Generac 006237-0 Owner’s Manual
Owner'sManual
AutomaticStandbyGenerator
Usethispageto recordimportantinformationaboutyourgeneratorset.
,._ Recordtheinformationfoundonyourunitdatalabelonthispage.Forthe
location of the unit data label, see Section 2 General information. The
unit has a label plateaffixed to the inside partition, to the leftof the control
panel console as shown in Figures 2-1, 2-2, and 2-3. For directions on
MODEL[
SERIAL[
VOLTS[
AMPS i
1 PH, 60 Hz, RPM 5600
RAINPROOF ENCLOSURE FITTED
CLASS H INSULATION
RATED AMBIENT TEMP - 25°C
FOR STANDBY SERVICE
NEUTRAL FL©AWIN@
MAX LOAD UNBALANCE-50%
how to open the top lid and remove the front panel, see Section 3 Opera-
tion. The Unit Identification label provides the following information:
• Model Number
• Serial Number
• Control Panel Part Number
• Voltage Rating of the unit
• Maximum Current Rating of the unit (AMPS)
When contacting an Authorized Service Dealer about parts and service,
always supply the complete model number and serial number of the unit.
Operation and Maintenance: Proper maintenance and care of the gen-
erator ensures a minimum number of problems and keepsoperating
expenses at a minimum. 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 replace-
ment of parts are the responsibility of the owner/operator and, as such,
are not considered defects in materials orworkmanship within the terms
of the warranty, individual operating habits and usage may contribute to
the need for additional maintenance or service.
When the generator requires servicing or repairs, contact an Authorized
Service Dealer for assistance. Authorized service technicians are factory-
trained and are capable of handling all service needs.
Tofind your Local AUTHORIZED SERVICE DEALER
WHITEWATER, WIS
MADE IN U.S.A.
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED
SERVICE DEALER, please call this
number:
1-800-333-1322
or, visit the dealer Iocator at:
www.generac.comlServicelDealerLocatorl
WARNING!
California Proposition 65
Engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects, and other reproductive harm.
WARNING!
California Proposition 65
This product contains or emits chemicals known to the state of California to cause cancer,
birth defects, and other reproductive harm.
Table of Contents
Section 1 --Safety ............................................................................ 1
1.1 -- General Safety ........................................................................ 2
1.2 -- General Safety Hazards ................................................................. 2
1.3 -- Exhaust Hazards ...................................................................... 3
1.4 -- Electrical Hazards ..................................................................... 3
1.5 -- Fire Hazards .......................................................................... 3
1.6 -- Explosion Hazards ..................................................................... 3
Section 2- General Information .................................................................. 5
2.1 -- The Generator ........................................................................ 5
2.2 -- Protection Systems .................................................................... 6
2.3 -- Emission Information ................................................................... 7
2.4 -- Specifications ......................................................................... 8
2.5 -- Accessories .......................................................................... 9
Section 3 -- Operation ......................................................................... 11
3.1 --Control Panel Interface ................................................................. 11
3.2 -- Using the Auto/Off/Manual Buttons ....................................................... 12
3.3 -- Interface Menu Displays ................................................................ 12
3.4 -- Automatic Transfer Operation ........................................................... 14
3.5- Turning the Generator Off When Operating Under Load ....................................... 15
3.6 -- Manual Transfer Operation .............................................................. 15
3.7 -- Side Compartment .................................................................... 16
3.8- Alarm Response Procedures ............................................................ 17
3.9 -- Battery Charger ...................................................................... 17
3.10 -- Setting the Exercise Timer ............................................................. 17
Section 4 -- Maintenance ...................................................................... 19
4.1 -- Performing Scheduled Maintenance ...................................................... 19
4.2 -- Service Schedule ..................................................................... 19
4.3 -- Checking Engine Oil Level .............................................................. 20
4.4 -- Changing the Engine Air Cleaner ......................................................... 22
4.5 -- Spark Plugs ......................................................................... 22
4.6 -- Valve Lash Adjustment ................................................................. 23
4.7 -- Battery Maintenance .................................................................. 24
4.8 -- Attention After Submersion ............................................................. 25
4.9- Corrosion Protection ................................................................... 25
4.10 -- Out of Service Procedure (includes removal and return from service) ............................ 25
Section 5- Troubleshooting .................................................................... 27
Section 6 -- Quick Reference Guide .............................................................. 29
Also included is Spanish, French Canadian and Portuguese.
This page intentionally left blank.
iii
Section 1
INTRODUCTION: Thank you for purchasing this compact, high performance, air-cooled, engine-driven stationary automatic standby generator
set. Everyeffort was made to make sure that the information and instructions in this manual were both accurate and current at the time the man-
ual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product or manual at any time without
prior notice.
This generator is designed to automatically supply electrical power to operate critical loads during a utility power failure. This unit is factory
installed in an all-weather metal enclosure and is intended exclusively for outdoor installation. This generator will operate using either vapor
withdrawn liquid propane (LP) or natural gas (NG).
NOTE:Whenproperlysized,thisgeneratorissuitablefor supplyingtypicalresidentialloads suchas Induction Motors(sump pumps,
refrigerators,airconditioners,furnaces,etc.),ElectronicComponents(computer,monitor,TV,etc.),LightingLoadsandMicrowaves.
READ THIS MANUAL THOROUGHLY: The operator is responsible for proper and safe use of this equipment. The manufacturer strongly recom-
mends that the operator read and thoroughly understand the instructions and contents of this owner's manual before attempting to use theequip-
ment. Ifany portion of this publication is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing
procedures.
SAVE THESE INSTRUCTIONS: The manufacturer suggests that this manual and the rulesfor safe operation be copied and posted near the
unit's installation site. Safety should be stressed to all operators and potential operators of this equipment.
SAFETY: Throughout this manual, and on tagsand decals affixed to the unit, DANGER, WARNING, CAUTION and NOTE blocks are used to
alert personnel to special instructions about a particular operation, function or service that may be hazardous if performed incorrectly or care-
lessly. Observe them carefully. Their definitions are as follows:
INDICATESA HAZARDOUS SITUATIONOR ACTION WHICH, IF NOTAVOIDED, WILL RESULT IN DEATH OR SERIOUS
Safety
INJURY.
Indicates a hazardous situation or action which, ifnot avoided, could result in death or serious injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTE:Notescontainadditionalinformation important toan operationor procedure.
FourcommonlyusedsafetysymbolsaccompanytheDANGER,WARNINGandCAUTIONblocks.Thetypeof informationeachindicatesis as
follows:
Z_ This symbol points out important Safety Information that, if not followed, could endanger personal safetyand/or
A
/&
property of others.
This symbol points out a potential Explosion Hazard.
This symbol points out a potential Fire Hazard.
This symbol points out a potential Electrical Shock Hazard.
A
These "Safety Alerts" cannot eliminate the hazards that they signal. Strict compliance with these special instructions, plus common sense are
major accident prevention measures.
Automatic Standby Generator Owner's Manual 1
1.1 m General Safety
Study these safety rules carefully before operating or servicing this equipment. Becomefamiliar 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 byfailing
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 the manufacturer does not
specifically recommend, ensure that it is safe for personnel. 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
and maintain this equipment.
Potentially lethal voltages are generated by these machines. Ensure steps are taken to make the machine safe
beforeattempting to work on the generator.
Parts of the generator are rotating and/or hot during operation. Exercise care near a running generator.
The installation of this generator must always comply with applicable codes, standards, laws and regulations.
A running generator gives off DEADLY carbon monoxide, an odorless, colorless, poisonous gas. Breathing carbon
monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting, weakness,
sleepiness, inability to think clearly, fainting, unconsciousness or even death.
A CAUTION!
The control panel for this unit is intended to be operated by qualified service personnel only.
1.2 m General Safety Hazards
• For safety reasons, this equipment should only be installed, serviced and repaired by a Service Dealer or other competent, qualified electri-
cian or installation technician who is familiar with applicable codes, standards, regulations and product Installation Manual guidelines. The
operator also must comply with all such codes, standards, regulations and product installation Manual guidelines.
• The engine exhaust fumes contain carbon monoxide, which can be DEADLY.This dangerous gas, if breathed in sufficient concentrations, can
cause unconsciousness or even death. DO NOT alter or add to the exhaust system or do anything that might render the system unsafe or in
noncompliance with applicable codes and standards.
• Install a carbon monoxide alarm indoors, according to manufacturer's instructions/recommendations.
• Adequate, unobstructed flow of cooling and ventilating air is critical for 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. The generator MUST be installed and
operated outdoors only.
• Keep hands, feet, clothing, etc. away from drive belts, fans, and other moving or hot parts. Neverremove any drive belt or fan guard while the
unit is operating.
• When working on this equipment, remain alert at all times. Neverwork on the equipment when physically or mentally fatigued.
• Inspect the generator regularly, and contact the nearest Dealer for parts needing repair or replacement.
• Before performing any maintenance on the generator, remove the control panel fuse and disconnect the Negative (--) battery cable to pre-
vent accidental startup. When disconnecting battery cables always remove the NEGATIVE (NEG or "--") cable first, then remove the
POSITVE (POS, or "+") cable. When reconnecting the cables, connect the POSITIVE cable first, and the NEGATIVE cable last.
• Never use thegenerator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result indangerous operating
conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.
2 Automatic Standby Generator Owner's Manual
1.3 m Exhaust Hazards
Generator engine exhaust contains DEADLY carbon monoxide, an odorless, colorless, poisonous gas. Breathing carbon monoxide can
cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting, weakness, sleepiness, inability to think clearly, fainting,
unconsciousness or even death. Ifany carbon monoxide poisoning symptom is experienced, move into fresh air and immediately seek med-
ical attention.
This generator is designed for OUTDOOR installation ONLY.Never operate the generator inside any garage or other enclosed space.
1.4 m Electrical Hazards
All generators covered by this manual produce dangerous electrical voltages that can causefatal electrical shock. Utility power delivers
extremely high and dangerous voltages to thetransfer switch, as does the standby generator when it is in operation. Avoid contact with bare
wires, terminals, connections, etc. while the unit is running. Ensure all appropriate covers, guards and barriers are in place, secured and/or
locked before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce potential
shock hazard.
Donot handleanykindofelectricaldevicewhilestandinginwater,while barefoot,orwhilehandsorfeetarewet.DANGEROUSELECTRI-
CALSHOCKMAYRESULT.
• This is an Automatic Standby Generator, the generator may crank and start at any time when utility is lost. When this occurs, load circuits are
transferred to the STANDBY (generator) power source. To prevent injury, before working on this generator (for inspection, service or mainte-
nance), always put the generator into the OFF mode and remove the 7.5 Amp fuse from the generator control panel.
• 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.
• Neverwear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may getcaught in moving
components resulting in injury.
1.5 Fire Hazards
• For fire safety,the generator must be installed and maintained properly, installation MUST always comply with applicable codes, standards,
laws, regulationsand product installation Manual guidelines. 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 in
accordance with the manufacturer's instructions and recommendations. Following proper installation, do nothing that mightalter asafe instal-
lation and render the unit in noncompliance with the aforementioned codes, standards, laws and regulations.
• Keep a fire extinguisher near the generator at all times. Extinguishers rated "ABC" by the National Fire Protection Association are appropriate
for use on the standby generator. Keepthe extinguisher properly charged and befamiliar with its use. Consult the local fire department with
any questions pertaining to fire extinguishers.
1.6 Explosion Hazards
• Donot smoke around the generator. Wipe up any fuel oroil spills immediately. Ensurethat no combustible materials are left in the generator
compartment, or on or near the generator as FIRE or EXPLOSION may result. Keepthe area surrounding the generator clean and free from
debris.
• Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. install the fuel supply system according to appli-
cable fuel-gas codes. Before placing the home standby electric system into service, fuel system lines must be properly purged and leak
tested according to applicable code. After installation, inspect the fuel system periodically for leaks. No leakage can be permitted.
Automatic Standby Generator Owner's Manual 3
Ifthis generator is used to power electrical load circuits normally powered by a utility powersource, it is
required by code to install a transfer switch. The transfer switch must effectively isolatethe electrical system
from the utility distribution system when the generator is operating (NEC 702). Failure to isolate an electrical
system by such means will result in damage to the generator and also may result in injury or death to utility
powerworkers due to backfeed of electrical energy.
4 Automatic Standby Generator Owner's Manual
Section 2
2.1 m The Generator
EXHAUST
ENCLOSURE
General Information
CONTROL
OIL
DIPSTICK
\
PANEL
CIRCU IT
BREAKERS
AIR FILTER
FUEL INLET
(BACK)
FUEL
REGULATOR
COMPOSITE BASE
Figure 2-1" GH-410 Enqine 8kW Unit
EXHAUST
ENCLOSURE
COMPOSITE BASE
OIL FILTER
OIL FILTER
OIL FILLCAP
OIL FILL CAP
BATTERYCOMPARTMENT
CONTROL
PANEL
/
CIRCUIT
BREAKERS
/
FUEL
INLET
(BACK)
FUEL
REG ULATO R
:
BATTERYCOM PARTM ENT
Figure 2-2:GH-530 Enqine 11kW Unit
Automatic Standby Generator Owner's Manual 5
/
CONTROL
CIRCUIT
PANEL
BREAKERS
EXHAUST
ENCLOSURE
COMPOSITE BASE
OIL FILTER OIL FILL CAP
BATTERYCOM PARTMENT
Y
FUEL
INLET
/(BACK)
REGULATOR
\
Figure 2-3:GT-990/GT-999 Enqines, 13-20kW Unit
2.2 m Protection Systems
The generator may haveto runfor long periods of time with no operator present to monitor the engine/generator conditions. Therefore, the gen-
erator is equipped with a number of systems to automatically shut down the unit to protect it against potentially damaging conditions. Some of
these systems are as follows:
• LowOil PressureSensor
• HighTemperatureSensor
• OvercrankSensor
• OverspeedSensor
• RPMSensor
The control panel contains a display which alerts the operator when a fault condition occurs. The above list is not all inclusive. For more informa-
tion about alarms and control panel operation, see Section 3 Operation.
• Under-frequency Sensor
• Undervoltage Sensor
• Overvoltage Sensor
• Internal Failure Sensor
• Low Battery Voltage Alarm
6 Automatic Standby Generator Owner's Manual
2.3 m Emission Information
The U.S. Environmental Protection Agency (EPA)requires that this generator complywith exhaust emission standards. This generator is certified
to meet the applicable EPA emission levels, and iscertified for use as a stationary engine for standby power generation. Any other use may be a
violation of federal and/or local laws. To ensure that the engine complies with the applicable emission standards for the duration of the engine's
life, it is important to follow the maintenance specifications in the Section 4 Maintenance. This generator is certified to operate on Liquid Propane
Vaporfuel or pipeline Natural Gas.
For generators 13kWand greater, the Emission Control System code is EM (Engine Modification). The Emission Control System on this
generator consists of the following components:
• Airlnduction System
• Intake Pipe/Manifold
• Air Cleaner
• Fuel Metering System
• Carburetor/MixerAssembly
• Fuel Regulator
• Ignition System
• Spark Plug
• Ignition Module
• Exhaust System
• Exhaust Manifold
• Muffler
• Catalyst (ll kW generator only)
Automatic Standby Generator Owner's Manual 7
2.4 -- Specifications
2.4.1 -- Generator
Model 8kW 11kW 13kW 14kW 15kW 16kW 17kW 20kW
RatedVoltage 240
RatedMaximumLoad
Current(Amps)at240 33.3 45.8 54.2 58.3 62.5 66.6 70.8 83.3
Volts(LP)*
MainCircuitBreaker 35Amp 50Amp 55 Amp 60Amp 60Amp 65Amp 65 Amp 100Amp
Phase 1
RatedAC Frequency 60 Hz
BatteryRequirement Group26R, 12Voltsand 525CCAMinimum(GeneracPartNo.0H3421S
Weight(unitonly in 360/163.3 407/184.6 435/197.3 435/197.3 471/213.6 471/213.6 Steel- 451/204.6
Ibs./kilos) 471/213.6
Enclosure Steel/
NormalOperating Thisunit istested in accordancetoUL2200standardswithan operatingtemperatureof-200F (-29oC) to 122oF (500C). Forareaswheretem-
Range peraturesfallbelow32°F (0°C)a coldweatherkit ishighlyrecommended.Whenoperatedabove770F (250C)theremaybeadecreasein engine
These generatorsareratedin accordancewithUL2200,Safety Standardfor StationaryEngineGeneratorAssemblies,andCSA-C22.2No.100-04
Standardfor MotorsandGenerators.
* NaturalGasratingswilldependonspecificfuelBtu/joulescontent.Typicalderatesarebetween10-20%offtheLP gasrating.
** Circuitsto be movedmustbe protectedbysamesizebreaker.Forexample,a 15ampcircuitin themainpanelmustbea 15ampcircuitin thetransferswitch.
Steel Steel Steel Steel Steel Steel Aluminum
power.Pleasereferencetheenginespecificationssection.
Aluminum-
437/198.2
Aluminum
2.4.2 -- Engine
Model 8kW 11kW 13/14/15/16/17kW 20kW
Type of Engine GH-410 GT-530 GT-990 GT-999
Number of Cylinders 1 2 2 2
Displacement 410cc 530cc 992cc 999cc
Cylinder Block Aluminum w/Cast Iron Sleeve
Recommended Spark Plug RC14YC BPR6HS RC14YC RC12YC
Spark Plug Gap 0.76mm (0.030") 0.76mm (0.030") 1.02mm (0.040") 0.76mm (0.030")
Starter 12VDC
Oil Capacity Including Filter Approx. 1.5 Qts./1.4L Approx. 1.7 Qts./1.6L Approx. 1.9 Qts/1.8L Approx. 1.9 Qts/1.8L
Recommended Oil Filter Part #070185E
Recommended Air Filter Part #0E9371A Part #0E9371A Part #0J8478 Part #0J8478
Engine power is subject to and limited by such factors as fuel Btu/joules content, ambient temperature and altitude. Engine power decreases about 3.5
percent for each 1,000 feet (304.8 meters) above sea level, and also will decrease about 1 percent for each 6° C (10° F) above 15° C (60oF) ambient tem-
perature.
The specification sheet for your generator was included in the documentation provided with the unit at the time of purchase. For additional
copies, consult your local Authorized Service Dealer for your specific generator model.
8 Automatic Standby Generator Owner's Manual
2.4.3 m Fuel Requirements
The engine has been fitted with a dual fuel carburetion system. The unit will run on natural gas or LP gas (vapor), but it has been factory set to
run on natural gas. The fuel system will be configured for the available fuel source during installation.
Recommended fuels should have a btu content of at least 1,000 Btus percubic foot (37.26 megjoules per cubic meter) for natural gas, or at least
2,500 Btus percubic foot (93.15 megajoules per cubic meter) for LP gas (vapor).
NOTE:If convertingto LPgasfrom naturalgas,a minimumLPtanksizeof250gallons(946liters) isrecommended.Seethe Installa-
tionManualfor completeproceduresanddetails.
Gaseous fuels such as natural gas and liquid 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
2.4.4 m Battery Requirements
Group 26R, 12V,minimum 525CCA (Generac Part No.0H3421S).
For proper battery maintenance procedures, see Section 4 Maintenance.
2.4.5 -- Battery Charger
The battery charger is integrated into the control panel module in all models. It operates as a "Smart Charger" which ensures output charging lev-
els are safe and continuously optimized to promote maximum battery life.
2.4.6 _ Engine Oil Requirements
For proper oil viscosity, see chart in Figure 4-1: Recommended Oil Based on Temperature.
2.5 m Accessories
There are performance enhancing accessories available for air-cooled generators.
Accessory Description
Cold Weather Kit Recommended in areas where temperatures regularly fall below 320 F(0° C).
Scheduled Maintenance Kit Includes all pieces necessary to perform maintenance on the generator along with oil recommendations.
Auxiliary Transfer Switch Lock- Enables any of the transfer switches to completely lock out one large electrical load by tying into its control system.
out
Fascia Skirt Wrap Standard on all 20kW units. It is available for all other current production air-cooled units. It snaps together to pro-
vide a smoothing, contoured look as well as rodent/insect protection.
Mobile Link TM Provides a personalized web portal that displays the generator's status, maintenance schedule, event history and
much more. This portal is accessible via computer, tablet or smart phone. Sends emails and/or text notifications the
moment there is anychange in the generator's status. Notification settings can be customized to what type of alert is
sent and how often. For more information, visit www.standbystatus.com.
Touch-Up Paint Kit Very important to maintain the look and integrity of the generator enclosure. This kit includes touch-up paint and
instructions.
Contact a Dealer for additional information on accessories.
Automatic Standby Generator Owner's Manual 9
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