Generac 7077 Guardian 3-Phase Air Cooled Generator User Manual

Owner’s Manual

3 Phase 60 Hz Air-Cooled Generators

20 kW

SAVE THIS MANUAL FOR FUTURE REFERENCE

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1-888-GENERAC

(888-436-3722)

(000209a)

WARNING

This product is not intended to be used in

a critical life support application. Failure to

adhere to this warning could result in

death or serious injury.

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. 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

make sure that 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:

Prod Date Week:

Volts:

LPV Amps:

NG Amps:

Hz:

Phase:

Controller P/N:

(000005)

WARNING

California Proposition 65. This product contains or

emits chemicals known to the state of California to

cause cancer, birth defects, and other reproductive

harm.

(000004)

WARNING

California Proposition 65. Engine exhaust and some

of its constituents are known to the state of California

to cause cancer, birth defects, and other reproductive

harm.

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

Section 1: Safety Rules & General

Information

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

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

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

Safety Rules .........................................................2

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

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

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

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

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

Section 2: General Information

The Generator ......................................................5

Specifications ......................................................6

Generator ....................................................................6

Engine .........................................................................6

Protection Systems .............................................7

Emission Information ..........................................7

Fuel Requirements ..............................................7

Battery Requirements .........................................7

Battery Charger ....................................................7

Engine Oil Requirements ....................................7

Activating the Generator .....................................7

Replacement Parts ..............................................8

Accessories ..........................................................8

Section 3: Operation

Site Prep Verification ...........................................9

Generator Enclosure ...........................................9

Opening the Lid ...........................................................9

Removing the Front Access Panel ..............................9

Intake Side Panel Removal .........................................9

Main Line Circuit Breaker (Generator Disconnect) ......9

LED Indicator Lights ..................................................10

Control Panel Interface .....................................11

Using the AUTO/OFF/MANUAL Interface ........11

Interface Menu Displays ....................................11

The LCD Panel ..........................................................11

Menu System Navigation ..........................................12

Setting the Exercise Timer ............................... 14

Battery Charger ................................................. 14

Manual Transfer Operation ............................... 15

Transfer to Generator Power Source ........................15

Transfer to Utility Power Source ................................16

Automatic Transfer Operation ......................... 16

Automatic Sequence of Operation .................. 16

Utility Failure ..............................................................16

Cranking ....................................................................16

Cold Smart Start ........................................................17

Load Transfer ............................................................17

Shutting Generator Down While Under Load

Or During An Extended Outage ....................... 17

To turn the generator OFF ........................................17

To turn the generator back ON ..................................17

Section 4: Maintenance

Maintenance ....................................................... 19

Preparing for Maintenance ............................... 19

To turn the generator OFF: .......................................19

To turn the generator back ON: .................................19

Performing Scheduled Maintenance ............... 19

Service Schedule ............................................... 20

Maintenance Log .......................................................20

Checking Engine Oil Level ............................... 21

Engine Oil Requirements ..........................................21

Changing the Oil and Oil Filter ......................... 22

Servicing the Air Cleaner .................................. 22

Spark Plugs ........................................................ 22

Valve Clearance Adjustment ............................ 23

Check Valve Clearance .............................................23

Adjust Valve Clearance .............................................23

Battery Maintenance ......................................... 24

Cleaning the Sediment Trap ............................. 25

Perform Leak Test ............................................. 25

Attention After Submersion ............................. 26

Corrosion Protection ........................................ 26

Table of Contents

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

Remove From, and Return To Service

Procedure ...........................................................26

Remove From Service .............................................. 26

Return to Service ...................................................... 27

Section 5: Troubleshooting / Quick

Reference Guide

Generator Troubleshooting ..............................29

Quick Reference Guide .....................................30

Safety Rules & General Information

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

Section 1: Safety Rules & General 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 that is 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.

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

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.

SAVE THESE INSTRUCTIONS: The manufacturer

suggests that this manual and the rules for safe operation

be copied and posted near the unit installation site.

Safety should be stressed to all operators and potential

operators of this equipment.

Throughout this publication and on tags and decals

affixed to the generator, DANGER, WARNING, and

CAUTION blocks are used to alert personnel to special

instructions about a particular operation that may be

hazardous if performed incorrectly or carelessly. Observe

them carefully. Their definitions are as follows:

NOTE: Notes provide additional information important to

a procedure or component.

These safety alerts cannot eliminate the hazards they

indicate. Observing safety precautions and strict compli-

ance with the special instructions while performing the

action or service are essential to preventing accidents.

The operator is responsible for proper and safe use of

the equipment. The manufacturer strongly recommends

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

manual and thoroughly understand all instructions before

using this equipment. The manufacturer also strongly

recommends instructing other users to properly start and

operate the unit. This prepares them if they need to

operate the equipment in an emergency.

How to Obtain Service

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 for decal

location. Record the model and serial numbers in the

spaces provided on the inside front cover of this manual.

(000100a)

WARNING

Consult Manual. Read and understand manual

completely before using product. Failure to

completely understand manual and product

could result in death or serious injury.

(000001)

DANGER

Indicates a hazardous situation which, if not avoided,

will result in death or serious injury.

(000002)

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

(000003)

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

Safety Rules & General Information

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

Safety Rules

Study these SAFETY RULES carefully before installing,

operating, or servicing this equipment. Become familiar

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

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

properly installed, operated, and maintained. Many

accidents are caused by failing to follow simple and

fundamental rules or precautions.

The manufacturer cannot anticipate every possible

circumstance that might involve a hazard. The 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 the manufacturer does not

specifically recommend, verify that it is safe for others

and does not render the generator unsafe.

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

(000209a)

WARNING

This product is not intended to be used in

a critical life support application. Failure to

adhere to this warning could result in

death or serious injury.

WARNING

This unit is not intended for use as a prime power

source. It is intended for use as an intermediate power

supply in the event of temporary power outage only.

See individual unit specifications for required

maintenance and run times pertaining to use.

(000247)

(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.

(000182)

WARNING

Only qualified service personnel may install, operate,

and maintain this equipment. Failure to follow proper

installation requirements could result in death, serious

injury, and damage to equipment or property.

(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.

(000155)

WARNING

Only a trained and licensed electrician should perform

wiring and connections to unit. Failure to follow proper

installation requirements could result in death, serious

injury, and damage to equipment or property.

(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 Rules & General 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 Rules & General 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 that the generator is

installed in accordance with the manufacturer’s

instructions and recommendations. Following

proper installation, do nothing that might alter a

safe installation and render the unit in

noncompliance with the aforementioned codes,

standards, laws, and regulations.

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.

(000151)

DANGER

Connection of fuel source must be done by a qualified

professional technician or contractor. Incorrect installation

of this unit will result in death, serious injury, and damage

to equipment and property damage.

(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.

General Information

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

Section 2: General Information

The Generator

Figure 2-1. Components and Control Locations

A. Lock with Cover E. Battery Compartment

(Battery not supplied)

I. Main AC/Control

Wiring holes

N. Sediment Trap

B. Main Line Circuit

Breaker (Generator

Disconnect)

F. Exhaust Enclosure J.

Oil Fill Cap

Oil Filter

Fuel Regulator

Fuel Inlet

C. Airbox with Air Cleaner G. Status LED Indicators L. Composite Base Q. Data Plate Location

D. Control Panel H. Oil Drain M. Oil Dipstick

003736

General Information

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

Specifications

Generator

Engine

The specification sheet for your generator was included in the documentation provided with the unit at the time of

purchase. For additional copies, consult your local Independent Authorized Service Dealer (IASD) for your specific

generator model.

Model 20 kW

Rated Voltage 208

Power Factor 0.8

Rated Maximum Load Current (Amps) at Rated

Voltage with LP*

69.4

Main Line Circuit Breaker

(Generator Disconnect)

80 Amp

Phase 3

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 (lbs/kilos)

(without battery)

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 20 kW

Type of Engine Generac G-Force 1000

Number of Cylinders 2

Displacement 999 cc

Cylinder Block Aluminum w/ cast iron sleeve

Recommended Spark Plug

See

Replacement Parts

Spark Plug Gap 0.040 in (1.02 mm)

Valve Clearance 0.002–0.004 in

(0.05–0.1 mm)

Starter 12 VDC

Oil Capacity Including Filter 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 about 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 7

Protection Systems

The generator may need to run for long periods of time

with no operator present to monitor the engine/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 which alerts 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 will indicate a condition on the

generator that should be addressed, but will not shut the

generator down. An alarm will shut the generator down to

protect the system from any damage. In the event of an

alarm, an owner can clear the alarm and restart the

generator prior to contacting an IASD. If the intermittent

issue occurs again, contact an IASD.

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 that the engine complies with the

applicable emissions standards for the duration of the

product’s life.

This generator is certified to operate on Liquid Propane

Vapor fuel or pipeline Natural Gas.

The Emission Control System code is EM (Engine

Modification). The Emission Control System on this

generator consists of the following:

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 cubic foot (37.26 megajoules per cubic

meter) for natural gas, or at least 2500 BTUs per cubic foot

(93.15 megajoules per cubic meter) for LP gas (vapor).

NOTE: If converting to LP gas from natural gas, a

minimum LP tank size of 250 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,

which ensures output charging levels are safe and

continuously optimized to promote maximum battery life.

Engine Oil Requirements

See Engine Oil Requirements in the Maintenance

section for proper oil viscosity.

Activating the Generator

The generator should be activated upon initial start-up.

See the installation manual for complete instructions.

• High Temperature

• Low Oil Pressure

• Overcrank

• Overspeed

• Overvoltage

• Undervoltage

• Overload

• Underspeed

• RPM Sensor Loss

• Controller Fault

• Wiring Error

• Fuse Problem

• 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

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

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 and accessories. See also http://

www.ordertree.com/generac/air-cooled-homestandby-generators/.

Description 20 kW

26R Exide Battery 0H3421S

Spark Plug

0G0767A

(RC12YC or equivalent)

Oil Filter 070185E

Air Filter 0J8478

Control Panel Fuse 0D7178T

Transfer Switch Fuses 073590A

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.

Auxiliary Transfer Switch Lockout Enables any of the transfer switches to completely lock out one large electrical load by tying

into its control system.

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

This offers a sleek, contoured appearance as well as offering protection from rodents and

insects by covering the lifting holes located in the base. Requires use of the mounting pad

shipped with the generator.

Mobile Link™ (USA only) Provides a personalized web portal that displays the generator status, maintenance

schedule, event history, and much more. This portal is accessible via computer, tablet, or

smart phone. Sends emails and/or text notifications the moment there is any change in the

generator’s status. Notification settings can be customized to what type of alert is sent and

how often. 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.

Wireless Local Monitor The Wireless Local Monitor is completely wireless and battery powered, and provides owners

with instant generator status updates without ever leaving the house. Status lights (red,

yellow, and green) alert owners when the generator needs attention. Magnetic backing

permits refrigerator mounting and gives a 600 ft (183 m) line of sight communication.

Operation

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

Section 3: Operation

Site Prep Verification

The generator must be installed so that airflow into and out

of the generator is not impeded. Verify that 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 that 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

See Figure 3-1. The lid will be locked. A set of keys is

taped to the cardboard on top of the generator on the

intake side.

1. Remove the tape to remove the keys.

2. Use the keys to open the lid of the generator.

The enclosed keys provided with this unit are intended

for service personnel use only.

Figure 3-1. Key Location

Opening the Lid

See Figure 3-3. Two locks secure the lid—one on each

side (A). 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 that 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). Do not pull

the panel away from the enclosure before lifting up (D).

Intake Side Panel Removal

See Figure 3-4. The intake side panel (A) must be

removed to access the battery compartment, fuel

regulator, and sediment trap.

1. Raise the lid and remove the front panel.

2. Use an Allen wrench to remove two mounting

screws (B) and the L-bracket screw (C).

3. Lift the intake panel up and away from the

generator.

NOTE: Always lift the intake side panel straight up

before pulling away from enclosure. Do not pull the panel

away from the enclosure before lifting up (D).

Main Line Circuit Breaker (Generator

Disconnect)

This is a 3-pole breaker rated according to relevant

specifications. See (A) in Figure 3-2.

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).

NOTE: DO NOT lock out the MLCB during normal

generator operation. Doing so will compromise automatic

standby functionality.

Figure 3-2. Main Breaker

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

003619

003740

Operation

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

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

Figure 3-4. Intake Side Panel Removal

LED Indicator Lights

See Figure 3-5. Three LEDs are visible behind a

translucent lens on the generator side panel. These

LEDs indicate the operating status of the generator.

• Green LED READY light (A) is illuminated when

utility is present and the control panel button is in

the AUTO position. 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 MAINTENANCE light (C) is illuminated

when scheduled maintenance is due.

NOTE: Yellow MAINTENANCE or WARNING LED may

be on at the same time as either the Red or Green LED.

001797

002961

Operation

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

Figure 3-5. LED Indicator Lights

Control Panel Interface

See Figure 3-6. The control panel interface (A) is located

under the lid of the enclosure. Verify that 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.

The 7.5A fuse is located beneath the rubber cover (B) to

the right of the control panel.

Verify that both the left and right side locks are securely

out of the way before closing the unit.

Figure 3-6. Generator Control Panel

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 the

interconnect wires is not warrantable.

Interface Menu Displays

The LCD Panel

001791

001798

Button Description of Operation

AUTO

This button 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 on this button will flash if

running in Automatic mode and the connected

loads are running under generator power (utility

is lost).

OFF

This button shuts down the engine and

prevents automatic operation of the unit.

MANUAL

This button cranks and starts the generator.

Transfer to standby power will not occur unless

there is a utility failure.

The blue LED on this button will flash if running

in manual mode and the connected loads are

running under generator power (utility is lost).

Feature Description

HOME

page

Default page that is displayed if no buttons are

pressed for 60 seconds. Normally shows

current status message and the 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 will be

displayed. Press the OFF button and then

press the ENTER button to clear an alarm or

warning.

Display

Backlight

Normally off. The backlight will automatically

light 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; Debug.

Operation

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

Menu System Navigation

To get to the MENU, use the ESCAPE button from any page. You may need to press the ESCAPE button several times

before reaching the MENU page. Navigate to the desired menu by using the

↑/↓ buttons. When the desired menu is

displayed and flashing, press the ENTER button.

Figure 3-7. Navigation Menu

EVOLUTION 2.0 HSB MENU MAP

“Run Log”

ESC

ENTER

SYSTEM DATE/TIME

SUB MENUS

HISTORY

Exercise Time

14:00 Wednesday

Firmware Update

Press Enter

ESC

ENTER

Current Date/Time

2/12/16 12:22

ESC

ENTER

ESC

ENTER

ESC

ENTER

ENTERENTER

ENTER

ESC

Switched to “OFF”

Hours of Protection

0 (H)

Language

English

Fuel Selection

NG or LP

Firmware Update:

Insert USB

“Alarm Log”

- Alarm Log +

- Run Log +

- 1 thru 50 +

Warning Message(s)

Charger Warning

Charger Missing AC

Low Battery

Battery Problem

Exercise Set Error

USB Warning

Download Failure

Running Manual

Running-Utility Lost

Running-Remote Start

Running-2 Wire Start

Running - Exercise

Switched Off

Stopped - Auto

Stopped - Alarm

Alarm Message(s)

High Temperature

Low Oil Pressure

Overcrank

Overspeed

Overvoltage

Undervoltage

Overload

Underspeed

RPM Sensor Loss

Controller Fault

Wiring Error

Stepper Overcurrent

Fuse Problem

Auxiliary Shutdown

ESC

Select Min (0-59)

- 0 +

ESC

Select Hour (0-23)

- 14 +

ESC ESC

Quiet Test Mode ?

- YES or NO +

Select Frequency

- WEEKLY +

- BIWEEKLY +

- MONTHLY +

Language

+ English -

Fuel Selection

+ NG or LP -

ENTER

Cold Smart Start?

YES or NO

ESC

Cold Smart Start?

- YES or NO +

Language

+ Espanol -

Note: Menu functions and features may vary

depending on unit model and firmware revision.

Generator Activated

Service Unit

* only if replacing factory default controller

USB

Operation

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

Figure 3-8. Navigation Menu

UP ARROW =

DOWN ARROW = -

ESC

BATTERY

DEALER

EXAMPLE:

Inspect Battery 200 RnHr or 12/27/16

and

Next Maintenance 200 RnHr or 12/27/16

Current Date/Time

02/14/16 07:40

ESC

ENTER

ESC ENTER

ESC

ESC ESC

ENTER

ENTERENTER

ESC

Maint. Log

Run Hrs

Scheduled

ENTER

Select Month (1-12)

- 2 +

Run Hours (H)

0.0

ENTER

Select Date (1-31)

- 13 +

ENTER

Select Year (0-99)

- 13 +

ENTER

Access Requires Password

Possible Message(s):

Corrupted File

Invalid File

File Not Found

Unsupported Device*

"Current: V XXXX "

"USB: V XXXX"

"Are You Sure?"

"- Yes or No +"

ESC

ENTER

ESC ENTER

ESCENTER

Select “Yes” then Press “Enter” to continue or Press “ESCAPE” to escape out of updating.

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

does this twice. When update is complete the unit returns to Install Wizard menu.

When the controller powers up the very first screen displays the version number for a few seconds.

When update is complete remove Thumb Drive, then follow the Install Wizard Menu.

- 1 thru 50 +

"Battery Maintained"

"Schedule A Serviced"

"Schedule B Serviced"

"Maintenance Reset"

"Inspect Battery"

"Service Schedule A"

"Service Schedule B"

ESC

Select Min (0-59)

- 0 +

ESC

Select Hour (0-23)

- 14 +

Language

+ Francais -

Language

+ Portuguese -

Battery Condition

“Good” “Inspect Battery” or “Check Battery”

Select Day

- Wednesday +

004514

* Re-try using a higher quality USB drive.

Operation

14 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 then shuts down.

NOTE:

The exercise timer does not 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:

If the installer tests the generator prior to

installation, press the ENTER button to skip setting up the

exercise timer.

NOTE:

The exercise feature will operate only when the

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

procedure is performed. The current date/time will need to

be reset every time the 12 volt battery is disconnected and

then reconnected, and/or when the fuse is removed.

Table 3-1

details the exercise information and programming

options.

Figure 3-9

illustrates the engine speed profile

during a typical exercise cycle.

The exercise timer must be reset if the 7.5 amp fuse is

removed.

Figure 3-9. Low Speed Exercise Profile

Battery Charger

NOTE: The battery charger is integrated into the control

module in all models.

The battery charger operates as a smart charger that 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.

2600

2800

3000

3200

3400

3600

3800

1800

2000

2200

2400

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

001403

Exercise Speed (RPM)

Exercise Time

Table 3-1. Generator Exercise Characteristics

Generator Size 20 kW

Low Speed Exercise 1950 rpm

Exercise Frequency

Options

Weekly/Bi-Weekly/

Monthly

Exercise Time Length 5 minutes

Operation

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

Manual Transfer Operation

Prior to automatic operation, manually exercise the

transfer switch to verify that there is no interference with

proper operation of the mechanism. Manual operation of

the transfer switch is required if electronic operation

should fail.

Transfer to Generator Power Source

1. Verify generator is OFF.

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

disconnect) to OFF (OPEN).

3. Turn off the utility power supply to the transfer

switch using the means provided (such as a main

line utility breaker).

4. Use the manual transfer handle (A in Figure 3-10)

inside the transfer switch to move the main

contacts to STANDBY (loads connected to the

standby power source).

5. Press the control panel MANUAL button to crank

and start the engine.

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

minutes.

7. Set the MLCB (generator disconnect) to ON

(CLOSED). The standby power source now

powers the loads.

Figure 3-10. 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.

004083

MANUAL

• Will not transfer to generator if utility is present.

• Will transfer to generator if utility fails (below 132 volts for five consecutive seconds) after

warm-up.

• Will transfer back when utility returns for 15 consecutive seconds. The engine will continue to

run until removed from the MANUAL mode.

AUTO

• Will start and run if utility fails for five consecutive seconds (factory default).

• 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 175 volts) for 15 seconds.

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

is pressed or a shutdown alarm is present.

• Once utility power is returned, the generator will shut down after 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 fails during exercise for 10 seconds

(varies based on

Cold Smart Start) and will switch to AUTO.

Operation

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

Transfer to Utility Power Source

When utility power has been restored, transfer to utility

source and shut down the generator. 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 two minutes at no-load to stabilize

the internal temperature.

3. Press the control panel OFF button. The engine

will shut down.

4. Verify that 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 3-10)

inside the transfer switch.

6. Turn on the utility power supply to the transfer

switch using the means provided.

7. Press the control panel AUTO button.

8. Return the MLCB (generator disconnect) to ON

(CLOSED).

Automatic Transfer Operation

Proceed as follows to select automatic operation:

1. Verify that the transfer switch main contacts are set

to UTILITY (loads connected to the utility power

source).

2. Verify that normal utility power source voltage is

available to transfer switch terminal lugs N1, N2,

and N3.

3. Press the AUTO button on the control panel

interface.

4. Set the MLCB (generator disconnect) to ON

(CLOSED).

The generator will start automatically when utility source

voltage drops below a preset level. Loads are transferred

to the standby power source after the unit starts.

Automatic Sequence of

Operation

Utility Failure

If the generator is set to AUTO, when utility fails (below

132 volts) a five second (factory default/dealer

programmable) line interrupt delay time is started. The

engine cranks and starts if the utility is still gone when the

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

once 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 175 volts) 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:

• The system will go through 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.

Operation

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

Cold Smart Start

The Cold Smart Start feature is enabled at the factory, but

can be disabled in the EDIT menu. The generator will

monitor ambient temperature when Cold Smart Start is

enabled. The warm-up delay will be adjusted based on

prevailing conditions.

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 5 seconds if

the ambient temperature is at or above the fixed

temperature.

A check for proper output voltage build up 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 that

a cleaning cycle of the internal electrical connections can

be attempted.

The cleaning cycle is an extended warming up period

which lasts for several minutes while the normal genera-

tor 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 An

Extended Outage

Proceed as follows to turn the generator off during utility

outages to perform maintenance or conserve fuel:

To turn the generator OFF

Turn the generator off before performing any

maintenance. This is to prevent accidental startup.

1. Turn the main utility disconnect OFF (OPEN).

2. Lift lid and turn the MLCB (generator disconnect)

on the generator to OFF (OPEN).

3. Allow generator to run and cool down for one

minute with no load.

4. Press the OFF mode button on the controller.

5. Remove the 7.5 amp fuse from the control panel.

6. With the generator shut down, remove the front

panel.

7. Perform required maintenance procedure(s).

To turn the generator back ON

1. Install the front panel.

2. Install the 7.5 amp fuse in the control panel.

3. Complete the Installation Wizard information.

4. Place controller in AUTO. Allow the unit to run for

one minute with no load.

5. Set the MLCB (generator disconnect) on the

generator to ON (CLOSED).

6. 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.

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

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

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Maintenance

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

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

To turn the generator OFF:

Turn the generator off before performing any

maintenance. This is to prevent accidental startup.

1. Turn the main utility disconnect OFF (OPEN).

2. Lift lid and turn the MLCB (generator disconnect)

on the generator to OFF (OPEN).

3. Press the OFF mode button on the controller.

4. Remove the 7.5 amp fuse from the control panel.

5. With the generator shut down, remove the front

and intake side panel. (See Intake Side Panel

Removal.)

6. Perform required maintenance procedure(s).

To turn the generator back ON:

1. Install the intake side panel and front panel. (See

Intake Side Panel Removal.)

2. Install the 7.5 amp fuse in the control panel.

3. Set the MLCB (generator disconnect) on the

generator to ON (CLOSED).

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

The system is now in automatic mode.

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 plugs in accordance with the Service

Schedule.

The controller will prompt for Schedule A or Schedule B

maintenance to be performed. See Service Schedule for

recommendations.

Since most maintenance alerts will occur at the same

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

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

is cleared, the next active alert will be displayed.

(000182)

WARNING

Only qualified service personnel may install, operate,

and maintain this equipment. Failure to follow proper

installation requirements could result in death, serious

injury, and damage to equipment or property.

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

20 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

Check enclosure louvers for dirt and debris *

●

Check lines and connections for fuel or oil leaks

●

Check engine oil level

●

Check for water intrusion **

●

Check battery condition, electrolyte level, and state

of charge

●● ●

Replace engine oil and oil filter †

●●

Replace engine air filter

●

Clean; Check gap; Replace spark plugs

●

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 the intake and discharge louvers on the sides of the enclosure. Clean any debris (dirt,

grass clippings, etc.) which have accumulated inside the enclosure.

** Verify that all sources of potential water intrusion such as water sprinklers, roof run-off, rain gutter down spouts, and sump pump discharges are directed away

from the generator enclosure.

† Change engine oil and filter after the first 25 hours of operation. In cold weather conditions (ambient below 40 °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 21

Checking Engine Oil Level

The oil level should be checked daily when power

outages necessitate running the generator for extended

periods. Proceed as follows to check the engine oil level:

1. Run the generator for a cool-down period of

approximately one minute.

2. Turn the main utility disconnect off.

3. Turn the main line circuit breaker (MLCB)

(generator disconnect) on the generator to OFF

(OPEN).

4. Turn the generator off.

5. Press the control panel OFF button. Wait five

minutes.

6. Remove the oil dipstick and wipe it dry with a clean

cloth.

7. Completely insert the oil dipstick into the oil dipstick

tube and remove it.

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

“FULL” mark on the oil dipstick.

9. If necessary, remove the oil fill cap and add oil to

the engine (with the oil dipstick removed) until the

level reaches the “FULL” mark and insert the oil

dipstick and fill cap.

To restart the generator:

1. Press the control panel AUTO button.

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

minutes.

3. Set the generator disconnect (MLCB) 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

To maintain the product warranty, the engine oil should

be serviced in accordance with the recommendations of

this manual. For your convenience, Generac

Maintenance Kits are available that include engine oil, oil

filter, air filter, spark plug(s), a shop towel, and 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.

(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

22 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:

1. Press the MANUAL button on the control panel to

start the engine, and run it until it is thoroughly

warmed up. Press the control panel OFF button to

shut down the engine.

2. See Figure 4-1. A few minutes after the engine

stops, and when it has cooled slightly, lift the lid

and 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

3. Replace the cap after the oil has drained.

Reposition and secure the hose with the retaining

clip.

4. Remove the old 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 3/4 to one full turn.

7. Refill the engine with the proper recommended oil.

See Engine Oil Requirements.

8. Press the MANUAL button on the control panel to

start the engine, run for one minute, and check for

leaks.

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

the engine. Wait five minutes.

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

OVERFILL.

11. Reinsert oil dipstick and/or reattach fill cap.

12. To return the unit to AUTO mode, press the control

panel AUTO button.

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

collection center.

Servicing the Air Cleaner

Proceed as follows to service the air cleaner:

Press the OFF button on the control panel to stop the

generator. Then lift the lid and remove the front pane

2. See Figure 4-2. Remove the cover clips (A) and air

cleaner cover (B).

Figure 4-2. Servicing Air Cleaner

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. Verify that the air inlet duct (D) is properly

connected to the air cleaner cover.

8. Press the AUTO button on the control panel to

return the unit to AUTO mode.

Spark Plugs

Proceed as follows to check the spark plug(s) gap and

replace the 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 the spark plug(s) and check the condition.

Install a new plug(s) if the old plug(s) is worn or if

reuse is questionable.

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

wire brush and commercial solvent. Do not blast

the plug(s) to clean.

5. Check the spark plug gap using a wire feeler

gauge. See Figure 4-3. Replace the spark plug if

the gap is out of specification. See General

Information.

6. Reinstall 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.

003742

003741

Maintenance

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

Figure 4-3. Spark Plug Gap Measurement

Valve Clearance Adjustment

Check the valve clearance after the first 25 hours of

operation, then after 400 hour intervals. Adjust if

necessary.

Important: Please contact an IASD for service

assistance. Proper valve clearance is essential for

prolonging the life of the engine.

Check Valve Clearance

NOTE: The engine should be cool before checking the

valve clearance. Adjustment is not needed if valve

clearance is within the dimensions provided in

Specifications.

1. Close fuel valve and disconnect battery to avoid

accidental start-up.

2. Remove spark plug wires, and position wires away

from plugs.

3. Remove spark plugs.

4. Remove the four screws attaching the valve cover.

Remove and discard the gasket.

5. Make sure the piston is at top dead center (TDC) of

its compression stroke (both valves closed). To

move the piston to TDC, remove the intake screen

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. Check the valve clearance between the rocker arm

and valve stem with a feeler gauge.

7. Install replacement valve cover gasket.

8. Install valve cover. Tighten fasteners in a cross

pattern, torquing to 60 in-lbs. (6.8 Nm).

Adjust Valve Clearance

See Figure 4-4. Proceed as follows to adjust the 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 the four screws attaching the valve cover.

Remove and discard gasket.

4. Make sure the piston is at top dead center (TDC) of

its compression stroke (both valves closed).

5. Loosen the rocker jam nut (C) using a 13 mm

wrench.

Figure 4-4. Valve Clearance Adjustment

6. Turn the pivot ball stud (D) using a 10 mm Allen

wrench while checking clearance between the

rocker arm (E) and the valve stem (F) with a feeler

gauge. Adjust clearance as per Specifications.

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

ball stud is turned.

7. When valve clearance is correct, hold the pivot ball

stud (B) in place with a wrench and tighten the

rocker arm jam nut. Torque the jam nut to 174 in-

lbs (19.68 Nm).

8. After tightening the jam nut, recheck 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 60 in-lbs (6.8 Nm).

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 torque to 18 ft-lbs (25 Nm).

12. Reattach the spark plug wire to the spark plug.

13. Repeat the process for the other cylinder if

necessary.

000211

002380

Maintenance

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

Battery Maintenance

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. Lift the lid to gain access to the controller and press

the OFF button to shut down the generator, then

remove the front panel.

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

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

Panel Removal.)

4. See Figure 4-8. Disconnect the white battery

charger cable.

5. See Figure 4-5. Inspect the battery posts and

cables for tightness and corrosion. Tighten and

clean as necessary.

Figure 4-5. Battery Cables

6. (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.

7. When inspection is complete, reconnect the battery

cables, the battery charger cable, reinstall the

intake side panel, and reinstall the 7.5 amp fuse.

Place the controller in AUTO mode.

Complete the Installation Wizard Menu.

10.

Reinstall the front panel and close the generator lid.

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 amp fuse from the generator

control panel.

• Disconnect the battery charger as directed in

Battery Maintenance.

• Remove all jewelry—watches, rings, metal objects,

etc.

• 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.

–

001832

(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

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

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

• 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 when near the battery.

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

• Discharge static electricity from the body before

touching the battery by first touching a grounded

metal surface.

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. Lift the lid to gain access to the controller and press

the OFF button to shut down the generator, then

remove the front panel.

2. Remove the intake side panel (see Intake Side

Panel Removal).

3. Turn the generator fuel supply off.

4. Remove the battery.

See

Figure 4-6

. Unscrew and remove the cap (A).

Figure 4-6. Cleaning the Sediment Trap

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

accumulated moisture and particles from the cap

and body (B).

7. Wipe the inside of each component with a clean,

dry, lint-free cloth.

8. Seal the threads of the cap with appropriate

sealing compound. Install the cap and hand-

tighten.

9. Tighten the cap with an appropriately sized pipe

wrench. DO NOT overtighten.

10. 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.

11. Install the battery.

12. Install the intake side panel, put the generator into

AUTO mode and close the lid.

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 4-7. 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 4-7. 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.

001821

(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

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

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 won’t

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

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 the engine and let it warm up.

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

and allow the engine to stop.

3. Once the engine has stopped, set the generator

MLCB (generator disconnect) to OFF (OPEN).

4. Turn off the utility power to the transfer switch.

5. See Figure 4-8. Remove battery charger AC input

T1/Neutral cable (has white sleeve) at controller.

Figure 4-8. Disconnect Battery Charger Cable

6. Remove the 7.5 amp fuse from the generator’s

control panel.

7. Disconnect the battery cables. Remove the

negative cable first.

8. Drain the oil completely while the engine is still

warm, and then refill the crankcase with oil.

9. Attach a tag to the engine indicating the viscosity

and classification of the new oil in the crankcase.

10. Remove the spark plug(s) and spray a fogging

agent into the spark plug(s) threaded openings.

Reinstall and tighten the spark plug(s) to

specification.

11. Remove the battery and store it in a cool, dry room

on a wooden board.

12. Clean and wipe down the entire generator.

13. Turn on utility power to the transfer switch.

002389

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)

Maintenance

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

Return to Service

Proceed as follows to return the unit to service after

storage:

1. Verify utility power is off.

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

classification. Drain and refill with proper oil, if

necessary.

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

unsealed batteries to the proper level with distilled

water. DO NOT use tap water. Recharge the

battery to 100% state of charge. Replace the

battery if defective.

4. Clean and wipe down the entire generator.

5. Verify that the 7.5 amp fuse is removed from the

generator control panel.

6. Reconnect the battery. Observe battery polarity.

Damage may occur if the battery is connected

incorrectly. Install positive cable first.

7. Reconnect the battery charger AC input T1/Neutral

cable (white sleeve) at controller.

8. Open the fuel shutoff valve.

9. Insert the 7.5 amp fuse into the generator control

panel.

10. Complete the Installation Wizard information.

11. Press the MANUAL button to start the unit. Allow

the unit to warm up for a few minutes.

12. Press the control panel OFF button to stop the unit.

13. Turn on the utility power to the transfer switch.

14. Set the control panel to AUTO.

The generator is ready for service.

NOTE: The exercise timer and current date and time

must be reset when a battery is dead or has been

disconnected.

Maintenance

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

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Troubleshooting / Quick Reference Guide

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

Section 5: Troubleshooting / Quick Reference Guide

Generator Troubleshooting

Problem Cause Correction

Engine will not

crank.

1. Blown fuse.

2. Loose, corroded, or defective battery cables.

3. Defective starter contact.

4. Defective starter motor.

5. Discharged battery.

1. Correct short circuit condition by replacing 7.5

amp fuse in generator control panel. Contact an

Independent Authorized Service Dealer (IASD) if

fuse continues to blow.

2. Tighten, clean, or replace as necessary.*

3. *See #2.

4. *See #2.

5. Charge or replace battery.

Engine cranks but

will not start.

1. No fuel.

2. Defective fuel solenoid (FS).

3. Open Wire 14 from controller.

4. Defective spark plug(s).

5. Valve clearance out of adjustment.

1. Replenish fuel / turn on fuel valve.

2. *

3. *

4. Clean; check gap; replace plug(s) if necessary.

5. Reset valve clearance.

Engine starts hard

and runs rough.

1. Air cleaner plugged or damaged.

2. Defective spark plug(s).

3. Incorrect fuel pressure.

4. Fuel selector in wrong position.

5. Valve(s) out of adjustment.

6. Internal engine issue.

1. Check and clean air cleaner.

2. Clean; check gap; replace plug(s) as needed.

3. 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.

4. Turn fuel conversion valve to correct position.

5. Adjust valve clearance.

6. *

Generator is set to

OFF, but the engine

continues to run.

1. Controller wired incorrectly.

2. Defective control board.

1. *

2. *

No AC output from

generator.

1. Main line circuit breaker (MLCB) (generator dis-

connect) is OFF (OPEN).

2. Generator internal failure.

3. Engine may be warming up. Refer to Cold Smart

Start.

1. Reset generator disconnect to ON (CLOSED).

2. *

3. Check the controller screen to verify status.

No transfer to

standby after utility

source failure.

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

2. Defective transfer switch coil.

3. Defective transfer relay.

4. Transfer relay circuit open.

5. Defective control logic board.

6. Engine may be warming up. Refer to Cold Smart

Start.

1. Reset generator disconnect to ON (CLOSED).

2. *

3. *

4. *

5. *

6. Check the controller screen to verify status.

Unit consumes

large amounts of oil.

1. Excessive engine oil.

2. Defective engine breather.

3. Improper type or viscosity of oil.

4. Damaged gasket, seal, or hose.

5. Restricted air filter.

1. Adjust oil to proper level.

2. *

3. See Engine Oil Requirements.

4. Check for oil leaks.

5. Replace air filter.

* Contact an IASD for assistance.

Troubleshooting / Quick Reference Guide

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

Quick Reference Guide

To clear an active alarm, press the OFF button, the ENTER button, and then press AUTO. If the alarm reoccurs,

contact an IASD.

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 bat-

tery 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.

FUSE PROBLEM RED

Unit will not start in

AUTO with utility loss.

Check the LEDs /

screen for alarms.

Check the 7.5 amp fuse. If it is blown,

replace it with an ATO 7.5 amp fuse. If the

fuse is intact, contact an IASD.

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.

Troubleshooting / Quick Reference Guide

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

MISWIRE RED

Unit will not start in

AUTO with utility loss.

Check the LEDs /

screen for alarms.

Contact an IASD.

OVERVOLTAGE RED

Unit will not start in

AUTO with utility loss.

Check the LEDs /

screen for alarms.

Contact an IASD.

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 bat-

tery 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.

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

Troubleshooting / Quick Reference Guide

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

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Troubleshooting / Quick Reference Guide

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

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Troubleshooting / Quick Reference Guide

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

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Part No. 10000003882 Rev. C 05/02/17

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)

Generac 7077 Guardian 3-Phase Air Cooled Generator

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