions pertaining to fire extinguishers, consult the local fire department.

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.

• This generator set 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

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

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:

Model 004742-0: Provides 15,000 watts (15 kW) of 1 phase power.

Model 004744-0: Provides 20,000 watts (20 kW) of 1 phase power.

Model 004746-0: Provides 25,000 watts (25 kW) of 1 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 generator. It is supplied in either a NEMA 1 enclosure or a NEMA 3R enclosure. 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.

If a transfer switch is not included, one may be purchased separately from an Authorized Dealer.

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, 3-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

1.6 GENERATOR FUEL SYSTEM

This unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is preferred, contact an authorized service dealer.

Section 1 - General Information

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

Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges.

Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.4 to 0.5 psi) at all load ranges.

NOTE:

A seperate gas line and regulator may be needed to assure proper gas pressure to the generator. Improper gas pressure can cause hard starting and affect engine durability.

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

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).

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Section 1 - General Information

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

Model Rating Phase Actual Current C/B Rating* % over rating Circuit Breaker

004742-0 15,000 1 62.5 70 112% 70A BQ2 004744-0 20,000 1 83.3 90 108% 90A BQ2 004746-0 25,000 1 104.2 125 120% 125A BQ2

* Amp Rating of C/B structured under model.

Figure 1.2 - Main Circuit Breaker

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 - Printed Circuit Board Assembly

1.7.5 PCB OPERATION LED’S

• LED 1 is RED. This LED will be 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 will be on when the circuit board battery charger is on. This LED will cycle on and off with the battery charger, 4.85 hours on then 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.

1.7.7 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. The manufacturer normally uses an AGC fuse rated at 30 amps.

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 his 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.

1.10 SPECIFICATIONS

1.10.1 GENERATOR SPECIFICATIONS

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17 1

U12

U14

U13

U15

U10

U16

U17

C 3

C 2

C 3

C 4

C 5

CR16

C 0

C 1

C 4

C 0

C 2

C 6

CR1

CR7

C 7

C 3

C 4

C 5

C 8

C23

C24

C19

C20

C21

C13

R 6

R 1

R 3

R 7

R 8

R 2

R 3

R 4

R 5

R 6

R 7

R 0

R 1

R 2

R 3

R 5

R 6

R 7

R 8

R 0

R 1

R 2

R 3

R 4

R 6

R 7

R 0

R 1

R 2

R 3

R 7

R 1

R 2

R 3

R 5

R 7

R 0

R 1

R 2

R 4

R 5

R 6

R77

R 8

SW1

R 4

R 0

R 5

R 1

CR37

Q13

C 8

C 0

C25

R 2

Q11

Q12

M C5

CR41

U18

U19

R 3

U20

C14

C15

C16

C10

C11C1

C17

C18

C12

C22

R 4

Q14

Q16

R 8

R 4

R 5

R 6

R 7

R 8

Q15

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Section 1 — General Information

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

1-Phase

Model 4746-0 4744-0 4742-0 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

PRE-PACKAGED STANDB

LED

2002 GENERAC POWER SYSTEMS, ASSY #076009

FOR 50H

T R

1.10.2 ENGINE SPECIFICATIONS

Make..............................................................................Mitsubishi

Displacement ..............................................92 inches

(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........................4.0 U.S. quarts (3.8 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

Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges.

Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.4 to 0.5 psi) at all load ranges.

NOTE:

Fuel consumption is given at rated maximum continuous power output when using natural gas rated at 1000 Btu per cubic foot; or 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.

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 vapor, 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

NOTE:

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

Serious injury or damage may occur if not configured properly. Please consult an Authorized Service Dealer with any questions.

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Section 1 — General Information

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

Port 1

PLUG

NG FUEL SYSTEM

FUEL HOSE

BRASS HOSE FITTING

PORT 1

HOUSING PORTS

FUEL HOSE

BRASS HOSE FITTING

OUT

OUT PORT 2

HOUSING PORTS

DANGER

Port 2

LP FUEL SYSTEM

PLUG

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 half soft water. Cooling system capacity is about 8 U.S. quarts (7.6 liters). Use only soft 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. DO NOT use any soluble oil inhibitor 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. Group the critical (essential) loads together and wire them into a separate “emergency” distribution panel.

This generator can be installed in conjunction with a standard “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.

After the system has been installed, do nothing that might render the installation in noncompliance with such codes, standards and regulations.

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 an

Authorized Service Dealer.

Section 2 — Installation

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

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 5 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 6 inches thick and should extend beyond the enclosure to a distance of at least 3 inches on all sides. See pages 54-55 for generator major dimensions.

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.

NOTE:

The manufacturer recommends the use of a “GTS” type transfer switch in conjunction with this generator.

Figure 2.1 – Basic Standby Electric System

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Section 2 — Installation

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

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 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 equal

the ampere rating of the normal incoming utility service.

• The transfer switch is installed between the utility

service entrance and the building distribution panel.

2.7 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

The manufacturer 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 GTS-type switch, it will be 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

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

DANGER

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 certain that normal source voltage at the transfer switch is correct and the system is ready for 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 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

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

DANGER

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” (Page 7) 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” (Page 7) and “Engine Oil Recommendations” (Page 8).

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” and “Coolant” (Page 7).

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 “GTS” type automatic transfer switch.

When using a standard GTS type transfer switch, 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

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Section 3 — Operation

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

SET EXERCISE

AUTO

OFF

TIME

MANUAL

FAULT

INDICATOR

HOURS

15A. AGC

FUSE

15 AMP

FUSE

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 3-position switch as follows:

• Set the switch to “Auto” for fully automatic operation. See “Automatic Operation”.

• 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

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

Fuse protects the control console’s DC control circuit against electrical overload. If the fuse has melted open because of an overload, engine cranking and startup cannot occur. If the fuse needs to be replaced, use only an identical 15-amp replacement fuse. (Type AGC)

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 + 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 permits programming the generator to start and exercise automatically. “See Weekly Exercise Cycle.”

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 RETRANSFER AND SHUTDOWN

When utility power source voltage has been restored, electrical loads may be transferred back to that source and the generator can be shut down as follows:

• Verify that utility power supply voltage to the trans-

fer switch has been positively turned “Off,” using whatever means provided (such as utility main line circuit breaker).

• Set the generator’s main circuit breaker to its “Off”

or “Open” position.

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

minutes, to stabilize internal unit temperatures.

• On the generator console, set the Auto-Off-Manual

switch to “Off”. Wait for engine to come to a complete stop.

• For transfer to utility position, refer to the Owner’s

Manual of the particular transfer switch.

• Turn on the utility power supply to the transfer

switch, using whatever means provided (such as a utility main line circuit breaker). The utility power source now powers the loads.

3.5 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” posi-

tion.

• Set the generator main circuit breaker to its “On”

or “Closed” position.

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Section 3 - Operation

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

DANGER

3.6 WEEKLY EXERCISE CYCLE

The generator will start and exercise once every 7 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.

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 7 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 or control panel fuse is removed, the exercise timer needs to be reset for correct automatic exercise operation.

Figure 3.2 - “Set Exercise” Switch

3.7 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 6 months, whichever comes first.)

2.Retorque cylinder head. (See Torque Specs, page

7.)

3.Retorque intake and exhaust manifold. (See Torque Specs, page 7.)

Section 4 — Maintenance

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

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, page

7.)

2.Retorque intake and exhaust manifold. (See Torque Specs, page 7.)

3.Check engine compression.

4.Check valve clearance.

4.2 COOLING SYSTEM

Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snot.

Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See Section 9 for installation drawings and vent locations.)

The exhaust system parts from this product get extremely hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.

4.3 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM

Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via a 30 amp fuse. These overcurrent protection devices will open if the circuit is overloaded.

If a circuit breaker opens or a fuse element melts, find the cause of the overload before resetting the circuit breaker or replacing the fuse.

4.4 CHECKING FLUID LEVELS

4.4.1 CHECK ENGINE OIL

Check engine crankcase oil level (Figure 4.1) at least every 20 hours of operation, or prior to use.

• Remove oil dipstick and wipe dry with a clean, lint-free cloth.

• Install oil dipstick, then remove again.

• Oil should be between FULL and ADD marks.

• If oil level is below the dipstick ADD mark, remove oil fill cap. Add the recommended oil to bring oil level up to the FULL mark. DO NOT FILL ABOVE THE “FULL” MARK. See page 6 for recommended oils.

Figure 4.1 - Oil Dipstick and Oil Fill Cap

4.4.2 BATTERY FLUID

Check battery electrolyte fluid at least once weekly. Fluid should cover separators in all battery cells. If fluid level is low, add distilled water to cover tops of separators. DO NOT USE TAP WATER IN BATTERY.

4.4.3 ENGINE COOLANT

Check coolant level in coolant recovery bottle. See Specifications, page 8

• Add recommended coolant mixture as necessary.

• Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact an Authorized Service Dealer. Inspect cooling system and coolant recovery system for leaks.



Section 4 — Maintenance

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

OIL DIPSTIC

4.5 MAINTENANCE OWNER/ OPERATOR CAN PERFORM

4.5.1 CHECK ENGINE OIL LEVEL

Refer to “Checking Fluid Levels” on page 15.

4.5.2 CHECK BATTERY

• Check battery fluid level each week as outlined

under “Check Fluid Levels”.

• Check battery cables for condition, tightness, cor-

rosion or damage. Clean, tighten or replace as necessary.

4.5.3 EXERCISE SYSTEM

Start the generator engine at least once every seven days and let it run at least 20 minutes. See page 14, “Weekly Exercise Cycle”.

4.5.4 INSPECT COOLING SYSTEM

• Inspect engine cooling system at least once each

month.

• Check hoses for damage, deterioration, leaks, etc.

Correct any discrepancies found.

• Check hose clamps for tightness.

4.5.5 CHECK ENGINE COOLANT LEVEL

See “Checking Fluid Levels” on page 15.

4.5.6 PERFORM VISUAL INSPECTION

Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.

4.5.7 INSPECT EXHAUST SYSTEM

Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage.

4.5.8 CHECK FAN BELT

• Inspect fan belts every three months. Replace any

damaged, deteriorated, worn or otherwise defective belt.

• Check fan belt tension. Thumb pressure, exerted

midway between pulleys, should deflect about 3/8 to 3/4 inch. Adjust belt tension as required.

4.5.9 INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

Do not attempt to adjust the governor. Only qualified service facilities should adjust the governor. Excessively high operating speeds are dangerous and increase the risk of personal injury. Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life. Correct rated frequency and voltage are supplied only at the proper governed speed. Some connected electrical load devices may be damaged by incorrect frequency and/or voltage. Only qualified service technicians should adjust the governed speed.

4.5.10 CHANGING ENGINE OIL

Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies.

Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down and drain immediately as follows:

1. Remove OIL DRAIN HOSE from its retaining clip.

2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container.

3. When all oil has drained, install and tighten OIL DRAIN HOSE CAP, and re-install into its retaining clip.

4. Turn OIL FILTER (Figure 4.2) counterclockwise and remove. Dispose of old filter.

Figure 4.2 - Oil Filter

5. Apply light coating of new engine oil to seal of new oil filter. Install FILTER and tighten by hand only. DO NOT OVERTIGHTEN.

6. Remove OIL FILL CAP. Add recommended oil (see SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK “FULL” MARK. Crankcase oil capacity is 4.0 U.S. quarts (3.8 liters).

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Section 4 — Maintenance

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

DANGER

OIL FILTER

After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK “ADD” MARK.

7. Start engine and check for oil leaks.

4.5.11 CHANGING THE ENGINE AIR CLEANER

To replace the engine air cleaner, (part number

59402), simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover (Figure 4.3).

Figure 4.3 – Engine Air Cleaner

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

4.5.12 SPARK PLUGS

Reset the spark plug gap or replace the spark plugs as necessary. See Section 6.

1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean.

2. Remove the spark plugs and check the condition. Replace the spark plugs if worn or if reuse is questionable. See the “Service Schedule,” Section 6, for recommended inspection.

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.5-0.6 mm (0.020-0.025 inch) by carefully bending the ground electrode (Figure 4.4).

Figure 4.4 – Setting the Spark Plug Gap

4.5.13 COOLANT CHANGE

Every year, have Authorized Service Facility drain, flush and refill the cooling system. See SPECIFICATIONS (page 8) for cooling system recommendations.

4.6 MISCELLANEOUS MAINTENANCE

4.6.1 CLEANING THE GENERATOR

Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance.

Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dry, low pressure air to remove any accumulations of dirt. The generator is housed inside an all-weather enclosure, clean the enclosure with a soft, damp cloth or sponge and water.

Once each year have the generator cleaned and inspected by an Authorized Service Dealer. That dealer will use dry, low pressure air to clean internal windings. Parts inside the control console should be cleaned and inspected at this time as well.

Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low, the generator may require drying.

4.6.2 BATTERY

All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery. If such information is not available, observe the following precautions when handling a battery:

• DO NOT use jumper cables and a booster battery to crank or start the generator engine.

• DO NOT recharge a weak battery while it is installed in the generator. Remove battery from generator and recharge in a well-ventilated area, away from fuel vapors, sparks, heat or flames.

• Battery electrolyte fluid is an extremely caustic

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Section 4 — Maintenance

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

SET PLUG GAP AT 0.5-0.6 mm

(0.020-0.025 inch)

Air Cleaner

(Doors Removed for Clarity)

sulfuric solution that can cause severe burns. DO NOT permit fluid to contact eyes, skin, clothing, painted surfaces, wiring insulation, etc. If any battery fluid is spilled, flush the affected area with clear water immediately.

• Always wear safety glasses, rubber apron and gloves when handling a battery.

• Batteries give off explosive hydrogen gas while charging. The gas can form an explosive mixture around the battery for several hours after charging. Any spark, heat or flames can ignite the gas and cause an explosion which can shatter the battery, causing blindness or other serious injury.

4.6.3 BATTERY MAINTENANCE

The battery should be inspected per the “Service Schedule,” Section 6. The following procedure should be followed for inspection:

1. Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries

and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES.

3. Have the state of charge and condition checked.

This should be done with an automotive-type battery hydrometer.

Do not use any jumper cables or booster battery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging.

Be sure the Auto/Off/Manual switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.

Be sure the utility power supply is turned off, or sparking may occur at the battery posts as the cables are attached and cause an explosion.

4.6.4 BATTERY REPLACEMENT

When replacing batteries, use the same number and the type of battery that follows:

NOTE:

The BCI number should be located directly on the battery.



Section 4 — Maintenance

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

BCI Group No. CCA

26/26R 525 @ 0 deg. F

PERIODIC REPLACEMENT PARTS

Part Name Manufacturer’s Part Number

Oil Filter # 0A45310244 Radiator Cap # 046627 Air Cleaner # 059402 Spark Plug # 0A45310275

DANGER

Section 4 — Maintenance

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

4.7 SCHEDULED MAINTENANCE

Following is a recommended maintenance schedule for small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to determine the next required maintenance interval.

Service Maintenance Interval Information:

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

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

tial problem areas.

Performed monthly or following each 10 hours of operation of the unit and requires approximately .5 manhours per unit to complete.

This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning:

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

• Disable the generator set from starting and/or connecting to the load by setting the control panel Auto-Off-Manual switch to the “OFF” position.

• Remove the control panel fuse.

• Turn off the battery charger.

• Remove the negative battery cable.

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

om burning out sensitive control panel components and circuits

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

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

required, and to identify any potential problem areas.

Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit and requires approximately 2.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer.

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

and to identify any potential problem areas.

Performed semi-annually or following each 50 hours of operation of the unit and requires approximately 1.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer.

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

to identify any potential problem areas.

Performed annually or following each 100 hours of operation of the unit and requires approximately 4.0 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an Authorized Service Dealer.

Section 4 — Maintenance

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

Maintenance Level 1 Level 2 Level 3 Level 4

Tasks Recom- Task Required Task Required Task Task

mended Comp. to be done Comp. to be done Comp. Required Comp.

to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date-

monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials)

10 hrs. 30 hrs. 50 hrs. 100 hrs.

1. Disable the unit from operating per the first page warning.

2. Check the engine oil level. Adjust as necessary.

3. Check the engine coolant level. Adjust as necessary.

4. Check the engine coolant thermal protection level. Correct as necessary.

5. Check the natural gas delivery system on gas engine driven units. Tighten connections as necessary.

6. Check the air inlets and outlets for debris. Clean as necessary.

7. Check the battery electrolyte level if accessible. Adjust as necessary.

8. Check the battery posts, cables, and charger for loose connections, corrosion, and proper operation. Correct as necessary.

9. Check the unit wiring for loose connections, corrosion, and damage. Correct as necessary.

10. Check the engine accessory drive belts for wear, weather cracking, and damage. Replace as necessary.

11. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary.

12. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary.

Section 4 — Maintenance

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

Maintenance Level 1 Level 2 Level 3 Level 4

Tasks

Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp.

to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date-

monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Initials)

10 hrs. 30 hrs. 50 hrs. 100 hrs.

13. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary.

14. Start and exercise the unit at full rated load (use a load bank if the site load is not enough) for at least 2 hours looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary.

15. Change the engine oil.

16. Replace the engine oil filter(s).

17. Replace the engine air filter(s).

18. Replace the engine fuel filter(s) on diesel engine driven units and re-prime the fuel system.

19. Check the engine spark plugs on gas engine driven units. Clean and re-gap or replace as necessary.

20. Perform a 5 minute no-load operational run of the unit looking for any post service problems.

21. Return the unit to standby setup for operation when required.

Section 5 — Troubleshooting

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

TROUBLESHOOTING POINTS

PROBLEM CAUSE CORRECTION

Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse.

2. Loose or corroded or defective 2. Tighten, clean or replace battery cables. battery cables as necessary.

3. Defective starter contactor. 3. Replace contactor.

4. Defective starter motor. 4. Replace starter motor.

5. Dead or Defective Battery. 5. Remove, change or replace battery.

6. 7.5 amp inline fuse blown. 6. Replace fuse.

Engine cranks but won't start 1. Out of fuel. 1. Replenish fuel.

2. Fuel solenoid (FS) is defective 2. Replace solenoid.

3. Open Wire #14 from Engine Control 3. Reconnect wire. circuit board.

4. Spark plugs defective. 4. Clean, regap or replace plugs.

Engine starts hard, runs rough. 1. Flame arrestor (air cleaner) plugged or 1. Clean or replace as needed.

damaged.

2. Plugged fuel line. 2. Unclog fuel line.

3. Defective spark plugs. 3. Clean, regap or replace plugs.

Engine starts then shuts down. 1. Engine oil level is low. 1. Check oil and add oil as needed.

2. Engine is overheated. 2. Check cooling system for leaks.

3. Defective Low Oil Pressure Switch 3. Replace switch.

4. Defective Coolant Temperature Switch 4. Replace switch.

5. Defective Control Module circuit board. 5. Replace board.

6. Coolant Level is Low. 6. Repair leak - Add coolant.

7. Defective Low Coolant Level Switch 7. Replace Switch.

Auto/Off/Manual Switch at OFF, 1. Defective Auto/Off/Manual switch 1. Replace switch. engine continues to run 2. Open/disconnected wire #15A between 2. Reconnect/close wire.

Auto/Off/Manual switch and Control Module circuit board.

3. Defective Control Module circuit board 3. Replace board.

No AC output from generator. 1. Check main line circuit breaker. 1. Reset to ON or CLOSED.

2. Check circuit breaker & fuses. 2. Reset and replace, if necessary.

3. Transfer switch set to NORMAL position 3. Set to GENERATOR position.

4. Generator internal failure. 4. Contact an Authorized facility.

5. Thermal circuit breaker open. 5. Auto-reset - Wait 5 min. and

attempt restart.

+ 55 hidden pages

Generac Power Systems 004742-0, 004744-0, 004746-0 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual