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REVIEWED BLD2024-0058+Manufacturer_Specifications_and_Installation_Instructions+1.3.2024_4.51.50_PM+3981443GENERAL Owner's Manual 60 Hz Air -Cooled Generators 10kWto24kW 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. (000209b) Register your Generac product at: W1NW.GENERAC.COM 1-888-G ENERAC (888-436-3722) Para espanol, visita: http://www.generac.com/service-supporYproduct-support-lookup Pour le franrais, visitor: http:flwww.generac.com/service-supporUproduct-support-lookup Use this page to record important information about this generator. Model: Serial: Production Date: Volts: LPV Amps: NG Amps: Hz: Phase: Controller P/N: STA MAC ID: SSID: Record tie information found on the unit data label on this page. See General Information for the location of the unit data laDe . The unit has a label plate affixed to the inside par- tition, to the left of the control panel console as shown in Fig- ure 2-9, 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 ownerloperator and are not consid- ered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage may con- tribute 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/Dea/er-Locator. AMARNING CANCER AND REPRODUCTIVE HARM www. P65Warnings.ca.gov. (000393a ) Owner's Manual for 60 Hz Air -Cooled Generators Table of Contents Section 1: Safety Information Introduction..................................................................1 Read This Manual Thoroughly....................................1 SafetyRules.................................................................1 Haw to Obtain Service.................................................1 General Hazards...........................................................2 Exhaust Hazards..........................................................3 Electrical Hazards........................................................3 FireHazards.................................................................3 Explosion Hazards.......................................................4 Battery Hazards............................................................4 Section 2: General Information Generator Components and Control Locations ........7 DataDecals .................................................................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 AUTOIOFFIMANUAL Buttons ..................17 Operating Modes........................................................'18 Interface Menu Displays............................................18 LCDPanel.................................................................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 Uti ity Failj e..............................................................22 Cranking....................................................................22 Cold Smart Start........................................................22 CleaningCycle..........................................................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 Malm.enance Log.......................................................26 Checking Engine Oil Level........................................27 Engine (ail 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 Pe fermi,ig 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 1 Quick Reference Guide Generator Troubleshooting......................................35 Quick Reference Guide.............................................37 Owner's Manual for 60 Hz Air -Cooled Generators Table of Contents This page intentionally left blank. Owner's Manual for 60 Hz Air -Cooled Generators Safety Information Section 1: Safety Information Introduction Thank you for purchasing this compact, high perfor- mance, air-cooled, engine-diiven generator. It is designed to automatically s iDvly electrical power to oper- ate critical loads during a uti ity Dower 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 suoij ying typical residential loads such as induction i-rotors (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-Fio module, which allows the genera- tor owner to monitor generator status from anywhere they have Internet access. NOTE: Wi-Fie) is a registered trademark of Wi-Fi Alli- ancea. The information in this manual is accurate based on products produced at the time of publication. The manu- facturer reserves the right to make technical updates, corrections, and product revisions at any time without notice. Read This Manual Thoroughly Safety Rules The manufacturer cannot anticipate every possible cir- cumstance 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 spe- cifically 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 haz- ardous if performed incorrectly or carelessly. Observe them carefully. Alert definitions are as follows: 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. WARNING ACAUTION Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury. (000,00a) 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 start- ing, 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 fol- lowed 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. (000002) Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. (000003) 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 V,Inen t:,ie ini: regjires servicing or repairs, contact Gen- erac 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. Owner's Manual for 60 HzAir-CooledGenerators Safety Information General Hazards 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) 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 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. (000209b) WARNING 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. (000247a) AWARN'ING 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) 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. (444182a) AWARNING 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. (000187) ,AWARNING 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. (QQQ155a) AWARNING 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. (000,15) AWARNING Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury. (000111) WARNING s slllssc s is,. 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) 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 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) QWARNING 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 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 generator regularly, and contact the near- est IASD for parts needing repair or replacement. Owner's Manual for 60 Hz Air -Cooled Generators Safety Information Exhaust Hazards npYa I !Lei =1 Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. <x AWARNING 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 injurryy. (000178a) `WARNING Equipment and property damage. ❑o 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) f ' AWARNING 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. (000281) Electrical Hazards I ! . Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury. (000144) ! ! 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) r111 Le 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. (000237) !. - Electrocution. Verify electrical system is properly grounded before applying power. Failure to do so will result in death or serious injury. (000152) Electrocution. Da not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) ` + ! Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury. (000104) 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) Fire Hazards AWARNIN 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) 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. (000218) 1AWARNING1 A&V 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) Owner's Manual for 60 Hz Air -Cooled Generators Safety Information 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. fo00100a] AWARNING �J 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) AWARNING 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. (000,47) Comply with regulations the local agency for workplace health and safety has established. Also, verify that the generator is installed in accordance with the manufac- turer'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. Explosion Hazards 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. (000192) 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. (000151a) A -0= - 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) Battery Hazards Electrocution. ❑❑ not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) 44 WARNING Explosion. Do not dispose of batteries in a fire. Batteries are explosive. Electrolyte solution can cause bums and blindness. Jf electrolyte contacts skin or eyes, flush with water and seek immediate medical attention. (000162) AWARNINO 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. .------ . AWARNIN 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) lj�� JAWARNIING 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. {000138a} AWARNIN Risk of burn. Do not open or mutilate batteries. Batteries contain electrolyte solution which can cause bums and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention. (000163a) Owner's Manual for 60 Hz Air -Cooled Generators Safety Information 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) 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: httpJlbatterycouncii.org Owner's Manual for 60 HzAir-CooledGenerators Safety Information This page intentionally left blank. Owner's Manual for 60 Hz Air -Cooled Generators General Information Section 2: General Information Generator Components and Control Locations .-z 00181s Figure 2-1. 40 kW —Components and Control Locations A Lock with cover F Oil fill cap/dipstick K Oil drain hose ❑ Fuel inlet B Main line circuit breaker G Status LED indicators L Composite base P Wi-Fi module (generator disconnect) C Control panel H Airbox with air cleaner M Sediment trap Q Data decal location D Battery compartment J Oil filter N Fuel regulator R Auxiliary shutdown switch (battery not supplied) E Exhaust enclosure Owner's Manual for 60 HzAir-CooledGenerators 7 General Information a Figure 2-2. 13 kW-16 kW —Components and Control Locations 009340a A Lock with cover F Exhaust enclosure L Composite base Q Data decal location B Main line circuit breaker G Status LED indicators M Sediment trap R Auxiliary shutdown switch (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 K Oil filter P Wi-Fi module (battery not supplied) 8 Owner's Manual for 60 Hz Air -Cooled Generators General Information 001786 Figure 2-3. 20 kW-24 kW —Components and Control Locations A Lock with cover B Main line circuit breaker (generator disconnect) C Airbox with air cleaner D Control panel E Battery compartment (battery not supplied) F Exhaust enclosure L Composite base G Status LED indicators M Oil dipstick H Oil drain hose N Sediment trap J Oil fill cap O Fuel regulator K Oil filter P Fuel inlet Q Wi-Fi module R Data decal location S Auxiliary shutdown switch T Auxiliary shutdown switch Owner's Manual for 60 HzAir-CooledGenerators 9 General Information Data Decals Two decals on the generator provide information about the unit itself and required fuel inlet pressure for correct opera- tion. GENERAC MODEL SOOOM SERIAL XKKQOWX ITEM ND,; DUMB* PROD DATE: 2$xxlxxlxx VOLTS: 20J240 1 PHASE LPV AhPS 1MA117 tfz 60 NO ANP& I825/81.3 RPM 3800 INSULATION CLAW. F to PF CONTROLLER PJN OJ8371C COUNTRY OF OMM USA _D(1TY RTrx XD 023 x D 020 — RATED AIBFW TEMP. WC NEUTRAL FLUTING AK . UNULANC131 LOAD CAPACITY: Zix tow RAFFRODF ENCLOSURE — •av � r� � WE 113D EXER Rk* -- NBTE WFE 4 00 CHM MU)- NOTE 5 60 qM NW NP7E 0 M S Jrav—"'-- xmE 7 po cww rE:q.---'--^ Dada: Polka etWM we FUEL INLET Fl..YOnd ae� . oFnw. I&TUR& ors M� nRa MW KHr PRESVAie in ■c WU rUffi PAM ffmm U VArM MR ram Prelem n xe K"� � n>� � FIJD( HOW {GH�ECI my 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 mini- mum and maximum inlet pressures for natu- ral gas (NG) and liquid propane (LIP) supply. Space is provided for installer to enter maxi- mum flow rates based on installed pipe sizes and lengths. 10 Owner's Manual for 60 Hz Air -Cooled Generators General Information Specifications Generator Model 10 kW 13 16 kW 20 kW 22 kW 24 kW Rated voltage 240 Rated maximum load current (amps) at rated 41.7 54.2 8 _ 83.3 91.7 voltage with LP' 70 amp 90 amp 100 amp Main line circuit breaker 45 amp 60 amp (generator disconnect) Phase 1 Rated AC frequency 60 Hz Battery requirement 12 volts, Group 26R-540CCA Minimum or Group 35AGM-65OCCA Minimum (field supplied) (see Replacement Parts) Enclosure Aluminum Weight (lb I kg) 3381153 385 1175 4201 191 4361 198 445 / 202 455 / 206 (without battery) 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 Normal operating range recommended. When operated above 77 °F (25 °C), there may be a decrease in engine power. See Engine. 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. x NG ratings will depend on specific fuel joules/BTU content. Typical derates are between 10-20% off the LP gas rating. Engine Model 10 kW 13/16 kW 20-24 kW ngine type G-Force7m 400 Series G-Force rm 800 Series G-Force rm 1000 Series umber of cylinders 1 2 2 Displacement 460 cc 816 cc 999 cc Cylinder block Aluminum with cast iron sleeve 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 0.002-0.004 in (0.05-0.1 m m) NIA 0.002-0.004 in (0.05-0.1 m m ) Starter 12 VDC Oil capacity including filter Approx. 1.1 qt (1.03 L) Approx. 2.2 qt (2.1 L) Approx. 1.9 ct (1.8 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 BTUljoules, 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 °G) above 60 °F (15 °C) ambient temperature. A detailed specification sheet for a particular generator is available from a local IASD. Owner's Manual for 60 HzAir-CooledGenerators 11 General Information 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 those systems include: Alarms: • High Temperature • Underspeed • Low Oil Pressure • RPM Sensor Loss • Overcrank • Controller Fault • Overspeed • Wiring Error • Overvoltage • Stepper Overcurrent • Undervoltage • Overload Warnings: • Charger Warning • Exercise Set Error • Charger Missing AC • USB Warning • Low Battery • Download Failure • Battery Problem The control panel contains a display alerting the operator when a fault condition occurs. The above list is not all- inclusive. See Operation for more information about alarms and control panel operation. NOTE: Awarning indicates a condition on the generator which should be addressed, but will not shut down gener- ator. An alarm shuts down the generator to protect sys- tem from any damage. In event of an alarm, an owner can clear the alarm and restart generator prior to contact- ing an IASD. Contact an IASD if the intermittent issue occurs again. 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 emis- sions compliance decal on the engine to determine appli- cable standards. See the included emissions warranty for emissions warranty information. Follow the maintenance specifications in this manual to ensure the engine com- plies 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 Modifi- cation). The Emission Control System on this generator consists of the following: 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 0= ,* 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. (444145) 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 sys- tem 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 137.26 megajoules per rn for natural gas, or at least 2,500 BTUs per ft3 (93.15 mega - joules per m3) for LP gas. NOTE: If converting to LP gas from NG, a minimum LP tank size of 250 gal (946 Q is recommended. See instal- lation manual for complete procedures and details. Battery Requirements 12 volts, Group 26R Wet Cell 540CCA minimum or Group 35 AGM 65000A minimum (not included with unit). See Battery Maintenance for correct battery main- tenance proced:i res. Battery Charger The battery charge is integrated into the control panel module in all models. It operates as a smart charger, ver- ifying output chargigg levels are safe and continuously optimized to promote maximum battery life. A kit is pro- vided to install a fuse in transfer switch for T1 battery charger connection. Fallow installation instructions pro- vided 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 General Information Activating the Generator Wi-Fi Module Generator should be activated upon initial startup. See Generator is equipped with a Wi-Fi module. See Wi-Fi installation manual for comuiete instructions. module owner's manual for further information. Replacement Parts Description 10 kW 13 kW 16 kW 20 kW 22 kW 24 kW 26R Exide battery OH3421S Spark plug 0G0767B (RC12YC or equivalent) OG0767A (RC12YC or equivalent) Oil filter 070185E Air filter OE9371 A OJ8478 Control panel fuse OD7178T Transfer switch fuses See transfer switch manual for part number Accessories NOTE: Performance enhancing accessories are available for air-cooled generators. Contact an IAS❑ or visit www.generac.com for additional information on replacement parts, accessories, and extended warranties. See also http://Www.ordertree. com/generac/air-cooled-homestandhy-generators/. Accessory Description Cold Weather Accessories*— • Battery Pad Warmer • Recommended in areas where temperatures fall below 0 *F (-18 *C). (Not necessary for use with AGM -style batteries) • Oil Warmer • Recommended in areas where temperatures fall below 0 *F (-18 *C). • Breather Warmer • Recommended in areas where heavy icing occurs. each sold separately Scheduled Maintenance Kit Includes all items necessary to perform complete routine maintenance on the gener- ator along with oil recommendations (oil not included). Fascia Base Wrap The fascia base wrap snaps together around the bottom of the new air-cooled gener- 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. Mobile Link 4G LTE Cellular The Mobile Link 4G LTE Cellular Accessory allows users to monitor generator status Accessory from anywhere in the world, using a smartphone, tablet, or PC. Easily access infor- mation such as the current operating status and maintenance alerts. Users can con- nect 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. Touch -Up Paint Kit If the generator enclosure is scratched or damaged, it is important to touch-up the paint to protect from future corrosion. The touch-up paint kit includes the necessary paint to correctly maintain or touch-up a generator enclosure. Extended Warranty Coverage Extend generator warranty coverage by purchasing extended warranty coverage. 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 GeneracO and Guardian products. Not available for CorepowerTM, PowerPactO, and EcoGenTh° products or all interna- tional purchases. Wi-Fi LP Fuel Level Monitor The Wi-Fi enabled LP fuel level monitor provides constant monitoring of a connected 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 avail- able through a free application to notify users when the LP tank needs a refill. Owner's Manual for 60 HzAir-CooledGenerators 13 General Information Accessory Description Smart Management Module Smart Management Modules (SMM's) are used to optimize the performance of a (53 and 100 amps) 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 t3.8 Q of ultra concentrated cleaning solution for metal and plastic surfaces. Makes 6 gal (22.7 Q 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 Operation Section 3: operation Site Prep Verification 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 ) 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 addi- tional information. Verify all shrubs or tall grasses within 3 ft (0.91 m) of intake and discharge louvers on the sides of the enclo- sure have been removed. Install generator on high ground where water levels will no! rise and egdanger it. This unit must not operate in or be suc�jected 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. 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 ser- vice 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. �o Figure 3-1. Opening the Lid .,uJ209 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 pres- sure 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. .—. Figure 3-2. Remove Front Access Panel 009210 Owner's Manual for 60 HzAir-CooledGenerators 15 Operation NOTE: Always lift front access panel straight up before pulling away from enclosure (B and Q. D❑ not pull panel away f om 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 sedi- ment 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. NOTE: Always lift intake side panel straight up before pul ing away from enclosure. Do not pull panel away from enclosure before lifting up (D). (q) 002961 Figure 3-3. Intake Side Panel Removal 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 rel- evant specifications. The generator MLCB (generator disconnect) can be locked in OFF (OPEN) for security. Use an appropriately - sized padlock (not included) with a shackle long enough to pass through both lock tabs (B). 001810 Figure 3-4. Main Line Circuit Breaker (MLCB) NOTE: DO NOT leave generator MLCB (generator dis- connect) locked in OFF (OPEN) during normal generator operation. Leaving generator MLCB (generator discon- nect) in OFF (OPEN) will prevent generator from power- ing structure during a power outage when placed in AUTO mode. LED Indicator Lights See Figure 3-5. Three LEDs are visible behind a translu- cent lens on the generator side panel. These LEDs indi- cate generator operating status. 001791 Figure 3-5. LED Indicator Lights • Green LED "Ready" light (A) illuminates when util- ity is present and control panel is in AUTO. LED 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. 16 Owner's Manual for 60 Hz Air -Cooled Generators Operation Auxiliary Shutdown Switch ACAUTI�N 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) All generators are equipped with an external means of shutting down the generator which complies with the lat- est 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 dis- ables restarts. Figure 3-6. FxternalAuxiliary 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 enclo- sure. 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 opera- tion of the generator. This includes operation by a servic- ing technician while conducting troubleshooting pro- cedures. NOTE: Wheneve possible, perfo-n- primary shutdown Using the AUTO/OFF/MANUALprocedure before disabling generator with auxiliary shut- down switch. Buttons See Figure 3-7. 13-24 kW generators also have an aux- iliary shutdown switch (A) located inside generator. Figure 3-7. In terna I A uxilia ry Sh utdown Switch (93-24kW) NOTE: Generator will not start if either switch is OPEN (0). Controller displays an "Auxiliary Shutdown" alarm, and red LED "Alarm" light illuminates. To clear this condi- tion, set switch or switches to CLOSED (1). Clear alarm Button Description of Operation Activates fully automatic system operation. Allows unit to automatically star and exercise generator according to exercise timer (see Set - AUTO ting the Exercise Timer). Green LED flashes when automatic transfer switch converts to generator power during a utility power outage. OFF Shuts down engine and prevents automatic operation of unit. Cranks and starts generator. Transfer to stand- by power will not occur unless there is a utility MANUAL failure. Blue LED flashes when automatic transfer switch converts to generator power during a utility power outage. NOTE: Damage caused by mis-wiring of interconnect wires is not warrantable. Owner's Manual for 60 HzAir-CooledGenerators 17 Operatio-i Operating Modes Mode Description • Will not transfer to standby if utility is present. • Transfers to sta•-d'-,y if utility drops below 65%u 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 8011/o of nominal) for 15 consecutive seconds (dealer prcgrarimabie). • Will not iransfer to utility unless utility returns. Unit will shu: down if OFF button is pressed or a shutdown alarm is present. • Unit will shut cown 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. Interface Menu Displays LCD Panel Feature Description Default page displayed if no buttons are pressed for 60 seconds. Ncrmally shows cur- rent status message. and :current date and time. Highest priority active alarmlwaming is automatically pcsted cri this page, as well as flashing the backlight .;hen such a condition HOME is detected. In t-e case of multiple alarmsl page warnings, only first message s 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. Display Normally off. The backlight will automatically Backlight illuminate and remain on for 30 seconds if operator presses any button. Allows operator to navigate to all other pages or sub-irenus by using arrow keys and ENTER bu::on. Page can be accessed at any MAIN time with se% a presses of the dedicated MENU ESCAPE outton. Eacn press of the ESCAPE page 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 EVOLUTION 2.0 / SYNC 3.0 HS13 MENU MAP Note: Menu funotlons and features may vary depending on unit model and firmware revlslon. Switched OFF Hours of Protection 0 (H j Cranking -Alarm 'Ala rm Message'. ----------------------- Running - Alarm "Alarm Message" ' Run nl ng Warming Up Runnlnp Hours of Prahectlon 0 (H) Cranking Pauaing For 13 sec Runnlnp ,doling Down C rankl ng -Warning 'Warn ingMessage " -- -------------------- RunnIng . Warning "'Warning Measage' --- Stopped -Warning 'WarningMeseage' ----------------------- Runningln Exerdee Hours of Prolectlon 0 (H) Cranking Altempt # 3 UtIIIty Loas Relay Pena i„ Fnr 77 ¢or• Ready to Run Hours of Prolectlon 0 (HI Swliched to'OFF- Hou ra of P rotectlo n 0 (H) " Hours of Protectlon and number of hours ndll flash every 5 seconds when dls played. Alarm Massage(s) High Engine Temp Low Oil Pressure Overcrank Overapaed RPM Sens Loss Underspsed Controller Fault FIRMWARE ERROR-7 WIRING ERROR Overvoltag e Undervoltags Overload Remove Load Low Volts Remove Load Step pe r Ova rcu rrent Auxlllary Shutdown Emergency Stop Fuse Problem Loss of Speed Signal Loss of Serial Llnk Warning Message(a) Low Battery Exerclso Set Error Service Schedule A Service Schedule B Inspect Battery Stopp Ing... FIRMWARE ERROR-8 Fuel Pressure Battery Problem Charger Warning Charger Mlasl ng AC Overload Warning SE EPRO M AS USE USE Warning Download Fallure Overload Warning No WIFI Module No WIFI Router Comma No WIFI Server Comma a AUM MANUAL a OFF UP ARROW = QT (0 Z ENTER ESCAPE DOWN ARROW = 006667a � CDCD n Q) C @ m N c� � C C D CD D < O i1 CD CCD v 0 w :3 CD Q 0 0 m � C 0 C M tS cn `C C CD CD to m 3 Z CD C 1 i� CD C CD Er CCDD a Q CD Cn Nm mn M 0 mm t? C C 4 E =rCD C C @ Q CD C17 3 @ CD Q V1 3 o CD C CD C � G7 ZT 0 CD C C Running Manual r ENTER — ESC Current Datalilme Running -Utility Lost ESC SYSTEM PArE£fIME ENTER [Ifenahledl: 10109I1B 07:40 Running-Rsmots Start Refer to the Wi-Fi manual for y lFl SUB MENUS Running-2 Wire Start flow charts relating to WI-FI----- - - Running-Exercise (If not enabled): Displays SETUP WIFI Switched Off ENTER Stopped -Auto 7Uf - KSrl]=XX 7WK5f AX:X7( t ENTER ESC Run Log 1 NOTE 1: Last 50logs ESC — SCER E HISTORY MAINT ENTERS displayed for each XX - X)QXMX XX:Xx Alarm Log (Alarm Log, Run Log, xXXXX ENTER EDIT DEALER Access Maint. Log). NOTE 2• D d ' Requires Password ate an time displayed for each Dccu re nce- ENTER NOTE 3: Error code displayed for each Alarm, Error Code Language ENTER + Language + Language + a rid Alarm Message ESC - swap every 5 E English i English - +Francois_ seconds. + Espanol Defaults to English. + PortuguBs - Select desired language Alarm Mesaaga(s) High EnglneTemp Low Oil Pressure Overcrank Overspead RPM Sense Lass Underapead Intemal Fault FIRMWARE ERROR-7 WIRING ERROR Overvoltage Undervoltage Overload Remove Load Low Volts Remove Load Stepper Ove rcu rra nt Auxiliary Shutdown E me rgency Stop Warning Massages) Low Battery Exercise Set Error Service ScheduleA Service Schedule B Inspect Battery Stopping.. - FIRMWARE ERROR-9 Battery Problem Charger Warning Charger Missing AC Oved Dad Cooldown SEEPROMABUSE USB Warning Download Failure Overload Warning ND WIFI + by scrolling through list. Fuel Selection JENTER Fuel Selection F NO of LP + —ESC + NG or LP- Time Zane Cou ntrylC ity ESC t ENTER Battery Maint. Log ENTER t ESC "Battery Maintained" 'Schedule A Serviced - 'Schedule B Serviced" "Maintenance Reset" -In spect Battery" "Service Schedule A" "Service Schedule B" Battery Condition "Good', "Inspect Battery' or "Check Battery' taC Run Hours [H) Run Hrs ENTER 0.0 Scheduled ENTEIR t j ESC EXAMPLE: Inspect Battery20D RnHrcr 12127118 and Next Maintenance 200 RnHr or 12J27M B NOTE 1: Last 50 maintenance logs displayed - NOTE 2: Date and time displayed for each occurence- Cold Smart Start? ENTER Cold SmartStart? f YES or NO + ESC - YES gr NO + Only if WI-FI Is disabled. -- - - - - - - - - -- Daturrlme automatically updates If connected to WI-FI, sC SC SC sc SC CurrardDateJTima ENTER Select Hour (0.23) ENTER Select Min (0.59) ENTERS Select Month (1-12) ENTER Select Date [1.31} ENTER Select Year (0-99) E211211812:22 4 14+ _0+ 2+ 13+ 13+ Exercise Time ENTER Select Frequency ENTERS Quiet Test Mode 7 ENTERS Select Hour (0-23) ENTER Select Mln (0-59) ENTER-« Select Day HIPPY Day Frequar4y - WEEKLY + YES or NO + 1d + - D + Wednesday + BIWEEKLY + MONTHLY + Flrmware Update ENTER Update from: ggg Firmware Update ENTERS Current: V 1.D1 ENTER Are Ygu Sure E YES 4 ESC + USB or WI-FI 4 <- Insert USB -> __ _ USB: V 1.05 -Yea or No + 1 y Possible Massage(sl: Refer to the Installation Wizard. Corrupted File 3eneratgrActivatad Service Unit ^- 'Only when WIFI Activated Invalid File File Nat Found • Re -try using a higher quality Unsupported Devlce' USB drive. File names on the USB cannot have more than 8 characters. anguage Update? ENTER <ENT� LOAD LANGUAGE ENTER Current: V 1.D1 E YES or NO 4 ESC <ESCa TO QUIT USB: V 1.05 ENTER Select YES, then press ENTERto continue or ESCAPE to cancel update. During lit I update process, the Blue "Manual" light Flashes, than the Green "Aida" light Flashes. WIFI Enable ENTERS WIFI Enable Are You Sure" Sequence then repeats. When update Is complete, the unit returns to Install Wizard menu. When the controller powers up, the First screen briefly displays theversion number. E YES or NO + ESC - YES or NO + - Yes or No + When update Is complete, remove USB Drive. Then follow the Install Wizard Menu. 006667a Operation Setting the Exercise Timer This generator is equlooed ,-J-h a configurable exercise timer. Configuration can be performed directly at the con- trol panel or though the Mobile Link application. There 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 automati- cally adjust for Daylight Saving Time. NOTE: The exercise feature will operate only when gen- erator 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 dis- connected and then reconnected, and/or when the fuse is removed. Low Speed Exercise (Quiet-TestTM) 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 approxi- mately 40 seconds and continue to run until Quiet -Test is complete, a total of five minutes. Table 3-9 details exercise information and programming options for all home standby generators. NOTE: If Quiet -Test is disabled, generator will exercise at trio rated rpm. Table 3-1. Generator Exercise Characteristics Generator Size 10-24 kW Exercise Frequency Weekly/ B i-We ekly/Monthly Options Exercise Time Length 5 minutes 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. NOTE: A warning is displayed on LCD when battery needs service. NOTE: Do not use external battery chargers. Manual Transfer Operation Electrocution. ❑o 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) Prior to automatic operation, manually exercise transfer switch to verify there is no interference with correct oper- ation 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). 002565 figure 3-11. Typical Manual Tra nsfer S witch 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. Owner's Manual for 60 HzAir-CooledGenerators 21 Operation 7. Set generator MLCB (generator disconnect) to ON (CLOSED). Standby power source now powers loads. Transfer to Utility Power Source Shut down generator and transfer to utility source after utility power Igas been restored. Proceed as follows to manually transfer w it! ity ,power and shut down genera- tor: 1. Set generator MLCB (generator disconnect) to OFF (OPEN). 2. Run engine for one minute at no-load to stabilize internal temperature. 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 avail- able 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 volt- age 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 u-11,1-.y 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 accept load (warm-up time has not elapsed), the control- ler completes start cycle and runs generator through its normal cool down cycle. However, load will remain on utility source. Cranking The system will control the cyclic cranking as follows: • 10 kW Unit: five cranking cycles as fo lows: 15 seconds cranking, seven seconds resting, followed by four additional cycles of seven seconds crank- ing followed by seven seconds resting. • 13-24 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 crank- ing 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 tem- perature 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 tempera- ture. Table 3-2. Cold Smart Start Set Points Generator size 10 kW-20 kW 22124 kW Fixed temperature 50 °F (10 °C) 20 °F (-7 °C) A check for correct output voltage buildup will be per- formed 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 clean- ing 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, genera- tor controller will display "Warming Up" on the display screen. The generator controller display will show "Under Volt- age" 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. 22 Owner's Manual for 60 Hz Air -Cooled Generators Operation Load Transfer The transfer of load when generator is running is depen- dent upon operating mode. Shutting Generator Down While Under Load or During a Utility Outage 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] 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. Owner's Manual for 60 Hz Air -Cooled Generators 23 Operation This page intentionally left blank. 24 Owner's Manual for 60 Hz Air -Cooled Generators Maintenance Section 4., Maintenance Maintenance Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be per- formed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be per- formed 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 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 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. (000182a) 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. 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 clear- ance 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 plugs), and valve clearance (where appli- cable, 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. Owner's Manual for 60 HzAir-CooledGenerators 25 Maintenance Service Schedule Daily If Running Every Schedule A Schedule IS Service Continuously or Yer EveryTWo Years EveryFour Years Before Each Use or 200 Hours or 400 Hours 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 t • ■ Replace engine air filter ■ Clean; inspect spark plug gap; replace if necessary ■ Inspect/adjust valve clearance (where applicable) $ ■ Inspect: clean sediment trap See cocal codes and guidelines. Contact the nearest IASD for assistance If necessary. x Remove any shrubs or to 'asses 'vi- rr -a've c ,o,vj 4i .Ain 3 I { . (0.91 m) of intake and discharge louvers on enclosure sides. Clean any debris (dirt, grass c,ippings. etc. i w-- c-- ray "ade accurruIa:ed inside enclosure. Verify all sources of potential water intrusion; as water spnnKiers, roof run-off, rain gutter downspouts, and sump pump discharges are directed away from generator er. closure. t Change engine oil and filter after first 25 hours of operation. In cold weather conditions (ambient below40 °F [4.4 °C]), or if unit is operated continuously in hot weather conditions (ambient above 85 T [29.4 °C]), change engine oil and filter every year or 100 hours of operation. $ Inspectfadjust valve clearance after first 25 hours of operation. (Excludes units with hydraulic lifters. See Engine.) 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 13 or 16 kW units with 816cc engines. Dates Performed: 26 Owner's Manual for 60 Hz Air -Cooled Generators Maintenance Checking Engine Oil Level AWARNING s,sllissl, , s , Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (000139) 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) 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 utili-y 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 run- ning 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 ae -ur ned ON (CLOSED). Engine Oil Requirements 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) Engine oil should be serviced in accordance with the rec- ommendations of this manual to maintain product war- ranty. 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 ail 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 suit- able container. Drain oil. 831 Figure 4-1. Oil Filter and Drain Location (10 kW) Owner's Manual for 60 HzAir-Cooled Generators 2' Maintenance 009342 Figure 4-2. Oil Filter and Drain Location (13-16 kW) Figure 4-3. Oil Filter and Drain Location (20-24 kWj 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 con- tacts oil filter adapter. Tighten filter an additional three-quarter to one full turn. 7. Fill engine with recommended oil. See Engine tail 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 to AUTO. 13. Close and lock lid. 14. Dispose of used oil and filter according to local, state, or national codes. Servicing the Air Cleaner 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. (000249) 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. (000580) 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 4-4. Servicing Air Cleaner (10 kWj 001814 Figure 4-5. Servicing Air Cleaner (13-24 kW) 4. Remove old air filter element (C) and discard. 5. Thoroughly clean air cleaner enclosure of any dust or debris. 6. Install a new air filter element. 7. Install air cleaner cover and fasten cover clips. 28 Owner's Manual for 60 Hz Air -Cooled Generators Maintenance 8. (13-24 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) �WARNlNG NA NAElectric shock. Do not disconnect spark plug wires with engine running. Doing so could result in death or serious injury. (000140a) 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 plugs) and inspect. Install now 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 wi e Drus" and commercial solvent. Do not blast spark plugs) to clean. NOTE: Clean spark plug(s) in emergency situations only. (D.herwise, 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. D00211 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. Vale 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 13 or 16 kW units with 816cc engine. See Engine. Inspect valve clearance after first 25 hours of operation, then afte 400 hour intervals. Adjust if necessary. Checking Valve Clearance WARNING Risk of Burn. Allow the engine to cool before performing the following procedure. Failure to do so could result in serious injury. (000560) 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) WARNING Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury. (000141) 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 com- pression 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 clock- wise, 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. Owner's Manual for 60 HzAir-CooledGenerators 29 Maintenance 6. See Figure 4-7 or Figure 4-6. Verify valve clear- ance between each rocker arm (E) and valve stem (F) with a feeler gauge. Figure 4-7. halve Clearance Adjustment (10 kW) 30 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-Ibs (9.0 Nm) 20-24 kW 60 in-Ibs (6.8 Nm) Adjusting Vale Clearance WARNING Risk of Burn. Allow the engine to cool before performing the following procedure. Failure to do so Gould result in serious injury. (000560) IMPORTANT NOTE: Valve lash not required on 13 or 16 kW units with 816cc engine. See Engine. See Figure 4-7 or Figure 4-8. Proceed as follows to ad- just valve clearance: NOTE: Allow engine to cool before adjusting valve clear- ance. 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-Ibs (6.0 Nm) 20-24 kW 174 in-Ibs (19.68 Nm) 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-Ibs (9.0 Nm) 20-24 kW 60 in-Ibs (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 plugs) and tighten to 18 ft-Ibs (25 Nm). 12. Attach spark plug wire(s) to spark plug(s). 13. Repeat process for other cylinder if equipped. Battery Maintenance rl a ici - Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) AWARNINI Explosion. Do not dispose of batteries in a fire. Batteries are explosive. Electrolyte solution can cause bums and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention. (000162) 30 Owner's Manual for 60 Hz Air -Cooled Generators Maintenance AWARNING 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. saaol37at AWARNING Explosion_ Batteries emit explosive gases. I' Always disconnect negative battery cable first to avoid spark. Failure to do so could result in death or serious injury. (000238) AWARNING 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) lj� AWARNING l�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. S17D0138a1 AWARNING 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. (DO 0163a ) 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. (413022$) 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://battetycouncii.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. • D❑ 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) bicaru)onate of soda to 1 gal (3.8 L) of water. Add bicarbona.e of soda solution until evi- dence of reaction (foaming) has ceased. Flush resulting liquid with water and dry area completely. • D❑ 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. 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 39 Owner's Manual for 60 HzAir-CooledGenerators 31 Maintenance 5. See Figure 4-10. Inspect battery posts and cables for tightness and corrosion. Tighten and clean as necessary. N 001832 Figure 4-10. Battery Cables 6. Unseated batteries only: Completely disconnect battery; removing negative battery cable first. Check batter;1 fluid level and, if necessary, fill with distilled water only. ❑O 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 bat- tery cable. 8. Connect battery charger cable. 9. Install intake side panel, and install 7.5 Afuse. 10. Press AUTO button on controller. 11. Install front panel and close generator lid. Cleaning the Sediment Trap The sediment tiara 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). 001821 Figure 4-f1. Cleaning the Sediment Trap 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 com- pound. 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 procedures). 2. Install intake side panel and front panel if removed. (See Intake Side Parcel 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 uti i.y 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. 32 Owner's Manual for 60 Hz Air -Cooled Generators Maintenance Performing Fuel System Leak Test 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. (0OQ192) All products are factory -tested before shipping to verify the performance and integrity of the fuel system. How- ever, 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. 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 sub- merged in water. Have an IASD thoroughly clean, dry, and inspect generates- following any suhmerslon in water. If the structure game l gas been flooded. is 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. Corrosion Protection Reg i ar 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 gen- erator), and fastener locations. If there is corrosion found on generator components (e.g. regulator, engine/alterna- tor mounts, fuel plenum, etc.), replace parts as neces- sary. 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. Fre- quent 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 WARNING 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. (000238) If generator cannot be exercised monthly, at a minimum, and will be out of service longer than 90 days, proceed as fo lows 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 OFF (OPEN) once engine has stopped. 4. Disconnect battery charger AC input T11Neutral 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 ail. 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. Owner's Manual for 60 HzAir-CooledGenerators 33 Maintenance Return to Service 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. (000133) 'ACAUTIUN +� Equipment damage. Do not make battery connections in reverse. Doing so will result in equipment damage. (000167a) Proceed as follows to return unit to service after storage: 1. Inspect engine tag for oil viscosity and classifica- tion. Drain and fill with recommended oil if neces- sary. 2. Verify state of battery. Fill all cells of unsealed bat- teries to correct level with distilled water. ❑O 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 Troubleshooting / Quick Reference Guide Section 5: Troubleshooting /Quick Reference Guide Generator Troubleshooting Problem Cause Correction Correct short circuit condition by replacing 7.5A Blown fuse. fuse in generator control panel. Contact an IASD if fuse continues to blow. Engine will not Loose, corroded, or faulty battery cables. crank Tighten, clean, or replace as necessary.* Faulty starter contact. Faulty starter motor. Discharged battery. Charge or replace battery. No fuel. Replenish fuel 1 turn on fuel valve. Faulty fuel solenoid (FS). Contact an IASD for assistance. Harness/wiring issue. Engine cranks but Faulty spark plug=s}. Clean; inspect spark plug gap; replace spark plug(s) if necessary. will not start Valve clearance out of adjustment, if applicable. See Engine. Inspect and adjust valve clearance. Plugged or damaged air cleaner. Inspect and clean air cleaner. Faulty spark plugs). Clean; inspect spark plug gap; replace spark plug(s) if necessary. Verify fuel pressure to regulator is 10-12 in Incorrect fuel pressure. water column (2.49-2.99 kPa) for LP gas, and Engine starts hard 3.5-7.0 in water column (0.87-1.74 kPa) for NG. and runs rough Fuel selector in wrong position. Set fuel conversion valve to correct position and program controller for fuel type. Valve clearance out of adjustment, if applicable. See Engine. Inspect and adjust valve clearance. Internal engine issue. Contact an IASD for assistance. Unit is set to OFF, Controller wired incorrectly. but engine Contact an IASD for assistance. continues to run Faulty control board. Generator MLCB (generator disconnect) is Set generator MLCB (generator disconnect) to OFF (OPEN). ON (CLOSED). No AC output from generator Generator internal failure. Contact an IASD for assistance. Engine may be warming up. See Cold Smart Start. Check the controller screen to verify status. Owner's Manual for 60 HzAir-CooledGenerators 35 Troubleshooting 1 Quick Reference Guide Problem Cause Correction Generator MLCB (generator disconnect) is Set generator MLCB (generator disconnect) to OFF (OPEN). ON (CLOSED). Faulty transfer switch coil. No transfer to standby after Faulty transfer relay. utility source Contact an IASD for assistance. Transfer relay circuit open. failure Faulty control logic board. Engine may be warming up. See Cold Smart Check controller screen to verify status. Start. Excessive engine oil. I Adjust oil to correct level. See Checking Engine Oil Level. Unit consumes Faulty engine breather. Contact an IASD for assistance. large amounts of Incorrect type or viscosity of oil. See Engine Oil Requirements. oil Damaged gasket, seal, or hose. Inspect for oil leaks. Restricted air filter. Replace air filter. Wi-Fi network connection Various. See Wi-Fi module owner's manual. broken or intermittent * Contact an IASD or visit www.generac.com for assistance. 36 Owner's Manual for 60 Hz Air -Cooled Generators 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 FLASHING Unit running in AUTO Check generator Check generator MLCB (generator NONE GREEN but no power in house. MLCB (generator disconnect). If it is ON, contact an IASD. disconnect). Inspect ventilation around generator, HIGH RED Unit shuts down during Check LEDs I screen intake, exhaust, and rear of generator. If TEMPERATURE operation. for alarms. no obstructions are present, contact an IASD. OVERLOAD RED Unit shuts down during Check LEDs I screen Clear alarm and remove household loads REMOVELOAD operation. for alarms. from generator. Put in AUTO and restart. Unit was running and Clear alarm and remove household loads RPM SENSE LOSS RED shut down, attempts to Check LEDs I screen from generator. Put into AUTO and restart. for alarms. restart. If generator does not start, contact an IASD. NOTACTIVATED NONE Unit will not start in Check if screen says See Activation section in installation AUTO with utility loss. unit not activated. manual. Unit will not start in Check screen for start If startup delay is greater than expected, NONE GREEN AUTO with utility loss. delay countdown. contact an IASD to adjust from Z to 1500 seconds. LOW OIL RED Unit will not start in Check LEDs i screen Check nil level and add oil as needed. If PRESSURE AUTO with utility loss. for alarms. oil level is correct, contact an IASD. Clear alarm. Using control panel, check ha::ery by navigating to BATTERY MENU RPM SENSE LOSS RED Unit will not start in Check LEDs I screen option from MA N MENU. If battery condi- AUTO with utility loss. for alarms. :ion displays GOOD, contact an IASD. If control panel displays CHECK BATTERY, replace ba<<ery. Verify fuel line shutoff valve is ON. Clear OVERCRANK RED Unit will not start in Check LEDs I screen alarm. Start unit in MANUAL. If it does not AUTO with utility loss. for alarms. start, or starts and runs rough, contact an IASD. LOW VOLTS RED Unit will not start in Check LEDs I screen Clear alarm and remove household loads REMOVELOAD AUTO with utility loss. for alarms. from generator. Put in AUTO and restart. OVERSPEE❑ RED Unit will not start in Check LEDs I screen Contact an IASD. AUTO with utility loss. for alarms. UNDERVOLTAGE RED Unit will not start in Check LEDs I screen Contact an IASD. AUTO with utility loss. for alarms. UNDERSPEED RED Unit will not start in Check LEDs I screen Contact an IASD. AUTO with utility loss. for alarms. STEPPER RED Unit will not start in Check LEDs I screen Contact an IASD. OVERCURRENT AUTO with utility loss. for alarms. WIRING ERROR RED Unit will not start in Check LEDs I screen Contact an IASD. AUTO with utility loss. for alarms. OVERVOLTAGE RED Unit will not start in Check LEDs I screen Contact an IASD. AUTO with utility loss. for alarms. Owner's Manual for 60 HzAir-CooledGenerators 37 Troubleshooting 1 Quick Reference Guide Active Alarm LED Problem Action Solution AUXILIARY Checkauxiliary Set auxiliary shutdown switches) to RED Unit will not start. SHUTDOWN shutdown switches CLOSED (1). Clear alarm. Clear alarm. Using control panel, check battery by na•.;i;gating to BATTERY MENU Yellow LED illuminated Check screen for option from f:1A N MENU. If battery oondi- LOW BATTERY YELLOW in any state. additional informatio -. :ion displays GOOD, coniam an ASD. If control panel displays CHECK BATTERY, replace battery. BATTERY Yellow LED illuminated Check screen for YELLOW Contact an IASD. PROBLEM in any state. additional information. CHARGER Yellow LED illuminated Check screen for YELLOW Contact an IASD. WARNING in any state. additional information. CHARGER Yellow LED illuminated Check screen for YELLOW Contact an IASD. MISSING AC in any state. additional information. Yellow LED illuminated Check screen for Perform SERVICE A maintenance. Press SERVICE A YELLOW in any state. additional information. ENTER to clear. Yellow LED illuminated Check sc-ee- for Perform SERVICE B maintenance. Press SERVICE B YELLOW in any state. additional information. ENTER to clear. INSPECT Yellow LED illuminated Check screen for YELLOW Inspect battery. Press ENTER to clear. BATTERY in any state. additional information. 38 Owner's Manual for 60 Hz Air -Cooled Generators Pa : No. ACiC:icir 7 C:i51 C:i5 Rev. A 05/07/2020 '202J Generac Power Systems, Inc. A c -ts reserved. S ec f cat ons are subject to change without notice. No ep oc.,ction allowed in any form without prior written co -se,: from Generac Power Systems, Inc. GENERACO Generac Power Systems, Inc. S45 W29290 Hwy. 59 Waukesha, WI 53189 1-888-GENE RAC (1-888-436-3722 ) www.generac.com