Owner’s Manual
60 Hz Air-Cooled Generators
10 kW to 22 kW
SAVE THIS MANUAL FOR FUTURE REFERENCE
®
Para español, visita: http://www.generac.com/service-support/product-support-lookup
Pour le français, visiter : http://www.generac.com/service-support/product-support-lookup
Register your Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
(888-436-3722)
(000209b)
WARNING
Loss of life. This product is not intended to
be used in a critical life support application.
Failure to adhere to this warning could result
in death or serious injury.
ii Owner’s Manual for 60 Hz Air-Cooled Generators
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 the information found on the unit data label on this
page. See General Information for the location of the unit
data label. 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 2-1 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
u
nit when contacting an Independent Authorized Service
Dealer (IASD) about parts and service.
Operation and Maintenance:
Correct maintenance and
care of the generator ensures a minimum number of prob-
lems and keeps operating expenses at a minimum. It is the
operator’s
responsibility to perform all safety inspections, to
verify all maintenance for safe operation is performed
promptly, and to have the equipment inspected periodically
by an IASD. Normal maintenance, service, and replacement
of parts are the responsibility of the owner/operator and are
not considered defects in materials or workmanship within
the terms of the warranty. Individual operating habits and
usage may contribute to the need for additional maintenance
or service.
When the generator requires servicing or repairs, Generac
r
ecommends 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/Service/DealerLocator/.
(000393a)
WARNING
CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov.
Installation Guidelines for 60 Hz Air-Cooled Generators iii
Table of Contents
Section 1: Safety Information
Introduction ..................................................................1
Read This Manual Thoroughly ....................................1
Safety Rules .................................................................1
How to Obtain Service .................................................1
General Hazards ...........................................................2
Exhaust Hazards ..........................................................3
Electrical Hazards ........................................................3
Fire Hazards .................................................................3
Explosion Hazards .......................................................4
Battery Hazards ............................................................4
Section 2: General Information
Generator ......................................................................7
Data Decals .................................................................10
Specifications .............................................................11
Generator ..................................................................11
Engine .......................................................................11
Protection Systems ...................................................12
Emissions ...................................................................12
Fuel Requirements .....................................................12
Battery Requirements ................................................12
Battery Charger ..........................................................12
Engine Oil Requirements ..........................................12
Activating the Generator ...........................................13
Wi-Fi Module ...............................................................13
Replacement Parts .....................................................13
Accessories ................................................................13
Section 3: Operation
Site Prep Verification .................................................15
Generator Enclosure .................................................15
Opening the Lid .........................................................15
Front Access Panel Removal ....................................15
Intake Side Panel Removal .......................................16
Main Line Circuit Breaker (Generator Disconnect) ....16
LED Indicator Lights ..................................................16
Auxiliary Shutdown Switch .......................................17
Control Panel Interface ..............................................17
Using the AUTO/OFF/MANUAL Interface .................17
Operating Modes ........................................................18
Interface Menu Displays ............................................18
LCD Panel .................................................................18
Menu System Navigation ..........................................19
Setting the Exercise Timer ........................................21
Battery Charger ..........................................................21
Manual Transfer Operation .......................................21
Transfer to Generator Power Source ........................21
Transfer to Utility Power Source ................................22
Automatic Transfer Operation ..................................22
Automatic Sequence of Operation ...........................22
Utility Failure ..............................................................22
Cranking ....................................................................22
Cold Smart Start ........................................................22
Cleaning Cycle ..........................................................22
Load Transfer ............................................................23
Shutting Generator Down While Under Load
or During a Utility Outage .........................................23
Section 4: Maintenance
Maintenance ...............................................................25
Preparing for Maintenance ........................................25
Performing Scheduled Maintenance ........................25
Service Schedule .......................................................26
Maintenance Log .......................................................26
Checking Engine Oil Level ........................................27
Engine Oil Requirements ..........................................27
Changing the Oil and Oil Filter .................................27
Servicing the Air Cleaner ..........................................28
Spark Plug(s) ..............................................................28
Valve Clearance Adjustment .....................................29
Checking Valve Clearance ........................................29
Adjusting Valve Clearance ........................................30
Battery Maintenance ..................................................30
Inspecting the Battery ................................................31
Cleaning the Sediment Trap .....................................32
Post Maintenance Checks .........................................32
Performing Fuel System Leak Test ...........................32
Attention After Submersion ......................................33
Corrosion Protection .................................................33
Remove From and Return To Service Procedure ...33
Remove From Service ...............................................33
Return to Service .......................................................33
Safety Information
Owner’s Manual for 60 Hz Air-Cooled Generators 1
Section 1: Safety Information
Introduction
Thank you for purchasing this compact, high perfor-
mance, air-cooled, engine-driven generator. It is
designed to automatically supply electrical power to oper
-
ate critical loads during a utility power failure.
This unit is factory installed in an all-weather, metal
enclosure intended exclusively for outdoor installation.
This generator will operate using either vapor withdrawn
liquid propane (LP) or natural gas (NG).
NOTE: This generator is suitable for supplying typical
residential loads such as induction motors (sump pumps,
refrigerators, air conditioners, furnaces, etc.), electronic
components (computer, monitor, TV, etc.), lighting loads,
and microwaves, when sized correctly. This unit is
equipped with a Wi-Fi
®
module, which allows the genera-
tor owner to monitor generator status from anywhere
they have Internet access.
NOTE: Wi-Fi
®
is a registered trademark of Wi-Fi Alli-
ance
®
.
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
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.
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:
NOTE: Notes contain additional information important to
a procedure and will be found within the regular text of
this manual.
These safety alerts cannot eliminate the hazards that
they indicate. Common sense and strict compliance with
the special instructions while performing the action or
service are essential to preventing accidents.
How to Obtain Service
When the unit requires servicing or repairs, contact 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.
(000100a)
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.
(000001)
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000002)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000003)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Safety Information
2 Owner’s Manual for 60 Hz Air-Cooled Generators
General Hazards
(000190)
DANGER
Loss of life. Property damage. Installation must always
comply with applicable codes, standards, laws and
regulations. Failure to do so will result in death
or serious injury.
Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
Failure to do so will result in death or serious injury.
(000191)
DANGER
(000209b)
WARNING
Loss of life. This product is not intended to
be used in a critical life support application.
Failure to adhere to this warning could result
in death or serious injury.
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)
(000130)
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.
(000182a)
WARNING
Equipment damage. Only qualified service personnel may
install, operate, and maintain this equipment. Failure to
follow proper installation requirements could result in death,
serious injury, and equipment or property damage.
(000187)
WARNING
Electrocution. Potentially lethal voltages are generated
by this equipment. Render the equipment safe before
attempting repairs or maintenance. Failure to do so
could result in death or serious injury.
(000155a)
WARNING
Electric shock. Only a trained and licensed electrician
should perform wiring and connections to unit. Failure
to follow proper installation requirements could result in
death, serious injury, and equipment or property damage.
(000115)
WARNING
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.
(000111)
WARNING
Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
to do so could result in death or serious injury.
(000108)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces could
result in severe burns or fire.
(000146)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.
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)
WARNING
(000228)
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury.
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)
Safety Information
Owner’s Manual for 60 Hz Air-Cooled Generators 3
Exhaust Hazards
Electrical Hazards
Fire Hazards
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)
DANGER
(000178a)
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to
the manufacturer’s instructions. Failure to do so
could result in death or serious injury.
WARNING
(000146)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.
WARNING
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)
(000144)
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000150)
DANGER
Electrocution. Never connect this unit to the electrical
system of any building unless a licensed electrician
has installed an approved transfer switch. Failure to
do so will result in death or serious injury.
(000237)
DANGER
Electrical backfeed. Use only approved switchgear to
isolate generator from the normal power source.
Failure to do so will result in death, serious injury,
and equipment damage.
(000152)
DANGER
Electrocution. Verify electrical system is
properly grounded before applying power.
Failure to do so will result in death or serious
injury.
(000188)
DANGER
Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
result in death or serious injury.
(000104)
DANGER
Electrocution. Water contact with a power
source, if not avoided, will result in death
or serious injury.
(000145)
DANGER
Electrocution. In the event of electrical accident,
immediately shut power OFF. Use non-conductive
implements to free victim from live conductor. Apply
first aid and get medical help. Failure to do so will
result in death or serious injury.
WARNING
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
(000218)
Fire and explosion. Installation must comply with all
local, state, and national electrical building codes.
Noncompliance could result in unsafe operation,
equipment damage, death, or serious injury.
WARNING
Fire hazard. Use only fully-charged fire
(000219)
extinguishers rated “ABC” by the NFPA. Discharged or
improperly rated fire extinguishers will not extinguish
electrical fires in automatic standby generators.
Safety Information
4 Owner’s Manual for 60 Hz Air-Cooled Generators
Comply with regulations the Occupational Safety and
Health Administration (OSHA) has established, or with
equivalent standards. Also, verify that the unit is applied,
used, and maintained in accordance with the manufac
-
turer's instructions and recommendations. Do nothing
that might alter safe application/usage and render the
unit in noncompliance with the aforementioned codes,
standards, laws, and regulations.
Explosion Hazards
Battery Hazards
(000100a)
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.
WARNING
(000257)
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.
(000147)
WARNING
Risk of Fire. Unit must be positioned in a
manner that prevents combustible material
accumulation underneath. Failure to do so
could result in death or serious injury.
(000192)
DANGER
Explosion and fire. Fuel and vapors are extremely
flammable and explosive. No leakage of fuel is
permitted. Keep fire and spark away. Failure to do
so will result in death or serious injury.
(000151a)
DANGER
Explosion and fire. Connection of fuel source must be
completed by a qualified professional technician or
contractor. Incorrect installation of this unit will result in
death, serious injury, and property and equipment damage.
(000174)
DANGER
Risk of fire. Allow fuel spills to completely dry
before starting engine. Failure to do so will
result in death or serious injury.
(000110)
WARNING
Risk of Fire. Hot surfaces could ignite
combustibles, resulting in fire. Fire could
result in death or serious injury.
(000188)
DANGER
Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
result in death or serious injury.
(000162)
WARNING
Explosion. Do not dispose of batteries in a fire.
Batteries are explosive. Electrolyte solution can cause
burns and blindness. If electrolyte contacts skin or eyes,
flush with water and seek immediate medical attention.
(000137a)
WARNING
Explosion. Batteries emit explosive gases while
charging. Keep fire and spark away. Wear protective
gear when working with batteries. Failure to do so
could result in death or serious injury.
(000164)
WARNING
Electrical shock. Disconnect battery ground
terminal before working on battery or battery
wires. Failure to do so could result in death
or serious injury.
(000138a)
WARNING
Risk of burns. Batteries contain sulfuric acid and
can cause severe chemical burns. Wear protective
gear when working with batteries. Failure to do
so could result in death or serious injury.
(000163a)
WARNING
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.
Safety Information
Owner’s Manual for 60 Hz Air-Cooled Generators 5
Always recycle batteries in accordance with local laws
and regulations. Contact your local solid waste collection
site or recycling facility to obtain information on local
recycling processes. For more information on battery
recycling, visit the Battery Council International website
at:
http://batterycouncil.org
WARNING
(000228)
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury.
Safety Information
6 Owner’s Manual for 60 Hz Air-Cooled Generators
This page intentionally left blank.
General Information
Owner’s Manual for 60 Hz Air-Cooled Generators 7
Section 2: General Information
F
001818
M
N
O
P
A
Q
D
C
B
E
L
K
J
H
A
G
R
Generator
Figure 2-1. 10 kW—Components and Control Locations
A. Lock with cover F. Oil fill cap/dipstick K. Oil drain hose O. Fuel inlet
B. Main line circuit breaker
(generator disconnect)
G. Status LED indicators L. Composite base P. Wi-Fi module
C. Control panel H. Airbox with air cleaner M. Sediment trap Q. Data decal location
D. Battery compartment
(battery not supplied)
J. Oil filter N. Fuel regulator R. Auxiliary shutdown switch
E. Exhaust enclosure
General Information
8 Owner’s Manual for 60 Hz Air-Cooled Generators
Figure 2-2. 13 kW–16 kW—Components and Control Locations
A. Lock with cover F. Exhaust enclosure L. Composite base Q. Data decal location
B. Main line circuit breaker
(generator disconnect)
G. Status LED indicators M. Sediment trap R. Auxiliary shutdown switch
C. Airbox with air cleaner H. Oil drain N. Fuel regulator S. Auxiliary shutdown switch
D. Control panel J. Oil fill cap/dipstick O. Fuel inlet
E. Battery compartment
(battery not supplied)
K. Oil filter P. Wi-Fi module
C
B
G
F
E
D
A
A
L
K
J
H
P
O
N
M
S
R
Q
009340
General Information
Owner’s Manual for 60 Hz Air-Cooled Generators 9
Figure 2-3. 20 kW–22 kW—Components and Control Locations
A. Lock with cover F. Exhaust enclosure L. Composite base Q. Wi-Fi module
B. Main line circuit breaker
(generator disconnect)
G. Status LED indicators M. Oil dipstick R. Data decal location
C. Airbox with air cleaner H. Oil drain N. Sediment trap S. Auxiliary shutdown switch
D. Control panel J. Oil fill cap O. Fuel regulator T. Auxiliary shutdown switch
E. Battery compartment
(battery not supplied)
K. Oil filter P. Fuel inlet
001786
N
M
O
P
Q
G
K
J
F
L
R
E
A
D
C
B
A
H
T
S
General Information
10 Owner’s Manual for 60 Hz Air-Cooled Generators
Data Decals
Two decals on the generator provide information about the unit itself and required fuel inlet pressure for correct opera-
tion.
The model data decal also displays
ce
rtification symbols by Underwriter’s
Laboratory (UL) and the Southwest Research
Institute (SwRI).
Model Data Decal
In
cludes important information about the
unit including:
• model number
• serial number
• production date
•voltage
• frequency
•amps
• country of origin
• rated ambient temperature
Fuel Inlet Pressure
D
isplays unit serial number, along with
minimum and maximum inlet pressures for
natural gas (NG) and liquid propane (LP)
supply. Space is provided for installer to
enter maximum flow rates based on installed
pipe sizes and lengths.
General Information
Owner’s Manual for 60 Hz Air-Cooled Generators 11
Specifications
Generator
Engine
A detailed specification sheet for a particular generator is available from a local IASD.
Model 10 kW 13 kW 16 kW 20 kW 22 kW
Rated voltage
240
Rated maximum load
current (amps) at rated
voltage with LP*
41.7 54.2 66.7 83.3 91.7
Main line circuit breaker
(generator disconnect)
45 amp 60 amp 70 amp 90 amp 100 amp
Phase 1
Rated AC frequency 60 Hz
Battery requirement
(field supplied)
12 volts, Group 26R-540CCA Minimum or Group 35AGM-650CCA Minimum
(see Replacement Parts)
Enclosure
Aluminum
Weight (lb/kg)
(without battery)
289/131 374/170 407/185 448/203 466/211
Normal operating range
This unit is tested in accordance to UL 2200 standards with an operating temperature of -20 °F (-29
°C) to 122 °F (50 °C). For areas where temperatures fall below 32 °F (0 °C), a cold weather kit is
recommended. When operated above 77 °F (25 °C), there may be a decrease in engine power. See
Engine.
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.
* NG ratings will depend on specific fuel joules/BTU content. Typical derates are between 10-20% off the LP gas rating.
Model 10 kW 13/16 kW 20/22 kW
Engine type
G-Force 400 Series G-Force 800 Series G-Force 1000 Series
Number of cylinders
122
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 mm)
N/A
0.002–0.004 in
(0.05–0.1 mm)
Starter
12 VDC
Oil capacity including filter
Approx. 1.1 qt (1.03 L) Approx. 2.2 qt (2.1 L) Approx. 1.9 qt (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 BTU/joules, ambient temperature, and altitude. Engine power
decreases approximately 3.5% for each 1,000 ft (304.8 m) above sea level, and also will decrease about 1% for each 10 °F (6 °C)
above 60 °F (15 °C) ambient temperature.
General Information
12 Owner’s Manual for 60 Hz Air-Cooled Generators
Protection Systems
The generator may need to run for long periods of time
with no operator present to monitor engine or generator
conditions. The generator is equipped with protection
systems to automatically shut down the unit to protect
against potentially damaging conditions. Some of these
systems include:
Alarms:
• High Temperature
• Low Oil Pressure
• Overcrank
• Overspeed
• Overvoltage
• Undervoltage
• Overload
• Underspeed
• RPM Sensor Loss
• Controller Fault
• Wiring Error
• Stepper Overcurrent
Warnings:
• Charger Warning
• Charger Missing AC
• Low Battery
• Battery Problem
• Exercise Set Error
• USB Warning
• Download Failure
The control panel contains a display 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: A
warning 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
em
issions warranty information. Follow the maintenance
specifications in this manual to ensure the engine com-
plies with applicable emission
s 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
cons
ists of the following:
:
Fuel Requirements
The engine has been fitted with a dual fuel carburetion
system. The unit will run on NG or LP gas, but has been
factory-configured to run on NG. The fuel system will be
configured for the available fuel source during installa-
tion.
Recommended fuels should have a BTU content of at
lea
st 1,000 BTUs per ft
3
(37.26 megajoules per m
3
) for
natural gas, or at least 2,500 BTUs per ft
3
(93.15 mega-
joules per m
3
) for LP gas.
NOTE: If
converting to LP gas from NG, a minimum LP
tank size of 250 gal (946 L) 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 650CCA minimum (not included with
unit.) See Battery Maintenance for correct battery main-
tenance procedures.
Battery Charger
The battery charger is integrated into the control panel
module in all models. It operates as a smart charger, ver-
ifying output charging levels are safe and continuously
op
timized to promote maximum battery life. A kit is pro-
vided to install a fuse in transfer switch for T1 battery
cha
rger connection. Follow installation instructions pro-
vided with kit.
NOTE: Do
not use external battery chargers.
Engine Oil Requirements
See Engine Oil Requirements for correct oil viscosity.
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
(000105)
DANGER
Explosion and Fire. Fuel and vapors are
extremely flammable and explosive. Add fuel
in a well ventilated area. Keep fire and spark
away. Failure to do so will result in death
or serious injury.
General Information
Owner’s Manual for 60 Hz Air-Cooled Generators 13
Activating the Generator
The generator should be activated upon initial startup.
See installation manual for complete instructions.
Wi-Fi Module
The generator is equipped with a Wi-Fi module. See Wi-
Fi module owner’s manual for further instruction.
Replacement Parts
Accessories
NOTE: Performance enhancing accessories are available for air-cooled generators. Contact an IASD or visit
www.generac.com for additional information on replacement parts, accessories, and extended warranties. See also
http://www.ordertree.com/generac/air-cooled-homestandby-generators/.
Description 10 kW 13 kW 16 kW 20 kW 22 kW
26R Exide battery 0H3421S
Spark plug 0G0767B (RC12YC or equivalent) 0G0767A (RC12YC or equivalent)
Oil filter 070185E
Air filter 0E9371A 0J8478
Control panel fuse 0D7178T
Transfer switch fuses See transfer switch manual for part number
Accessory Description
Cold Weather Accessories*—
• Battery Pad Warmer
• Oil Warmer
• Breather Warmer
* each sold separately
• Recommended in areas where temperatures fall below 0 °F (-18 °C).
(Not necessary for use with AGM-style batteries)
• Recommended in areas where temperatures fall below 0 °F (-18 °C).
• Recommended in areas where heavy icing occurs.
Scheduled Maintenance Kit Includes all pieces necessary to perform maintenance on the generator along with
oil recommendations.
Fascia Base Wrap The fascia base wrap snaps together around the bottom of the new air-cooled gen-
erators. 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™ Cellular Enabled
Accessory (USA only)
Provides a personalized web portal displaying generator status, maintenance
schedule, event history, and much more. This portal is accessible via computer, tab-
let, or smart phone. Sends emails and/or text notifications the moment there is any
change in generator’s status. Notification settings can be customized to what type
of alert is sent and how often. Visit www.MobileLinkGen.com for more information.
Touch-Up Paint Kit Very important to maintain the look and integrity of the generator enclosure. This kit
includes touch-up paint and instructions.
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 pur-
chase must be available upon request.
Available for Generac
®
and Guardian
®
products.
Not available for Corepower™, PowerPact™, and EcoGen™ products or all inter-
national purchases.
Wi-Fi LP Fuel Level Monitor The Wi-Fi enabled LP fuel level monitor provides constant monitoring of a con-
nected LP fuel tank. Monitoring LP tank level is an important step in making sure
your generator is ready to run during an unexpected power failure. Status alerts are
available through the Mobile Link™ application informing you when the LP tank
needs a refill.
General Information
14 Owner’s Manual for 60 Hz Air-Cooled Generators
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Operation
Owner’s Manual for 60 Hz Air-Cooled Generators 15
Section 3: Operation
Site Prep Verification
Generator must be installed to allow unimpeded airflow
into and out of generator.
Mechanical and gravity outdoor air intake openings for air
distribution and supply systems must be located not less
than 10 ft (3.05 m) horizontally from generator enclosure.
See Section 401.4 in the ICC Mechanical Code for 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 not rise and endanger it.
This unit must not operate in or be subjected to standing
water. Verify all potential water sources such as water
sprinklers, roof run-off, rain gutter downspouts, and sump
pump discharges are directed away from unit.
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.
Figure 3-1. Opening the Lid
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
Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
Failure to do so will result in death or serious injury.
(000191)
DANGER
009209
A
A
009210
A
B
C
D
Operation
16 Owner’s Manual for 60 Hz Air-Cooled Generators
NOTE: Always lift front access panel straight up before
pulling away from enclosure (B and C). Do not pull panel
away from the enclosure before lifting up (D).
Intake Side Panel Removal
See Figure 3-3. Intake side panel (A) must be removed
to access battery compartment, fuel regulator, and 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
pulling away from enclosure. Do not pull panel away from
enclosure before lifting up (D).
Figure 3-3. Intake Side Panel Removal
Main Line Circuit Breaker (Generator
Disconnect)
See Figure 3-4. This is a 2-pole breaker (A) rated
according to relevant specifications.
Breaker 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).
Figure 3-4. Main Line Circuit Breaker (MLCB)
NOTE: DO NOT leave breaker disconnect locked in OFF
(OPEN) during normal generator operation. Leaving
breaker in OFF (OPEN) will prevent generator from pow-
ering 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.
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.
002961
D
B
A
C
001810
BA
B
001791
A
C
B
Operation
Owner’s Manual for 60 Hz Air-Cooled Generators 17
Auxiliary Shutdown Switch
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. External Auxiliary Shutdown Switch
(all models)
NOTE: Whenever possible, perform primary shutdown
procedure before disabling generator with auxiliary shut-
down switch.
See Figure 3-7. 13–22 kW generators also have an aux-
iliary shutdown switch (A) located inside generator.
Figure 3-7. Internal Auxiliary Shutdown Switch (13–
22kW)
Generator will not start if either switch is OPEN (O). Con-
troller displays an “Auxiliary Shutdown” alarm, and red
LED “Alarm” light illuminates. To clear this condition, set
switch or switches to CLOSED (I). Clear alarm by press
-
ing 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.
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.
Using the AUTO/OFF/MANUAL
Interface
NOTE: Damage caused by mis-wiring of interconnect
wires is not warrantable.
CAUTION
(000399)
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.
005492
A
005491
A
Button Description of Operation
AUTO
Activates fully automatic system operation.
Allows unit to automatically start and exercise
generator according to exercise timer (see Set-
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.
MANUAL
Cranks and starts generator. Transfer to stand-
by power will not occur unless there is a utility
failure.
Blue LED flashes when automatic transfer
switch converts to generator power during a
utility power outage.
001798
A
B
Operation
18 Owner’s Manual for 60 Hz Air-Cooled Generators
Operating Modes Interface Menu Displays
LCD Panel
Feature Description
HOME
page
Default page displayed if no buttons are
pressed
for 60 seconds. Normally shows cur-
rent status message, and current date and
ti
me. Highest priority active alarm/warning is
automatically posted on this page, as well as
flashing the backlight when such a condition
is detected. In the case of multiple alarms/
warnings, only first message is displayed.
Press OFF button and then ENTER button to
clear an alarm or warning.
When “Hours of Protection” is displayed, this
represe
nts total time generator has been
monitoring utility supply and ready to provide
backup power if needed.
Display
Backlight
Normally off. The backlight will automatically
illu
minate and remain on for 30 seconds if
operator presses any button.
MAIN
MENU
pa
ge
Allows operator to navigate to all other pages
or
sub-menus by using arrow keys and
ENTER button. Page can be accessed at any
time with several presses of the dedicated
ESCAPE button. Each press of the ESCAPE
button takes operator to previous menu until
MAIN MENU displays. This page contains
information for History; Status; Edit; and
Debug.
Mode Description
MA
NUAL
• Will not transfer to standby if utility is present.
• Transfers to standby if utility drops below 65%
of nominal for five consecutive seconds (deal-
er programmable) after warm-up.
• Transfers back when utility returns for 15 con-
secutive seconds (dealer programmable).
Engine continues to run until removed from
MANUAL.
AUTO
• 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.
• Transfers to utility once utility returns (above
80% of nominal) for 15 consecutive seconds
(dealer programmable).
• Will not transfer to utility unless utility returns.
Unit will shut down if OFF button is pressed or
a shutdown alarm is present.
• Unit will shut down after one minute cool-down
time when utility power returns.
EXERCISE
• Will not exercise if unit is already running in
either AUTO or MANUAL.
• During exercise, controller will only transfer if
utility drops during exercise for five seconds
(dealer programmable), and will switch to
AUTO.
Operation
Owner’s Manual for 60 Hz Air-Cooled Generators 19
Menu System Navigation
Press ESCAPE button from any page to access the MENU. You may need to press the ESCAPE button several times
before reaching the MENU page. Navigate to the desired menu by using the
↑/↓ buttons. Press ENTER button when
desired menu is displayed and flashing,
Figure 3-9. Navigation Menu
EVOLUTION 2.0 / SYNC 3.0 HSB MENU MAP
Switched to “OFF”
Hours of Protection
0 (H)
Note: Menu functions and features may vary
depending on unit model and firmware revision.
* Hours of Protection and
number of hours will flash
every 5 seconds when
displayed.
*
Ready to Run
Hours of Protection
0 (H)
Utility Loss Delay
Pausing for 13 sec.
Cranking
Attempt # 3
Running in Exercise
Hours of Protection
0 (H)
Running
Cooling Down
Running - Warning
“Warning Message”
Warning Message(s)
Low Battery
Exercise Set Error
Service Schedule A
Service Schedule B
Inspect Battery
Stopping...
FIRMWARE ERROR-9
Fuel Pressure
Battery Problem
Charger Warning
Charger Missing AC
Overload Warning
SEEPROM ABUSE
USB Warning
Download Failure
Overload Warning
No WIFI Module
No WIFI Router Comms
No WIFI Server Comms
Cranking - Warning
“Warning Message”
Alarm Message(s)
High Engine Temp
Low Oil Pressure
Overcrank
Overspeed
RPM Sense Loss
Underspeed
Controller Fault
FIRMWARE ERROR-7
WIRING ERROR
Overvoltage
Undervoltage
Overload Remove Load
Low Volts Remove Load
Stepper Overcurrent
Auxiliary Shutdown
Emergency Stop
Fuse Problem
Loss of Speed Signal
Loss of Serial Link
Stopped - Warning
“Warning Message”
Cranking
Pausing for 13 sec
Running
Hours of Protection
0 (H)
Running
Warming Up
Running - Alarm
“Alarm Message”
Cranking - Alarm
“Alarm Message”
Switched OFF
Hours of Protection
0 (H)
UP ARROW =
+
DOWN ARROW =
-
006667a
Run Log
EXAMPLE:
Inspect Battery 200 RnHr or 12/27/18
and
Next Maintenance 200 RnHr or 12/27/18
Exercise Time
Å HH:MM Day Frequency Æ
ESC
+
–
++ +
–
ENTER
Current Date/Time
Å 2/12/16 12:22 Æ
ESCESCESCESC
ENTER
ESC
ENTER
ESC
ENTER
ESC
Maint. Log
Run Hrs
Scheduled
Select Month (1-12)
- 2 +
Run Hours (H)
0.0
Select Date (1-31)
- 13 +
Select Year (0-99)
- 13 +
Access
Requires Password
Language
Å English Æ
Fuel Selection
Å NG or LP Æ
Alarm Log
ENTER
ESC
ENTER
ESC
ENTER
ESC
"Battery Maintained"
"Schedule A Serviced"
"Schedule B Serviced"
"Maintenance Reset"
"Inspect Battery"
"Service Schedule A"
"Service Schedule B"
Warning Message(s)
Low Battery
Exercise Set Error
Service Schedule A
Service Schedule B
Inspect Battery
Stopping...
FIRMWARE ERROR-9
Battery Problem
Charger Warning
Charger Missing AC
Overload Cooldown
SEEPROM ABUSE
USB Warning
Download Failure
Overload Warning
No WIFI
Running Manual
Running-Utility Lost
Running–Remote Start
Running–2 Wire Start
Running–Exercise
Switched Off
Stopped - Auto
Select Min (0-59)
- 0 +
Select Hour (0-23)
- 14 +
Select Min (0-59)
- 0 +
Select Hour (0-23)
- 14 +
Quiet Test Mode ?
- YES or NO +
Select Frequency
- WEEKLY +
- BIWEEKLY +
- MONTHLY +
Language
+ English -
Fuel Selection
+ NG or LP -
Cold Smart Start?
Å YES or NO Æ
Cold Smart Start?
- YES or NO +
Language
+ Francais -
+ Espanol -
+ Português -
+ ...... -
Battery Condition
“Good”, “Inspect Battery” or
“Check Battery”
Select Day
- Wednesday +
Generator Activated
Service Unit
Language Update?
Å YES or NO Æ
WIFI Enable
Å YES or NO Æ
WIFI Enable
– YES or NO +
<ENT> LOAD LANGUAGE
<ESC> TO QUIT
ESC
ESC
ESC
ESC
ESC
ESC
ESC
ESC
Current Date/Time
10/09/18 07:40
ESC
ESC
ENTER
ESC
ENTER
ENTER
ENTER
Time Zone
Country/City
XX - XX/XX/XX XX:XX
XXXXX
XX - XX/XX/XX XX:XX
XXXXX
NOTE 1: Last 50 logs
displayed for each
(Alarm Log, Run Log,
Maint. Log).
NOTE 2: Date and time
displayed for each
occurence.
NOTE 3: Error code
displayed for each
Alarm, Error Code
and Alarm Message
swap every 5
seconds.
Battery
NOTE 1: Last 50 maintenance logs displayed.
NOTE 2: Date and time displayed for each
occurence.
(If enabled):
Refer to the Wi-Fi manual for
flow charts relating to Wi-Fi
(If not enabled): Displays SETUP WIFI
Only if Wi-Fi is disabled.
Date/Time automatically updates if connected to Wi-Fi.
Firmware Update
Å YES Æ
Current: V 1.01
USB: V 1.05
Are You Sure?
- Yes or No +
Update from:
Å USB or Wi-Fi Æ
Select YES, then press ENTER to continue or ESCAPE to cancel update. During
update process, the Blue “Manual” light flashes, then the Green “Auto” light flashes.
Sequence then repeats. When update is complete, the unit returns to Install Wizard
menu. When the controller powers up, the first screen briefly displays the version number.
When update is complete, remove USB Drive. Then follow the Install Wizard Menu.
Firmware Update
<- Insert USB ->
Possible Message(s):
Corrupted File
Invalid File
File Not Found
Unsupported Device*
* Re-try using a higher quality
USB drive. File names on the USB
cannot have more than 8 characters.
Refer to the Installation Wizard.
Only when WiFi Activated
SYSTEM
WIFI
DATE/TIME
SUB MENUS
HISTORY
EDIT
MAINT
DEALER
ESC
ENTER
ESC
ENTER
ESC
ENTER
ENTER
USB
ENTER ENTER
ENTER
ENTER
ENTER ENTER
ENTER
ENTER
ENTER
ENTER
Current: V 1.01
USB: V 1.05
Are You Sure?
- Yes or No +
ENTER
ENTER
ENTER
ENTER ENTER
ENTER
ENTER
ESC
ENTER
ESC
ENTER
Alarm Message(s)
High Engine Temp
Low Oil Pressure
Overcrank
Overspeed
RPM Sense Loss
Underspeed
Internal Fault
FIRMWARE ERROR-7
WIRING ERROR
Overvoltage
Undervoltage
Overload Remove Load
Low Volts Remove Load
Stepper Overcurrent
Auxiliary Shutdown
Emergency Stop
Defaults to English.
Select desired language
by scrolling through list.
ESC
ESCESCESCESC ESC
006667a
Operation
20 Owner’s Manual for 60 Hz Air-Cooled Generators
Figure 3-10. Navigation Menu
Operation
Owner’s Manual for 60 Hz Air-Cooled Generators 21
Setting the Exercise Timer
This generator is equipped with 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-Test™) Profile: Unit will
run at operating speed for approximately five seconds,
then drop speed to prepare for Quiet-Test. Speed will
drop to predetermined Quiet-Test speed after approxi
-
mately 40 seconds and continue to run until Quiet-Test is
complete, a total of five minutes.
Table 3-1 details exercise information and programming
options for all home standby generators.
NOTE: If Quiet-Test is disabled, generator will exercise
at the rated rpm.
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
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 OFF.
2. Set MLCB (generator disconnect) to OFF (OPEN).
3. Turn off utility power supply to transfer switch using
means provided (such as a main line utility
breaker).
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).
Figure 3-11. Typical Manual Transfer Switch
Operation
5. Press MANUAL button on control panel to crank
and start engine.
6. Allow engine to stabilize and warm up for a few
minutes.
Table 3-1. Generator Exercise Characteristics
Generator Size 10–22 kW
Exercise Frequency
Options
Weekly/Bi-Weekly/Monthly
Exercise Time Length 5 minutes
(000132)
DANGER
Electrocution. Do not manually transfer under load.
Disconnect transfer switch from all power sources
prior to manual transfer. Failure to do so will result in
death or serious injury, and equipment damage.
A
002565
Operation
22 Owner’s Manual for 60 Hz Air-Cooled Generators
7. Set 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 has been restored. Proceed as follows to
manually transfer to utility power and shut down genera-
tor:
1. Set MLCB (g
enerator disconnect) to OFF (OPEN).
2. Run
engine for one minute at no-load to stabilize
internal temperature.
3. Press
OFF button on control panel. Engine will
shut down.
4. V
erify 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
(A in Figure 3-11) inside transfer switch.
6. T
urn on utility power supply to transfer switch using
means provided.
7. Pr
ess AUTO button on control panel.
8. Retur
n MLCB (generator disconnect) to ON
(CLOSED).
9. Close and lock lid.
Automatic Transfer Operation
Proceed as follows to select automatic operation:
1. V
erify transfer switch main contacts are set to
UTILITY (loads connected to utility power source).
2. V
erify normal utility power source voltage is avail-
able to loads connected to transfer switch.
3. Pr
ess AUTO button on control panel.
4. Set
MLCB (generator disconnect) to ON
(CLOSED).
Generator will start automatically
when utility source volt-
age drops below a preset level. Loads are transferred to
stand
by power source after unit starts.
Automatic Sequence of Operation
Utility Failure
If generator is set to AUTO when utility fails (below 65%
of nominal), a five second (dealer programmable) line
interrupt delay time is started. The engine cranks and
starts if utility power is still unavailable 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 control-
ler 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
controller 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 follows: 15
seconds cranking, seven seconds resting, followed
by four additional cycles of seven seconds crank-
ing followed by seven seconds resting.
• 13–22 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 w
ill 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 22 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 e
lectrical 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 “W
arming Up” on the display
screen.
The generator controller
display will show “Under Volt-
age” if cleaning cycle fails to clear the obstruction. After
sever
al minutes, alarm message can be cleared, and the
generator restarted.
If the problem persists, make no further attempts to start.
Co
ntact an IASD.
Operation
Owner’s Manual for 60 Hz Air-Cooled Generators 23
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
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 main utility disconnect 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 MLCB (generator disconnect) to ON
(CLOSED).
6. Set main utility disconnect to ON (CLOSED).
The system now operates in automatic mode.
Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
Failure to do so will result in death or serious injury.
(000191)
DANGER
Operation
24 Owner’s Manual for 60 Hz Air-Cooled Generators
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Maintenance
Owner’s Manual for 60 Hz Air-Cooled Generators 25
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
Proceed as follows to prepare for maintenance:
1. Set main utility disconnect to OFF (OPEN).
2. Lift lid and set MLCB (generator disconnect) on
generator 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 plug(s), 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.
Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
Failure to do so will result in death or serious injury.
(000191)
DANGER
(000182a)
WARNING
Equipment damage. Only qualified service personnel may
install, operate, and maintain this equipment. Failure to
follow proper installation requirements could result in death,
serious injury, and equipment or property damage.
Maintenance
26 Owner’s Manual for 60 Hz Air-Cooled Generators
Service Schedule
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
Dates Performed:
Service
Daily If Running
Continuously or
Before Each Use
Every
Year
Schedule A
Every Two Years
or 200 Hours
Schedule B
Every Four Years
or 400 Hours
Inspect enclosure louvers for dirt and debris * ●
Inspect lines and connections for fuel or oil leaks ●
Inspect engine oil level ●
Inspect for water intrusion ** ●
Perform fuel system leak test ●
Inspect battery condition, electrolyte level, and
state of charge
●● ●
Replace engine oil and oil filter † ● ●
Replace engine air filter ●
Clean; inspect spark plug gap; replace if necessary ●
Inspect/adjust valve clearance (where applicable) ‡ ●
Inspect/clean sediment trap
See local codes and guidelines.
Contact the nearest IASD for assistance if necessary.
* Remove any shrubs or tall grasses which have grown within 3 ft (0.91 m) of intake and discharge louvers on enclosure sides.
Clean any debris (dirt, grass clippings, etc.) which may have accumulated inside enclosure.
** Verify all sources of potential water intrusion such as water sprinklers, roof run-off, rain gutter downspouts, and sump pump
discharges are directed away from generator enclosure.
† Change engine oil and filter after first 25 hours of operation. In cold weather conditions (ambient below 40 °F [4.4 °C]), or if unit
is operated continuously in hot weather conditions (ambient above 85 °F [29.4 °C]), change engine oil and filter every year or 100
hours of operation.
‡ Inspect/adjust valve clearance after first 25 hours of operation. (Excludes units with hydraulic lifters. See Engine.)
Maintenance
Owner’s Manual for 60 Hz Air-Cooled Generators 27
Checking Engine Oil Level
IMPORTANT NOTE: Verify oil level daily when
power outages necessitate running generator for
extended periods. Generator will shut down if oil
level is low.
Proceed as follows to check engine oil level:
1. Set main utility disconnect to OFF (OPEN).
2. Set MLCB (generator disconnect) on generator 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. The 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 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 MLCB (generator disconnect) on the generator
to ON (CLOSED).
The system is now operating in AUTO. The main utility
disconnect can be turned ON (CLOSED).
Engine Oil Requirements
Engine oil should be serviced in accordance with the rec-
ommendations of this manual to maintain product war-
ranty. Generac Maintenance Kits are available consisting
of engine oil, oil filter, air filter, spark plug(s), a shop
towel, and a funnel. These kits can be obtained from an
IASD.
All Generac oil kits meet minimum American Petroleum
Institute (API) Service Class SJ, SL, or better. Do not use
special additives.
Synthetic SAE 5W-30 for all temperature ranges. See
Engine.
Changing the Oil and Oil Filter
Proceed as follows to change oil and oil filter:
1. Lift lid and press MANUAL button on control panel
to start engine, and run until it is thoroughly warm-
ed 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 drain oil into a suitable con
-
tainer.
Figure 4-1. Oil Filter and Drain Location (10 kW)
(000139)
WARNING
Risk of burns. Allow engine to cool before
draining oil or coolant. Failure to do so could
result in death or serious injury.
(000210)
WARNING
Skin irritation. Avoid prolonged or repeated contact with
used motor oil. Used motor oil has been shown to cause
skin cancer in laboratory animals. Thoroughly wash
exposed areas with soap and water.
(000135)
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)
CAUTION
Engine damage. Verify proper type and quantity of
engine oil prior to starting engine. Failure to do so
could result in engine damage.
001831
B
A
Maintenance
28 Owner’s Manual for 60 Hz Air-Cooled Generators
Figure 4-2. Oil Filter and Drain Location (13–16 kW)
Figure 4-3. Oil Filter and Drain Location (20–22 kW)
3. Install cap on oil drain hose. Position and secure oil
drain hose with a 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 Oil
Requirements.
8. Press MANUAL button on control panel to start
engine. Run for one minute, and inspect for leaks.
9. Press OFF button on control panel to stop engine.
Wait five minutes.
10. Inspect oil level. Add oil as needed. DO NOT
OVERFILL.
11. Insert oil dipstick and/or attach fill cap.
12. Press AUTO button on control panel to return unit
to AUTO.
13. Close and lock lid.
14. Dispose of used oil and filter according to national,
state, or local codes.
Servicing the Air Cleaner
Proceed as follows to service air cleaner:
1. Lift lid and press OFF button on control panel to
stop generator. Remove front panel.
2. See Figure 4-4 or Figure 4-5. Remove cover clips
(A) and air cleaner cover (B).
Figure 4-4. Servicing Air Cleaner (10 kW)
Figure 4-5. Servicing Air Cleaner (13–22 kW)
3. Remove old air filter element (C) and discard.
4. Thoroughly clean air cleaner enclosure of any dust
or debris.
5. Install a new air filter element.
6. Install air cleaner cover and fasten cover clips.
7. (13-22 kW units only): Verify air inlet duct (D) is
correctly connected to air cleaner cover.
8. Press AUTO button on control panel to return unit
to AUTO.
Spark Plug(s)
Proceed as follows to inspect spark plug gap(s) and
replace spark plug(s) as necessary:
1. With generator OFF and engine cool, lift lid and
remove front panel.
2. Clean area around base of spark plug(s) to keep
dirt and debris out of engine.
009342
009342
B
A
009343
B
A
A
B
C
001820
001814
B
A
C
D
Maintenance
Owner’s Manual for 60 Hz Air-Cooled Generators 29
3. Remove spark plug(s) and inspect. Install new
plug(s) if existing plug(s) is worn or if reuse is ques
-
tionable.
4. Clean plug(s) by scraping or washing with a wire
brush and commercial solvent. Do not blast plug(s)
to clean.
NOTE: Clean spark plug in emergency situations only.
Otherwise, replace spark plug.
5. See Figure 4-6. Inspect spark plug gap using a
wire feeler gauge. Replace spark plug if gap is out
of specification. See
General Information.
Figure 4-6. Spark Plug Gap Measurement
NOTE: New spark plugs 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.
Valve Clearance Adjustment
IMPORTANT NOTE: Contact an IASD for service
assistance. Correct valve clearance is essential for
prolonging the life of the engine. Excludes units
equipped with hydraulic lifters. See Engine.
Inspect valve clearance after first 25 hours of operation,
then after 400 hour intervals. Adjust if necessary.
Checking Valve Clearance
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 wire(s)
away from 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). To move pis-
ton to TDC, remove intake baffle at the front of the
engine to access the flywheel nut. Use a large
socket and socket wrench to rotate flywheel nut
clockwise, which will rotate the crankshaft. Watch
piston through spark plug hole. Piston will move up
and down. Piston is at TDC when at its highest
point of travel.
6. See Figure 4-7 or Figure 4-8. Inspect valve clear-
ance between each rocker arm (E) and valve stem
(F) with a feeler gauge.
.
Figure 4-7. Valve Clearance Adjustment (10 kW)
000211
000211
WARNING
Risk of Burn. Allow the engine to cool before
performing the following procedure. Failure to
do so could result in serious injury.
(000560)
(000130)
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.
(000141)
WARNING
Accidental start-up. Disconnect spark plug wires when
working on unit. Failure to do so could result in death
or serious injury.
001812
C
D
F
E
Maintenance
30 Owner’s Manual for 60 Hz Air-Cooled Generators
Figure 4-8. Valve Clearance Adjustment (20–22 kW)
7. Install replacement valve cover gasket(s).
8. Install
valve cover(s). Tighten fasteners in a cross
pattern, tightening to:
Adjusting Valve Clearance
See Figure 4-7 or Figure 4-8. Proceed as follows to ad-
just valve clearance:
NOTE: Allo
w engine to cool before adjusting valve clear-
ance.
1. Re
move spark plug wire(s) and position wire(s)
away from plugs.
2. Remove s
park plug(s).
3. Remove
the four screws attaching valve cover.
Remove and discard gasket.
4. V
erify piston is at top dead center (TDC) of its com-
pression stroke (both valves closed).
5. L
oosen rocker jam nut (C) using a 10 mm wrench
(10 kW units) or 13 mm wrench (20–22 kW units.)
6. T
urn pivot ball stud (D) using a 14 mm wrench (10
kW units), or 10 mm hex key (20–22 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. Wh
en valve clearance is correct, hold pivot ball
stud (D) in place with a wrench and tighten rocker
arm jam nut. Tighten jam nut according to the fol-
lowing torque specifications:
10 kW 53 in-lbs (6.0 Nm)
20–22kW 174 in
-lbs (19.68 Nm)
8. After tightening jam nut, inspect valve clearance to
verify it did not change.
9. In
stall new valve cover gasket.
10. Insta
ll valve cover. Tighten fasteners in a cross pat-
tern. Tighten to:
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. Insta
ll spark plugs and tighten to 18 ft-lbs (25 Nm).
12. Atta
ch spark plug wire to spark plug.
13. Rep
eat process for other cylinder if equipped.
Battery Maintenance
10 kW 80 in-lb (9.0 Nm)
20–22kW 60 in-lb (6.8 Nm)
002380
F
C
E
D
WARNING
Risk of Burn. Allow the engine to cool before
performing the following procedure. Failure to
do so could result in serious injury.
(000560)
10 kW 80 in-lbs (9.0 Nm)
20–22kW 60 in-lbs (6.8 Nm)
(000188)
DANGER
Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
result in death or serious injury.
(000162)
WARNING
Explosion. Do not dispose of batteries in a fire.
Batteries are explosive. Electrolyte solution can cause
burns and blindness. If electrolyte contacts skin or eyes,
flush with water and seek immediate medical attention.
(000137a)
WARNING
Explosion. Batteries emit explosive gases while
charging. Keep fire and spark away. Wear protective
gear when working with batteries. Failure to do so
could result in death or serious injury.
(000164)
WARNING
Electrical shock. Disconnect battery ground
terminal before working on battery or battery
wires. Failure to do so could result in death
or serious injury.
Maintenance
Owner’s Manual for 60 Hz Air-Cooled Generators 31
Always recycle batteries in accordance with local laws
and regulations. Contact your local solid waste collection
site or recycling facility to obtain information on local
recycling processes. For more information on battery
recycling, visit the Battery Council International website
at: http://batterycouncil.org
Strictly observe the following precautions when working
on batteries:
• Remove 7.5A fuse from generator control panel.
• Disconnect battery charger as directed in Battery
Maintenance.
• Use tools with insulated handles.
• Wear rubber gloves and boots.
• Do not place tools or metallic objects on top of bat-
tery.
• Disconnect charging source prior to connecting or
disconnecting battery terminals.
• Wear full eye protection and protective clothing.
• If electrolyte contacts skin, wash it off immediately
with water.
• If electrolyte contacts eyes, flush thoroughly with
water immediately and seek medical attention.
• Wash down spilled electrolyte with an acid neutral-
izing agent. A common practice is to use a solution
o
f 1 lb (454 g) bicarbonate of soda to 1 gal (3.8 L)
of water. Add bicarbonate of soda solution until evi-
dence of reaction (foaming) has ceased. Flush
re
sulting liquid with water and dry area completely.
• DO NOT smoke near battery.
• DO NOT cause flame or spark in battery area.
• Discharge static electricity from the body before
touching battery by first touching a grounded metal
surface.
Battery should be regularly inspected per Service
Schedule. Contact an IASD for assist
ance if necessary.
Inspecting the Battery
Proceed as follows to inspect battery:
1. Pre
ss OFF button to shut down generator, then lift
lid and remove front panel.
2. Remov
e 7.5A fuse from control panel.
3. Remo
ve intake side panel. (See Intake Side Panel
Removal.)
4. See Figure 4-9. Inspect battery posts and cables
for tightness and corrosion. Tighten and clean as
ne
cessary.
–
+
001832
Figure 4-9. Battery Cables
5. Unsealed batteries only:
Completely disconnect
battery. Check battery fluid level and, if necessary,
fill with distilled water only. DO NOT use tap water.
Have an IASD or a qualified service technician ver-
ify state of charge an
d condition.
6. Con
nect battery cables, install intake side panel,
and install 7.5 A fuse when inspection is complete.
7. Pr
ess AUTO button on controller.
8. Insta
ll front panel and close generator lid.
(000138a)
WARNING
Risk of burns. Batteries contain sulfuric acid and
can cause severe chemical burns. Wear protective
gear when working with batteries. Failure to do
so could result in death or serious injury.
WARNING
(000228)
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury.
Maintenance
32 Owner’s Manual for 60 Hz Air-Cooled Generators
Cleaning the Sediment Trap
The sediment trap removes contaminants (moisture and
fine particles) from gaseous fuels before they enter the
fuel regulator. Accumulated moisture and particles must
be emptied from the sediment trap per local codes and
guidelines.
Proceed as follows to cle
an sediment trap:
1. Rem
ove intake side panel. See Intake Side Panel
Removal.
2. T
urn generator fuel supply OFF.
3. See Figure 4-10. Unscrew and remove cap (A).
001821
A
B
Figure 4-10. 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. Sea
l threads of cap with appropriate sealing com-
pound. Install cap and hand-tighten.
7. T
ighten cap with an appropriately sized pipe
wrench. DO NOT overtighten.
8. T
urn generator fuel supply ON. 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.
9. Install intake side panel.
Post Maintenance Checks
1. Perform required maintenance procedure(s).
2. Install
intake side panel and front panel if removed.
(See Intake Side Panel Removal and Front
Access Panel Removal.)
3. Install 7.5A
fuse in control panel.
4. Complete Install W
izard information.
5. Pr
ess AUTO button on control panel. Allow unit to
run for one minute with no load (if running during a
utility outage).
6. Set
MLCB (generator disconnect) on generator to
ON (CLOSED).
7. T
urn main utility disconnect ON (CLOSED).
The system is now in AUTO.
NOTE: If
correct utility is present at this time, generator
will perform its usual shutdown process.
Performing Fuel System Leak Test
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
bef
ore starting the generator. The entire fuel system
should be tested from supply to regulator.
See Figure 4-11. 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
du
ring normally-scheduled maintenance.
Figure 4-11. Connection Points to Leak Check
Inspect for leaks by spraying all connection points with a
no
n-corrosive gas leak detection fluid. The solution
should not be blown away or form bubbles.
(000192)
DANGER
Explosion and fire. Fuel and vapors are extremely
flammable and explosive. No leakage of fuel is
permitted. Keep fire and spark away. Failure to do
so will result in death or serious injury.
A
A
A
004038
Maintenance
Owner’s Manual for 60 Hz Air-Cooled Generators 33
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 generator following any submersion in water.
If the structure (home) has been flooded, it should be
inspected by a certified electrician to verify there will not
be any electrical problems during generator operation or
when utility power is returned.
Corrosion Protection
Regular scheduled maintenance should be conducted to
inspect unit for corrosion. Inspect all metal components
of generator, including base frame, brackets, alternator
can, the entire fuel system (inside and outside of the 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
If generator cannot be exercised monthly, at a minimum,
and will be out of service longer than 90 days, proceed as
follows to prepare generator for storage:
1. Start engine and allow it to warm up.
2. Close fuel shutoff valve in fuel supply line and
allow engine to stop.
3. Set generator MLCB (generator disconnect) to
OFF (OPEN) once engine has stopped.
4. Disconnect battery charger AC input T1/Neutral
cable (with white sleeve) at controller.
5. Remove 7.5A fuse from generator control panel.
6. Disconnect battery cables. Remove negative bat-
tery cable first.
7. Drain oil completely while engine is still warm, and
then fill crankcase with oil. See
Engine Oil
Requirements.
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.
Return to Service
Proceed as follows to return unit to service after storage:
1. Check tag on engine for oil viscosity and classifica-
tion. Drain and fill with correct oil if necessary.
2. Verify state of battery. Fill all cells of unsealed bat-
teries to correct level with distilled water. DO NOT
use tap water. Charge battery to 100% state of
charge. Replace battery if faulty.
3. Clean and wipe down generator enclosure.
4. Verify 7.5A fuse is removed from generator control
panel.
5. Connect battery. Observe battery polarity. Damage
will occur if battery is connected incorrectly. Install
positive 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 control panel OFF button to stop unit.
12. Set 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 a battery has been completely discharged or dis-
connected.
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)
(000133)
WARNING
Explosion. Batteries emit explosive gases.
Always connect positive battery cable first to
avoid spark. Failure to do so could result in
death or serious injury.
(000167a)
CAUTION
Equipment damage. Do not make battery
connections in reverse. Doing so will result
in equipment damage.
Maintenance
34 Owner’s Manual for 60 Hz Air-Cooled Generators
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Troubleshooting / Quick Reference Guide
Owner’s Manual for 60 Hz Air-Cooled Generators 35
Section 5: Troubleshooting / Quick Reference
Guide
Generator Troubleshooting
Problem Cause Correction
Engine will not
crank
Blown fuse.
Correct short circuit condition by replacing 7.5 A
fuse in generator control panel. Contact an IASD
if fuse continues to blow.
Loose, corroded, or faulty battery cables.
Tighten, clean, or replace as necessary.*Faulty starter contact.
Faulty starter motor.
Discharged battery. Charge or replace battery.
Engine cranks but
will not start
No fuel. Replenish fuel / turn on fuel valve.
Faulty fuel solenoid (FS).
Contact an IASD for assistance.
Open Wire 14 from controller.
Faulty spark plug(s). Clean; inspect gap; replace plug(s) if necessary.
Valve clearance out of adjustment, if
applicable. See Engine.
Inspect and adjust valve clearance.
Engine starts hard
and runs rough
Air cleaner plugged or damaged. Inspect and clean air cleaner.
Faulty spark plug(s). Clean; inspect gap; replace plug(s) as needed.
Incorrect fuel pressure.
Verify fuel pressure to regulator is 10–12 in
water column (2.49–2.99 kPa) for LP gas, and
3.5–7.0 in water column (0.87–1.74 kPa) for NG.
Fuel selector in wrong position. Set fuel conversion valve to correct position.
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,
but engine
continues to run
Controller wired incorrectly.
Contact an IASD for assistance.
Faulty control board.
No AC output
from generator
Main line circuit breaker (MLCB) (generator
disconnect) is OFF (OPEN).
Reset MLCB (generator disconnect) to ON
(CLOSED).
Generator internal failure. Contact an IASD for assistance.
Engine may be warming up. See Cold Smart
Start.
Check the controller screen to verify status.
Troubleshooting / Quick Reference Guide
36 Owner’s Manual for 60 Hz Air-Cooled Generators
No transfer to
standby after
utility source
failure
MLCB (generator disconnect) is OFF
(OPEN).
Reset MLCB (generator disconnect) to ON
(CLOSED).
Faulty transfer switch coil.
Contact an IASD for assistance.
Faulty transfer relay.
Transfer relay circuit open.
Faulty control logic board.
Engine may be warming up. See Cold Smart
Start.
Check controller screen to verify status.
Unit consumes
large amounts of
oil
Excessive engine oil. Adjust oil to correct level.
Faulty engine breather. Contact an IASD for assistance.
Incorrect type or viscosity of oil. See Engine Oil Requirements.
Damaged gasket, seal, or hose. Inspect for oil leaks.
Restricted air filter. Replace air filter.
Wi-Fi network
connection
broken or
intermittent
Various. See Wi-Fi module owner’s manual.
* Contact an IASD for assistance.
Problem Cause Correction
Troubleshooting / Quick Reference Guide
Owner’s Manual for 60 Hz Air-Cooled Generators 37
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 Things to Check Solution
NONE
FLASHING
GREEN
Unit running in AUTO
but no power in house.
Check MLCB. Check MLCB. If it is ON, contact an IASD.
HIGH
TEMPERATURE
RED
Unit shuts down during
operation.
Check LEDs / screen
for alarms.
Inspect ventilation around generator,
intake, exhaust, and rear of generator. If
no obstructions are present, contact an
IASD.
OVERLOAD
REMOVE LOAD
RED
Unit shuts down during
operation.
Check LEDs / screen
for alarms.
Clear alarm and remove household loads
from generator. Put in AUTO and restart.
RPM SENSE LOSS RED
Unit was running and
shut down, attempts to
restart.
Check LEDs / screen
for alarms.
Clear alarm and remove household loads
from generator. Put into AUTO and
restart. If generator does not start, contact
an IASD.
NOT ACTIVATED NONE
Unit will not start in
AUTO with utility loss.
Check if screen says
unit not activated.
See Activation in installation manual.
NONE GREEN
Unit will not start in
AUTO with utility loss.
Check screen for start
delay countdown.
If startup delay is greater than expected,
contact an IASD to adjust from 2 to 1500
seconds.
LOW OIL
PRESSURE
RED
Unit will not start in
AUTO with utility loss.
Check LEDs / screen
for alarms.
Check oil level and add oil as needed. If
oil level is correct, contact an IASD.
RPM SENSE LOSS RED
Unit will not start in
AUTO with utility loss.
Check LEDs / screen
for alarms.
Clear alarm. Using control panel, check
battery by navigating to BATTERY MENU
option from MAIN MENU. If battery
condition displays GOOD, contact an
IASD. If control panel displays CHECK
BATTERY, replace battery.
OVERCRANK RED
Unit will not start in
AUTO with utility loss.
Check LEDs / screen
for alarms.
Verify fuel line shutoff valve is ON. Clear
alarm. Start unit in MANUAL. If it does not
start, or starts and runs rough, contact an
IASD.
LOW VOLTS
REMOVE LOAD
RED
Unit will not start in
AUTO with utility loss.
Check LEDs / screen
for alarms.
Clear alarm and remove household loads
from the generator. Put in AUTO and
restart.
OVERSPEED RED
Unit will not start in
AUTO with utility loss.
Check LEDs / screen
for alarms.
Contact an IASD.
UNDERVOLTAGE RED
Unit will not start in
AUTO with utility loss.
Check LEDs / screen
for alarms.
Contact an IASD.
UNDERSPEED RED
Unit will not start in
AUTO with utility loss.
Check LEDs / screen
for alarms.
Contact an IASD.
STEPPER
OVERCURRENT
RED
Unit will not start in
AUTO with utility loss.
Check LEDs / screen
for alarms.
Contact an IASD.
WIRING ERROR RED
Unit will not start in
AUTO with utility loss.
Check LEDs / screen
for alarms.
Contact an IASD.
OVERVOLTAGE RED
Unit will not start in
AUTO with utility loss.
Check LEDs / screen
for alarms.
Contact an IASD.
Troubleshooting / Quick Reference Guide
38 Owner’s Manual for 60 Hz Air-Cooled Generators
AUXI L IARY
SHUTDOWN
RED Unit will not start.
C h e c k auxilia r y
shutdown switches
Set auxiliary shutdown switch(es) to
CLOSED (I). Clear alarm.
LOW BATTERY YELLOW
Yellow LED illuminated
in any state.
Check screen for
additional information.
Clear alarm. Using control panel, check
battery by navigating to BATTERY MENU
option from MAIN MENU. If battery
condition displays GOOD, contact an
IASD. If control panel displays CHECK
BATTERY, replace battery.
BATTERY
PROBLEM
YELLOW
Yellow LED illuminated
in any state.
Check screen for
additional information.
Contact an IASD.
CHARGER
WARNING
YELLOW
Yellow LED illuminated
in any state.
Check screen for
additional information.
Contact an IASD.
CHARGER
MISSING AC
YELLOW
Yellow LED illuminated
in any state.
Check screen for
additional information.
Contact an IASD.
SERVICE A YELLOW
Yellow LED illuminated
in any state.
Check screen for
additional information.
Perform SERVICE A maintenance. Press
ENTER to clear.
SERVICE B YELLOW
Yellow LED illuminated
in any state.
Check screen for
additional information.
Perform SERVICE B maintenance. Press
ENTER to clear.
INSPECT
BATTERY
YELLOW
Yellow LED illuminated
in any state.
Check screen for
additional information.
Inspect battery. Press ENTER to clear.
Active Alarm LED Problem Things to Check Solution
Part No. 10000024942 Rev. A 06/06/19
©2019 Generac Power Systems, Inc.
All rights reserved
Specifications are subject to change without notice.
No reproduction allowed in any form without prior written
consent from Generac Power Systems, Inc.
Generac Power Systems, Inc.
S45 W29290 Hwy. 59
Waukesha, WI 53189
1-888-GENERAC (1-888-436-3722)
www.generac.com
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