Generac 70432 Home Standby Generator WiFi Connectivity User Manual

Owner’s Manual

60 Hz Air-Cooled Generators

9 kW to 22 kW

SAVE THIS MANUAL FOR FUTURE REFERENCE

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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 your generator set.

Record the information found on your 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

partition, to the left of the control panel console as shown in

Figure 2-1 or Figure 2-2. See Operation for directions on

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

When contacting an Independent Authorized Service Dealer

(IASD) about parts and service, always supply the complete

model and serial numbers of the unit.

Operation and Maintenance: Proper maintenance and care

of the generator ensures a minimum number of problems

and keeps operating expenses at a minimum. It is the

operator’s responsibility to perform all safety checks, to

verify all maintenance for safe operation is performed

promptly, and to have the equipment checked periodically by

an IASD. Normal maintenance, service, and replacement of

parts are the responsibility of the owner/operator and are not

considered defects in materials or workmanship within the

terms of the warranty. Individual operating habits and usage

may contribute to the need for additional maintenance or

service.

When the generator requires servicing or repairs, Generac

recommends contacting an Independent Authorized Service

Dealer for assistance. Authorized service technicians are

factory–trained and are capable of handling all service

needs. To locate the nearest Independent Authorized

Service Dealer, please visit the dealer locator at:

www.generac.com/Service/DealerLocator/.

Model:

Serial:

Production Date:

Volts:

LPV Amps:

NG Amps:

Hz:

Phase:

Controller P/N:

STA MAC ID:

SSID:

(000393)

WARNING

Operating, servicing and maintaining this

equipment can expose you to chemicals

including engine exhaust, carbon monoxide,

phthalates, and lead, which are known to the

State of California to cause cancer and birth

defects or other reproductive harm. To

minimize exposure, avoid breathing exhaust,

do not idle the engine except as necessary,

service your equipment in a well-ventilated

area and wear gloves or wash your hands

frequently when servicing your equipment.

For more information go to

www.P65Warnings.ca.gov.

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

Section 1: Safety Information

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

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

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

How to Obtain Service .................................................2

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

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

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

Fire Hazards ................................................................4

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

Battery Hazards ...........................................................5

Section 2: General Information

The Generator ......................................................7

Data Decals ..........................................................9

Specifications ....................................................10

Generator ..................................................................10

Engine .......................................................................10

Protection Systems ...........................................11

Emission Information ........................................11

Fuel Requirements ............................................11

Battery Requirements .......................................11

Battery Charger ..................................................11

Engine Oil Requirements ..................................11

Activating the Generator ...................................12

Wi-Fi Module ......................................................12

Replacement Parts ............................................12

Accessories ........................................................12

Section 3: Operation

Site Prep Verification ........................................ 13

Generator Enclosure ......................................... 13

Opening the Lid .........................................................13

Removing the Front Access Panel ............................13

Intake Side Panel Removal .......................................14

Main Line Circuit Breaker (Generator Disconnect) ....14

LED Indicator Lights ..................................................14

Auxiliary Shutdown Switch .............................. 15

Control Panel Interface ..................................... 15

Using the AUTO/OFF/MANUAL Interface ........ 15

Interface Menu Displays ................................... 16

LCD Panel .................................................................16

Menu System Navigation ..........................................18

Setting the Exercise Timer ............................... 20

Battery Charger ................................................. 20

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 ........................................................23

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

Shutting Generator Down While Under Load

Or During A Utility Outage ................................ 23

Table of Contents

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

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 .........................28

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

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

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

Check Valve Clearance ............................................ 29

Adjust Valve Clearance ............................................. 30

Battery Maintenance ..........................................31

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

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

Perform Leak Test .............................................33

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

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

Remove From, and Return To Service

Procedure ...........................................................34

Remove From Service .............................................. 34

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

Section 5: Troubleshooting / Quick

Reference Guide

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

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

Safety Information

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

Section 1: Safety Information

Introduction

Thank you for purchasing this compact, high

performance, air-cooled, engine-driven generator. It is

designed to automatically supply electrical power to

operate critical loads during a utility power failure.

This unit is factory installed in an all-weather, metal

enclosure intended exclusively for outdoor installation.

This generator will operate using either vapor withdrawn

liquid propane (LP) or natural gas (NG).

NOTE: This generator is suitable for supplying typical

residential loads such as induction motors (sump pumps,

refrigerators, air conditioners, furnaces, etc.), electronic

components (computer, monitor, TV, etc.), lighting loads,

and microwaves, when sized properly. This unit is

equipped with a Wi-Fi® module, which enables the

generator owner to monitor generator status from

anywhere he or she has Internet access.

NOTE: Wi-Fi® is a registered trademark of Wi-Fi

Alliance®.

The information in this manual is accurate based on

products produced at the time of publication. The

manufacturer reserves the right to make technical

updates, corrections, and product revisions at any time

without notice.

Read This Manual Thoroughly

Study this manual carefully before installing, operating, or

servicing this equipment. Become familiar with this

owner’s manual and with the unit. The generator can

operate safely, efficiently, and reliably only if it is properly

installed, operated, and maintained. Many accidents are

caused by failing to follow simple and fundamental rules

or precautions.

If any section of this manual is not understood, contact

the nearest Independent Authorized Service Dealer

(IASD) for starting, operating, and servicing procedures.

This manual must be used in conjunction with the

appropriate installation manual and Wi-Fi manual.

SAVE THESE INSTRUCTIONS: The manufacturer

suggests this manual and the rules for safe operation be

copied and posted near the unit installation site. Safety

should be stressed to all operators and potential

operators of this equipment.

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

hazardous 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.

The operator is responsible for proper and safe use of

the equipment. The manufacturer strongly recommends

that if the operator is also the owner, to read the owner’s

manual and thoroughly understand all instructions before

using this equipment. The manufacturer also strongly

recommends instructing other users to properly start and

operate the unit. This prepares them if they need to

operate the equipment in an emergency.

(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

How to Obtain Service

Contact an IASD for assistance when the generator requires

servicing or repairs. Service technicians are factory-trained

and are capable of handling all service needs. Please visit

the dealer locator at:

www.generac.com/Service/

DealerLocator/

to locate the nearest IASD.

When contacting a dealer about parts and service,

always supply the complete model and serial numbers of

the unit as given on its data plate (decal), which is

located on the generator. See

Figure 2-1 or Figure 2-2

for decal location. Record the model and serial numbers

in the spaces provided on the inside front cover of this

manual.

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)

Safety Information

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

•

Inspect the generator regularly, and contact the

nearest IASD for parts needing repair or replacement.

Exhaust Hazards

• The generator must be installed and operated

outdoors only.

Electrical Hazards

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)

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)

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.

(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.

Safety Information

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

Fire Hazards

• Comply with regulations the Occupational Safety

and Health Administration (OSHA) has

established. Also verify the generator is installed in

accordance with the manufacturer’s instructions

and recommendations. Following proper

installation, do nothing that might alter a safe

installation and render the unit in noncompliance

with the aforementioned codes, standards, laws,

and regulations.

Explosion Hazards

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

Fire and explosion. Installation must comply

with all local, state, and national electrical

(000218)

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.

(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

to use required safety equipment could result

in death or serious injury.

(000257)

Electrocution. Refer to local codes and

standards for safety equipment required when

working with a live electrical system. Failure

(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.

Safety Information

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

Battery Hazards

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

(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

(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.

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)

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

The Generator

Figure 2-1. 9kW—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

001818

General Information

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

Figure 2-2. 11kW–22kW—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 (all models)

D. Control Panel J. Oil Fill Cap O. Fuel Regulator T. Auxiliary Shutdown

Switch (16kW–22kW)

E. Battery Compartment

(Battery not supplied)

K. Oil Filter P. Fuel Inlet

001786

General Information

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

Data Decals

Two decals on the generator provide information about

the unit itself and required fuel inlet pressure for proper

operation.

Model Data Decal

Includes important information about the

unit including:

• model number

• serial number

• production date

•voltage

• frequency

•amps

• country of origin

• rated ambient temperature.

The model data decal also displays

certification symbols by Underwriter’s

Laboratory (UL) and the Southwest Research

Institute (SwRI).

Fuel Inlet Pressure

Displays unit serial number, along with

minimum and maximum inlet pressures for

natural gas (NG) and liquid propane (LP)

supply. Space is provided for the installer to

enter maximum flow rates based on installed

pipe sizes and lengths.

General Information

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

Specifications

Generator

Engine

A detailed specification sheet for your particular generator is available from your local Independent Authorized Service

Dealer (IASD).

Model 9 kW 11 kW 16 kW 20 kW 22 kW

Rated Voltage 240

Rated Maximum Load

Current (Amps) at Rated

Voltage with LP*

37.5 45.8 66.6 83.3 91.7

Main Line Circuit Breaker

(Generator Disconnect)

40 Amp 50 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)

340/154 348/158 409/186 448/203 466/211

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.

* Natural gas ratings will depend on specific fuel joules/BTU content. Typical derates are between 10-20% off the LP gas rating.

Model 9 kW 11 kW 16/20/22 kW

Type of Engine G-Force 400 Series G-Force 500 Series G-Force 1000 Series

Number of Cylinders 1 2 2

Displacement 426 cc 530 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) 0.030 in (0.76 mm) 0.040 in (1.02 mm)

Valve Clearance

0.002–0.004 in

(0.05–0.1 mm)

0.002–0.004 in

(0.05–0.1 mm)

0.002–0.004 in

(0.05–0.1 mm)

Starter 12 VDC

Oil Capacity Including Filter Approx. 1.1 qt (1.03 L) Approx. 1.7 qt (1.6 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 1000 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

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

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:

Warnings:

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 the

generator. An alarm shuts down the generator to protect

the system from any damage. In the event of an alarm,

an owner can clear the alarm and restart the generator

prior to contacting an IASD. Contact an IASD if the

intermittent issue occurs again.

Emission Information

The United States Environmental Protection Agency (US

EPA) (and California Air Resources Board (CARB), for

engines/equipment certified to California standards)

requires that this engine/equipment complies with

exhaust and evaporative emissions standards. Locate

the emissions compliance decal on the engine to

determine applicable standards. For emissions warranty

information, please reference the included emissions

warranty. Follow the maintenance specifications in

Maintenance to ensure the engine complies with

applicable emissions standards for the duration of the

product’s life.

This generator is certified to operate on liquid propane

vapor fuel or pipeline natural gas.

The Emission Control System code is EM (Engine

Modification). The Emission Control System on this

generator consists of the following:

Fuel Requirements

The engine has been fitted with a dual fuel carburetion

system. The unit will run on natural gas or LP gas

(vapor), but it has been factory set to run on natural gas.

The fuel system will be configured for the available fuel

source during installation.

Recommended fuels should have a BTU content of at least

1000 BTUs per ft

(37.26 megajoules per m

) for natural

gas, or at least 2500 BTUs per ft

(93.15 megajoules per

) for LP gas (vapor).

NOTE:

If converting to LP gas from natural gas, a

minimum LP tank size of 250 gal (946 L) is recommended.

See the installation manual for complete procedures and

details.

Battery Requirements

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

650CCA minimum (not included with unit.) See

Maintenance

for proper battery maintenance procedures.

Battery Charger

The battery charger is integrated into the control panel

module in all models. It operates as a smart charger,

ensuring output charging levels are safe and

continuously optimized to promote maximum battery life.

A kit is provided to install a fuse in the transfer switch for

the T1 battery charger connection. Follow the installation

instructions provided with the kit.

NOTE: Do not use external battery chargers.

Engine Oil Requirements

See

Engine Oil Requirements in the Maintenance

section for proper oil viscosity.

• High Temperature

• Low Oil Pressure

• Overcrank

• Overspeed

• Overvoltage

• Undervoltage

• Overload

• Underspeed

• RPM Sensor Loss

• Controller Fault

• Wiring Error

• Stepper Overcurrent

• Charger Warning

• Charger Missing AC

• Low Battery

• Battery Problem

• Exercise Set Error

• USB Warning

• Download Failure

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

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

Activating the Generator

The generator should be activated upon initial start-up.

See the installation manual for complete instructions.

Wi-Fi Module

The generator is equipped with a Wi-Fi module. Refer to

the 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 9 kW 11 kW 16 kW 20 kW 22 kW

26R Exide Battery 0H3421S

Spark Plug

0G0767B

(RC12YC

or equivalent)

0E9368

(RL87YC

or equivalent)

0G0767A

(RC12YC or equivalent)

Oil Filter 070185E

Air Filter 0E9371A 0J8478

Control Panel Fuse 0D7178T

Transfer Switch Fuses Refer to 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 generators. 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, tablet, or smart phone. Sends

emails and/or text notifications the moment there is any change in the generator’s status.

Notification settings can be customized to what type of alert is sent and how often. 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 the 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 Generac

and Guardian

products.

Not available for Corepower™, PowerPact™, and EcoGen™ products or all international

purchases.

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

tank. Monitoring the 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 your LP tank needs a refill.

Operation

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

Section 3: Operation

Site Prep Verification

The generator must be installed to allow unimpeded airflow

into and out of the 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 the generator

enclosure. See Section 401.4 in the ICC Mechanical

Code for additional information.

Verify all shrubs or tall grasses within 3 ft (0.91 m) of the

intake and discharge louvers on the sides of the

enclosure have been removed. Install the generator on

high ground where water levels will not rise and

endanger it. This unit should 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 the generator enclosure.

Generator Enclosure

Enclosure lid is locked prior to shipment. A set of keys is

attached to the cardboard on top of the generator. An

additional set of keys is attached to the pallet bracket on

the front intake end of the generator.

NOTE:

Keys provided with this unit are intended for

service personnel use only.

Opening the Lid

Two locks secure the lid—one on each side (A in

Figure 3-

). Open the protective rubber cap to access the keyhole,

and press down on the lid above the side lock and unlock

the latch to properly open the lid.

Repeat for the other side. The lid may appear stuck if

pressure is not applied from the top.

Always verify the side locks are unlocked before

attempting to lift the lid.

Removing the Front Access Panel

Remove the front access panel by lifting it straight up and

out once the lid is open.

Always lift the front access panel straight up before pulling

it away from the enclosure (B and C in

Figure 3-1

). Do not

pull the panel away from the enclosure before lifting up (D

Figure 3-1

Figure 3-1. Side Lock Location and Front Panel Removal

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

001797

Operation

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

Intake Side Panel Removal

See

Figure 3-2. The intake side panel (A) must be

removed to access the battery compartment, fuel

regulator, and sediment trap.

1. Raise lid and remove front panel.

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

and L-bracket screw (C).

3. Lift intake panel up and away from the generator.

NOTE: Always lift intake side panel straight up before

pulling away from enclosure. Do not pull panel away from

the enclosure before lifting up (D).

Figure 3-2. Intake Side Panel Removal

Main Line Circuit Breaker (Generator

Disconnect)

This is a 2-pole breaker rated according to relevant

specifications. See “A” in

Figure 3-3.

The breaker can be locked in the OFF (OPEN) position

for security. Use an appropriately-sized padlock (not

included) with a shackle long enough to pass through

both lock tabs (B).

Figure 3-3. Main Breaker

NOTE: DO NOT lock out the MLCB during normal

generator operation. Doing so will compromise automatic

standby functionality.

LED Indicator Lights

Figure 3-4. LED Indicator Lights

See

Figure 3-4. Three LEDs are visible behind a

translucent lens on the generator side panel. These

LEDs indicate generator operating status.

• Green LED “Ready” light (A) is illuminated when

utility is present and the control panel is in AUTO

mode. The LED flashes when the automatic

transfer switch converts to generator power during

a utility power outage.

• Red LED “Alarm” light (B) is illuminated when the

generator is OFF or a fault is detected. Contact an

IASD.

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

illuminated when maintenance is required.

NOTE: Yellow LED may be illuminated at the same time

as either the red or green LED.

002961

001810

001791

Operation

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

Auxiliary Shutdown Switch

All generators are equipped with an external means of

shutting down the generator which complies with the latest

NEC code requirement. The primary generator shutdown

sequence is described in

Shutting Generator Down

While Under Load Or During A Utility Outage

See Figure 3-5. There is an auxiliary shutdown switch on

the exterior of the generator back panel. This switch

shuts down the generator and disables restarts.

Figure 3-5. External Auxiliary Shutdown Switch

(all models)

NOTE: Whenever possible, perform the primary

shutdown procedure before disabling the generator with

the auxiliary shutdown switch.

See

Figure 3-6. 16-22 kW generators also have an

auxiliary shutdown switch located inside the generator.

Figure 3-6. Internal Auxiliary Shutdown Switch (16-22kW)

The generator will not start if either switch is OPEN (O).

The controller displays an “Auxiliary Shutdown” alarm,

and the red LED “Alarm” light illuminates. To clear this

condition, set the switch or switches to CLOSED (I).

Clear the alarm by pressing the OFF mode button, and

then ENTER. The generator can then be placed back in

AUTO or MANUAL mode.

Control Panel Interface

See

Figure 3-7. The control panel interface (A) is located

under the enclosure lid. Verify both the left and right side

locks are unlocked before attempting to lift the lid of the

enclosure. Open the lid as directed in

Opening the Lid.

Figure 3-7. Generator Control Panel

The 7.5A fuse is located beneath the 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 the unit.

All appropriate panels must be in place during any

operation of the generator. This includes operation by a

servicing technician while conducting troubleshooting

procedures.

Using the AUTO/OFF/MANUAL

Interface

NOTE: Damage caused by mis-wiring of interconnect

wires is not warrantable.

005491

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

Button Description of Operation

AUTO

Activates fully automatic system operation. It

allows the unit to automatically start and

exercise the generator according to the

exercise timer (see

Setting the Exercise

Timer).

The green LED flashes when the automatic

transfer switch converts to generator power

during a utility power outage.

OFF

Shuts down the engine and prevents automatic

operation of the unit.

MANUAL

Cranks and starts the generator. Transfer to

standby power will not occur unless there is a

utility failure.

The blue LED flashes when the automatic

transfer switch converts to generator power

during a utility power outage.

001798

Operation

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

Interface Menu Displays

LCD Panel

Feature Description

HOME

page

Default page displayed if no buttons are

pressed for 60 seconds. Normally shows

current status message, and current date and

time. The 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 the first message is displayed.

Press the OFF mode button and then the

ENTER button to clear an alarm or warning.

When “Hours of Protection” is displayed, this

represents the total time the generator has

been monitoring utility supply and ready to

provide backup power if needed.

Display

Backlight

Normally off. The backlight will automatically

illuminate and remain on for 30 seconds if the

operator presses any button.

MAIN

page

Allows the operator to navigate to all other

pages or sub-menus by using the arrow keys

and the ENTER button. Page can be accessed

at any time with several presses of the

dedicated ESCAPE button. Each press of the

ESCAPE button takes the operator to the

previous menu until the MAIN MENU displays.

This page contains information for History;

Status; Edit; and Debug.

Operation

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

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Operation

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

Menu System Navigation

Press the 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 the ENTER

button when the desired menu is displayed and flashing,

Figure 3-8. 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 = -

006667

Operation

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

Figure 3-9. Navigation Menu

001359

006667

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

Language Update?

Å YES or NO Æ

WIFI Enable

Å YES or NO Æ

WIFI Enable

– YES or NO +

<ENT> LOAD LANGUAGE

<ESC> TO QUIT

ESC

Current Date/Time

10/09/18 07:40

ESC

ENTER

ESC

ENTER

Time Zone

Country/City

XX - XX/XX/XX XX:XX

XXXXX

XX - XX/XX/XX XX:XX

XXXXX

NOTE 1: Last 50 logs

displayed for each

(Alarm Log, Run Log,

Maint. Log).

NOTE 2: Date and time

displayed for each

occurence.

NOTE 3: Error code

displayed for each

Alarm, Error Code

and Alarm Message

swap every 5

seconds.

Battery

NOTE 1: Last 50 maintenance logs displayed.

NOTE 2: Date and time displayed for each

occurence.

(If enabled):

Refer to the Wi-Fi manual for

flow charts relating to Wi-Fi

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.

SYSTEM

WIFI

DATE/TIME

SUB MENUS

HISTOR

EDIT

MAINT

DEALER

ESC

ENTER

ESC

ENTER

ESC

ENTER

USB

ENTER ENTER

ENTER

ENTER ENTER

ENTER

Current: V 1.01

USB: V 1.05

Are You Sure?

- Yes or No +

ENTER

ENTER ENTER

ENTER

ESC

ENTER

ESC

ENTER

Alarm Message(s)

High Engine Temp

Low Oil Pressure

Overcrank

Overspeed

RPM Sense Loss

Underspeed

Internal Fault

FIRMWARE ERROR-7

WIRING ERROR

Overvoltage

Undervoltage

Overload Remove Load

Low Volts Remove Load

Stepper Overcurrent

Auxiliary Shutdown

Emergency Stop

Defaults to English.

Select desired language

by scrolling through list.

ESC

ESCESCESCESC ESC

Operation

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

Setting the Exercise Timer

This generator is equipped with a configurable exercise

timer. Configuration can be performed directly at the control

panel or though the Mobile Link™ application. There are two

settings for the exercise timer:

Day/Time:

The generator will start and exercise for the

period defined, on the day of the week and at the time of day

specified. During this exercise period, the unit runs for

approximately five minutes and then shuts down.

NOTE: If Wi-Fi is enabled, the exercise timer will

automatically adjust for Daylight Savings Time.

Exercise frequency:

Exercise frequency can be set to

Weekly, Biweekly, or Monthly. If Monthly is selected, the day

of the month must be selected from 1-28. The generator will

exercise on that day each month. Transfer of loads to the

generator output does not occur during the exercise cycle

unless utility power is lost.

NOTE:

The exercise feature will operate only when the

generator is in AUTO mode, and will not work unless this

procedure is performed. If Wi-Fi is NOT enabled, the current

date/time will need to be reset every time the 12 volt battery

is disconnected and then reconnected, and/or when the fuse

is removed.

Figure 3-10

illustrates an engine speed profile during a

typical exercise cycle.

Table 3-1

details exercise

information and programming options for all home standby

generators.

Figure 3-10. Low Speed Exercise Profile

NOTE: If Quiet Test is disabled, the generator will

exercise at the rated rpm.

Battery Charger

IMPORTANT NOTE: Contact an IASD if the controller

screen displays “CHARGER MISSING AC.”

NOTE: The 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

maximum battery life.

• charging levels are safe.

NOTE: A warning is displayed on the LCD when the

battery needs service.

NOTE: Do not use external battery chargers.

Table 3-1. Generator Exercise Characteristics

Generator Size 9–22 kW

Low Speed Exercise 1950 rpm

Exercise Frequency

Options

Weekly/Bi-Weekly/Monthly

Exercise Time Length 5 minutes

2600

2800

3000

3200

3400

3600

3800

Low Speed Exercise Profile—9–22 kW Generators

1800

2000

2200

2400

0 sec 5 s 10 s 15 s 20 s 25 s 30 s 35 s 40 s 45 s 1 min 5 min

Exercise Speed (RPM)

Exercise Time

004448

Operation

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

Manual Transfer Operation

Prior to automatic operation, manually exercise the

transfer switch to verify there is no interference with

proper operation of the mechanism. Manual operation of

the transfer switch is required if electronic operation

should fail.

Transfer to Generator Power Source

1. Verify generator is OFF.

2. Set main line circuit breaker (MLCB) (generator

disconnect) to OFF (OPEN).

3. Turn OFF utility power supply to the transfer switch

using the means provided (such as a main line

utility breaker).

4. See

Figure 3-11. Use the manual transfer handle

(A) inside the transfer switch to move the main

contacts to STANDBY (loads connected to the

standby power source).

5. Press control panel MANUAL mode button to crank

and start the engine.

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

minutes.

7. Set MLCB (generator disconnect) to ON

(CLOSED). The standby power source now

powers the loads.

Figure 3-11. Typical Manual Transfer Switch

Operation

(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.

002565

MANUAL

• Will not transfer to generator if utility is present.

• Will transfer to generator if utility drops (below 65% of nominal for five consecutive seconds;

dealer programmable) after warm-up.

• Will transfer back when utility returns for 15 consecutive seconds (dealer programmable).

The engine will continue to run until removed from MANUAL mode.

AUTO

• Will start and run if utility drops for five consecutive seconds (dealer programmable).

• Will start an engine warm-up timer (duration varies when

Cold Smart Start is enabled).

–Will not transfer if utility subsequently returns.

–Will transfer to generator if utility is not present.

• Will transfer to utility once utility returns (above 80% of nominal) for 15 consecutive seconds

(dealer programmable).

• Will not transfer to utility unless utility returns. The generator will shut down if the OFF mode

button is pressed or a shutdown alarm is present.

• Once utility power is returned, the generator will shut down after one minute cool-down time.

EXERCISE

• Will not exercise if generator is already running in either AUTO or MANUAL mode.

• During exercise, the controller will only transfer if utility drops during exercise for five seconds

(dealer programmable), and will switch to AUTO.

Operation

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

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 the

generator:

1. Set the MLCB (generator disconnect) to OFF

(OPEN).

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

the internal temperature.

3. Press the OFF mode button on the control panel.

The engine will shut down.

4. Verify utility power supply to the transfer switch is

turned OFF.

5. Move the main contacts to the UTILITY position

(loads connected to the utility power source) using

the manual transfer handle (A in

Figure 3-11)

inside the transfer switch.

6. Turn on the utility power supply to the transfer

switch using the means provided.

7. Press the AUTO mode button on the control panel.

8. Return the MLCB (generator disconnect) to ON

(CLOSED).

9. Close and lock the lid.

Automatic Transfer Operation

Proceed as follows to select automatic operation:

1. Verify transfer switch main contacts are set to

UTILITY (loads connected to the utility power

source).

2. Verify normal utility power source voltage is

available to loads connected to the transfer switch.

3. Press the AUTO mode button on the generator

control panel.

4. Set MLCB (generator disconnect) to ON

(CLOSED).

The generator will start automatically when utility source

voltage drops below a preset level. Loads are transferred

to standby power source after the unit starts.

Automatic Sequence of

Operation

Utility Failure

If the 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 the timer

expires. An engine warm-up timer will be initiated once

the engine is started. Timer duration varies depending on

whether or not

Cold Smart Start is enabled. The

controller will transfer the load to the generator when the

warm-up time expires. If the utility power is restored

(above 80% nominal) at any time from the initiation of the

engine start until the generator is ready to accept load

(warm-up time has not elapsed), the controller completes

the start cycle and runs the generator through its normal

cool down cycle. However, the load will remain on the

utility source.

Cranking

The system will control the cyclic cranking as follows:

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

seconds cranking, 7 seconds resting, followed by

four additional cycles of 7 seconds cranking

followed by 7 seconds resting.

• 11–22 kW Units: five cranking cycles as follows:

16 seconds cranking, 7 seconds resting, 16

seconds cranking, 7 seconds resting, followed by

three additional cycles of 7 seconds cranking

followed by 7 seconds resting.

NOTE: An alarm will be triggered if the generator does

not start after these five attempts.

Operation

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

Cold Smart Start

The generator will monitor ambient temperature when

Cold Smart Start is enabled. The warm-up delay will be

adjusted based on prevailing conditions. Cold Smart Start

is enabled at the factory, but can be disabled in the EDIT

menu.

See

Table 3-2. If the ambient temperature is below a

fixed temperature (based on model) upon startup in

AUTO mode, the generator will warm up for 30 seconds.

This allows the engine to warm before a load is applied.

The generator will startup with the normal warm-up delay

of five seconds if the ambient temperature is at or above

the fixed temperature.

A check for proper output voltage buildup will be

performed when the generator engine is started.

If some condition impedes normal voltage creation, such

as frost crystals or dust/dirt preventing a good electrical

connection, the start sequence will be interrupted so a

cleaning cycle of the internal electrical connections can

be attempted.

The cleaning cycle is an extended warming up period

which lasts for several minutes while the normal

generator voltage output is determined to be low. During

this cycle, the generator controller will display “Warming

Up” on the display screen.

The generator controller display will show “Under

Voltage” if the cleaning cycle fails to clear the obstruction.

After several minutes, the alarm message can be

cleared, and the generator restarted.

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

Contact an IASD.

Load Transfer

The transfer of load when the generator is running is

dependent upon the 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 the generator OFF:

1. Set the main utility disconnect to OFF (OPEN).

2. Set the generator MLCB (generator disconnect) to

OFF (OPEN).

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

approximately one minute.

4. At the controller, set the generator to OFF.

5. Remove the 7.5A fuse from the controller.

To turn the generator back ON:

1. Install 7.5A fuse in controller.

2. Confirm the generator MLCB (generator

disconnect) is OFF (OPEN).

3. At the controller, set the generator to AUTO mode.

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

and warm up for a few minutes.

5. Set the MLCB (generator disconnect) to ON

(CLOSED).

6. Set the main utility disconnect to ON (CLOSED).

The system now operates in automatic mode.

Table 3-2. Cold Smart Start Set Points

Generator Size 9 kW–20 kW 22 kW

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

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

performed by an Independent Authorized Service Dealer

(IASD). Regular maintenance, replacement, or repair of

the emissions control devices and systems may be

performed by any repair shop or person of the owner’s

choosing. To obtain emissions control warranty service

free of charge, the work must be performed by an IASD.

See the emissions warranty.

Preparing for Maintenance

1. Set main utility disconnect to OFF (OPEN).

2. Lift lid and set MLCB (generator disconnect) on

generator to OFF (OPEN).

3. Allow generator to run and cool down for one

minute with no load (if running during a utility

outage).

4. Press OFF mode button on controller.

5. Remove 7.5 A 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 proper generator operation.

Engine oil and oil filter must be changed, and valve

clearance adjusted after the first 25 hours of operation.

Emissions-critical maintenance must be performed as

scheduled in order for the emissions warranty to be valid.

Emissions-critical maintenance consists of servicing the

air filter and spark plug(s) in accordance with the

Service

Schedule

The controller will prompt for Schedule A or Schedule B

maintenance to be performed. Schedule A maintenance

consists of the oil, oil filter, and battery check. Schedule B

maintenance includes the oil, oil filter, battery check, air

cleaner, spark plug(s), and valve clearance.

Since most maintenance alerts occur at the same time

(most have two year intervals), only one will appear on

the control panel display at a time. Once the first alert is

cleared, the next active alert will be displayed.

(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.

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

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

●

Check for water intrusion **

●

Perform fuel system leak test

●

Check battery condition, electrolyte level, and state

of charge

●● ●

Replace engine oil and oil filter †

●●

Replace engine air filter

●

Clean; inspect spark plug gap; replace if necessary

●

Inspect/adjust valve clearance ‡

●

Inspect/clean sediment trap Consult 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 the 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 the 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.

‡ Check/adjust valve clearance after the first 25 hours of operation.

Maintenance

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

Checking Engine Oil Level

IMPORTANT NOTE: Check oil level daily when power

outages necessitate running the generator for

extended periods.

Proceed as follows to check engine oil level:

1. Set main utility disconnect to OFF (OPEN).

2. Set main line circuit breaker (MLCB) (generator

disconnect) on generator to OFF (OPEN).

3. Run generator for a cool-down period of

approximately one minute.

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

five minutes.

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

cloth.

6. Completely insert oil dipstick into oil dipstick tube

and remove it.

7. Observe oil level. The level should be at the

“FULL” mark on oil dipstick.

8. If necessary, remove oil fill cap and add oil to

engine (with oil dipstick removed) until level

reaches “FULL” mark. Insert oil dipstick and install

fill cap.

To restart the generator:

1. Press the control panel AUTO mode button.

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

minutes.

3. Set the generator disconnect on the generator to

ON (CLOSED).

4. The system is now operating in automatic mode.

The main utility disconnect can be turned ON

(CLOSED).

Engine Oil Requirements

o maintain the product warranty, the engine oil should be

serviced in accordance with the recommendations of this

manual. For your convenience, Generac Maintenance Kits

are available 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.

Required Oil

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

Engine in General Information.

(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.

Maintenance

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

Changing the Oil and Oil Filter

Proceed as follows to change the oil and oil filter:

Lift the lid and press the MANUAL mode button on

the control panel to start the engine, and run it until it

is thoroughly warmed up. Press the OFF mode

button on the control panel to shut down the engine.

2. See Figure 4-1 or Figure 4-2. A few minutes after

the engine stops, and when it has cooled slightly,

remove the front panel. Pull the oil drain hose (A)

free of its retaining clip. Remove the cap from the

hose and drain the oil into a suitable container.

Figure 4-1. Oil Filter and Drain Location (9 kW)

Figure 4-2. Oil Filter and Drain Location (11-22 kW)

3. Install the cap on the hose. Position and secure the

hose with the retaining clip.

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

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

gasket of the new filter.

6. Screw the new filter on by hand until its gasket

lightly contacts the oil filter adapter. Tighten the

filter an additional three-quarter to one full turn.

7. Fill the engine with the proper recommended oil.

See

Engine Oil Requirements.

8. Press the MANUAL mode button on the control

panel to start the engine. Run for one minute, and

check for leaks.

9. Press the OFF mode button on the control panel to

stop the engine. Wait five minutes.

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

OVERFILL.

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

12. Press AUTO mode button on the control panel to

return the unit to AUTO mode.

13. Close and lock the lid.

14. Dispose of the used oil and filter at a proper

collection center.

Servicing the Air Cleaner

Proceed as follows to service the air cleaner:

Lift the lid and press the OFF mode button on the

control panel to stop the generator. Remove the front

pane

2. See Figure 4-3 or Figure 4-4. Remove the cover

clips (A) and air cleaner cover (B).

Figure 4-3. Servicing Air Cleaner (9 kW)

Figure 4-4. Servicing Air Cleaner (11-22 kW)

3. Remove the old air filter element (C) and discard.

4. Thoroughly clean the air cleaner enclosure of any

dust or debris.

5. Install a new air filter element.

Install the air cleaner cover and fasten the cover clips.

7. (11-22 kW units only): Verify air inlet duct (D) is

properly connected to the air cleaner cover.

8. Press the AUTO mode button on the control panel

to return the unit to AUTO mode.

001831

001799

001820

001814

Maintenance

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

Spark Plug(s)

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

replace spark plug(s) as necessary:

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

lid and remove the front panel.

2. Clean the area around the base of the spark

plug(s) to keep dirt and debris out of the engine.

3. Remove spark plug(s) and inspect the condition.

Install new plug(s) if existing plug(s) is worn or if

reuse is questionable.

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. Inspect spark plug gap using a wire feeler gauge.

See

Figure 4-5. Replace spark plug if gap is out of

specification. See General Information.

NOTE: New spark plugs should have the gap checked

prior to installation.

6. Install the spark plug(s), and torque to 18.4 ft-lbs

(25 Nm).

7. Press the control panel AUTO button to return the

unit to AUTO mode.

Figure 4-5. Spark Plug Gap Measurement

Valve Clearance Adjustment

IMPORTANT NOTE: Contact an IASD for service

assistance. Proper valve clearance is essential for

prolonging the life of the engine.

Check valve clearance after the first 25 hours of

operation, then after 400 hour intervals. Adjust if

necessary.

Check Valve Clearance

NOTE: The engine should be cool before checking valve

clearance. Adjustment is not needed if valve clearance is

within the dimensions provided in

Engine.

1. Close fuel valve and disconnect battery to avoid

accidental start-up.

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 the gasket. (Repeat for

second cylinder, if equipped.)

5. Verify piston is at top dead center (TDC) of its

compression stroke (both valves closed). To move

the piston to TDC, remove the intake baffle at the

front of the engine to access the flywheel nut. Use

a large socket and socket wrench to rotate the

flywheel nut clockwise, which will rotate the

crankshaft. Watch the piston through the spark

plug hole. The piston should move up and down.

The piston is at TDC when it is at its highest point

of travel.

6. See

Figure 4-6 or Figure 4-7. Check the valve

clearance between each rocker arm (E) and valve

stem (F) with a feeler gauge.

Figure 4-6. Valve Clearance Adjustment (9 kW)

000211

001812

Maintenance

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

Figure 4-7. Valve Clearance Adjustment (11-22 kW)

7. Install replacement valve cover gasket(s).

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

pattern, torquing to:

Adjust Valve Clearance

See

Figure 4-6 or Figure 4-7. Proceed as follows to

adjust valve clearance:

NOTE: Allow engine to cool before adjusting valve

clearance.

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

away from plugs.

2. Remove spark plug(s).

3. Remove four screws attaching valve cover.

Remove and discard gasket.

4. Verify piston is at top dead center (TDC) of its

compression stroke (both valves closed).

5. Loosen rocker jam nut (C) using a 10 mm wrench

(9-11 kW units) or 13 mm wrench (16-22 kW units.)

6. Turn pivot ball stud (D) using a 14 mm wrench (9

kW units), 8 mm wrench (11 kW units), or 10 mm

hex key (16-22 kW units) while checking clearance

between rocker arm (E) and valve stem (F) with a

feeler gauge. Adjust clearance as per

Engine.

NOTE: Hold the rocker jam nut in place as the pivot ball

stud is turned.

7. When 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

following torque specifications:

8. After tightening jam nut, inspect valve clearance to

verify it did not change.

9. Install new valve cover gasket.

10. Install the valve cover. Tighten fasteners in a cross

pattern, torquing to:

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

not be possible to get all the screws in place. Verify the

valve cover gasket is in place.

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

12. Attach the spark plug wire to the spark plug.

13. Repeat the process for the other cylinder if

equipped.

9 kW 80 in-lb (9.0 Nm)

11–22kW 60 in-lb (6.8 Nm)

002380

9 kW 53 in-lb (6.0 Nm)

11 kW 72 in-lb (8.2 Nm)

16–22kW 174 in-lb (19.68 Nm)

9 kW 80 in-lb (9.0 Nm)

11–22kW 60 in-lb (6.8 Nm)

Maintenance

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

Battery Maintenance

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 the 7.5 A fuse from the generator control

panel.

• Disconnect the 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 the

battery.

• Disconnect the charging source prior to connecting

or disconnecting battery terminals.

• Wear full eye protection and protective clothing.

•

If electrolyte contacts the skin, wash it off immediately

with water

• If electrolyte contacts the eyes, immediately

thoroughly flush with water and seek medical

attention.

• Wash down spilled electrolyte with an acid

neutralizing agent. A common practice is to use a

solution of 1 lb (454 g) bicarbonate of soda to 1 gal

(3.8 L) of water. Add bicarbonate of soda solution

until the evidence of reaction (foaming) has

ceased. Flush the resulting liquid with water and

dry the area completely.

• DO NOT smoke near the battery.

• DO NOT cause flame or spark in the battery area.

• Discharge static electricity from the body before

touching the battery by first touching a grounded

metal surface.

The battery should be regularly inspected per the

Service Schedule. Contact an IASD for assistance if

necessary.

Proceed as follows to inspect the battery:

1. Press the OFF mode button to shut down the

generator, then lift the lid and remove the front

panel.

2. Remove the 7.5 A fuse from the control panel.

3. Remove the intake side panel. (See

Intake Side

Panel Removal.)

4. See Figure 4-8. Inspect battery posts and cables

for tightness and corrosion. Tighten and clean as

necessary.

(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

(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.

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)

Maintenance

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

Figure 4-8. Battery Cables

5. Unsealed batteries only: Completely disconnect

the battery. Check the battery fluid level and, if

necessary, fill with distilled water only. DO NOT

use tap water. Also, have an IASD or a qualified

service technician check the state of charge and

condition.

6. When inspection is complete, connect the battery

cables, install the intake side panel, and install the

7.5 A fuse.

Place the generator in auto by pressing the AUTO

mode button on the controller.

Install front panel and close generator lid.

Cleaning the Sediment Trap

The sediment trap removes contaminants (moisture and

fine particles) from gaseous fuels before they enter the

fuel regulator. Accumulated moisture and particles must

be emptied from the sediment trap per local codes and

guidelines.

Proceed as follows to clean the sediment trap:

1. Remove intake side panel (see

Intake Side Panel

Removal).

2. Turn the generator fuel supply OFF.

See

Figure 4-9

. Unscrew and remove cap (A).

Figure 4-9. 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 the inside of each component with a clean,

dry, lint-free cloth.

6. Seal the threads of the cap with appropriate

sealing compound. Install the cap and hand-

tighten.

7. Tighten the cap with an appropriately sized pipe

wrench. DO NOT overtighten.

8. Turn the generator fuel supply on. Check 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 the intake side panel.

Post Maintenance Checks

1. Perform required maintenance procedure(s).

2. Install the intake side panel and front panel if

removed. (See

Intake Side Panel Removal and

Removing the Front Access Panel.)

3. Install the 7.5 A fuse in the control panel.

4. Complete the Installation Wizard information.

5. Press the AUTO mode button on the control panel.

Allow the unit to run for one minute with no load (if

running during a utility outage).

6. Set the MLCB (generator disconnect) on the

generator to ON (CLOSED).

7. Turn the main utility disconnect ON (CLOSED).

The system is now in automatic mode.

NOTE: If proper utility is present at this time, the

generator will perform its usual shutdown process.

–

001832

001821

Maintenance

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

Perform Leak Test

All products are tested at the factory before shipping to

ensure the performance and integrity of the fuel system.

However, it is important to perform a final fuel system

leak test before starting the generator. The entire fuel

system should be tested from supply to regulator.

See

Figure 4-10. 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.

Figure 4-10. Connection Points to Leak Check

Check 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 the generator if it has been

submerged in water. Have an IASD thoroughly clean, dry,

and inspect the 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

perform a visual inspection of the unit for corrosion. Inspect

all metal components of the generator, including the base

frame, brackets, alternator can, the entire fuel system

(inside and outside of the generator), and fastener

locations. If there is corrosion found on generator

components (e.g. regulator, engine/alternator mounts, fuel

plenum, etc.), replace parts as necessary.

Periodically wash and wax the enclosure using automotive

type products. Do not spray the unit with a hose or power

washer. Use warm, soapy water and a soft cloth. Frequent

washing is recommended in salt water/coastal areas.

Spray engine linkages with a light oil such as WD-40.

(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.

004038

Maintenance

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

Remove From, and Return To

Service Procedure

Remove From Service

If the generator cannot be exercised monthly, at a

minimum, and will be out of service longer than 90 days,

proceed as follows to prepare the generator for storage:

1. Start engine and allow it to warm up.

2. Close fuel shutoff valve in the fuel supply line and

allow engine to stop.

3. Once the engine has stopped, set the generator

MLCB (generator disconnect) to OFF (OPEN).

4. Disconnect battery charger AC input T1/Neutral

cable (with white sleeve) at controller.

5. Remove 7.5 A fuse from the generator control

panel.

6. Disconnect battery cables. Remove the negative

cable first.

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

and then fill crankcase with oil. See

Engine Oil

Requirements

8. Attach a tag to the engine indicating the viscosity

and classification 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 the generator enclosure.

Return to Service

Proceed as follows to return the unit to service after

storage:

1. Check the tag on the engine for oil viscosity and

classification. Drain and fill with proper oil, if

necessary.

2. Check the state of the battery. Fill all cells of

unsealed batteries to the proper level with distilled

water. DO NOT use tap water. Recharge the

battery to 100% state of charge. Replace the

battery if defective.

3. Clean and wipe down the generator enclosure.

4. Verify 7.5 A fuse is removed from generator control

panel.

5. Connect battery. Observe battery polarity. Damage

may occur if the battery is connected incorrectly.

Install positive cable first.

6. Connect battery charger AC input T1/Neutral cable

(with white sleeve) at controller.

7. Open the fuel shutoff valve.

8. Insert 7.5 A fuse into the generator control panel.

9. Complete the Installation Wizard procedure

(diagrammed in the generator installation manual).

10. Press the MANUAL mode button to start the unit.

Allow the unit to warm up for a few minutes.

11. Press the control panel OFF mode button to stop

the unit.

12. Set the MLCB (generator disconnect) to ON

(CLOSED).

13. Press the AUTO mode button on the control panel.

The generator is ready for service.

NOTE: The exercise timer and current date and time

must be reset if a battery has been completely

discharged or disconnected.

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.

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

Independent Authorized Service Dealer (IASD) if

fuse continues to blow.

Loose, corroded, or defective battery cables. Tighten, clean, or replace as necessary.*

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

Defective starter motor. Tighten, clean, or replace as necessary.*

Discharged battery. Charge or replace battery.

Engine cranks but

will not start.

No fuel. Replenish fuel / turn on fuel valve.

Defective fuel solenoid (FS). Replenish fuel / turn on fuel valve.

Open Wire 14 from controller. Replenish fuel / turn on fuel valve.

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

Valve clearance out of adjustment. Reset valve clearance

Engine starts hard

and runs rough.

Air cleaner plugged or damaged. Inspect and clean air cleaner.

Defective spark plug(s). Clean; inspect gap; replace plug(s) as needed.

Incorrect fuel pressure.

Confirm fuel pressure to regulator is 10–12 in water

column (19–22 mm Hg) for LP, and 3.5–7.0 in water

column (9–13 mm Hg) for natural gas.

Fuel selector in wrong position. Turn fuel conversion valve to correct position.

Valve(s) out of adjustment. Adjust valve clearance.

Internal engine issue. Contact an IASD for assistance.

Generator is set to

OFF, but the engine

continues to run.

Controller wired incorrectly. Contact an IASD for assistance.

Defective control board. Contact an IASD for assistance.

No AC output from

generator.

Main line circuit breaker (MLCB) (generator

disconnect) is OFF (OPEN).

Reset generator disconnect to ON (CLOSED).

Generator internal failure. Contact an IASD for assistance.

Engine may be warming up.

Refer to

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 generator disconnect to ON (CLOSED).

Defective transfer switch coi Contact an IASD for assistance

Defective transfer relay. Contact an IASD for assistance

Transfer relay circuit open. Contact an IASD for assistance

Defective control logic board. Contact an IASD for assistance

Engine may be warming up.

Refer to

Cold Smart Start.

Check the controller screen to verify status.

Unit consumes

large amounts of oil.

Excessive engine oil. Adjust oil to proper level.

Defective engine breather. Contact an IASD for assistance

Improper type or viscosity of oil

See

Engine Oil Requirements

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

Restricted air filter. Replace air filter.

* 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 the OFF mode button on the control panel, then the ENTER button, and finally the

AUTO mode button. Contact an IASD if the 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 the LEDs /

screen for alarms.

Check ventilation around the 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 the LEDs /

screen for alarms.

Clear alarm and remove household loads

from the generator. Put in AUTO and

restart.

RPM SENSE LOSS RED

Unit was running and

shut down, attempts to

restart.

Check the LEDs /

screen for alarms.

Clear alarm and remove household loads

from the 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.

Refer to “Activation” in installation

manual.

NONE GREEN

Unit will not start in

AUTO with utility loss.

Check screen for start

delay countdown.

If the 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 the 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 the LEDs /

screen for alarms.

Clear alarm. Using the control panel,

check the battery by navigating to the

BATTERY MENU option from the MAIN

MENU. If battery condition displays

GOOD, contact an IASD. If control panel

displays CHECK BATTERY, replace the

battery.

OVERCRANK RED

Unit will not start in

AUTO with utility loss.

Check the LEDs /

screen for alarms.

Check fuel line shutoff valve is ON. Clear

alarm. Start the 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 the 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 the LEDs /

screen for alarms.

Contact an IASD.

UNDERVOLTAGE RED

Unit will not start in

AUTO with utility loss.

Check the LEDs /

screen for alarms.

Contact an IASD.

UNDERSPEED RED

Unit will not start in

AUTO with utility loss.

Check the LEDs /

screen for alarms.

Contact an IASD.

STEPPER

OVERCURRENT

RED

Unit will not start in

AUTO with utility loss.

Check the LEDs /

screen for alarms.

Contact an IASD.

MISWIRE RED

Unit will not start in

AUTO with utility loss.

Check the LEDs /

screen for alarms.

Contact an IASD.

Troubleshooting / Quick Reference Guide

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

OVERVOLTAGE RED

Unit will not start in

AUTO with utility loss.

Check the LEDs /

screen for alarms.

Contact an IASD.

AUXILIARY

SHUTDOWN

RED Unit will not start.

Check auxiliary

shutdown switches

Set auxiliary shutdown switch(es) to

CLOSED (I). Clear alarm.

LOW BATTERY YELLOW

Yellow LED illuminated

in any state.

Check the screen for

additional information.

Clear alarm. Using the control panel,

check the battery by navigating to the

BATTERY MENU option from the MAIN

MENU. If battery condition displays

GOOD, contact an IASD. If control panel

displays CHECK BATTERY, replace the

battery.

BATTERY

PROBLEM

YELLOW

Yellow LED illuminated

in any state.

Check the screen for

additional information.

Contact an IASD.

CHARGER

WARNING

YELLOW

Yellow LED illuminated

in any state.

Check the screen for

additional information.

Contact an IASD.

CHARGER

MISSING AC

YELLOW

Yellow LED illuminated

in any state.

Check the screen for

additional information.

Contact an IASD.

SERVICE A YELLOW

Yellow LED illuminated

in any state.

Check the screen for

additional information.

Perform SERVICE A maintenance. Press

ENTER to clear.

SERVICE B YELLOW

Yellow LED illuminated

in any state.

Check the screen for

additional information.

Perform SERVICE B maintenance. Press

ENTER to clear.

INSPECT

BATTERY

YELLOW

Yellow LED illuminated

in any state.

Check the screen for

additional information.

Inspect battery. Press ENTER to clear.

Active Alarm LED Problem Things to Check Solution

Part No. 10000006551 Rev. C 03/16/18

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)

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Product's Documents

Operating Manual

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