Generac G007171-0, G007172-0, G007223-0, G007224-0, G007225-0 Owner's Manual

...

Page 1

Owner’s Manual

(000209b)

WARNING

Loss of life. This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury.

60 Hz Air-Cooled Generators

10 kW to 24 kW

WWW.GENERAC.COM

1-888-GENERAC

(888-436-3722)

Para español, visita: http://www.generac.com/service-support/product-support-lookup

Pour le français, visiter : http://www.generac.com/service-support/product-support-lookup

SAVE THIS MANUAL FOR FUTURE REFERENCE

Page 2

Use this page to record important information about this generator.

(000393a)

WARNING

CANCER AND REPRODUCTIVE HARM

www.P65Warnings.ca.gov.

Record the information found on the unit data label on this

Model:

Serial:

Production Date:

Volts:

LPV Amps:

NG Amps:

Hz:

Phase:

Controller P/N:

STA MAC ID:

page. See General Information for the location of the unit data label. The unit has a label plate affixed to the inside partition, to the left of the control panel console as shown in Fig-

ure 2-1, Figure 2-2, or Figure 2-3. See Operation for

directions on how to open the top lid and remove the front panel.

Always supply the complete model and serial numbers of the unit when contacting an Independent Authorized Service Dealer (IASD) about parts and service.

Operation and Maintenance: Correct maintenance and care of the unit ensures a minimum number of problems, and keeps operating expenses at a minimum. It is the operator’s responsibility to perform all safety inspections, to verify all maintenance for safe operation is performed promptly, and to have the equipment inspected periodically by an IASD. Normal maintenance, service, and replacement of parts are the responsibility of the owner/operator and are not considered defects in materials or workmanship 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, Generac recommends contacting an IASD for assistance. Authorized service technicians are factory-trained and are capable of handling all service needs. To locate the nearest IASD, please visit the dealer locator at:

www.generac.com/Dealer-Locator.

SSID:

ii Owner’s Manual for 60 Hz Air-Cooled Generators

Page 3

Table of Contents

Section 1: Safety Information

Introduction ..................................................................1

Read This Manual Thoroughly ....................................1

Safety Rules .................................................................1

How to Obtain Service .................................................1

General Hazards ...........................................................2

Exhaust Hazards ..........................................................3

Electrical Hazards ........................................................3

Fire Hazards .................................................................3

Explosion Hazards .......................................................4

Battery Hazards ............................................................4

Section 2: General Information

Generator Components and Control Locations ........7

Data Decals .................................................................10

Specifications .............................................................11

Generator ..................................................................11

Engine .......................................................................11

Protection Systems ...................................................12

Emissions ...................................................................12

Fuel Requirements .....................................................12

Battery Requirements ................................................12

Battery Charger ..........................................................12

Engine Oil Requirements ..........................................12

Activating the Generator ...........................................13

Wi-Fi Module ...............................................................13

Replacement Parts .....................................................13

Accessories ................................................................13

Section 3: Operation

Site Prep Verification .................................................15

Generator Enclosure .................................................15

Opening the Lid .........................................................15

Front Access Panel Removal ....................................15

Intake Side Panel Removal .......................................16

Main Line Circuit Breaker (Generator Disconnect) ....16

LED Indicator Lights ..................................................16

Auxiliary Shutdown Switch .......................................17

Control Panel Interface ..............................................17

Using the AUTO/OFF/MANUAL Buttons ..................17

Operating Modes ........................................................18

Interface Menu Displays ............................................18

LCD Panel .................................................................18

Menu System Navigation ..........................................19

Setting the Exercise Timer ........................................ 21

Battery Charger ..........................................................21

Manual Transfer Operation .......................................21

Transfer to Generator Power Source ........................21

Transfer to Utility Power Source ................................22

Automatic Transfer Operation ..................................22

Automatic Sequence of Operation ...........................22

Utility Failure ..............................................................22

Cranking ....................................................................22

Cold Smart Start ........................................................ 22

Cleaning Cycle ..........................................................22

Load Transfer ............................................................23

Shutting Generator Down While Under

Load or During a Utility Outage ................................23

Section 4: Maintenance

Maintenance ............................................................... 25

Preparing for Maintenance ........................................25

Performing Scheduled Maintenance ........................ 25

Service Schedule .......................................................26

Maintenance Log .......................................................26

Checking Engine Oil Level ........................................ 27

Engine Oil Requirements ..........................................27

Changing the Oil and Oil Filter .................................27

Servicing the Air Cleaner .......................................... 28

Spark Plug(s) .............................................................. 29

Valve Clearance Adjustment .....................................29

Checking Valve Clearance ........................................29

Adjusting Valve Clearance ........................................30

Battery Maintenance .................................................. 30

Inspecting the Battery ................................................31

Cleaning the Sediment Trap ..................................... 32

Post Maintenance Checks .........................................32

Performing Fuel System Leak Test ...........................33

Attention After Submersion ......................................33

Corrosion Protection .................................................33

Remove From and Return To Service Procedure ...33

Remove From Service ...............................................33

Return to Service .......................................................34

Section 5: Troubleshooting / Quick

Reference Guide

Generator Troubleshooting ...................................... 35

Quick Reference Guide .............................................37

Owner’s Manual for 60 Hz Air-Cooled Generators 0

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Table of Contents

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i Owner’s Manual for 60 Hz Air-Cooled Generators

Page 5

Section 1: Safety Information

(000100a)

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

WARNING

(000001)

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

(000002)

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

(000003)

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Safety Information

Introduction

Thank you for purchasing this compact, high performance, air-cooled, engine-driven generator. It 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 intended exclusively for outdoor installation. This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).

NOTE: This generator is suitable for supplying typical residential loads such as induction motors (sump pumps, refrigerators, air conditioners, furnaces, etc.), electronic components (computer, monitor, TV, etc.), lighting loads, and microwaves, when sized correctly. This unit is equipped with a Wi-Fi tor owner to monitor generator status from anywhere they have Internet access.

NOTE: Wi-Fi

ance

The information in this manual is accurate based on products produced at the time of publication. The manufacturer reserves the right to make technical updates, corrections, and product revisions at any time without notice.

module, which allows the genera-

is a registered trademark of Wi-Fi Alli-

Safety Rules

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The alerts in this manual, and on tags and decals affixed to the unit, are not all inclusive. If using a procedure, work method, or operating technique that the manufacturer does not specifically recommend, verify that it is safe for others and does not render the equipment unsafe.

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

Read This Manual Thoroughly

If any section of this manual is not understood, contact the nearest Independent Authorized Service Dealer (IASD) or Generac Customer Service at 1-888-436-3722 (1-888-GENERAC), or visit www.generac.com for starting, operating, and servicing procedures. The owner is responsible for correct maintenance and safe use of the unit.

This manual must be used in conjunction with all other supporting product documentation supplied with the product.

SAVE THESE INSTRUCTIONS for future reference. This manual contains important instructions that must be followed during placement, operation, and maintenance of the unit and its components. Always supply this manual to any individual that will use this unit, and instruct them on how to correctly start, operate, and stop the unit in case of emergency.

Owner’s Manual for 60 Hz Air-Cooled Generators 1

NOTE: Notes contain additional information important to a procedure and will be found within the regular text of this manual.

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

How to Obtain Service

When the unit requires servicing or repairs, contact Generac Customer Service at 1-888-GENERAC (1-888-436-

3722) or visit www.generac.com for assistance.

When contacting Generac Customer Service about parts and service, always supply the complete model and serial number of the unit as given on its data decal located on the unit. Record the model and serial numbers in the spaces provided on the front cover of this manual.

Page 6

Safety Information

(000190)

DANGER

Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury.

(000191)

DANGER

Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury.

(000209b)

WARNING

Loss of life. This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury.

(000247a)

Equipment damage. This unit is not intended for use as a prime power source. It is intended for use as an intermediate power supply in the event of temporary power outage only. Doing so could result in death, serious injury, and equipment damage.

WARNING

(000130)

Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury.

WARNING

(000182a)

WARNING

Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(000187)

WARNING

Electrocution. Potentially lethal voltages are generated by this equipment. Render the equipment safe before attempting repairs or maintenance. Failure to do so could result in death or serious injury.

(000155a)

WARNING

Electric shock. Only a trained and licensed electrician should perform wiring and connections to unit. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(000115)

Moving Parts. Do not wear jewelry when starting or operating this product. Wearing jewelry while starting or operating this product could result in death or serious injury.

WARNING

(000111)

WARNING

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.

(000108)

WARNING

Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire.

(000146)

WARNING

Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.

Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to operate or service this equipment and could result in death or serious injury.

(000215a)

WARNING

(000228)

Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death, or serious injury.

(000216)

WARNING

Injury and equipment damage. Do not use generator as a step. Doing so could result in falling, damaged parts, unsafe equipment operation, and could result in death or serious injury.

General Hazards

• Inspect generator regularly, and contact the near-

est IASD for parts needing repair or replacement.

2 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 7

Exhaust Hazards

(000103)

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

DANGER

(000178a)

WARNING

Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury.

(000146)

WARNING

Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.

WARNING

(000281)

Fire risk. Fuel and vapors are extremely flammable. Do not operate indoors. Doing so could result in death, serious injury, or property or equipment damage.

(000144)

DANGER

Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.

(000150)

Electrocution. Never connect this unit to the electrical system of any building unless a licensed electrician has installed an approved transfer switch. Failure to do so will result in death or serious injury.

DANGER

(000237)

DANGER

Electrical backfeed. Use only approved switchgear to isolate generator from the normal power source. Failure to do so will result in death, serious injury, and equipment damage.

(000152)

DANGER

Electrocution. Verify electrical system is properly grounded before applying power. Failure to do so will result in death or serious injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

(000145)

DANGER

Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury.

WARNING

(000217)

Fire hazard. Do not obstruct cooling and ventilating airflow around the generator. Inadequate ventilation could result in fire hazard, possible equipment damage, death or serious injury.

WARNING

(000218)

Fire and explosion. Installation must comply with all local, state, and national electrical building codes. Noncompliance could result in unsafe operation, equipment damage, death, or serious injury.

WARNING

(000219)

Fire hazard. Use only fully-charged fire extinguishers rated “ABC” by the NFPA. Discharged or improperly rated fire extinguishers will not extinguish electrical fires in automatic standby generators.

Safety Information

Electrical Hazards

Fire Hazards

Owner’s Manual for 60 Hz Air-Cooled Generators 3

Page 8

Safety Information

(000100a)

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

WARNING

Electrocution. Refer to local codes and standards for safety equipment required when working with a live electrical system. Failure to use required safety equipment could result in death or serious injury.

(000257)

(000147)

WARNING

Risk of Fire. Unit must be positioned in a manner that prevents combustible material accumulation underneath. Failure to do so could result in death or serious injury.

(000192)

DANGER

Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury.

(000151a)

DANGER

Explosion and fire. Connection of fuel source must be completed by a qualified professional technician or contractor. Incorrect installation of this unit will result in death, serious injury, and property and equipment damage.

(000174)

DANGER

Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury.

(000110)

WARNING

Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

(000162)

Explosion. Do not dispose of batteries in a fire. Batteries are explosive. Electrolyte solution can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.

WARNING

(000137a)

WARNING

Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

(000164)

WARNING

Electrical shock. Disconnect battery ground terminal before working on battery or battery wires. Failure to do so could result in death or serious injury.

(000138a)

WARNING

Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

(000163a)

Risk of burn. Do not open or mutilate batteries. Batteries contain electrolyte solution which can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.

WARNING

Comply with regulations the local agency for workplace health and safety has established. Also, verify that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws, and regulations.

Battery Hazards

Explosion Hazards

4 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 9

Always recycle batteries in accordance with local laws

WARNING

(000228)

and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. For more information on battery recycling, visit the Battery Council International website at: http://batterycouncil.org

Safety Information

Owner’s Manual for 60 Hz Air-Cooled Generators 5

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Safety Information

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6 Owner’s Manual for 60 Hz Air-Cooled Generators

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Section 2: General Information

Generator Components and Control Locations

General Information

Figure 2-1. 10 kW—Components and Control Locations

A Lock with cover F Oil fill cap/dipstick K Oil drain hose O Fuel inlet

B Main line circuit breaker

(generator disconnect)

C Control panel H Airbox with air cleaner M Sediment trap Q Data decal location

D Battery compartment

(battery not supplied)

E Exhaust enclosure

G Status LED indicators L Composite base P Wi-Fi module

J Oil filter N Fuel regulator R Auxiliary shutdown switch

001818

Owner’s Manual for 60 Hz Air-Cooled Generators 7

Page 12

General Information

009340a

Figure 2-2. 14 kW–18 kW—Components and Control Locations

A Lock with cover F Exhaust enclosure L Composite base Q Data decal location

B Main line circuit breaker

(generator disconnect)

C Airbox with air cleaner H Oil drain hose N Fuel regulator S Auxiliary shutdown switch

D Control panel J Oil fill cap/dipstick O Fuel inlet

E Battery compartment

(battery not supplied)

G Status LED indicators M Sediment trap R Auxiliary shutdown switch

K Oil filter P Wi-Fi module

8 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 13

General Information

001786

Figure 2-3. 20 kW–24 kW—Components and Control Locations

A Lock with cover F Exhaust enclosure L Composite base Q Wi-Fi module

B Main line circuit breaker

(generator disconnect)

C Airbox with air cleaner H Oil drain hose N Sediment trap S Auxiliary shutdown switch

D Control panel J Oil fill cap O Fuel regulator T Auxiliary shutdown switch

E Battery compartment

(battery not supplied)

G Status LED indicators M Oil dipstick R Data decal location

K Oil filter P Fuel inlet

Owner’s Manual for 60 Hz Air-Cooled Generators 9

Page 14

General Information

Data Decals

Two decals on the generator provide information about the unit itself and required fuel inlet pressure for correct operation.

Model Data Decal

Includes important information about the unit including:

• model number

• serial number

• production date

• voltage

• frequency

• amps

• country of origin

• rated ambient temperature

The model data decal also displays certifica-

tion symbols by Underwriter’s Laboratory (UL) and the Southwest Research Institute (SwRI).

Fuel Inlet Pressure

Displays unit serial number, along with minimum and maximum inlet pressures for natural gas (NG) and liquid propane (LP) supply. Space is provided for installer to enter maximum flow rates based on installed pipe sizes and lengths.

10 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 15

Specifications

Generator

General Information

Model

Rated voltage

Rated maximum load current (amps) at rated voltage with LP*

Main line circuit breaker (generator disconnect)

Phase 1

Rated AC frequency

Battery requirement (field supplied)

Enclosure

Weight (lb / kg) (without battery)

Normal operating range

These generators are rated in accordance with UL 2200, Safety Standard for Stationary Engine Generator Assemblies, and CSAC22.2 No. 100-04 Standard for Motors and Generators. * NG ratings will depend on specific fuel joules/BTU content. Typical derates are between 10-20% off the LP gas rating.

10 kW

41.7 58.3 75.0 83.3 91.7 100.0

45 amp 60 amp 80 amp 90 amp 100 amp

338 / 153 385 / 175 420 / 191 436 / 198 445 / 202 455 / 206

This unit is tested in accordance to UL 2200 standards with an operating temperature of -20 °F (-29 °C) to 122 °F (50 °C). For areas where temperatures fall below 32 °F (0 °C), a cold weather kit is recommended. When operated above 77 °F (25 °C), there may be a decrease in engine power. See

Engine.

14 kW

12 volts, Group 26R-540CCA Minimum or Group 35AGM-650CCA Minimum

18 kW 20 kW 22 kW 24 kW

240

60 Hz

(see Replacement Parts)

Aluminum

Engine

Model 10 kW 14/18 kW 20–24 kW

Engine type

Number of cylinders

Displacement

Cylinder block

Recommended spark plug See Replacement Parts

Spark plug gap 0.020 in (0.508 mm) 0.040 in (1.02 mm)

Hydraulic lifters No Yes No

Valve clearance

Starter

Oil capacity including filter

Recommended oil filter

Recommended air filter

Engine power is subject to and limited by such factors as fuel BTU/joules, ambient temperature, and altitude. Engine power decreases approximately 3.5% for each 1,000 ft (304.8 m) above sea level, and also will decrease approximately 1% for each 10 °F (6 °C) above 60 °F (15 °C) ambient temperature.

G-Force™ 400 Series G-Force™ 800 Series G-Force™ 1000 Series

1 2 2

460 cc 816 cc 999 cc

Aluminum with cast iron sleeve

0.002–0.004 in (0.05–0.1 mm)

Approx. 1.1 qt (1.03 L) Approx. 2.2 qt (2.1 L) Approx. 1.9 qt (1.8 L)

See Replacement Parts

N/A

12 VDC

0.002–0.004 in (0.05–0.1 mm)

A detailed specification sheet for a particular generator is available from a local IASD.

Owner’s Manual for 60 Hz Air-Cooled Generators 11

Page 16

General Information

(000105)

Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury.

DANGER

Protection Systems

The generator may need to run for long periods of time with no operator present to monitor engine or generator conditions. The generator is equipped with protection systems to automatically shut down the unit to protect against potentially damaging conditions. Some of these systems include:

Alarms:

• High Temperature

• Low Oil Pressure

• Overcrank

• Overspeed

• Overvoltage

• Undervoltage

• Overload

Warnings:

• Charger Warning

• Charger Missing AC

• Low Battery

• Battery Problem

The control panel contains a display alerting the operator when a fault condition occurs. The above list is not allinclusive. See Operation for more information about alarms and control panel operation.

NOTE: A warning indicates a condition on the generator which should be addressed, but will not shut down generator. An alarm shuts down the generator to protect system from any damage. In event of an alarm, an owner can clear the alarm and restart generator prior to contacting an IASD. Contact an IASD if the intermittent issue occurs again.

• Underspeed

• RPM Sensor Loss

• Controller Fault

• Wiring Error

• Stepper Overcurrent

• Exercise Set Error

• USB Warning

• Download Failure

System Components

Air induction

Fuel metering

Ignition

Exhaust

- Intake manifold

- Air cleaner

- Carburetor and mixer assembly

- Fuel regulator

- Spark plug

- Ignition module

- Exhaust manifold

- Muffler

Fuel Requirements

The engine has been fitted with a dual fuel carburetion system. The unit will run on NG or LP gas (vapor), but has been factory-configured to run on NG. 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 per ft natural gas, or at least 2,500 BTUs per ft joules per m

NOTE: If converting to LP gas from NG, a minimum LP tank size of 250 gal (946 L) is recommended. See installation manual for complete procedures and details.

) for LP gas.

(37.26 megajoules per m3) for

(93.15 mega-

Emissions

The United States Environmental Protection Agency (US EPA) (and California Air Resources Board (CARB), for engines/equipment certified to California standards) requires this engine/equipment to comply with exhaust and evaporative emissions standards. Locate the emissions compliance decal on the engine to determine applicable standards. See the included emissions warranty for emissions warranty information. Follow the maintenance specifications in this manual to ensure the engine complies with applicable emissions standards for the duration of the product’s life.

This generator is certified to operate on liquid propane vapor fuel or pipeline natural gas.

The Emission Control System code is EM (Engine Modification). The Emission Control System on this generator consists of the following:

Battery Requirements

12 volts, Group 26R Wet Cell 540CCA minimum or Group 35 AGM 650CCA minimum (not included with unit). See Battery Maintenance for correct battery maintenance procedures.

Battery Charger

The battery charger is integrated into the control panel module in all models. It operates as a smart charger, verifying output charging levels are safe and continuously optimized to promote maximum battery life. A kit is provided to install a fuse in transfer switch for T1 battery charger connection. Follow installation instructions provided with kit.

NOTE: Do not use external battery chargers.

Engine Oil Requirements

See Engine Oil Requirements for correct oil viscosity.

12 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 17

General Information

Activating the Generator

Generator should be activated upon initial startup. See installation manual for complete instructions.

Wi-Fi Module

Generator is equipped with a Wi-Fi module. See Wi-Fi module owner’s manual for further information.

Replacement Parts

Description 10 kW 14 kW 18 kW 20 kW 22 kW 24 kW

26R Exide battery 0H3421S

Spark plug 0G0767B (RC12YC or equivalent) 0G0767A (RC12YC or equivalent)

Oil filter 070185E

Air filter 0E9371A 0J8478

Control panel fuse 0D7178T

Transfer switch fuses See transfer switch manual for part number

Accessories

NOTE: Performance enhancing accessories are available for air-cooled generators. Contact an IASD or visit

www.generac.com for additional information on replacement parts, accessories, and extended warranties. See also http://www.ordertree.com/generac/air-cooled-homestandby-generators/.

Accessory Description

Cold Weather Accessories*—

• Battery Pad Warmer

• Oil Warmer

• Breather Warmer

* each sold separately

Scheduled Maintenance Kit Includes all items necessary to perform complete routine maintenance on the gener-

Fascia Base Wrap The fascia base wrap snaps together around the bottom of the new air-cooled gener-

Mobile Link Accessories

Touch-Up Paint Kit If the generator enclosure is scratched or damaged, it is important to touch-up the

Extended Warranty Coverage Extend generator warranty coverage by purchasing extended warranty coverage.

Wi-Fi LP Fuel Level Monitor The Wi-Fi enabled LP fuel level monitor provides constant monitoring of a connected

Cellular

• Recommended in areas where temperatures fall below 0 °F (-18 °C).

(Not necessary for use with AGM-style batteries)

• Recommended in areas where temperatures fall below 0 °F (-18 °C).

• Recommended in areas where heavy icing occurs.

ator along with oil recommendations (oil not included).

ators. This offers a sleek, contoured appearance as well as protection from rodents and insects by covering the lifting holes located in the base. Requires use of the mounting pad shipped with the generator.

The Mobile Link family of Cellular Accessories allow users to monitor generator status from anywhere in the world, using a smartphone, tablet, or PC. Easily access information such as the current operating status and maintenance alerts. Users can connect an account with an authorized service dealer for fast, friendly, and proactive service. With Mobile Link, users are taken care of before the next power outage.

paint to protect from future corrosion. The touch-up paint kit includes the necessary paint to correctly maintain or touch-up a generator enclosure.

Covers both parts and labor. Extended coverage can be purchased within 12 months of the end-user’s purchase date. This extended coverage is applicable to registered units and end-user proof of purchase must be available upon request. Available for Generac Not available for Corepower™, PowerPact tional purchases.

LP fuel tank. Monitoring the LP tank’s fuel level is an important step in verifying the generator is ready to run during an unexpected power failure. Status alerts are available through a free application to notify users when the LP tank needs a refill.

and Guardian® products.

, and EcoGen™ products or all interna-

Owner’s Manual for 60 Hz Air-Cooled Generators 13

Page 18

General Information

Accessory Description

Smart Management Module (50 and 100 amps)

Smart Management Modules (SMM’s) are used to optimize the performance of a standby generator. They manage large electrical loads upon startup and shed them to aid in recovery when overloaded. In many cases, using SMM’s can reduce the overall size and cost of the system.

Ultrasonic Cleaning Solution 1 gal (3.8 L) of ultra concentrated cleaning solution for metal and plastic surfaces.

Makes 6 gal (22.7 L) of cleaning solution.

All Surface Protectant All surface protectant for vinyl, rubber, and plastics. Creates a barrier to seal and

protect surfaces from water and UV rays while renewing the look of the surface.

14 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 19

Section 3: Operation

(000191)

DANGER

Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury.

009209

009210

Operation

Site Prep Verification

Generator must be installed to allow unimpeded airflow into and out of generator.

Mechanical and gravity outdoor air intake openings for air distribution and supply systems must be located not less than 10 ft (3.05 m) horizontally from generator enclosure. See Section 401.4 in the ICC Mechanical Code for additional information.

Verify all shrubs or tall grasses within 3 ft (0.91 m) of intake and discharge louvers on the sides of the enclosure have been removed. Install generator on high ground where water levels will not rise and endanger it. This unit must not operate in or be subjected to standing water. Verify all potential water sources such as water sprinklers, roof run-off, rain gutter downspouts, and sump pump discharges are directed away from unit.

3. Press down on lid above side lock, and unlock latch to correctly open lid.

4. Repeat for other side. Lid may appear stuck if pressure is not applied from the top.

NOTE: Always verify side locks are unlocked before attempting to lift lid.

Front Access Panel Removal

See Figure 3-2. Remove front access panel (A) by lifting straight up and out once lid is open.

Generator Enclosure

Enclosure lid is locked prior to shipment. A set of keys is attached to cardboard on top of generator. An additional set of keys is attached to pallet bracket on the front intake end of generator.

NOTE: Keys provided with this unit are intended for service personnel use only.

Opening the Lid

1. Use keys to open generator lid.

2. See Figure 3-1. Two locks (A) secure lid; one on

each side. Open protective rubber cap to access keyhole.

Figure 3-1. Opening the Lid

Owner’s Manual for 60 Hz Air-Cooled Generators 15

Figure 3-2. Remove Front Access Panel

Page 20

Operation

002961

NOTE: Always lift front access panel straight up before pulling away from enclosure (B and C). Do not pull panel away from the enclosure before lifting up (D).

Intake Side Panel Removal

See Figure 3-3. Intake side panel (A) must be removed to access battery compartment, fuel regulator, and sediment trap.

1. Raise lid and remove front panel.

2. Use a hex key to remove two mounting screws (B)

and L-bracket screw (C).

3. Lift intake panel up and away from generator.

001810

NOTE: Always lift intake side panel straight up before pulling away from enclosure. Do not pull panel away from enclosure before lifting up (D).

Figure 3-4. Main Line Circuit Breaker (MLCB)

NOTE: DO NOT leave generator MLCB (generator disconnect) locked in OFF (OPEN) during normal generator operation. Leaving generator MLCB (generator disconnect) in OFF (OPEN) will prevent generator from powering structure during a power outage when placed in AUTO mode.

LED Indicator Lights

See Figure 3-5. Three LEDs are visible behind a translucent lens on the generator side panel. These LEDs indicate generator operating status.

001791

Figure 3-5. LED Indicator Lights

Figure 3-3. Intake Side Panel Removal

• Green LED “Ready” light (A) illuminates when util-

ity is present and control panel is in AUTO. LED

Main Line Circuit Breaker (Generator Disconnect)

See Figure 3-4. This is a 2-pole main line circuit breaker (MLCB) (generator disconnect) (A) rated according to relevant specifications.

The generator MLCB (generator disconnect) can be locked in OFF (OPEN) for security. Use an appropriatelysized padlock (not included) with a shackle long enough

flashes when automatic transfer switch converts to generator power during a utility power outage.

• Red LED “Alarm” light (B) illuminates when gener-

ator is OFF or a fault is detected. Contact an IASD.

• Yellow LED “Non-Critical Alert” light (C) illuminates

when maintenance is required.

NOTE: Yellow LED may be illuminated at the same time as either the red or green LED.

to pass through both lock tabs (B).

16 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 21

Operation

Equipment Damage. The auxiliary shutdown switch is not to be used to power down the unit under normal operating circumstances. Doing so will result in equipment damage.

(000399)

CAUTION

Auxiliary Shutdown Switch

All generators are equipped with an external means of shutting down the generator which complies with the latest NEC code requirement. Primary generator shutdown sequence is described in Shutting Generator Down

While Under Load or During a Utility Outage.

See Figure 3-6. An auxiliary shutdown switch (A) is located on the exterior of the generator back panel. This auxiliary shutdown switch shuts down generator and disables restarts.

005492

Figure 3-6. External Auxiliary Shutdown Switch

(all models)

by pressing OFF button, and then ENTER. The generator can then be placed in AUTO or MANUAL.

Control Panel Interface

See Figure 3-8. The control panel interface (A) is located under the enclosure lid. Verify both left and right side locks are unlocked before attempting to lift lid of enclosure. Open lid as directed in Opening the Lid.

001798

Figure 3-8. Generator Control Panel

The 7.5A fuse is located beneath rubber cover (B) to the right of the control panel.

Verify both left and right side locks are securely out of the way before closing unit.

All appropriate panels must be in place during any operation of the generator. This includes operation by a servicing technician while conducting troubleshooting procedures.

NOTE: Whenever possible, perform primary shutdown procedure before disabling generator with auxiliary shutdown switch.

See Figure 3-7. 14–24 kW generators also have an auxiliary shutdown switch (A) located inside generator.

Figure 3-7. Internal Auxiliary Shutdown Switch

(14–24kW)

NOTE: Generator will not start if either switch is OPEN (O). Controller displays an “Auxiliary Shutdown” alarm, and red LED “Alarm” light illuminates. To clear this condition, set switch or switches to CLOSED (I). Clear alarm

Owner’s Manual for 60 Hz Air-Cooled Generators 17

Using the AUTO/OFF/MANUAL Buttons

Button Description of Operation

Activates fully automatic system operation. Allows unit to automatically start and exercise generator according to exercise timer (see Set-

AUTO

005491

OFF

MANUAL

NOTE: Damage caused by mis-wiring of interconnect wires is not warrantable.

ting the Exercise Timer).

Green LED flashes when automatic transfer switch converts to generator power during a utility power outage.

Shuts down engine and prevents automatic operation of unit.

Cranks and starts generator. Transfer to standby power will not occur unless there is a utility failure. Blue LED flashes when automatic transfer switch converts to generator power during a utility power outage.

Page 22

Operation

Operating Modes Interface Menu Displays

Mode Description

• Will not transfer to standby if utility is present.

• Transfers to standby if utility drops below 65%

of nominal for five consecutive seconds

MANUAL

(dealer programmable) after warm-up.

• Transfers back when utility returns for 15 con-

secutive seconds (dealer programmable). Engine continues to run until removed from MANUAL.

• Starts and runs if utility drops for five consecu-

tive seconds (dealer programmable).

• Starts an engine warm-up timer (duration var-

ies when Cold Smart Start is enabled).

–Will not transfer if utility subsequently

returns.

–Transfers to standby if utility is not present.

AUTO

• Transfers to utility once utility returns (above

80% of nominal) for 15 consecutive seconds (dealer programmable).

• Will not transfer to utility unless utility returns.

Unit will shut down if OFF button is pressed or a shutdown alarm is present.

• Unit will shut down after one minute cool-down

time when utility power returns.

• Will not exercise if unit is already running in

either AUTO or MANUAL.

EXERCISE

• During exercise, controller will only transfer if

utility drops during exercise for five seconds (dealer programmable), and will switch to AUTO.

LCD Panel

Feature Description

Default page displayed if no buttons are pressed for 60 seconds. Normally shows current status message, and current date and time. Highest priority active alarm/warning is automatically posted on this page, as well as

flashing the backlight when such a condition HOME page

Display Backlight

MAIN MENU page

is detected. In the case of multiple alarms/

warnings, only first message is displayed.

Press OFF button and then ENTER button to

clear an alarm or warning.

When “Hours of Protection” is displayed, this

represents total time generator has been

monitoring utility supply and ready to provide

backup power if needed.

Normally off. The backlight will automatically

illuminate and remain on for 30 seconds if

operator presses any button.

Allows operator to navigate to all other pages

or sub-menus by using arrow keys and

ENTER button. Page can be accessed at any

time with several presses of the dedicated

ESCAPE button. Each press of the ESCAPE

button takes operator to previous menu until

MAIN MENU displays. This page contains

information for History; Status; Edit; and

Debug.

18 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 23

Operation

EVOLUTION 2.0 / SYNC 3.0 HSB MENU MAP

Switched to “OFF”

Hours of Protection

0 (H)

Note: Menu functions and features may vary

depending on unit model and firmware revision.

* Hours of Protection and

number of hours will flash

every 5 seconds when

displayed.

Ready to Run

Hours of Protection

0 (H)

Utility Loss Delay

Pausing for 13 sec.

Cranking

Attempt # 3

Running in Exercise

Hours of Protection

0 (H)

Running

Cooling Down

Running - Warning

“Warning Message”

Warning Message(s)

Low Battery

Exercise Set Error

Service Schedule A

Service Schedule B

Inspect Battery

Stopping...

FIRMWARE ERROR-9

Fuel Pressure

Battery Problem

Charger Warning

Charger Missing AC

Overload Warning

SEEPROM ABUSE

USB Warning

Download Failure

Overload Warning

No WIFI Module

No WIFI Router Comms

No WIFI Server Comms

Cranking - Warning

“Warning Message”

Alarm Message(s)

High Engine Temp

Low Oil Pressure

Overcrank

Overspeed

RPM Sense Loss

Underspeed

Controller Fault

FIRMWARE ERROR-7

WIRING ERROR

Overvoltage

Undervoltage

Overload Remove Load

Low Volts Remove Load

Stepper Overcurrent

Auxiliary Shutdown

Emergency Stop

Fuse Problem

Loss of Speed Signal

Loss of Serial Link

Stopped - Warning

“Warning Message”

Cranking

Pausing for 13 sec

Running

Hours of Protection

0 (H)

Running

Warming Up

Running - Alarm

“Alarm Message”

Cranking - Alarm

“Alarm Message”

Switched OFF

Hours of Protection

0 (H)

UP ARROW =

DOWN ARROW =

Menu System Navigation

Press ESCAPE button from any page to access the MENU. If needed, press ESCAPE button several times to reach the MENU page. Navigate to the desired menu by using the ↑/↓ buttons. Press ENTER button when desired menu is displayed and flashing,

006667a

Figure 3-9. Navigation Menu

Owner’s Manual for 60 Hz Air-Cooled Generators 19

Page 24

Operation

Run Log

EXAMPLE:

Inspect Battery 200 RnHr or 12/27/18

and

Next Maintenance 200 RnHr or 12/27/18

Exercise Time

Å HH:MM Day Frequency Æ

ESC

–

++ +

–

ENTER

Current Date/Time

Å 2/12/16 12:22 Æ

ESCESCESCESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

Maint. Log

Run Hrs

Scheduled

Select Month (1-12)

- 2 +

Run Hours (H)

0.0

Select Date (1-31)

- 13 +

Select Year (0-99)

- 13 +

Access

Requires Password

Language

Å English Æ

Fuel Selection

Å NG or LP Æ

Alarm Log

ENTER

ESC

ENTER

ESC

ENTER

ESC

"Battery Maintained"

"Schedule A Serviced"

"Schedule B Serviced"

"Maintenance Reset"

"Inspect Battery"

"Service Schedule A"

"Service Schedule B"

Warning Message(s)

Low Battery

Exercise Set Error

Service Schedule A

Service Schedule B

Inspect Battery

Stopping...

FIRMWARE ERROR-9

Battery Problem

Charger Warning

Charger Missing AC

Overload Cooldown

SEEPROM ABUSE

USB Warning

Download Failure

Overload Warning

No WIFI

Running Manual

Running-Utility Lost

Running–Remote Start

Running–2 Wire Start

Running–Exercise

Switched Off

Stopped - Auto

Select Min (0-59)

- 0 +

Select Hour (0-23)

- 14 +

Select Min (0-59)

- 0 +

Select Hour (0-23)

- 14 +

Quiet Test Mode ?

- YES or NO +

Select Frequency

- WEEKLY +

- BIWEEKLY +

- MONTHLY +

Language

+ English -

Fuel Selection

+ NG or LP -

Cold Smart Start?

Å YES or NO Æ

Cold Smart Start?

- YES or NO +

Language

+ Francais -

+ Espanol -

+ Português -

+ ...... -

Battery Condition

“Good”, “Inspect Battery” or

“Check Battery”

Select Day

- Wednesday +

Generator Activated

Service Unit

Language Update?

Å YES or NO Æ

WIFI Enable

Å YES or NO Æ

WIFI Enable

– YES or NO +

<ENT> LOAD LANGUAGE

<ESC> TO QUIT

ESC

Current Date/Time

10/09/18 07:40

ESC

ENTER

ESC

ENTER

Time Zone

Country/City

XX - XX/XX/XX XX:XX

XXXXX

XX - XX/XX/XX XX:XX

XXXXX

NOTE 1: Last 50 logs

displayed for each

(Alarm Log, Run Log,

Maint. Log).

NOTE 2: Date and time

displayed for each

occurence.

NOTE 3: Error code

displayed for each

Alarm, Error Code

and Alarm Message

swap every 5

seconds.

Battery

NOTE 1: Last 50 maintenance logs displayed.

NOTE 2: Date and time displayed for each

occurence.

(If enabled):

Refer to the Wi-Fi manual for

flow charts relating to Wi-Fi

(If not enabled): Displays SETUP WIFI

Only if Wi-Fi is disabled.

Date/Time automatically updates if connected to Wi-Fi.

Firmware Update

Å YES Æ

Current: V 1.01

USB: V 1.05

Are You Sure?

- Yes or No +

Update from:

Å USB or Wi-Fi Æ

Select YES, then press ENTER to continue or ESCAPE to cancel update. During

update process, the Blue “Manual” light flashes, then the Green “Auto” light flashes.

Sequence then repeats. When update is complete, the unit returns to Install Wizard

menu. When the controller powers up, the first screen briefly displays the version number.

When update is complete, remove USB Drive. Then follow the Install Wizard Menu.

Firmware Update

<- Insert USB ->

Possible Message(s):

Corrupted File

Invalid File

File Not Found

Unsupported Device*

* Re-try using a higher quality

USB drive. File names on the USB

cannot have more than 8 characters.

Refer to the Installation Wizard.

Only when WiFi Activated

SYSTEM

WIFI

DATE/TIME

SUB MENUS

HISTORY

EDIT

MAINT

DEALER

ESC

ENTER

ESC

ENTER

ESC

ENTER

USB

ENTER ENTER

ENTER

ENTER ENTER

ENTER

Current: V 1.01

USB: V 1.05

Are You Sure?

- Yes or No +

ENTER

ENTER ENTER

ENTER

ESC

ENTER

ESC

ENTER

Alarm Message(s)

High Engine Temp

Low Oil Pressure

Overcrank

Overspeed

RPM Sense Loss

Underspeed

Internal Fault

FIRMWARE ERROR-7

WIRING ERROR

Overvoltage

Undervoltage

Overload Remove Load

Low Volts Remove Load

Stepper Overcurrent

Auxiliary Shutdown

Emergency Stop

Defaults to English.

Select desired language

by scrolling through list.

ESC

ESCESCESCESC ESC

006667a

Figure 3-10. Navigation Menu

20 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 25

Operation

(000132)

Electrocution. Do not manually transfer under load. Disconnect transfer switch from all power sources prior to manual transfer. Failure to do so will result in death or serious injury, and equipment damage.

DANGER

002565002565

Setting the Exercise Timer

This generator is equipped with a configurable exercise timer. Configuration can be performed directly at the control panel or though the Mobile Link are two settings for the exercise timer:

Day/Time: Generator will start and exercise for period defined, on day of week and at time of day specified. During this exercise period, unit runs for approximately five minutes and then shuts down.

Exercise frequency: Exercise frequency can be set to Weekly, Biweekly, or Monthly. If Monthly is selected, day of month must be selected from 1–28. Generator will exercise on that day each month. Transfer of loads to generator output does not occur during exercise cycle unless utility power is lost.

NOTE: If Wi-Fi is enabled, exercise timer will automatically adjust for Daylight Saving Time.

NOTE: The exercise feature will operate only when generator is in AUTO, and will not work unless this procedure is performed. If Wi-Fi is NOT enabled, current date/time will need to be reset every time the 12 volt battery is disconnected and then reconnected, and/or when the fuse is removed.

Low Speed Exercise (Quiet-Test™) Profile: Unit will run at operating speed for approximately five seconds, then drop speed to prepare for Quiet-Test. Speed will drop to predetermined Quiet-Test speed after approximately 40 seconds and continue to run until Quiet-Test is complete, a total of five minutes.

Table 3-1 details exercise information and programming

options for all home standby generators.

application. There

NOTE: A warning is displayed on LCD when battery needs service.

NOTE: Do not use external battery chargers.

Manual Transfer Operation

Prior to automatic operation, manually exercise transfer switch to verify there is no interference with correct operation of the mechanism. Manual operation of transfer switch is required if electronic operation should fail.

Transfer to Generator Power Source

1. Verify generator is in OFF mode.

2. Set generator MLCB (generator disconnect) to

OFF (OPEN).

3. Turn off utility power supply to transfer switch using means provided (such as a utility MLCB).

4. See Figure 3-11. Use manual transfer handle (A) inside transfer switch to move main contacts to STANDBY (loads connected to standby power source).

NOTE: If Quiet-Test is disabled, generator will exercise at the rated rpm.

Table 3-1. Generator Exercise Characteristics

Generator Size 10–24 kW

Exercise Frequency

Options

Exercise Time Length 5 minutes

Weekly/Bi-Weekly/Monthly

Battery Charger

IMPORTANT NOTE: Contact an IASD if controller screen displays “CHARGER MISSING AC.”

NOTE: Battery charger is integrated into the control

module in all models.

The battery charger operates as a smart charger which verifies:

• output is continually optimized to promote maxi-

mum battery life.

• charging levels are safe.

Owner’s Manual for 60 Hz Air-Cooled Generators 21

Figure 3-11. Typical Manual Transfer Switch

Operation

5. Press MANUAL button on control panel to crank and start engine.

6. Allow engine to stabilize and warm up for a few minutes.

002565

Page 26

Operation

7. Set generator MLCB (generator disconnect) to ON (CLOSED). Standby power source now powers loads.

accept load (warm-up time has not elapsed), the controller completes start cycle and runs generator through its normal cool down cycle. However, load will remain on utility source.

Transfer to Utility Power Source

Shut down generator and transfer to utility source after utility power has been restored. Proceed as follows to manually transfer to utility power and shut down generator:

1. Set generator MLCB (generator disconnect) to OFF (OPEN).

2. Run engine for one minute at no-load to stabilize internal temperature.

3. Press OFF button on control panel. Engine will shut down.

4. Verify utility power supply to transfer switch is turned off.

5. Set main contacts to UTILITY (loads connected to utility power source) using manual transfer handle inside transfer switch.

6. Turn on utility power supply to transfer switch using means provided (such as a utility MLCB).

7. Press AUTO button on control panel.

8. Set generator MLCB (generator disconnect) to ON

(CLOSED).

9. Close and lock lid.

Automatic Transfer Operation

Proceed as follows to select automatic operation:

1. Verify transfer switch main contacts are set to UTILITY (loads connected to utility power source).

2. Verify normal utility power source voltage is available to loads connected to transfer switch.

3. Press AUTO button on control panel.

4. Set generator MLCB (generator disconnect) to ON

(CLOSED).

Generator will start automatically when utility source voltage drops below a preset level. Loads are transferred to standby power source after unit starts.

Automatic Sequence of Operation

Utility Failure

If generator is set to AUTO when utility fails (below 65% of nominal), a five second (dealer programmable) line interrupt delay time is started. The engine cranks and starts if utility power is not available when timer expires. An engine warm-up timer will be initiated once engine is started. Timer duration varies depending on whether or not Cold Smart Start is enabled. The controller will transfer load to generator when warm-up time expires. If utility power is restored (above 80% nominal) at any time from initiation of engine start until generator is ready to

22 Owner’s Manual for 60 Hz Air-Cooled Generators

Cranking

The system will control the cyclic cranking as follows:

• 10 kW Unit: five cranking cycles as follows: 15

seconds cranking, seven seconds resting, followed by four additional cycles of seven seconds cranking followed by seven seconds resting.

• 14–24 kW Units: five cranking cycles as follows:

16 seconds cranking, seven seconds resting, 16 seconds cranking, seven seconds resting, followed by three additional cycles of seven seconds cranking followed by seven seconds resting.

NOTE: An alarm will be triggered if generator does not start after these five attempts.

Cold Smart Start

Cold Smart Start is factory-enabled, but can be disabled in the EDIT menu. Generator will monitor ambient temperature when Cold Smart Start is enabled. The warm-up delay will be adjusted based on prevailing conditions.

See Table 3-2. If ambient temperature is below a fixed temperature (based on model) upon startup in AUTO, generator will warm up for 30 seconds. This allows engine to warm before a load is applied. The generator will startup with normal warm-up delay of five seconds if ambient temperature is at or above the fixed temperature.

Table 3-2. Cold Smart Start Set Points

Generator size 10 kW–20 kW 22/24 kW

Fixed temperature 50 °F (10 °C) 20 °F (-7 °C)

A check for correct output voltage buildup will be performed when generator engine is started.

Cleaning Cycle

If some condition impedes normal voltage creation, such as frost crystals or dust/dirt preventing a good electrical connection, start sequence will be interrupted so a cleaning cycle of the internal electrical connections can be attempted.

Cleaning cycle is an extended warm up period which lasts for several minutes while normal generator voltage output is determined to be low. During this cycle, generator controller will display “Warming Up” on the display screen.

The generator controller display will show “Under Voltage” if cleaning cycle fails to clear the obstruction. After several minutes, alarm message can be cleared, and the generator restarted.

If the problem persists, make no further attempts to start. Contact an IASD.

Page 27

Load Transfer

Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury.

(000191)

DANGER

The transfer of load when generator is running is dependent upon operating mode.

Shutting Generator Down While Under Load or During a Utility Outage

IMPORTANT NOTE: To avoid equipment damage, follow these steps, in order, during utility outages. Shutdowns may be required during utility outages to perform routine maintenance or to conserve fuel.

To turn generator OFF:

1. Set utility MLCB to OFF (OPEN).

2. Set generator MLCB (generator disconnect) to

OFF (OPEN).

3. Allow generator to run for cool-down for approxi-

mately one minute.

4. Set generator to OFF at the controller.

5. Remove 7.5A fuse from controller.

To turn generator back ON:

1. Install 7.5A fuse in controller.

2. Verify generator MLCB (generator disconnect) is

OFF (OPEN).

3. Set generator to AUTO mode at the controller.

4. Generator will start and run. Allow generator to run

and warm up for a few minutes.

5. Set generator MLCB (generator disconnect) to ON

(CLOSED).

6. Set utility MLCB to ON (CLOSED).

The system now operates in automatic mode.

Operation

Owner’s Manual for 60 Hz Air-Cooled Generators 23

Page 28

Operation

This page intentionally left blank.

24 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 29

Section 4: Maintenance

(000191)

DANGER

Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury.

(000182a)

WARNING

Maintenance

Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be performed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner’s choosing. To obtain emissions control warranty service free of charge, the work must be performed by an IASD. See the emissions warranty.

Preparing for Maintenance

Performing Scheduled Maintenance

It is important to perform maintenance as specified in the

Service Schedule for correct generator operation.

Engine oil and oil filter must be changed, and valve clearance adjusted (where applicable, see Engine) after first 25 hours of operation.

Emissions-critical maintenance must be performed as scheduled in order for emissions warranty to be valid. Emissions-critical maintenance consists of servicing the air filter and spark plug(s) in accordance with Service

Schedule.

Controller will prompt for Schedule A or Schedule B maintenance to be performed. Schedule A maintenance consists of oil, oil filter, and battery check. Schedule B maintenance includes oil, oil filter, battery check, air cleaner, spark plug(s), and valve clearance (where applicable, see Engine).

Since most maintenance alerts occur at the same time (most have two year intervals), only one will appear on control panel display at a time. Once first alert is cleared, the next active alert will be displayed.

Proceed as follows to prepare unit for maintenance:

1. Set utility MLCB to OFF (OPEN).

2. Lift lid and set generator MLCB (generator discon-

nect) to OFF (OPEN).

3. If running during a utility outage, allow generator to

run and cool down for one minute with no load.

4. Press OFF button on controller.

5. Remove 7.5A fuse from control panel.

6. Remove front panel and intake side panel.

Owner’s Manual for 60 Hz Air-Cooled Generators 25

Page 30

Maintenance

Service Schedule

Daily If Running

Service

Inspect enclosure louvers for dirt and debris * ●

Inspect lines and connections for fuel or oil leaks ●

Check engine oil level ●

Inspect for water intrusion ** ●

Perform fuel system leak test ●

Check battery condition, electrolyte level, and state of charge

Replace engine oil and oil filter † ● ●

Replace engine air filter ●

Clean; inspect spark plug gap; replace if necessary ●

Inspect/adjust valve clearance (where applicable) ‡ ●

Inspect/clean sediment trap

Contact the nearest IASD for assistance if necessary.

* Remove any shrubs or tall grasses which have grown within 3 ft (0.91 m) of intake and discharge louvers on enclosure sides. Clean any debris (dirt, grass clippings, etc.) which may have accumulated inside enclosure.

** Verify all sources of potential water intrusion such as water sprinklers, roof run-off, rain gutter downspouts, and sump pump discharges are directed away from generator enclosure.

† Change engine oil and filter after first 25 hours of operation. In cold weather conditions (ambient below 40 °F [4.4 °C]), or if unit is operated continuously in hot weather conditions (ambient above 85 °F [29.4 °C]), change engine oil and filter every year or 100 hours of operation.

‡ Inspect/adjust valve clearance after first 25 hours of operation. (Excludes units with hydraulic lifters. See Engine.)

Continuously or

Before Each Use

Every

Year

● ● ●

See local codes and guidelines.

Schedule A

Every Two Years

or 200 Hours

Schedule B

Every Four Years

or 400 Hours

NOTE: Contact an IASD or visit www.generac.com for additional information on replacement parts.

Maintenance Log

Battery Inspection and Charge Check

Dates Performed:

Oil, Oil Filter, Air Filter, and Spark Plug Replacement

Dates Performed:

Valve Adjustment

NOTE: Not required on 14 or 18 kW units with 816cc engines.

Dates Performed:

26 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 31

Maintenance

(000139)

WARNING

Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury.

(000210)

WARNING

Skin irritation. Avoid prolonged or repeated contact with used motor oil. Used motor oil has been shown to cause skin cancer in laboratory animals. Thoroughly wash exposed areas with soap and water.

(000135)

Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage.

CAUTION

(000135)

Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage.

CAUTION

Checking Engine Oil Level

IMPORTANT NOTE: Verify oil level daily when power outages necessitate running generator for extended periods. Generator will shut down if oil level is low.

Proceed as follows to check engine oil level:

1. Set utility MLCB to OFF (OPEN).

2. Set generator MLCB (generator disconnect) to

OFF (OPEN).

3. Allow generator to run for a cool-down period of

approximately one minute, if generator was running during an outage.

4. Press OFF button to turn generator off. Wait five

minutes.

5. See Figure 2-1, Figure 2-2, or Figure 2-3.

Remove oil dipstick and wipe it dry with a clean cloth.

6. Completely insert oil dipstick into oil dipstick tube

and remove.

7. Observe oil level. Oil level should be at FULL mark

on oil dipstick.

8. If necessary, remove oil fill cap and add recom-

mended oil to engine (with oil dipstick removed) until oil level reaches FULL mark. Insert oil dipstick and install fill cap. See Engine Oil Requirements.

To restart generator:

1. Press AUTO button on control panel.

2. Allow generator to start and warm up for a few min-

utes.

3. Set generator MLCB (generator disconnect) to ON

(CLOSED).

The system is now operating in AUTO. The utility MLCB can be turned ON (CLOSED).

Owner’s Manual for 60 Hz Air-Cooled Generators 27

Engine Oil Requirements

Engine oil should be serviced in accordance with the recommendations of this manual to maintain product warranty. Generac maintenance kits consisting of engine oil, oil filter, air filter, spark plug(s), a shop towel, and a funnel are available through an IASD.

All Generac oil kits meet minimum American Petroleum Institute (API) Service Class SJ, SL, or better. Do not use special additives.

Synthetic SAE 5W-30 for all temperature ranges. See

Engine.

Changing the Oil and Oil Filter

Proceed as follows to change oil and oil filter:

1. Lift lid and press MANUAL button on control panel to start engine, and run unit until it is thoroughly warmed up. Press OFF button on control panel to shut down engine.

2. See Figure 4-1, Figure 4-2, or Figure 4-3. Remove front panel when unit has cooled. Pull oil drain hose (A) free of retaining clip. Remove cap from oil drain hose and place free end into a suitable container. Drain oil.

001831

Figure 4-1. Oil Filter and Drain Location (10 kW)

Page 32

Maintenance

009342

(000249)

WARNING

Risk of fire. Never operate engine without the air cleaner installed. Operating engine without the air cleaner could result in death or serious injury.

(000580)

WARNING

Explosion and fire. Never clean air filter element with gasoline or low flash-point detergents. Doing so could result in death, serious injury, or equipment damage.

001814

009342

Figure 4-2. Oil Filter and Drain Location (14–18 kW)

Servicing the Air Cleaner

Proceed as follows to service air cleaner:

1. Lift lid and press OFF button on control panel to stop generator.

2. Remove front panel.

3. See Figure 4-4 or Figure 4-5. Remove cover clips

(A) and air cleaner cover (B).

Figure 4-3. Oil Filter and Drain Location (20–24 kW)

009343

3. Install cap on oil drain hose. Position and secure oil drain hose with the retaining clip.

4. Remove oil filter (B) by turning it counterclockwise.

5. Apply a light coating of clean engine oil to gasket of

new filter.

6. Screw new filter on by hand until gasket lightly contacts oil filter adapter. Tighten filter an additional

Figure 4-4. Servicing Air Cleaner (10 kW)

001820

three-quarter to one full turn.

7. Fill engine with recommended oil. See Engine Oil

Requirements.

8. Press MANUAL button on control panel to start engine. Run for one minute, and inspect for leaks.

9. Press OFF button on control panel to stop engine. Wait five minutes.

10. Inspect oil level. Add oil as needed. DO NOT OVERFILL.

11. Insert oil dipstick and/or attach fill cap.

12. Press AUTO button on control panel to return unit

001814

to AUTO.

13. Close and lock lid.

14. Dispose of used oil and filter according to local,

state, or national codes.

Figure 4-5. Servicing Air Cleaner (14–24 kW)

4. Remove old air filter element (C) and discard.

5. Thoroughly clean air cleaner enclosure of any dust

or debris.

28 Owner’s Manual for 60 Hz Air-Cooled Generators

6. Install a new air filter element.

7. Install air cleaner cover and fasten cover clips.

Page 33

Maintenance

(000140a)

WARNING

Electric shock. Do not disconnect spark plug wires with engine running. Doing so could result in death or serious injury.

000211

WARNING

(000560)

Risk of Burn. Allow the engine to cool before performing the following procedure. Failure to do so could result in serious injury.

(000130)

Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury.

WARNING

(000141)

WARNING

Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury.

8. (14–24 kW units only): Verify air inlet duct (D) is

correctly connected to air cleaner cover.

9. Press AUTO button on control panel to return unit

to AUTO.

Spark Plug(s)

Proceed as follows to inspect spark plug gap(s) and replace spark plug(s) as necessary:

1. With generator OFF and engine cool, lift lid and

remove front panel.

2. Clean area around base of spark plug(s) to keep

dirt and debris out of engine.

3. Remove spark plug(s) and inspect. Install new

spark plug(s) if existing spark plug(s) is worn, or if reuse is questionable.

4. Clean spark plug(s) by scraping or washing with a

wire brush and commercial solvent. Do not blast spark plug(s) to clean.

Valve Clearance Adjustment

IMPORTANT NOTE: Contact an IASD for service assistance. Correct valve clearance is essential for prolonging the life of the engine. Excludes units equipped with hydraulic lifters. See Engine.

IMPORTANT NOTE: Valve lash not required on 14 or 18 kW units with 816cc engine. See Engine.

Inspect valve clearance after first 25 hours of operation, then after 400 hour intervals. Adjust if necessary.

Checking Valve Clearance

NOTE: Clean spark plug(s) in emergency situations only.

Otherwise, replace spark plug(s).

5. See Figure 4-6. Inspect spark plug gap(s) using a

wire feeler gauge. Replace spark plug(s) if spark plug gap is out of specification. See General Infor-

mation.

Figure 4-6. Spark Plug Gap Measurement

NOTE: New spark plug(s) should have spark plug gap checked prior to installation.

6. Install spark plug(s), and tighten to 18.4 ft-lbs (25

Nm).

7. Press AUTO button to return unit to AUTO mode.

Owner’s Manual for 60 Hz Air-Cooled Generators 29

NOTE: Engine should be cool before checking valve clearance. Adjustment is not needed if valve clearance is within dimensions provided in Engine.

Proceed as follows to check valve clearance.

1. Close fuel valve and disconnect battery to avoid accidental startup.

2. Remove spark plug wire(s), and position spark plug wire(s) away from spark plug(s).

3. Remove spark plug(s).

4. Remove the four screws attaching the valve cover.

Remove and discard gasket. (Repeat for second cylinder, if equipped.)

5. Verify piston is at top dead center (TDC) of its compression stroke (both valves closed).

NOTE: To move piston to TDC, remove intake baffle at front of the engine to access the flywheel nut. Use a large socket and socket wrench to rotate flywheel nut clockwise, which will rotate the crankshaft. Watch piston through spark plug hole. Piston will move up and down. Piston is at TDC when at its highest point of travel.

Page 34

Maintenance

002380

WARNING

(000560)

Risk of Burn. Allow the engine to cool before performing the following procedure. Failure to do so could result in serious injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

(000162)

WARNING

6. See Figure 4-7 or Figure 4-8. Verify valve clear-

ance between each rocker arm (E) and valve stem (F) with a feeler gauge.

001812

Figure 4-7. Valve Clearance Adjustment (10 kW)

1. Remove spark plug wire(s) and position spark plug wire(s) away from spark plug(s).

2. Remove spark plug(s).

3. Remove the four screws attaching valve cover.

Remove and discard gasket.

4. Verify piston is at TDC of its compression stroke (both valves closed).

5. Loosen rocker jam nut (C) using a 10 mm wrench (10 kW units) or 13 mm wrench (20–24 kW units).

6. Turn pivot ball stud (D) using a 14 mm wrench (10 kW units), or 10 mm hex key (20–24 kW units)

while inspecting clearance between rocker arm (E) and valve stem (F) with a feeler gauge. Adjust clearance as per Engine.

NOTE: Hold rocker jam nut in place as pivot ball stud is turned.

7. When valve clearance is correct, hold pivot ball stud in place with a wrench and tighten rocker arm jam nut. Tighten jam nut according to:

10 kW 53 in-lbs (6.0 Nm)

20–24 kW 174 in-lbs (19.68 Nm)

002380

Figure 4-8. Valve Clearance Adjustment (20–24 kW)

7. Install replacement valve cover gasket(s).

8. Install valve cover(s). Tighten fasteners in a cross

pattern, tightening to:

10 kW 80 in-lbs (9.0 Nm)

20–24 kW 60 in-lbs (6.8 Nm)

Adjusting Valve Clearance

8. Inspect valve clearance to verify it did not change.

9. Install new valve cover gasket.

10. Install valve cover. Tighten fasteners in a cross pat-

tern. Tighten to:

10 kW 80 in-lbs (9.0 Nm)

20–24 kW 60 in-lbs (6.8 Nm)

NOTE: Start all four screws before tightening, or it will

not be possible to get all screws in place. Verify valve cover gasket is in place.

11. Install spark plug(s) and tighten to 18 ft-lbs (25 Nm).

12. Attach spark plug wire(s) to spark plug(s).

13. Repeat process for other cylinder if equipped.

Battery Maintenance

IMPORTANT NOTE: Valve lash not required on 14 or 18 kW units with 816cc engine. See Engine.

See Figure 4-7 or Figure 4-8. Proceed as follows to adjust valve clearance:

NOTE: Allow engine to cool before adjusting valve clearance.

30 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 35

Maintenance

(000137a)

WARNING

Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

(000238)

Explosion. Batteries emit explosive gases. Always disconnect negative battery cable first to avoid spark. Failure to do so could result in death or serious injury.

WARNING

(000164)

WARNING

Electrical shock. Disconnect battery ground terminal before working on battery or battery wires. Failure to do so could result in death or serious injury.

(000138a)

WARNING

Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

(000163a)

WARNING

(000228)

002389

• Do not place tools or metallic objects on top of bat-

tery.

• Disconnect charging source prior to connecting or

disconnecting battery terminals.

• Wear full eye protection and protective clothing.

• If electrolyte contacts skin, wash it off immediately

with water.

• If electrolyte contacts eyes, flush thoroughly with

water immediately and seek medical attention.

• Wash down spilled electrolyte with an acid neutral-

izing agent. A common practice is to use a solution of 1 lb (454 g) bicarbonate of soda to 1 gal (3.8 L) of water. Add bicarbonate of soda solution until evidence of reaction (foaming) has ceased. Flush resulting liquid with water and dry area completely.

• DO NOT smoke near battery.

• DO NOT cause flame or spark in battery area.

• Discharge static electricity from the body before

touching battery by first touching a grounded metal surface.

Battery should be regularly inspected per Service

Schedule. Contact an IASD for assistance if necessary.

Always recycle batteries in accordance with local laws and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. For more information on battery recycling, visit the Battery Council International website at: http://batterycouncil.org

Strictly observe the following precautions when working on batteries:

• Remove 7.5A fuse from generator control panel.

• Disconnect battery charger as directed in Inspect-

ing the Battery.

• Use tools with insulated handles.

• Wear rubber gloves and boots.

Owner’s Manual for 60 Hz Air-Cooled Generators 31

Inspecting the Battery

Proceed as follows to inspect battery:

1. Press OFF button to shut down generator, then lift

lid and remove front panel.

2. Remove 7.5A fuse from control panel.

3. Remove intake side panel. (See Intake Side Panel

Removal.)

4. See Figure 4-9. Disconnect white battery charger

cable.

Figure 4-9. Disconnecting Battery Charger Cable

Page 36

Maintenance

–

001821

5. See Figure 4-10. Inspect battery posts and cables for tightness and corrosion. Tighten and clean as necessary.

001832

Figure 4-10. Battery Cables

6. Unsealed batteries only: Completely disconnect battery, removing negative battery cable first. Check battery fluid level and, if necessary, fill with distilled water only. DO NOT use tap water. Have an IASD or a qualified service technician verify state of charge and condition.

7. Connect positive battery cable, then negative battery cable.

8. Connect battery charger cable.

9. Install intake side panel, and install 7.5 A fuse.

10. Press AUTO button on controller.

11. Install front panel and close generator lid.

Cleaning the Sediment Trap

The sediment trap removes contaminants (moisture and fine particles) from gaseous fuels before they enter the fuel regulator. Accumulated moisture and particles must be emptied from the sediment trap per local codes and guidelines.

Proceed as follows to clean sediment trap:

1. Remove intake side panel. See Intake Side Panel

Removal.

2. Turn generator fuel supply OFF.

3. See Figure 4-11. Unscrew and remove cap (A).

4. Use a clean-out tool (not provided) to remove

accumulated moisture and particles from cap and body (B).

5. Wipe inside of each component with a clean, dry, lint-free cloth.

6. Seal threads of cap with appropriate sealing compound. Install cap and hand-tighten.

7. Tighten cap with an appropriately sized pipe wrench. DO NOT overtighten.

8. Turn generator fuel supply ON. Inspect for leaks by spraying all connection points with a non-corrosive gas leak detection fluid. Solution should not be blown away or form bubbles.

9. Install intake side panel.

Post Maintenance Checks

Proceed as follows to perform post maintenance checks:

1. Perform required maintenance procedure(s).

2. Install intake side panel and front panel if removed.

(See Intake Side Panel Removal and Front

Access Panel Removal.)

3. Install 7.5A fuse in control panel.

4. Complete Install Wizard information.

5. Press AUTO button on control panel. Allow unit to

run for one minute with no load (if running during a utility outage).

6. Set generator MLCB (generator disconnect) to ON (CLOSED).

7. Set utility MLCB to ON (CLOSED).

The system is now in AUTO.

NOTE: If correct utility is present at this time, generator will perform its usual shutdown process.

Figure 4-11. Cleaning the Sediment Trap

32 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 37

Maintenance

(000192)

DANGER

Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury.

(000238)

Explosion. Batteries emit explosive gases. Always disconnect negative battery cable first to avoid spark. Failure to do so could result in death or serious injury.

WARNING

Performing Fuel System Leak Test

All products are factory-tested before shipping to verify the performance and integrity of the fuel system. However, it is important to perform a final fuel system leak test before starting the generator. The entire fuel system should be tested from supply to regulator.

See Figure 4-12. Perform a final fuel system leak test after generator installation. The test will identify possible leaks at all connection points (A).

It is best practice to perform a fuel system leak test during normally-scheduled maintenance.

Corrosion Protection

Regular scheduled maintenance should be conducted to inspect unit for corrosion. Inspect all metal components of generator, including base frame, brackets, alternator can, the entire fuel system (inside and outside of the generator), and fastener locations. If there is corrosion found on generator components (e.g. regulator, engine/alternator mounts, fuel plenum, etc.), replace parts as necessary.

Periodically wash and wax enclosure using automotive type products. Do not spray unit with a hose or power washer. Use warm, soapy water and a soft cloth. Frequent washing is recommended in salt water/coastal areas. Spray engine linkages with a light oil such as WD-

40.

Remove From and Return To Service Procedure

Remove From Service

If generator cannot be exercised monthly, at a minimum, and will be out of service longer than 90 days, proceed as follows to prepare generator for storage:

1. Start engine and allow it to warm up.

2. Close fuel shutoff valve in fuel supply line and

allow engine to stop.

3. Set generator MLCB (generator disconnect) to

004038

Figure 4-12. Connection Points to Leak Check

Inspect for leaks by spraying all connection points with a non-corrosive gas leak detection fluid. The solution should not be blown away or form bubbles.

Attention After Submersion

DO NOT start or operate generator if it has been submerged in water. Have an IASD thoroughly clean, dry, and inspect generator following any submersion in water. If the structure (home) has been flooded, it should be inspected by a certified electrician to verify there will not be any electrical problems during generator operation or when utility power is returned.

Owner’s Manual for 60 Hz Air-Cooled Generators 33

OFF (OPEN) once engine has stopped.

4. Disconnect battery charger AC input T1/Neutral

cable (with white sleeve) at controller.

5. Remove 7.5A fuse from generator control panel.

6. Disconnect battery cables. Remove negative bat-

tery cable first.

7. Drain oil completely while engine is still warm, and

then fill crankcase with oil. See Changing the Oil

and Oil Filter.

8. Attach a tag to engine indicating viscosity and clas-

sification of the new oil in the crankcase.

9. Remove spark plug(s) and spray a fogging agent

into spark plug(s) threaded openings. Install and tighten spark plug(s) to specification.

10. Remove battery and store in a cool, dry place.

11. Clean and wipe down generator enclosure.

Page 38

Maintenance

(000133)

WARNING

Explosion. Batteries emit explosive gases. Always connect positive battery cable first to avoid spark. Failure to do so could result in death or serious injury.

(000167a)

Equipment damage. Do not make battery connections in reverse. Doing so will result in equipment damage.

CAUTION

Return to Service

Proceed as follows to return unit to service after storage:

1. Inspect engine tag for oil viscosity and classification. Drain and fill with recommended oil if necessary.

2. Verify state of battery. Fill all cells of unsealed batteries to correct level with distilled water. DO NOT use tap water. Charge battery to 100% state of charge. Replace battery if faulty.

3. Clean and wipe down generator enclosure.

4. Verify 7.5A fuse is removed from generator control

panel.

5. Connect battery. Observe battery polarity. Damage will occur if battery is connected incorrectly. Install positive battery cable first.

6. Connect battery charger AC input T1/Neutral cable (with white sleeve) at controller.

7. Open fuel shutoff valve.

8. Insert 7.5 A fuse into generator control panel.

9. Complete Install Wizard procedure (diagrammed in

generator installation manual).

10. Press MANUAL button to start unit. Allow unit to warm up for a few minutes.

11. Press OFF button to stop unit.

12. Set generator MLCB (generator disconnect) to ON

(CLOSED).

13. Press AUTO button on control panel.

The generator is ready for service.

NOTE: Exercise timer and current date and time must be reset if battery is discharged or has been disconnected.

34 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 39

Troubleshooting / Quick Reference Guide

Section 5: Troubleshooting / Quick Reference

Guide

Generator Troubleshooting

Problem Cause Correction

Correct short circuit condition by replacing 7.5 A

Blown fuse.

fuse in generator control panel. Contact an IASD if fuse continues to blow.

Engine will not crank

Engine cranks but will not start

Engine starts hard and runs rough

Loose, corroded, or faulty battery cables.

Tighten, clean, or replace as necessary.*Faulty starter contact.

Faulty starter motor.

Discharged battery. Charge or replace battery.

No fuel. Replenish fuel / turn on fuel valve.

Faulty fuel solenoid (FS).

Contact an IASD for assistance.

Harness/wiring issue.

Faulty spark plug(s).

Valve clearance out of adjustment, if applicable. See Engine.

Plugged or damaged air cleaner. Inspect and clean air cleaner.

Faulty spark plug(s).

Incorrect fuel pressure.

Fuel selector in wrong position.

Clean; inspect spark plug gap; replace spark plug(s) if necessary.

Inspect and adjust valve clearance.

Clean; inspect spark plug gap; replace spark plug(s) if necessary.

Verify fuel pressure to regulator is 10–12 in water column (2.49–2.99 kPa) for LP gas, and

3.5–7.0 in water column (0.87–1.74 kPa) for NG.

Set fuel conversion valve to correct position and program controller for fuel type.

Valve clearance out of adjustment, if applicable. See Engine.

Internal engine issue. Contact an IASD for assistance.

Unit is set to OFF, but engine continues to run

No AC output from generator

Owner’s Manual for 60 Hz Air-Cooled Generators 35

Controller wired incorrectly.

Faulty control board.

Generator MLCB (generator disconnect) is OFF (OPEN).

Generator internal failure. Contact an IASD for assistance.

Engine may be warming up. See Cold Smart

Start.

Inspect and adjust valve clearance.

Contact an IASD for assistance.

Set generator MLCB (generator disconnect) to ON (CLOSED).

Check the controller screen to verify status.

Page 40

Troubleshooting / Quick Reference Guide

Problem Cause Correction

No transfer to standby after utility source failure

Unit consumes large amounts of oil

Wi-Fi network connection broken or intermittent

Generator MLCB (generator disconnect) is OFF (OPEN).

Set generator MLCB (generator disconnect) to ON (CLOSED).

Faulty transfer switch coil.

Faulty transfer relay.

Contact an IASD for assistance.

Transfer relay circuit open.

Faulty control logic board.

Engine may be warming up. See Cold Smart

Start.

Excessive engine oil.

Check controller screen to verify status.

Adjust oil to correct level. See Checking Engine

Oil Level.

Faulty engine breather. Contact an IASD for assistance.

Incorrect type or viscosity of oil. See Engine Oil Requirements.

Damaged gasket, seal, or hose. Inspect for oil leaks.

Restricted air filter. Replace air filter.

Various. See Wi-Fi module owner’s manual.

* Contact an IASD or visit www.generac.com for assistance.

36 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 41

Troubleshooting / Quick Reference Guide

Quick Reference Guide

To clear an active alarm, press OFF button on the control panel, then the ENTER button, and finally the AUTO button. Contact an IASD if alarm reoccurs.

Active Alarm LED Problem Action Solution

NONE

HIGH

TEMPERATURE

OVERLOAD

REMOVE LOAD

RPM SENSE LOSS RED

NOT ACTIVATED NONE

NONE GREEN

LOW OIL

PRESSURE

RPM SENSE LOSS RED

FLASHING

GREEN

RED

Unit running in AUTO

but no power in house.

Unit shuts down during

operation.

Unit shuts down during

operation.

Unit was running and

shut down, attempts to

restart.

Unit will not start in

AUTO with utility loss.

Unit will not start in

AUTO with utility loss.

Unit will not start in

AUTO with utility loss.

Unit will not start in

AUTO with utility loss.

Check generator

MLCB (generator

disconnect).

Check LEDs / screen

for alarms.

Check LEDs / screen

for alarms.

Check LEDs / screen

for alarms.

Check if screen says

unit not activated.

Check screen for start

delay countdown.

Check LEDs / screen

for alarms.

Check LEDs / screen

for alarms.

Check generator MLCB (generator disconnect). If it is ON, contact an IASD.

Inspect ventilation around generator, intake, exhaust, and rear of generator. If no obstructions are present, contact an IASD.

Clear alarm and remove household loads from generator. Put in AUTO and restart.

Clear alarm and remove household loads from generator. Put into AUTO and restart. If generator does not start, contact an IASD.

See Activation section in installation manual.

If startup delay is greater than expected, contact an IASD to adjust from 2 to 1500 seconds.

Check oil level and add oil as needed. If oil level is correct, contact an IASD.

Clear alarm. Using control panel, check battery by navigating to BATTERY MENU option from MAIN MENU. If battery condition displays GOOD, contact an IASD. If control panel displays CHECK BATTERY, replace battery.

Verify fuel line shutoff valve is ON. Clear

OVERCRANK RED

LOW VOLTS

REMOVE LOAD

OVERSPEED RED

UNDERVOLTAGE RED

UNDERSPEED RED

STEPPER

OVERCURRENT

WIRING ERROR RED

OVERVOLTAGE RED

Owner’s Manual for 60 Hz Air-Cooled Generators 37

RED

Unit will not start in

AUTO with utility loss.

Unit will not start in

AUTO with utility loss.

Unit will not start in

AUTO with utility loss.

Unit will not start in

AUTO with utility loss.

Unit will not start in

AUTO with utility loss.

Unit will not start in

AUTO with utility loss.

Unit will not start in

AUTO with utility loss.

Unit will not start in

AUTO with utility loss.

Check LEDs / screen

for alarms.

Check LEDs / screen

for alarms.

Check LEDs / screen

for alarms.

Check LEDs / screen

for alarms.

Check LEDs / screen

for alarms.

Check LEDs / screen

for alarms.

Check LEDs / screen

for alarms.

Check LEDs / screen

for alarms.

alarm. Start unit in MANUAL. If it does not start, or starts and runs rough, contact an IASD.

Clear alarm and remove household loads from generator. Put in AUTO and restart.

Contact an IASD.

Page 42

Troubleshooting / Quick Reference Guide

Active Alarm LED Problem Action Solution

AUXILIARY

SHUTDOWN

LOW BATTERY YELLOW

BATTERY

PROBLEM

CHARGER

WARNING

CHARGER

MISSING AC

SERVICE A YELLOW

SERVICE B YELLOW

INSPECT BATTERY

RED Unit will not start.

YELLOW

Yellow LED illuminated

in any state.

Yellow LED illuminated

in any state.

Yellow LED illuminated

in any state.

Yellow LED illuminated

in any state.

Yellow LED illuminated

in any state.

Yellow LED illuminated

in any state.

Yellow LED illuminated

in any state.

Check auxiliary

shutdown switches

Check screen for

additional information.

Check screen for

additional information.

Check screen for

additional information.

Check screen for

additional information.

Check screen for

additional information.

Check screen for

additional information.

Check screen for

additional information.

Set auxiliary shutdown switch(es) to CLOSED (I). Clear alarm.

Contact an IASD.

Perform SERVICE A maintenance. Press ENTER to clear.

Perform SERVICE B maintenance. Press ENTER to clear.

Inspect battery. Press ENTER to clear.

38 Owner’s Manual for 60 Hz Air-Cooled Generators

Page 43

Page 44

Part No. A0000973303 Rev. A 10/09/2020

©2020 Generac Power Systems, Inc. All rights reserved. Specifications are subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc.

Generac Power Systems, Inc.

S45 W29290 Hwy. 59 Waukesha, WI 53189

1-888-GENERAC (1-888-436-3722)

www.generac.com

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