Generac 8 kW 0062450 Standby Generator Manual

Generac 8 kW 0062450 Standby Generator Manual
Owner’s Manual
60 Hz Air-Cooled Generators
8 kW to 22 kW
000918
WARNING
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.
(000209a)
Register your Generac product at:
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
Use this page to record important information about your generator set.
Model:
Serial:
Prod Date Week:
Volts:
LPV Amps:
NG Amps:
Hz:
Phase:
Controller P/N:
Record the information found on your unit data label on this
page. For the location of the unit data label, see General
Information. The unit has a label plate affixed to the inside
partition, to the left of the control panel console as shown in
Figure 2-1 and Figure 2-2. For directions on how to open
the top lid and remove the front panel, see Operation.
When contacting an Independent Authorized Service Dealer
about parts and service, always supply the complete model
number and serial number of the unit.
Operation and Maintenance: Proper maintenance and care
of the generator ensures a minimum number of problems
and keeps operating expenses at a minimum. It is the
operator’s responsibility to perform all safety checks, to
make sure that all maintenance for safe operation is
performed promptly, and to have the equipment checked
periodically by an Independent Authorized Service Dealer.
Normal maintenance, service and replacement of parts are
the responsibility of the owner/operator and, as such, are not
considered defects in materials or workmanship within the
terms of the warranty. Individual operating habits and usage
may contribute to the need for additional maintenance or
service.
When the generator requires servicing or repairs, Generac
recommends contacting an Independent Authorized Service
Dealer for assistance. Authorized service technicians are
factory-trained and are capable of handling all service
needs.To locate the nearest Independent Authorized Service
Dealer, please visit the dealer locator at:
www.generac.com/Service/DealerLocator/.
WARNING
California Proposition 65. Engine exhaust and some
of its constituents are known to the state of California
to cause cancer, birth defects, and other reproductive
harm.
(000004)
WARNING
California Proposition 65. This product contains or
emits chemicals known to the state of California to
cause cancer, birth defects, and other reproductive
harm.
(000005)
ii
Owner’s Manual for 60 Hz Air-cooled Generators
Table of Contents
Section 1: Safety Rules & General
Information
Table of Contents
Automatic Transfer Operation ......................... 16
Automatic Sequence of Operation .................. 16
Introduction ..........................................................1
Utility Failure ..............................................................16
Read This Manual Thoroughly ....................................1
Cranking ....................................................................16
How to Obtain Service .................................................1
Cold Smart Start ........................................................16
Safety Rules .........................................................1
Load Transfer ............................................................16
General Hazards .........................................................2
Shutting Generator Down While Under Load . 16
Exhaust Hazards .........................................................3
To turn the generator OFF: .......................................16
Electrical Hazards .......................................................3
To turn the generator back ON: .................................16
Fire Hazards ................................................................4
Explosion Hazards ......................................................4
Section 2: General Information
The Generator ......................................................5
Generator ....................................................................6
Protection Systems .............................................7
Emission Information ..........................................7
Fuel Requirements ..............................................7
Battery Requirements .........................................7
Battery Charger ....................................................7
Engine Oil Requirements ....................................7
Section 4: Maintenance
Maintenance ....................................................... 17
Performing Scheduled Maintenance ............... 17
Service Schedule ............................................... 17
Checking Engine Oil Level ............................... 18
Engine Oil Recommendations ...................................18
Changing the Oil and Oil Filter ......................... 19
Changing the Engine Air Cleaner .................... 19
Spark Plugs ........................................................ 19
Valve Clearance Adjustment ............................ 20
Check Valve Clearance .............................................20
Adjust Valve Clearance .............................................20
Section 3: Operation
Battery Maintenance ......................................... 20
Site Prep Verification ...........................................9
Attention After Submersion ............................. 21
Side Compartment ...............................................9
Corrosion Protection ........................................ 21
Main Circuit Breaker (Generator Disconnect) ..............9
LED Indicator Lights ....................................................9
120V GFCI Outlet/15 Amp Breaker
(16-22 kW Only) ..........................................................9
Generator Enclosure ...........................................9
Control Panel Interface .....................................11
Setting the Exercise Timer ................................14
Remove From/ To Service Procedure ............. 22
Remove From Service ...............................................22
Return to Service .......................................................22
Section 5: Troubleshooting
Section 6: Quick Reference Guide
Battery Charger ..................................................14
Manual Transfer Operation ...............................14
Transfer to Generator Power Source ........................15
Transfer Back to Utility Power Source .......................15
Owner’s Manual for 60 Hz Air-Cooled Generators
iii
Table of Contents
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iv
Owner’s Manual for 60 Hz Air-Cooled Generators
Section 1: Safety Rules & General Information
Section 1: Safety Rules & General Information
Introduction
CAUTION
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.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
This unit is factory installed in an all-weather, metal
enclosure that is intended exclusively for outdoor
installation. This generator will operate using either vapor
withdrawn liquid propane (LP) or natural gas (NG).
NOTE: Notes provide additional information important to
a procedure or component.
NOTE: When sized properly, 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.
Read This Manual Thoroughly
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000100a)
If any portion of this manual is not understood, contact
the nearest Independent Authorized Service Dealer for
starting, operating and servicing procedures.
This manual must be used in conjunction with the
appropriate Owner’s Manual.
SAVE THESE INSTRUCTIONS: The manufacturer
suggests that this manual and the rules for safe operation
be copied and posted near the unit installation site.
Safety should be stressed to all operators and potential
operators of this equipment.
Throughout this publication and on tags and decals
affixed to the generator, DANGER, WARNING, and
CAUTION 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. Their definitions are as follows:
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000001)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000002)
Owner’s Manual for 60 Hz Air-cooled Generators
(000003)
These safety warnings cannot eliminate the hazards they
indicate. Observing safety precautions and strict
compliance with the special instructions while performing
the action or service are essential to preventing accidents.
The operator is responsible for proper and safe use of
the equipment. The manufacturer strongly recommends
that if the operator is also the owner, to read the Owner’s
Manual and thoroughly understand all instructions before
using this equipment. The manufacturer also strongly
recommends instructing other users to properly start and
operate the unit. This prepares them if they need to
operate the equipment in an emergency.
How to Obtain Service
When the generator requires servicing or repairs, contact
an Independent Authorized Service Dealer for assistance.
Service technicians are factory-trained and are capable of
handling all service needs. For assistance locating a
dealer, go to www.generac.com/Service/DealerLocator/.
When contacting a dealer about parts and service,
always supply the complete model number and serial
number of the unit as given on its data decal, which is
located on the generator. Refer to Figure 2-1 and Figure
2-2 for decal location. Record the model number and
serial numbers in the spaces provided on the inside front
cover of this manual.
Safety Rules
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar
with this Owner’s Manual and with the unit. The
generator can operate safely, efficiently and reliably only
if it is properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and
fundamental rules or precautions.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warnings in
this manual and on tags and decals affixed to the unit are,
therefore, not all-inclusive. If using a procedure, work
method, or operating technique the manufacturer does not
specifically recommend, verify that it is safe for others.
Also, make sure the procedure, work method or operating
technique utilized does not render the generator unsafe.
1
Section 1: Safety Rules & General Information
General Hazards
WARNING
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.
(000190)
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.
(000191)
WARNING
WARNING
Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
to do so could result in death or serious injury.
(000111)
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.
(000108)
(000187)
WARNING
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.
(000209a)
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.
(000146)
WARNING
WARNING
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.
(000130)
Risk of injury. Do not operate or service this
machine if not fully alert. Fatigue can impair the
ability to service this equipment and could result
in death or serious injury.
(000215)
WARNING
WARNING
(000182)
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.
(000228)
WARNING
WARNING
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.
See individual unit specifications for required
maintenance and run times pertaining to use.
(000247)
WARNING
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 damage to equipment or property. (000155)
2
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.
(000115)
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. (000216)
Inspect the generator regularly, and contact the nearest
Independent Authorized Service Dealer for parts needing
repair or replacement.
Owner’s Manual for 60 Hz Air-cooled Generators
Section 1: Safety Rules & General Information
Exhaust Hazards
DANGER
DANGER
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)
Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
result in death or serious injury.
(000188)
DANGER
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.
(000178a)
Adequate, unobstructed flow of cooling and ventilating air
is critical to correct generator operation. Do not alter the
installation or permit even partial blockage of ventilation
provisions, as this can seriously affect safe operation of
the generator. The generator must be installed and
operated outdoors only.
Electrocution. Water contact with a power
source, if not avoided, will result in death
or serious injury.
(000104)
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000144)
DANGER
Electrical Hazards
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000144)
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.
(000145)
DANGER
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.
(000150)
DANGER
Electrical backfeed. Use only approved switchgear to
isolate generator when electrical utility is the primary
power source. Failure to do so will result in death,
serious injury, and equipment damage.
(000131a)
DANGER
Electrocution. Verify electrical system is
properly grounded before applying power.
Failure to do so will result in death or serious
injury.
(000152)
Owner’s Manual for 60 Hz Air-cooled Generators
3
Section 1: Safety Rules & General Information
Fire Hazards
Explosion Hazards
DANGER
WARNING
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. (000217)
(000192)
DANGER
WARNING
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.
Connection of fuel source must be done by a qualified
professional technician or contractor. Incorrect installation
of this unit will result in death, serious injury, and damage
to equipment and property damage.
(000151)
(000218)
WARNING
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.
(000219)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000100a)
DANGER
Risk of fire. Allow fuel spills to completely dry
before starting engine. Failure to do so will
result in death or serious injury.
(000174)
WARNING
Risk of Fire. Hot surfaces could ignite
combustibles, resulting in fire. Fire could
result in death or serious injury.
(000110)
WARNING
Risk of electrocution. Refer to NFPA 70E for
safety equipment required when working with
with a live electrical system. Failure to use
required safety equipment could result in
death or serious injury.
(000221)
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. (000147)
Comply with regulations the Occupational Safety and
Health Administration (OSHA) 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.
4
Owner’s Manual for 60 Hz Air-cooled Generators
Section 2: General Information
Section 2: General Information
The Generator
J
L
I
H
I
J
K
L
H
G
A
A
G
K
F
F
E
E
B
000908
B
D
C
000909
D
C
Figure 2-1. GH-410 Engine 8 kW Unit (Left) and GH-530 Engine 11 kW Unit (Right)
L
K
J
I
H
A
G
F
B
000910
C
E
D
Figure 2-2. GT-990/GT-999 Engines, 16-22 kW Units
A.
Exhaust Enclosure
D.
Battery Compartment
G.
Circuit Breakers
J.
Oil Fill Cap
B.
Composite Base
E.
Fuel Regulator
H.
Control Panel
K.
Air Filter
C.
Oil Filter
F.
Fuel Inlet (Back)
I.
Data Label
L.
Oil Dipstick
Owner’s Manual for 60 Hz Air-cooled Generators
5
Section 2: General Information
Specifications
Generator
Model
8 kW
11 kW
16 kW
Rated Voltage
Rated Maximum Load
Current (Amps) at Rated
Voltage*
Main Circuit Breaker
20 kW
22 kW
240
33.3
45.8
66.6
83.3
91.7
35 Amp
50 Amp
65 Amp
90 Amp
100 Amp
Phase
1
Rated AC Frequency
60 Hz
Battery Requirement
Group 26R, 12 Volts and 540 CCA Minimum (see Replacement Parts)
Enclosure
Aluminum
Weight (lbs/kilos)
378/171.5
Normal Operating Range
Aluminum/Steel
Aluminum/Steel
394/178.7 (Steel)
455/206.4 (Steel)
358/162.4 (Aluminum) 419/190 (Aluminum)
Steel
Aluminum
505/229
476/216
This unit is tested in accordance to UL 2200 standards with an operating temperature of -20 ºF (-29 ºC) to 122 ºF
(50 ºC). For areas where temperatures fall below 32 ºF (0 ºC) a cold weather kit is recommended. When operated
above 77 ºF (25 ºC) there may be a decrease in engine power. (Please reference the engine specifications section.
These generators are rated in accordance with UL 2200, Safety Standard for Stationary Engine Generator Assemblies, and CSA-C22.2 No. 100-04
Standard for Motors and Generators.
* Natural Gas ratings will depend on specific fuel joules/Btu content. Typical derates are between 10-20% off the LP gas rating.
** Circuits to be moved must be protected by same size breaker. For example, a 15 amp circuit in the main panel must be a 15 amp circuit in the
transfer switch.
Engine
Model
Type of Engine
Number of Cylinders
Displacement
8 kW
11 kW
16 kW
20/22 kW
GH-410
GTH-530
GT-990
GT-999
1
2
2
2
410 cc
530 cc
992 cc
999 cc
Cylinder Block
Aluminum w/ cast iron sleeve
see Replacement Parts
Recommended Spark Plug
Spark Plug Gap
0.508 mm (0.020 in)
0.76 mm (0.030 in)
1.02 mm (0.040 in)
1.02 mm (0.040 in)
Valve Clearance
0.05 - 0.1 mm
(0.002 - 0.004 in)
0.05 - 0.1 mm
(0.002 - 0.004 in)
0.05 - 0.1 mm
(0.002 - 0.004 in)
0.05 - 0.1 mm
(0.002 - 0.004 in)
Approx. 1.9 qt/ 1.8 l
Approx. 1.9 qt/ 1.8 l
Starter
Oil Capacity Including Filter
12 VDC
Approx. 1.5 qt/ 1.4 l
Approx. 1.7 qt/ 1.6 l
Recommended Oil Filter
see Replacement Parts
Recommended Air Filter
see Replacement Parts
Engine power is subject to and limited by such factors as fuel Btu/joules, ambient temperature and altitude. Engine power decreases about 3.5 percent
for each 1000 feet (304.8 meters) above sea level, and also will decrease about 1 percent for each 6 ºC (10 ºF) above 15 ºC (60 ºF) ambient temperature.
The specification sheet for your generator was included in the documentation provided with the unit at the time of
purchase. For additional copies, consult your local Independent Authorized Service Dealer for your specific generator
model.
6
Owner’s Manual for 60 Hz Air-cooled Generators
Section 2: General Information
Protection Systems
The generator may have to run for long periods of time
with no operator present to monitor the engine/generator
conditions. Therefore, the generator is equipped with a
number of systems to automatically shut down the unit to
protect it against potentially damaging conditions. Some
of these systems are as follows:
Alarms:
• High Temperature
• Low Oil Pressure
• Overcrank
• Overspeed
• Overvoltage
• Undervoltage
• Overload
• Underspeed
• RPM Sensor Loss
• Controller Fault
• Wiring Error
• Fuse Problem
• Stepper Overcurrent
Warnings:
•
•
•
•
Charger Warning
Charger Missing AC
Low Battery
Battery Problem
• Exercise Set Error
• USB Warning
• Download Failure
The control panel contains a display which alerts the
operator when a fault condition occurs. The above list is
not all inclusive. For more information about alarms and
control panel operation, see Section 3 Operation.
NOTE: A warning will indicate a condition, on the
generator, that should be addressed but not shut the
generator down. An alarm will shut the generator down to
protect the system from any damage. In the event of an
alarm, an owner can clear the alarm and restart the
generator prior to contacting an Independent Authorized
Service Dealer. If the intermittent issue occurs again,
contact an Independent Authorized Service Dealer.
Emission Information
The United States Environmental Protection Agency (US
EPA) (and California Air Resources Board (CARB), for
engines/equipment certified to California standards)
requires that this engine/equipment complies with
exhaust and evaporative emissions standards. Locate
the emissions compliance decal on the engine to
determine applicable standards. For emissions warranty
information, please reference the included emissions
warranty. It is important to follow the maintenance
specifications in Section 4 Maintenance to ensure that
the engine complies with the 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:
Owner’s Manual for 60 Hz Air-cooled Generators
System
Components
Air Induction
- Intake Manifold
- Air Cleaner
Fuel Metering
- Carburetor and Mixer Assembly
- Fuel Regulator
Ignition
- Spark Plug
- Ignition Module
Exhaust
- Exhaust Manifold
- Muffler
Fuel Requirements
DANGER
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.
(000105)
The engine has been fitted with a dual fuel carburetion
system. The unit will run on natural gas or LP gas
(vapor), but it has been factory set to run on natural gas.
The fuel system will be configured for the available fuel
source during installation.
Recommended fuels should have a BTU content of at
least 1000 Btus per cubic foot (37.26 megajoules per
cubic meter) for natural gas, or at least 2500 BTUs per
cubic foot (93.15 megajoules per cubic meter) for LP gas
(vapor).
NOTE: If converting to LP gas from natural gas, a
minimum LP tank size of 250 gallons (946 liters) is
recommended. See the Installation Manual for complete
procedures and details.
Battery Requirements
Group 26R, 12V, minimum 540 CCA.
For proper battery maintenance procedures, see Section
4 Maintenance.
Battery Charger
The battery charger is integrated into the control panel
module in all models. It operates as a Smart Charger
which ensures output charging levels are safe and
continuously optimized to promote maximum battery life.
Engine Oil Requirements
For proper oil viscosity, see chart in Figure 4-1.
7
Section 2: General Information
Replacement Parts
Description
8 kW
11 kW
26R Exide Battery
Spark Plug
16 kW
20 kW
22 kW
0G0767A
0G0767A
0H3421S
0G0767B
0E9368
Oil Filter
0E7585A
070185E
Air Filter
0E9371A
0J8478
Control Panel Fuse
0D7178T
Transfer Switch Fuses
073590A
Accessories
Performance enhancing accessories are available for air-cooled generators.
Accessory
Description
Cold Weather Kit
Recommended in areas where temperatures fall below 32 ºF (0 ºC).
Scheduled Maintenance Kit
Includes all pieces necessary to perform maintenance on the generator along
with oil recommendations.
Auxiliary Transfer Switch Lockout
Enables any of the transfer switches to completely lock out one large electrical
load by tying into its control system.
Fascia Base Wrap
The fascia base wrap snaps together around the bottom of the new air-cooled
generators. This offers a sleek, contoured appearance as well as offering
protection from rodents and insects by covering the lifting holes located in the
base. Requires use of the mounting pad shipped with the generator.
Mobile Link™ (USA only)
Provides a personalized web portal that displays the generator status,
maintenance schedule, event history and much more. This portal is accessible
via computer, tablet or smart phone. Sends emails and/or text notifications the
moment there is any change in the generator’s status. Notification settings can
be customized to what type of alert is sent and how often. For more
information, visit www.MobileLinkGen.com.
Touch-Up Paint Kit
Very important to maintain the look and integrity of the generator enclosure.
This kit includes touch-up paint and instructions.
Wireless Local Monitor
Completely wireless and battery powered, the Wireless Local Monitor provides
you with instant status without ever leaving the house. Status lights (red,
yellow and green) alert owners when the generator needs attention. Magnetic
backing permits refrigerator mounting and gives a 600 foot line of sight
communication.
Extended Warranty Coverage
Extend your generator warranty coverage by purchasing extended warranty
coverage. Covers both parts and labor. Extended coverage can be purchased
within 12 months of the end-users purchase date.
This extended coverage is applicable to registered units and end-user proof of
purchase must be available upon request.
Available for Generac®, Guardian® and Centurion® products. Not available for
Corepower™ and EcoGen™ products or all international purchases.
NOTE: Contact an Independent Authorized Service Dealer or visit www.generac.com for additional information on
replacement parts, accessories, and extended warranties.
8
Owner’s Manual for 60 Hz Air-cooled Generators
Section 3: Operation
Section 3: Operation
Site Prep Verification
Main Circuit Breaker (Generator Disconnect)
It is important that the generator is installed in such a way
that the airflow into and out of the generator is not
impeded. Verify that all shrubs or tall grasses have been
removed within 3 ft. (0.91m) of the intake and discharge
louvers on the sides of the enclosure. It is also important
that the generator is not subject to water intrusion. Verify
that all potential sources such as water sprinklers, roof
run-off, rain gutter down spouts and sump pump
discharges are directed away from the generator
enclosure.
This is a 2-pole breaker rated according to relevant
specifications. See “A” in Figure 3-1.
LED Indicator Lights
See “B” in Figure 3-1.
• Green LED “Ready” light is on when utility is
present and the control panel button is in the AUTO
position. This also indicates when the generator is
running.
• Red LED “Alarm” light is on when the generator is
OFF or a fault is detected. Contact an authorized
servicing dealer.
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.
(000191)
Turn the generator OFF before performing maintenance.
Remove 7.5 Amp fuse, T1 and T2 battery charge fuses,
and disconnect battery cables to prevent accidental start
up. Disconnect the NEGATIVE (-) cable first, then
disconnect the POSITIVE (+) cable. When connecting
the cables, connect the POSITIVE cable first, the
NEGATIVE cable last.
WARNING
(000182)
Side Compartment
Local codes may require this compartment to be locked.
A hasp is provided so the owner/operator can secure the
compartment with a padlock. Check local codes for side
compartment locking requirements.
• Yellow LED “Maintenance” light.
NOTE: Yellow LED may be on at the same time as either
the Red or Green LED.
120V GFCI Outlet/15 Amp Breaker
(16-22 kW Only)
Some units are equipped with an external 15 Amp, 120
volt GFCI convenience outlet located in the top corner of
the compartment. See “C” in Figure 3-1.
When the generator is running, in the absence of utility
power, this outlet may also be used to power items
outside the home such as lights or power tools. This
outlet may also be used when utility power is present by
running the generator in manual mode.
This outlet does not provide power if the generator is not
running. Do not use this outlet when the generator is in
Exercise mode. This outlet is protected by a 15 Amp
circuit breaker in the side compartment.
Generator Enclosure
The lid will be locked. A set of keys is attached to the
circuit breaker box door with a cable tie.
1.
Cut the cable tie to remove the keys.
2.
Use the keys to open the lid of the generator.
NOTE: The enclosed keys provided with this unit are
intended for service personnel use only.
B
000931
C
A
Figure 3-1. Open Side Compartment
Owner’s Manual for 60 Hz Air-cooled Generators
9
Section 3: Operation
3.
There are two locks securing the lid, one on each
side (A in Figure 3-3). To properly open the lid,
press down, on the lid, above the side lock and
unlock the latch.
4.
Repeat for the other side. If pressure is not applied
from the top, the lid may appear stuck.
NOTE: Always verify that the side locks are unlocked
before attempting to lift the lid.
5.
000932
Figure 3-2. Circuit Breaker Box and Keys
(As Shipped)
Once the lid is open, remove the front access
panel by lifting it up and out.
NOTE: Always the lift the front access panel up before
pulling away from enclosure (B and C in Figure 3-3). Do
not pull the panel away from the enclosure before lifting
up (D in Figure 3-3).
A
A
000597
B
C
D
001028
Figure 3-3. Side Lock Location and Front Panel Removal
10
Owner’s Manual for 60 Hz Air-cooled Generators
Section 3: Operation
Control Panel Interface
The Control Panel Interface is located under the lid of the
enclosure. Before attempting to lift the lid of the
enclosure, verify that both left and right side locks are
unlocked. To remove the front cover, lift the cover straight
up to disengage the side hooks, then tilt and lift it away
from the unit.
When closing the unit, verify that both left and right side
locks are securely locked.
NOTE: All appropriate panels must be in place during
any operation of the generator. This includes operation
by
a
servicing
technician,
while
conducting
troubleshooting procedures.
000425
Figure 3-4. Generator Control Panel
Using the Auto/Off/Manual Interface
Button
Description of Operation
AUTO
Selecting this button activates fully automatic system operation. It also allows the unit to automatically
start and exercise the generator according to the exercise timer (see Setting the Exercise Timer ).
OFF
This button shuts down the engine and also prevents automatic operation of the unit.
MANUAL
This button will crank and start the generator. Transfer to standby power will not occur unless there is a
utility failure.
NOTE: Damage caused by mis-wiring of the interconnect wires is not warrantable.
Interface Menu Displays
The LCD display
Feature
Description
HOME page
The default page which will be displayed if no buttons are pressed for 60 seconds. This page normally
shows the current Status message and the current date and time. The highest priority active Alarm/
Warning will be automatically posted on this page as well as flashing the backlight when such a condition is detected. In the case of multiple Alarms/Warnings, only the first message will be displayed. To
clear an Alarm or Warning, press the OFF button and then press the ENTER key.
Display Backlight
Normally off. If the operator presses any button, the backlight will automatically light and remain on for
30 seconds.
MAIN MENU page
Allows the operator to navigate to all other pages or sub-menus by using the Arrows and Enter buttons. This page can be accessed at any time with several presses of the dedicated Escape button.
Each press of the Escape button takes the operator to the previous menu until the MAIN MENU displays. This page contains information for - History; Status; Edit; Debug.
Menu System Navigation
To get to the MENU, use the “Escape” button from any page. It may require pressing it several times before getting to
the MENU page. Navigate to the desired menu by using the ↑/↓ buttons. When the desired menu is displayed and
flashing, press the “Enter” button. See Figure 3-5 Navigation Menu.
Owner’s Manual for 60 Hz Air-cooled Generators
11
Section 3: Operation
EVOLUTION/SYNC2.0 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.
ESC
Running Manual
Running-Utility Lost
Running-Remote Start
Running-2 Wire Start
Running - Exercise
Switched Off
Stopped - Auto
Stopped - Alarm
ENTER
SYSTEM
DATE/TIME
ENTER
Battery Condition
BAT-
ESC
“Good” “Inspect Battery” or “Check Battery”
SUB MENUS
ENTER
- 1 thru 50 +
ENTER
ENTER
- Run Log +
“Run Log”
ESC
ENTER
ESC
- 1 thru 50 +
ENTER
ESC
- Alarm Log +
ENTER
HISTORY
ESC
“Alarm Log”
EDI
Warning Message(s)
Charger Warning
Charger Missing AC
Low Battery
Battery Problem
Exercise Set Error
USB Warning
Download Failure
Alarm Message(s)
High Temperature
Low Oil Pressure
Overcrank
Overspeed
Overvoltage
Undervoltage
Overload
Underspeed
RPM Sensor Loss
Controller Fault
Wiring Error
Stepper Overcurrent
Fuse Problem*
ENTER
ENTER
Language
ESC
English
ENTER
Fuel Selection
ESC
YES or NO
+
Language
+
+ English -
-
+ Espanol -
-
ESC
Fuel Selection
+ NG or LP -
NG or LP ENTER
Cold Smart Start?
ESC
Language
ESC
Cold Smart Start?
- YES or NO +
ESC
ENTER
Current Date/Time
ESC
2/12/13 12:22
ESC
Select Hour (0-23)
ENTER
- 14 +
- 0 +
ESC
*“Fuse Problem” on Firmware
1.11 and older ONLY
ESC
ENTER
Exercise Time
ESC
14:00 Wednesday
Firmware Update
Press Enter
ESC
Select Frequency
- WEEKLY +
- BIWEEKLY +
- MONTHLY +
ENTER
ESC
Select Min (0-59)
ENTER
Quiet Test Mode
?
Quiet Test Mode only
on certain models
Firmware Update
Insert USB
Figure 3-5. Navigation Menu
12
Owner’s Manual for 60 Hz Air-cooled Generators
Section 3: Operation
Current Date/Time
UP ARROW =
+
02/14/13 07:40
ESC
DOWN ARROW =
ENTER
-
Run Hours (H)
0.0
ESC
MAINT:
ESC
MAIN
ENTER
DEALER
Run Hrs
Scheduled
Maint. Log
Access Requires Password
ENTER
ESC
ENTER
Language
+
Language
+ Francais -
-
+ Portuguese -
ENTER
ESC
- 1 thru 50 +
"Battery Maintained"
"Schedule A Serviced"
"Schedule B Serviced"
"Maintenance Reset"
"Inspect Battery"
"Service Schedule A"
"Service Schedule B"
+
EXAMPLE:
Inspect Battery 200 RnHr or 12/27/13
and
Next Maintenance 200 RnHr or 12/27/13
Select “Yes” then Press “Enter” to continue or Press “ESCAPE” to escape out of updating.
During update process the Blue “Manual” light flashes, then the Green “Auto” light flashes.
Sequence does this twice. When update is complete the unit returns to Install Wizard menu.
When the controller powers up the very first screen displays the version number for a few seconds.
When update is complete remove Thumb Drive, then follow the Install Wizard Menu.
ESC
ENTER
Select Month (1-12)
ESC
ENTER
Select Date (1-31)
- 2 +
Select Hour (0-23)
ENTER
Select Min (0-59)
- 13 +
ESC
ENTER
"Current:V XXXX "
V XXXX"
ENTER
Select Day
- 0 +
"USB:
ENTER
Select Year (0-99)
ESC
- 14 +
Possible Message(s)
Corrupted File
Invalid File
File Not Found
Unsupported Device
ENTER
- 13 +
ESC
ENTER
ESC
- Wednesday +
ENTER
ESC
"Are You Sure?"
"- Yes or No +"
000428b
Figure 3-6. Navigation Menu
Owner’s Manual for 60 Hz Air-cooled Generators
13
Section 3: Operation
Setting the Exercise Timer
This generator is equipped with a configurable exercise
timer. There are two settings for the exercise timer.
While providing the necessary periodic exercise
operation, the lower rpm also reduces fuel consumption,
engine wear and noise.
Day/Time: Once set, the generator will start and exercise
for the period defined, on the day of the week and at the
time of day specified. During this exercise period, the unit
runs for approximately 5 or 12 minutes, depending on the
model, and then shuts down.
Low Speed Exercise Profile - 22 kW Generators
3800
3600
Exercise Speed (RPM)
3400
Exercise frequency (how often the exercise will take
place): It can be set to Weekly, Biweekly or Monthly. If
Monthly is selected, the day of the month must be
selected from 1-28. The generator will exercise on that
day each month. Transfer of loads to the generator
output does not occur during the exercise cycle unless
utility power is lost.
3200
3000
2800
2600
2400
2200
2000
1800
0 sec
15 s
20 s
25 s
30 s
35 s
40 s
45 s
1 min
5 min
000905
Figure 3-7.
3200
Low Speed Exercise Profile - 16 to 20 kW Generators
3000
Exercise Speed (RPM)
Table 3-1 details the exercise information and
programming options for all Home Standby generators.
Figure 3-7 illustrates the engine speed profile during a
typical exercise cycle for 22 kW generators. Figure 3-8
shows the engine speed profile for 16-20 kW generators.
8-11 kW generators exercise at a constant 3600 rpm.
10 s
Exercise Time
NOTE: If the installer tests the generator prior to
installation, press the “enter” button to skip setting up the
exercise timer.
NOTE: The exercise feature will operate only when the
generator is placed in the AUTO mode and will not work
unless this procedure is performed. The 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.
5s
2800
2600
2400
2200
2000
0 sec
5s
10 s
1 min
5 min
Exercise Time
000906
Figure 3-8.
Table 3-1. Generator Exercise Characteristics
Generator Size
8 kW
11 kW
16 kW / 20 kW
22 kW
Low Speed Exercise
n/a *
n/a *
2400 rpm
1950 rpm
Exercise Frequency
Options
Weekly/Bi-Weekly/
Monthly
Weekly/Bi-Weekly/
Monthly
Weekly/Bi-Weekly/
Monthly
Weekly/Bi-Weekly/
Monthly
Exercise Time Length
12 minutes
12 minutes
5 minutes
5 minutes
* exercises at 3600 rpm
Battery Charger
NOTE: The battery charger is integrated into the control
module in all models.
The battery charger operates as a Smart Charger that
ensures:
• Output is continually optimized to promote
maximum battery life.
Manual Transfer Operation
DANGER
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.
(000132)
• Charging levels are safe.
NOTE: A warning is displayed on the LCD when the
battery needs service.
14
Owner’s Manual for 60 Hz Air-cooled Generators
Section 3: Operation
Prior to automatic operation, manually exercise the
transfer switch to verify that there is no interference with
proper operation of the mechanism. Manual operation of
the transfer switch is required if electronic operation
should fail.
7.
Set the main circuit breaker (Generator Disconnect)
to ON or CLOSED. The standby power source now
powers the loads.
Transfer to Generator Power Source
1.
Verify generator is in the OFF mode.
2.
Set the main circuit breaker
Disconnect) to OFF or OPEN.
3.
Turn off the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).
4.
Use the manual transfer handle (A in Figure 3-9)
inside the transfer switch to move the main
contacts to the STANDBY position (loads
connected to the standby power source).
5.
To crank and start the engine, press the control
panel MANUAL button.
6.
Allow the engine to stabilize and warm up for a few
minutes.
(Generator
A
B
000228
Figure 3-9. Manual Transfer Switch Operation
• Will not transfer to generator if utility is present.
MANUAL
• Will transfer to generator if utility fails (below 65% of nominal for 5 consecutive seconds).
• Will transfer back when utility returns for 15 consecutive seconds. The engine will continue to
run until removed from the MANUAL mode.
• Will start and run if utility fails for 5 consecutive seconds. (factory default)
• Will start a 5 second engine warm-up timer.
–Will not transfer if utility subsequently returns.
AUTO
–Will transfer to generator if utility is not present.
• Will transfer back to utility once utility returns (above 80% of nominal) for 15 seconds.
• Will not transfer back to utility unless utility returns. The generator will shut down if the OFF
button is pressed or a shutdown alarm is present.
• Once utility power is returned, the generator will shut down after 1 minute cool-down time.
• Will not exercise if generator is already running in either AUTO or MANUAL mode.
EXERCISE
• During exercise, the controller will only transfer if utility fails during exercise for 10 seconds,
and will switch to AUTO.
Transfer Back to Utility Power Source
When utility power has been restored, transfer back to
utility source and shut down the generator. To manually
transfer back to utility power and shut down the
generator:
1.
2.
3.
Set the Main Circuit Breaker
Disconnect) to OFF or OPEN.
4.
Verify that utility power supply to the transfer switch
is turned OFF.
5.
Use the manual transfer handle (A in Figure 3-9)
inside the transfer switch to move the main
contacts back to the UTILITY position (loads
connected to the utility power source).
6.
Turn on the utility power supply to the transfer
switch using the means provided.
7.
Press the control panel AUTO button.
(Generator
Allow the engine to run for 2 minutes at no-load to
stabilize the internal temperatures.
Press the control panel OFF button. The engine
should shut down.
Owner’s Manual for 60 Hz Air-cooled Generators
15
Section 3: Operation
Automatic Transfer Operation
To select automatic operation:
1.
Make sure the transfer switch main contacts are
set to the UTILITY position (loads connected to the
utility power source).
2.
Be sure that normal UTILITY power source voltage
is available to transfer switch terminal lugs N1 and
N2.
3.
Press the AUTO button on the control panel
interface.
4.
Set the main circuit breaker (Generator
Disconnect) to the ON (Closed) position.
With these steps complete, the generator will start
automatically when utility source voltage drops below a
preset level. After the unit starts, loads are transferred to
the standby power source.
Automatic Sequence of Operation
Utility Failure
With the generator set to AUTO, when utility fails (below
65% of nominal) a 5 second (dealer programmable) line
interrupt delay time is started. If utility is still gone when
the timer expires, the engine will crank and start. Once
started, a 5 second engine warm-up timer will be
initiated. When the warm-up time expires, the controller
will transfer the load to the generator. If the utility power is
restored (above 80% nominal) at any time from the
initiation of the engine start until the generator is ready to
accept load (5 second warm-up time has not elapsed),
the controller will complete the start cycle and run the
generator through its normal cool down cycle, however,
the load will remain on the utility source.
Cranking
The system will control the cyclic cranking as follows:
• 8 kW Unit: 5 cranking cycles as follows: 15 second
crank, seven (7) second rest, followed by four (4)
additional cycles of seven (7) second cranks
followed by seven (7) second rests.
• 11 - 22 kW Units: 5 cranking cycles as follows: 16
second crank, seven (7) second rest, 16 second
crank, seven (7) second rest, followed by three (3)
additional cycles of seven (7) second cranks
followed by seven (7) second rests.
Cold Smart Start
The Cold Smart Start feature can be enabled in the EDIT
menu. With Cold Smart Start enabled, the generator will
monitor ambient temperature and the warm-up delay will
be adjusted based on prevailing conditions.
16
On a startup in AUTO mode, if the ambient temperature
is below a fixed temperature (based on model) the
generator will warm-up for 30 seconds. This allows the
engine to warm before a load is applied. If the ambient
temperature is at or above the fixed temperature, the
generator will startup with the normal warm-up delay of 5
seconds.
When the generator engine is started, a check for proper
output voltage build up will be performed.
If some condition impedes normal voltage creation, such
as frost crystals or dust/dirt prevent a good electrical
connection, the start sequence will be interrupted so that
a cleaning cycle of the internal electrical connections can
be attempted.
The cleaning cycle is an extended “Warming Up” period
which lasts for several minutes while the normal
generator voltage output is determined to be low. During
this cycle, the generator controller will display the
“Warming Up” on the display screen.
If the cleaning cycle fails to clear the obstruction, the
generator controller display will show the “Under Voltage”
message.
After several minutes, the alarm message can be
cleared, and a restart of the generator attempted.
If the problem persists, make no further attempts to start.
Contact an independent authorized service dealer.
Load Transfer
The transfer of load when the generator is running is
dependent upon the operating mode:
Shutting Generator Down While
Under Load
IMPORTANT NOTE: To turn the generator off during
utility outages to perform maintenance, or conserve fuel,
follow these steps:
To turn the generator OFF (while running in
AUTO and online):
1.
Turn the main utility disconnect OFF.
2.
Turn the main line circuit breaker (MLCB) on the
generator to OFF (OPEN).
3.
Turn the generator OFF.
To turn the generator back ON:
1.
Put the generator back into AUTO and allow to
start and warm-up for a few minutes.
2.
Set the MLCB on the generator to ON.
The system will now be operating in automatic mode.
The main utility disconnect can be turned ON (CLOSED).
To shut the unit OFF, this complete process must be
repeated.
Owner’s Manual for 60 Hz Air-cooled Generators
Section 4: Maintenance
Section 4: Maintenance
Maintenance
Performing Scheduled Maintenance
Regular maintenance will improve performance and
extend engine/equipment life. The manufacturer
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. However, to obtain emissions control warranty
service free of charge, the work must be performed by an
IASD. See the emissions warranty.
It is important to perform maintenance as specified in the
Service Schedule for proper generator operation and to
ensure that the generator complies with the applicable
emission standards for the duration of its useful life.
Service and repairs may be performed by any qualified
service person or repair shop.
WARNING
Engine oil and filter must be changed and valve
clearance adjusted after the first 25 hours of operation.
Additionally, emissions critical maintenance must be
performed as scheduled in order for the Emissions
Warranty to be valid. Emissions critical maintenance
consists of servicing the air filter and spark plugs in
accordance with the Service Schedule.
The controller will prompt for Schedule A or Schedule B
maintenance to be performed. See Service Schedule for
recommendations.
(000182)
Since most maintenance alerts will occur at the same
time (most have two year intervals), only one will appear
on the control panel display at any one time. Once the
first alert is cleared, the next active alert will be displayed.
Service Schedule
Service
Daily If Running Continuously
or Before Each Use
Check Enclosure Louvers for Dirt and Debris *
●
Check Lines and Connections for
Fuel or Oil Leaks
●
Check Engine Oil Level
●
Every
Year
Check for Water Intrusion **
●
Check Battery Condition, Electrolyte Level, and
State of Charge
●
Replace Engine Oil and Oil Filter †
Schedule A
Every Two Years
or 200 Hours
Schedule B
Every Four Years
or 400 Hours
●
●
●
●
Replace Engine Air Filter
●
Replace/Gap Spark Plugs
●
Inspect/Adjust Valve Clearance ‡
●
Contact the nearest Independent Authorized Service Dealer for assistance if necessary.
* Remove any shrubs or tall grasses which have grown within 3 ft. (0.91m) of the intake and discharge louvers on the sides of the enclosure. Clean any debris (dirt,
grass clippings, etc.) which have accumulated inside the enclosure.
** Verify that all sources of potential water intrusion such as water sprinklers, roof run-off, rain gutter down spouts and sump pump discharges are directed away from
the generator enclosure.
† Change engine oil and filter after the first 25 hours of operation. In cold weather conditions (ambient below 40 ºF / 4.4 ºC),
or if unit is operated continuously in hot weather conditions (ambient above 85 ºF / 29.4 ºC), change engine oil and filter
every year or 100 hours of operation.
‡ Check/adjust valve clearance after the first 25 hours of operation.
NOTE: Contact an Independent Authorized Service Dealer or visit www.generac.com for additional information on
replacement parts.
Owner’s Manual for 60 Hz Air-cooled Generators
17
Section 4: Maintenance
Maintenance Log
Battery inspection and charge check
Dates Performed:
Oil, oil filter, air filter and spark plug replacement
Dates Performed:
Valve Adjustment
Dates Performed:
Checking Engine Oil Level
WARNING
Risk of burns. Allow engine to cool before
draining oil or coolant. Failure to do so
could result in death or serious injury.
(000139)
disconnect. Then, turn the generator main circuit
breaker to the OFF position.
2.
Press the control panel OFF button. Wait 5
minutes.
3.
Remove the dipstick and wipe it dry with a clean
cloth.
4.
Completely insert the dipstick and again remove it.
5.
Observe the oil level. The level should be at the
“FULL” mark on the dipstick.
6.
If necessary, remove the oil fill cap and add oil to
the engine until the level reaches the “FULL” mark
and reinsert the dipstick and fill cap.
7.
Press the control panel AUTO button.
8.
If the generator was running during a utility outage,
first turn the main circuit breaker to the ON
position. Then, turn ON the needed loads in the
residence.
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.
(000210)
CAUTION
Engine damage. Verify proper type and quantity of
engine oil prior to starting engine. Failure to do so
could result in engine damage.
(000135)
When power outages necessitate running the generator
for extended periods, the oil level should be checked
daily. To check the engine oil level:
1.
18
If the generator is running during a utility outage,
first turn OFF all associated loads running in the
residence using the electrical panel main
Engine Oil Recommendations
To maintain the product warranty, the engine oil should
be serviced in accordance with the recommendations of
this Manual. For your convenience, Generac
Maintenance Kits are available that include engine oil, oil
filter, air filter, spark plug(s), a shop towel and funnel.
These kits can be obtained from an Independent
Authorized Service Dealer (IASD).
Owner’s Manual for 60 Hz Air-cooled Generators
Section 4: Maintenance
All Generac oil kits meet minimum American Petroleum
Institute (API) Service Class SJ, SL, or better. Use no
special additives. Select the appropriate viscosity oil
grade according to the expected operating temperature.
Synthetic oil also can be used in the appropriate weight
as standard.
6.
Screw the new filter on by hand until its gasket
lightly contacts the oil filter adapter. Then, tighten
the filter an additional 3/4 to one full turn.
7.
Refill the engine with the proper recommended oil.
For recommended oil, see Figure 4-1.
8.
Start the engine, run for 1 minute, and check for leaks.
9.
Shutdown the engine and recheck the oil level. Add
oil as needed. DO NOT OVER FILL.
10.
Re-insert dipstick and/or reattach fill cap.
11.
Press the Control Panel AUTO button.
12.
Dispose of the used oil and filter at a proper
collection center.
SAE 30
10W-30
Synthetic 5W-30
000399
Figure 4-1. Recommended Oil Based on
Temperature
• SAE 30 above 32 ºF (0 ºC)
• SAE 10W-30 between 40 º and -10 ºF
(4 º and -23 ºC)
• Synthetic SAE 5W-30 for all temperature ranges
CAUTION
Engine damage. Verify proper type and quantity of
engine oil prior to starting engine. Failure to do so
could result in engine damage.
(000135)
Changing the Oil and Oil Filter
1.
2.
3.
Start the engine by pressing the MANUAL button
on the control panel and allow the engine to run
until it is thoroughly warmed up. Then, press the
Control Panel OFF button to shut down the engine.
A few minutes after the engine shuts OFF, when it
has cooled slightly, lift the lid and remove the front
panel. Pull the oil drain hose free of its retaining
clip. See A in Figure 4-2 Remove the cap from the
hose and drain the oil into a suitable container.
After the oil has drained, replace the cap onto the
end of the oil drain hose. Reposition and secure
the hose with the retaining clip.
4.
With the oil drained, remove the old oil filter by
turning it counterclockwise. For filter location, see
B in Figure 4-2.
5.
Apply a light coating of clean engine oil to the
gasket of the new filter.
Owner’s Manual for 60 Hz Air-cooled Generators
B
A
000599
Figure 4-2. Oil Filter and Drain Location
Changing the Engine Air Cleaner
1.
With the generator shut down, lift the lid and
remove the front panel.
2.
Remove the cover clips and air cleaner cover (1122 kW), or disengage the wire clip and open the air
cleaner access door (8 kW).
3.
Pull out the old air filter and discard.
4.
Thoroughly clean the air cleaner enclosure of any
dust or debris.
5.
Install a new air cleaner.
6.
Install the air cleaner cover and cover clips (11-22
kW), or close the air cleaner access door and
engage the wire clip (8 kW).
Spark Plugs
Reset the spark plug(s) gap or replace the spark plug(s)
as necessary:
1.
With the generator shut down, lift the lid and
remove the front panel.
2.
Clean the area around the base of the spark
plug(s) to keep dirt and debris out of the engine.
3.
Remove the spark plug(s) and check the condition.
Install a new plug(s) if the old plug is worn or if
reuse is questionable.
19
Section 4: Maintenance
Clean the plug(s) by scraping or washing with a
wire brush and commercial solvent. Do not blast
the plug(s) to clean.
4.
Check the spark plug gap using a wire feeler
gauge. See Figure 4-3. If the gap is out of
specification, replace the spark plug. See Section 2
Specifications.
5.
• Remove spark plug wires and position wires away
from plugs.
• Remove spark plugs.
• Make sure the piston is at top dead center (TDC) of
its compression stroke (both valves closed). To get
the piston at TDC, remove the intake screen at the
front of the engine to gain access to the flywheel
nut. Use a large socket and socket wrench to
rotate the nut and hence the engine in a clockwise
direction. While watching the piston through the
spark plug hole. The piston should move up and
down. The piston is at TDC when it is at its highest
point of travel.
Adjust Valve Clearance
See Figure 4-4:
000211
Figure 4-3. Spark Plug Gap Adjustment
Valve Clearance Adjustment
Check the valve clearance after the first 25 hours of
operation, then after 400 hour intervals. Adjust if
necessary.
Important: Please contact an Independent Authorized
Service Dealer for service assistance. Proper valve
clearance is essential for prolonging the life of the
engine.
B
C
D
A
• The engine should be cool before adjustment.
• Remove spark plug wires and position wires away
from plugs.
• Remove spark plugs.
• Remove the four screws attaching the valve cover.
Remove and discard gasket.
• Loosen the rocker jam nut (A) using a 10mm Allen
or 13mm Allen wrench.
• Turn the pivot ball stud (B) while checking
clearance between the rocker arm (C) and the
valve stem (D) with a feeler gauge. Correct
clearance is in the specification in Section 2
Specifications.
NOTE: Hold the rocker arm jam nut in place as the pivot
ball stud is turned.
• When valve clearance is correct, hold the pivot ball
stud in place with the Allen wrench and tighten the
rocker arm jam nut. Tighten the jam nut to 174 inlbs (19.68 Nm) torque. After tightening the jam nut,
recheck valve clearance to make sure it did not
change.
• Install new valve cover gasket.
• Install the valve cover. Tighten fasteners in a cross
pattern, torquing to 48 in-lbs (5.4 Nm).
NOTE: Start all four screws before tightening or it will
not be possible to get all the screws in place. Make sure
the valve cover gasket is in place.
000602
Figure 4-4. Valve Clearance Adjustment
Check Valve Clearance
• Install spark plugs.
• Re-attach the spark plug wire to the spark plug.
• Repeat the process for the other cylinder, if
necessary.
• The engine should be cool before checking.
Adjustment is not needed if valve clearance is
within
the
specification
in
Section
2
Specifications.
20
Owner’s Manual for 60 Hz Air-cooled Generators
Section 4: Maintenance
Battery Maintenance
The battery should be regularly inspected per the
Service Schedule:
1.
With the generator shut down, lift the lid and
remove the front panel.
2.
Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
3.
Check the battery fluid level of unsealed batteries,
and if necessary, fill with distilled water only. DO
NOT use tap water. Also, have the Independent
Authorized Service Dealer or a qualified Service
Technician check the state of charge and condition.
WARNING
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.
(000162)
Strictly observe the following precautions when working
on batteries:
• Remove the 7.5 Amp fuse from the generator
control panel.
• Remove all jewelry—watches, rings, metal objects,
etc.
• Use tools with insulated handles.
• Wear rubber gloves and boots.
• Do not lay tools or metallic objects on top of the
battery.
• Disconnect the charging source prior to connecting
or disconnecting battery terminals.
• Wear full eye protection and protective clothing.
• Where electrolyte contacts the skin, wash it off
immediately with water.
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention.
• Wash down spilled electrolyte with an aid
WARNING
(000137a)
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.
(000164)
neutralizing agent. A common practice is to use a
solution of 500 grams (1 pound) bicarbonate of
soda to 4 liters (1 gallon) of water. The bicarbonate
of soda solution is to be added until the evidence of
reaction (foaming) has ceased. The resulting liquid
is to be flushed with water and the area dried.
• DO NOT smoke when near the battery.
• DO NOT cause flame or spark in the battery area.
• Discharge static electricity from the body before
touching the battery by first touching a grounded
metal surface.
Attention After Submersion
WARNING
(000138a)
WARNING
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.
(000228)
If the generator has been submerged in water, it MUST
NOT be started and operated. Following any submersion
in water, have an Independent Authorized Service Dealer
thoroughly clean, dry, and inspect the generator. If the
structure (home) has been flooded, it should be
inspected by a certified electrician to ensure there won’t
be any electrical problems during generator operation or
when utility power is returned.
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
Owner’s Manual for 60 Hz Air-cooled Generators
21
Section 4: Maintenance
Corrosion Protection
Regular scheduled maintenance should be conducted to
perform a visual inspection of the unit for corrosion.
Inspect all metal components of the generator. Example:
Base frame, enclosure, brackets, alternator can, the
entire fuel system (inside and outside of the generator)
and fastener locations. If there is corrosion found on
generator components (i.e. regulator, engine/alternator
mounts, fuel plenum, etc.), replace parts as necessary.
Periodically wash and wax the enclosure using
automotive type products. Do not spray the 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 the generator cannot be exercised every 7 days and
will be out of service longer than 90 days, prepare the
generator for storage:
1.
Start the engine and let it warm up.
2.
Close the fuel shutoff valve in the fuel supply line
and allow the unit to shut down.
3.
Once the unit has shut down, set the generator
main circuit breaker (Generator Disconnect) to
OFF (OPEN).
4.
Turn off the utility power to the transfer switch.
5.
Remove the 7.5 Amp fuse from the generator’s
control panel.
6.
Disconnect the battery cables. Remove negative
cable first.
7.
Remove battery charger AC input T1/Neutral cable
(has white sleeve) at controller.
8.
While the engine is still warm, drain the oil
completely, and then refill the crankcase with oil.
9.
Attach a tag to the engine indicating the viscosity
and classification of the new oil in the crankcase.
10.
Remove the spark plug(s) and spray a fogging
agent into the spark plug(s) threaded openings.
Reinstall and tighten the spark plug(s).
11.
Remove the battery and store it in a cool, dry room
on a wooden board.
12.
Clean and wipe down the entire generator.
Return to Service
To return the unit to service after storage:
22
1.
Verify utility power is OFF.
2.
Check the tag on the engine for oil viscosity and
classification. If necessary, drain and refill with
proper oil.
3.
Check the state of the battery. Fill all cells of
unsealed batteries to the proper level with distilled
water. DO NOT use tap water. Recharge the
battery to 100% state of charge. If defective,
replace the battery.
4.
Clean and wipe down the entire generator.
5.
Make sure the 7.5 Amp fuse is removed from the
generator Control Panel.
6.
Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected
incorrectly. Install positive cable first.
7.
Reconnect the battery charger AC input T1/Neutral
cable (has white sleeve) at controller.
8.
Open the fuel shutoff valve.
Owner’s Manual for 60 Hz Air-cooled Generators
Section 5: Troubleshooting
Section 5: Troubleshooting
System Diagnosis
Problem
Cause
Correction
1. Fuse blown.
1. Correct short circuit condition by replacing
7.5 Amp fuse in generator control panel.
2. Loose, corroded or defective battery
cables.
2. Tighten, clean or replace as necessary.*
3. Defective starter contact.
3. *See #2.
4. Defective starter motor.
4. *See #2.
5. Dead battery.
5. Charge or replace battery.
1. Out of fuel.
1. Replenish fuel / Turn on fuel valve.
2. Defective fuel solenoid (FS).
2. *
3. Open Wire 14 from engine control board.
3. *
4. Defective spark plug(s).
4. Clean, re-gap or replace plug(s).
5. valve clearance out of adjustment.
5. Reset valve clearance.
1. Air cleaner plugged or damaged.
1. Check / replace air cleaner.
2. Defective spark plug(s).
2. Clean, re-gap or replace plug(s).
3. Fuel pressure incorrect.
3. Confirm fuel pressure to regulator is 10-12
in. water column (19-22 mm mercury) for LP,
and 3.5 - 7 in. water column (9-13mm
mercury) for natural gas.
4. Fuel selector in wrong position.
4. Turn fuel conversion valve to correct
position.
Generator is set to OFF, but the
engine continues to run.
1. Controller wired incorrectly
1. *
2. Defective control board.
2. *
No AC output from generator.
1. Main line circuit breaker is in the OFF (or
OPEN) position.
1. Reset circuit breaker to ON (or CLOSED).
2. Generator internal failure.
2. *
1. Main line circuit breaker is in the OFF (or
OPEN) position.
1. Reset circuit breaker to ON (or CLOSED).
2. Defective transfer switch coil.
2. *
3. Defective transfer relay.
3. *
4. Transfer relay circuit open.
4. *
5. Defective control logic board.
5. *
1. Engine over filled with oil.
1. Adjust oil to proper level.
2. Engine breather defective.
2. *
3. Improper type or viscosity of oil.
3. See Engine Oil Requirements.
4. Damaged gasket, seal or hose.
4. Check for oil leaks.
Engine will not crank.
Engine cranks but will not start.
Engine starts hard and runs
rough.
No transfer to standby after
utility source failure.
Unit consumes large amounts
of oil.
* Contact an Independent Authorized Service Dealer for assistance.
Owner’s Manual for 60 Hz Air-cooled Generators
23
Section 5: Troubleshooting
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24
Owner’s Manual for 60 Hz Air-cooled Generators
Section 6: Quick Reference Guide
Section 6: Quick Reference Guide
System Diagnosis
To clear an active alarm, press the ENTER button twice and then press AUTO. If the alarm reoccurs, contact an Independent Authorized Service Dealer.
Table 6-1. System Diagnosis
Active Alarm
NONE
LED
GREEN
Problem
Things to Check
Solution
Unit running in AUTO but
Check MLCB.
no power in house.
Check MLCB if the MLCB is in the ON
position. If it is in the ON position contact
the Independent Authorized Service
Dealer.
Check the LED’s /
Screen for alarms.
Check ventilation around the generator,
intake, exhaust and rear of generator. If no
obstruction contact Independent
Authorized Service Dealer.
HIGH
TEMPERATURE
RED
Unit shuts down during
operation.
OVERLOAD
REMOVE LOAD
RED
Unit shuts down during
operation.
Check the LED’s /
Screen for alarms.
Clear alarm and remove household loads
from the generator. Put back in AUTO and
restart.
RPM SENSE LOSS
RED
Unit was running and
shuts down, attempts to
restart.
Check the LED’s /
Screen for alarms.
Clear alarm and remove household loads
from the generator. Put back in AUTO and
restart. If generator does not start, contact
Independent Authorized Service Dealer.
NOT ACTIVATED
NONE
Unit will not start in
AUTO with utility loss.
See if screen says unit Refer to activation section in Owner’s
not activated.
Manual.
NONE
GREEN
Unit will not start in
AUTO with utility loss.
If the start up delay is greater than
Check screen for start expected, contact Independent Authorized
delay countdown.
Service Dealer to adjust from 2 to 1500
seconds.
LOW OIL
PRESSURE
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
Screen for alarms.
Check Oil Level / Add Oil Per Owners
Manual. If oil level is correct contact
Independent Authorized Service Dealer.
Check the LED’s /
Screen for alarms.
Clear alarm. Using the control panel, check
the battery by navigating to the BATTERY
MENU option from the MAIN MENU. If it
states battery is GOOD, contact
Independent Authorized Service Dealer. If
it states CHECK BATTERY, replace the
battery.
RPM SENSE LOSS
RED
Unit will not start in
AUTO with utility loss.
OVERCRANK
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
Screen for alarms.
Check fuel line shutoff valve is in the ON
position. Clear alarm. Attempt to start the
unit in MANUAL. If it does not start or starts
and runs rough, contact Independent
Authorized Service Dealer.
LOW VOLTS
REMOVE LOAD
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
Screen for alarms.
Clear alarm and remove household loads
from the generator. Put back in AUTO and
restart.
FUSE PROBLEM
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
Screen for alarms.
Check the 7.5amp fuse. If it is bad replace
it with an ATO 7.5Amp fuse, if not contact
Independent Authorized Service Dealer.
Owner’s Manual for 60 Hz Air-cooled Generators
25
Section 6: Quick Reference Guide
Table 6-1. System Diagnosis (Continued)
Active Alarm
LED
Problem
Things to Check
Solution
OVERSPEED
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
Screen for alarms.
Contact Independent Authorized Service
Dealer.
UNDERVOLTAGE
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
Screen for alarms.
Contact Independent Authorized Service
Dealer.
UNDERSPEED
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
Screen for alarms.
Contact Independent Authorized Service
Dealer.
STEPPER
OVERCURRENT
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
Screen for alarms.
Contact Independent Authorized Service
Dealer.
MISWIRE
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
Screen for alarms.
Contact Independent Authorized Service
Dealer.
OVERVOLTAGE
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
Screen for alarms.
Contact Independent Authorized Service
Dealer.
LOW BATTERY
YELLOW
Clear alarm. Using the control panel, check
the battery by navigating to the BATTERY
MENU option from the MAIN MENU. If it
Yellow LED illuminated in Check the screen for
states battery is GOOD contact
any state.
additional information.
Independent Authorized Service Dealer. If
it states CHECK BATTERY, replace the
battery.
BATTERY
PROBLEM
YELLOW
Yellow LED illuminated in Check the screen for Contact Independent Authorized Service
any state.
additional information. Dealer.
CHARGER
WARNING
YELLOW
Yellow LED illuminated in Check the screen for Contact Independent Authorized Service
any state.
additional information. Dealer.
SERVICE A
YELLOW
Yellow LED illuminated in Check the screen for Perform SERVICE A maintenance. Press
any state.
additional information. ENTER to clear.
SERVICE B
YELLOW
Yellow LED illuminated in Check the screen for Perform SERVICE B maintenance. Press
any state.
additional information. ENTER to clear.
INSPECT BATTERY
YELLOW
Yellow LED illuminated in Check the screen for
Inspect Battery. Press ENTER to clear.
any state.
additional information.
26
Owner’s Manual for 60 Hz Air-cooled Generators
0K5801
Rev G
11/02/16
©2016 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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