Generac 7290 Home Standby Generator WiFi Connectivity User Manual

SAVE THIS MANUAL FOR FUTURE REFERENCE

Owner’s Manual

60 Hz Air-Cooled Generators

10 kW to 26 kW

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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 this generator.

Record the information found on the unit data

label on this page. See General Information

for the location of the unit data label. The unit

has a label plate affixed to the inside partition,

to the left of the control panel console as

shown in Figure 2-1, Figure 2-2, or Figure 2-

3. See Operation for directions on how to

open the top lid and remove the front panel.

Always supply the complete model and serial

numbers of the unit when contacting an Inde-

pendent Authorized Service Dealer (IASD)

about parts and service.

Operation and Maintenance: Correct main-

tenance and care of the unit ensures a mini-

mum number of problems, and keeps

operating expenses at a minimum. It is the

operator’s responsibility to perform all safety

inspections, to verify all maintenance for safe

operation is performed promptly, and to have

the equipment inspected periodically by an

IASD. Normal maintenance, service, and

replacement of parts are the responsibility of

the 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

IASD for assistance. Authorized service tech-

nicians are factory-trained and are capable of

handling all service needs. To locate the near-

est IASD, please visit the dealer locator at:

www.generac.com/Dealer-Locator.

Model:

Serial:

Production Date:

Volts:

LPV Amps:

NG Amps:

Hz:

Phase:

Controller P/N:

STA MAC ID:

SSID:

(000393a)

WARNING

CANCER AND REPRODUCTIVE HARM

www.P65Warnings.ca.gov.

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

Table of Contents

Section 1: Safety Information

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

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

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

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

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

Exhaust Hazards............................. 2

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

Fire Hazards.................................... 3

Explosion Hazards .......................... 3

Battery Hazards .............................. 4

Section 2: General Information

Generator Components and

Control Locations ............................ 5

Data Decals..................................... 8

Specifications .................................. 9

Generator ............................................9

Engine .................................................9

Protection Systems ....................... 10

Emissions...................................... 10

Fuel Requirements........................ 10

Battery Requirements ................... 10

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

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

Activating the Generator ............... 11

Wi-Fi Module................................. 11

Replacement Parts........................ 11

Accessories................................... 11

Section 3: Operation

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

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

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

Front Access Panel Removal ............13

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

Main Line Circuit Breaker (Generator

Disconnect) .......................................14

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

Generator Emergency Shutdown

Switch ........................................... 15

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

Using the AUTO/OFF/MANUAL

Buttons.......................................... 15

Operating Modes........................... 16

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

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

Menu System Navigation .............. 17

Setting the Exercise Timer ............ 19

Battery Charger ............................. 19

Manual Transfer Operation............ 19

Transfer to Generator Power

Source ...............................................19

Transfer to Utility Power Source ........20

Automatic Transfer Operation ....... 20

Automatic Sequence of

Operation....................................... 20

Utility Failure ......................................20

Cranking ............................................20

Cold Smart Start ................................20

Cleaning Cycle ..................................21

Load Transfer ....................................21

Shutting Generator Down While Under

Load or During a Utility Outage ..... 21

Section 4: Maintenance

Maintenance .................................. 22

Preparing for Maintenance ............ 22

Performing Scheduled

Maintenance .................................. 22

Service Schedule........................... 23

Maintenance Log ...................................23

Checking Engine Oil Level ............ 24

Engine Oil Requirements ..................24

Changing the Oil and Oil Filter ...... 24

Servicing the Air Cleaner............... 25

Spark Plug(s)................................. 26

Valve Clearance Adjustment ......... 26

Checking Valve Clearance ................26

Adjusting Valve Clearance ................27

Battery Maintenance...................... 27

Inspecting the Battery ........................28

Cleaning the Sediment Trap.......... 29

Post Maintenance Checks............. 29

Performing Fuel System Leak Test ...29

Attention After Submersion............ 30

Corrosion Protection...................... 30

Remove From and Return To

Service Procedure ......................... 30

Remove From Service .......................30

Return to Service ...............................30

Section 5: Troubleshooting /

Quick Reference Guide

Generator Troubleshooting............ 32

Quick Reference Guide ................. 34

Safety Information

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

Section 1: Safety Information

Introduction

Thank you for purchasing this compact, high

performance, air-cooled, engine-driven gen-

erator. 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 out-

door 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 condi-

tioners, furnaces, etc.), electronic components

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

and microwaves, when sized correctly. This

unit is equipped with a Wi-Fi

module, which

allows the generator owner to monitor genera-

tor status from anywhere they have 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

If any section of this manual is not under-

stood, contact the nearest Independent

Authorized Service Dealer (IASD) or Gen-

erac Customer Service at 1-888-436-3722

(1-888-GENERAC), or visit www.gen-

erac.com for starting, operating, and servic-

ing procedures. The owner is responsible for

correct maintenance and safe use of the unit.

This manual must be used in conjunction with

all other supporting product documentation

supplied with the product.

SAVE THESE INSTRUCTIONS for future ref-

erence. This manual contains important

instructions that must be followed during

placement, operation, and maintenance of

the unit and its components. Always supply

this manual to any individual that will use this

unit, and instruct them on how to correctly

start, operate, and stop the unit in case of

emergency.

Safety Rules

The manufacturer cannot anticipate every

possible 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 that the manufacturer

does not specifically 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, WARN-

ING, CAUTION, and NOTE blocks are used

to alert personnel to special instructions

about a particular operation that may be haz-

ardous if performed incorrectly or carelessly.

Observe them carefully. Alert definitions are

as follows:

NOTE: Notes contain additional information

important to a procedure and will be found

within the regular text of this manual.

These safety alerts cannot eliminate the haz-

ards that they indicate. Common sense and

strict compliance with the special instructions

while performing the action or service are

essential to preventing accidents.

(000100a)

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

(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

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

How to Obtain Service

When the unit requires servicing or repairs,

contact Generac Customer Service at 1-888-

GENERAC (1-888-436-3722) or visit

www.generac.com for assistance.

When contacting Generac Customer Service

about parts and service, always supply the

complete model and serial number of the unit

as given on its data decal located on the unit.

Record the model and serial numbers in the

spaces provided on the front cover of this

manual.

General Hazards

• Inspect generator regularly, and contact the

nearest IASD for parts needing repair or

replacement.

Exhaust 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.

(000191)

DANGER

Automatic start-up. Disconnect utility power and

render unit inoperable before working on unit.

Failure to do so will result in death or serious injury.

(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.

(000247a)

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.

WARNING

(000130)

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.

WARNING

(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)

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.

WARNING

(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.

Risk of injury. Do not operate or service this machine

if not fully alert. Fatigue can impair the ability to

operate or service this equipment and could result in

death or serious injury.

(000215a)

WARNING

(000228)

Environmental Hazard. Always recycle batteries at an

official recycling center in accordance with all local

laws and regulations. Failure to do so could result in

environmental damage, death, or serious injury.

(000216)

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.

(000103)

Asphyxiation. Running engines produce carbon

monoxide, a colorless, odorless, poisonous

gas. Carbon monoxide, if not avoided, will

result in death or serious injury.

DANGER

Safety Information

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

Electrical Hazards

Fire Hazards

Comply with regulations the local agency for

workplace health and safety has established.

Also, verify that the generator is installed in

accordance with the manufacturer’s instruc-

tions and recommendations. Following

proper installation, do nothing that might alter

a safe installation and render the unit in non-

compliance with the aforementioned codes,

standards, laws, and regulations.

Explosion Hazards

(000178a)

WARNING

Asphyxiation. Always use a battery operated carbon

monoxide alarm indoors and installed according to

the manufacturer’s instructions. Failure to do so

could result in death or serious injury.

(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

(000281)

Fire risk. Fuel and vapors are extremely

flammable. Do not operate indoors. Doing

so could result in death, serious injury, or

property or equipment damage.

(000144)

DANGER

Electrocution. Contact with bare wires,

terminals, and connections while generator

is running will result in death or serious injury.

(000150)

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.

DANGER

(000237)

DANGER

Electrical backfeed. Use only approved switchgear to

isolate generator from the normal power source.

Failure to do so will result in death, serious injury,

and equipment damage.

(000152)

DANGER

Electrocution. Verify electrical system is

properly grounded before applying power.

Failure to do so will result in death or serious

injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while

working on this equipment. Doing so will

result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power

source, if not avoided, will result in death

or serious injury.

(000145)

DANGER

Electrocution. In the event of electrical accident,

immediately shut power OFF. Use non-conductive

implements to free victim from live conductor. Apply

first aid and get medical help. Failure to do so will

result in death or serious injury.

WARNING

(000217)

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.

WARNING

(000218)

Fire and explosion. Installation must comply with all

local, state, and national electrical building codes.

Noncompliance could result in unsafe operation,

equipment damage, death, or serious injury.

WARNING

(000219)

Fire hazard. Use only fully-charged fire extinguishers

rated “ABC” by the NFPA. Discharged or improperly

rated fire extinguishers will not extinguish electrical

fires in automatic standby generators.

(000100a)

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

Electrocution. Refer to local codes and standards for

safety equipment required when working with a live

electrical system. Failure to use required safety

equipment could result in death or serious injury.

(000257)

(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.

Safety Information

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

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 pro-

cesses. For more information on battery

recycling, visit the Battery Council Interna-

tional website at: http://batterycouncil.org.

(000174)

DANGER

Risk of fire. Allow fuel spills to completely dry

before starting engine. Failure to do so will

result in death or serious injury.

(000110)

WARNING

Risk of Fire. Hot surfaces could ignite

combustibles, resulting in fire. Fire could

result in death or serious injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while

working on this equipment. Doing so will

result in death or serious injury.

(000162)

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.

WARNING

(000137a)

WARNING

Explosion. Batteries emit explosive gases while

charging. Keep fire and spark away. Wear protective

gear when working with batteries. Failure to do so

could result in death or serious injury.

(000164)

WARNING

Electrical shock. Disconnect battery ground

terminal before working on battery or battery

wires. Failure to do so could result in death

or serious injury.

(000138a)

WARNING

Risk of burns. Batteries contain sulfuric acid and can

cause severe chemical burns. Wear protective gear

when working with batteries. Failure to do so could

result in death or serious injury.

(000163a)

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

(000228)

Environmental Hazard. Always recycle batteries at an

official recycling center in accordance with all local

laws and regulations. Failure to do so could result in

environmental damage, death, or serious injury.

General Information

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

Section 2: General Information

Generator Components and Control Locations

Figure 2-1. 10 kW—Components and Control Locations

A Lock with cover G Status LED indicators N Fuel regulator

B Main line circuit breaker

(generator disconnect)

H Airbox with air cleaner O Fuel inlet

C Control panel J Oil filter P Wi-Fi module

D Battery compartment

(battery not supplied)

K Oil drain hose Q Data decal location

E Exhaust enclosure L Composite base R Generator emergency shut-

down switch

F Oil fill cap/dipstick M Sediment trap

001818

General Information

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

Figure 2-2. 14 kW–18 kW—Components and Control Locations

A Lock with cover G Status LED indicators N Fuel regulator

B Main line circuit breaker

(generator disconnect)

H Oil drain hose O Fuel inlet

C Airbox with air cleaner J Oil fill cap/dipstick P Wi-Fi module

D Control panel K Oil filter Q Data decal location

E Battery compartment

(battery not supplied)

L Composite base R Generator emergency shut-

down switch

F Exhaust enclosure M Sediment trap S Generator emergency shut-

down switch

009340a

General Information

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

Figure 2-3. 20 kW–26 kW—Components and Control Locations

A Lock with cover H Oil drain hose P Fuel inlet

B Main line circuit breaker

(generator disconnect)

J Oil fill cap Q Wi-Fi module

C Airbox with air cleaner K Oil filter R Data decal location

D Control panel L Composite base S Generator emergency

shutdown switch

E Battery compartment

(battery not supplied)

M Oil dipstick T Generator emergency

shutdown switch

F Exhaust enclosure N Sediment trap

G Status LED indicators O Fuel regulator

001786

General Information

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

Data Decals

Two decals on the generator provide information about the unit itself and required fuel inlet pres-

sure for correct 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 Under-

writer’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 installer to enter

maximum flow rates based on

installed pipe sizes and lengths.

General Information

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

Specifications

Generator

Engine

A detailed specification sheet for a particular generator is available from a local IASD.

Model 10 kW 14 kW 18 kW 20 kW 22 kW 24 kW 26 kW

Rated voltage 240

Rated maximum load cur-

rent (amps) at rated volt-

age with LP*

41.7 58.3 75.0 83.3 91.7 100.0 108.3

Main line circuit breaker

(generator disconnect)

45 amp 60 amp 80 amp 90 amp 100 amp 110 amp

Phase 1

Rated AC frequency 60 Hz

Battery requirement

(field supplied)

0H3421S

Enclosure Aluminum

Weight (lb / kg)

(without battery)

338 / 153 385 / 175 420 / 191 436 / 198 445 / 202 455 / 206 518 / 235

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 tempera-

tures fall below 32 °F (0 °C), a cold weather kit is recommended. When oper-

ated 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 Genera-

tor Assemblies, and CSA-C22.2 No. 100-04 Standard for Motors and Generators.

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

LP gas rating.

Model 10 kW 14/18 kW 20–26 kW

Engine type G-Force™ 400 Series G-Force™ 800 Series G-Force™ 1000 Series

Number of cylinders 1 2 2

Displacement 460 cc 816 cc 999 cc

Cylinder block Aluminum with cast iron sleeve

Recommended spark plug 0G0767B 0G0767A

Spark plug gap 0.020 in (0.508 mm) 0.040 in (1.02 mm)

Hydraulic lifters No Yes No

Valve clearance 0.002–0.004 in

(0.05–0.1 mm)

N/A

0.002–0.004 in

(0.05–0.1 mm)

Starter 12 VDC

Oil capacity including filter Approx. 1.1 qt (1.03 L) Approx. 2.2 qt (2.1 L) Approx. 1.9 qt (1.8 L)

Recommended oil filter 070185ES

Recommended air filter 0E9371AS 0J8478S

Engine power is subject to and limited by such factors as fuel BTU/joules, ambient temperature, and alti-

tude. Engine power decreases approximately 3.5% for each 1,000 ft (304.8 m) above sea level, and also

will decrease approximately 1% for each 10 °F (6 °C) above 60 °F (15 °C) ambient temperature.

General Information

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

Protection Systems

The generator may need to run for long peri-

ods of time with no operator present to moni-

tor engine or generator conditions. The

generator is equipped with protection sys-

tems to automatically shut down the unit to

protect against potentially damaging condi-

tions. 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 Opera-

tion 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 generator. An alarm shuts

down the generator to protect system from

any damage. In event of an alarm, an owner

can clear the alarm and restart generator prior

to contacting an IASD. Contact an IASD if the

intermittent issue occurs again.

Emissions

The United States Environmental Protection

Agency (US EPA) (and California Air

Resources Board (CARB), for engines/equip-

ment certified to California standards)

requires this engine/equipment to comply

with exhaust and evaporative emissions

standards. Locate the emissions compliance

decal on the engine to determine applicable

standards. See the included emissions war-

ranty for emissions warranty information. Fol-

low the maintenance specifications in this

manual to ensure the engine complies with

applicable emissions standards for the dura-

tion 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 fol-

lowing:

NOTE: Under U.S. EPA regulations, a mixer

adjustment kit may be required when

operating over 2,000 ft (609.6 m) above sea

level. Contact an IASD for high altitude*

adjustment information.

*High altitude is any elevation over

2,000 ft (609.6 m).

Fuel Requirements

The engine has been fitted with a dual fuel

carburetion system. The unit will run on NG

or LP gas (vapor), but has been factory-con-

figured to run on NG. The fuel system will be

configured for the available fuel source

during installation.

Recommended fuels should have a BTU con-

tent of at least 1,000 BTUs per ft

(37.26

megajoules per m

) for natural gas, or at

least 2,500 BTUs per ft

(93.15 megajoules

per m

) for LP gas.

NOTE: If converting to LP gas from NG, a

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

recommended. See installation manual for

complete procedures and details.

Battery Requirements

12 volts, Group 26R Wet Cell 540CCA (Part

number 0H3421S) minimum or Group 35

AGM 650CCA minimum.

• High Temperature

• Low Oil Pressure

• Overcrank

• Overspeed

• Overvoltage

• Undervoltage

• Overload

• Underspeed

• RPM Sensor

Loss

• Controller Fault

• Wiring Error

• Stepper

Overcurrent

• Charger Warning

• Charger Missing

• 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)

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.

DANGER

General Information

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

Battery Charger

The battery charger is integrated into the

control panel module in all models. It oper-

ates as a smart charger, verifying output

charging levels are safe and continuously

optimized to promote maximum battery life. A

kit is provided to install a fuse in transfer

switch for T1 battery charger connection. Fol-

low installation instructions provided with kit.

NOTE: Do not use external battery chargers.

Engine Oil Requirements

See Engine Oil Requirements for correct oil

viscosity.

Activating the Generator

Generator should be activated upon initial

startup. See installation manual for complete

instructions.

Wi-Fi Module

Generator is equipped with a Wi-Fi module.

See Wi-Fi module owner’s manual for further

information.

Replacement Parts

Accessories

NOTE: Performance enhancing accessories are available for air-cooled generators. Contact an

IASD or visit www.generac.com for additional information on replacement parts, accessories, and

extended warranties. See also http://www.ordertree.com/generac/air-cooled-homestandby-

generators/.

Description 10 kW 14 kW 18 kW 20 kW 22 kW 24 kW 26 kW

26R Battery 0H3421S

Spark plug 0G0767B 0G0767A

Oil filter 070185ES

Air filter 0E9371A 0J8478

Control panel fuse 0D7178T

Transfer switch

fuses

See transfer switch manual for part number

Accessory Description

Cold Weather

Accessories*

• Battery Pad Warmer

• Oil Warmer

• Breather Warmer

* each sold separately

• Recommended in areas where temperatures fall below 0 °F (-18

°C). (Not necessary for use with AGM-style batteries)

• Recommended in areas where temperatures fall below 0 °F (-18

°C).

• Recommended in areas where heavy icing occurs.

Scheduled Maintenance

Kit

Includes all items necessary to perform complete routine mainte-

nance on the generator along with oil recommendations (oil not

included).

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.

General Information

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

Mobile Link

Cellular

Accessories

The Mobile Link family of Cellular Accessories allow users to monitor

generator status from anywhere in the world, using a smartphone,

tablet, or PC. Easily access information such as the current operating

status and maintenance alerts. Users can connect an account with an

authorized service dealer for fast, friendly, and proactive service. With

Mobile Link, users are taken care of before the next power outage.

Touch-Up Paint Kit If the generator enclosure is scratched or damaged, it is important to

touch-up the paint to protect from future corrosion. The touch-up paint

kit includes the necessary paint to correctly maintain or touch-up a

generator enclosure.

Extended Warranty

Coverage

Extend generator warranty coverage by purchasing extended war-

ranty 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.

LTE LP Fuel Level

Monitor

The LTE enabled LP fuel level monitor provides constant monitoring

of a connected LP fuel tank. Monitoring the LP tank’s fuel level is an

important step in verifying the generator is ready to run during an

unexpected power failure. Status alerts are available through a free

application to notify users when the LP tank needs a refill.

Base Plug Kit Base plugs snap into the lifting holes on the base of air-cooled home

standby generators. This offers a sleek, contoured appearance, as

well as offers protection from rodents and insects by covering the lift-

ing holes located in the base. Base plug kit contains four base plugs,

sufficient for use on a single air-cooled home standby generator.

Smart Management

Module

(50 and 100 amps)

Smart Management Modules (SMM’s) are used to optimize the per-

formance of a standby generator. They manage large electrical loads

upon startup and shed them to aid in recovery when overloaded. In

many cases, using SMM’s can reduce the overall size and cost of the

system.

High Altitude Kit A high altitude kit may be required when operating over 2,000 ft (610

m) above sea level per U.S. EPA regulations. Operating the engine

with the incorrect engine configuration at a given altitude may

increase emissions and decrease fuel efficiency and performance.

Accessory Description

Operation

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

Section 3: Operation

Site Prep Verification

Generator must be installed to allow unim-

peded airflow into and out of generator.

Mechanical and gravity outdoor air intake

openings for air distribution and supply sys-

tems must be located not less than 10 ft (3.05

m) horizontally from generator enclosure.

See Section 401.4 in the ICC Mechanical

Code for additional information.

Verify all shrubs or tall grasses within 3 ft

(0.91 m) of intake and discharge louvers on

the sides of the enclosure have been

removed. Install generator on high ground

where water levels will not rise and endanger

it. This unit must not operate in or be sub-

jected to standing water. Verify all potential

water sources such as water sprinklers, roof

run-off, rain gutter downspouts, and sump

pump discharges are directed away from

unit.

Generator Enclosure

Enclosure lid is locked prior to shipment. A

set of keys is attached to cardboard on top of

generator. An additional set of keys is

attached to pallet bracket on the front intake

end of generator.

NOTE: Keys provided with this unit are

intended for service personnel use only.

Opening the Lid

1. Use keys to open generator lid.

2. See Figure 3-1. Two locks (A) secure lid;

one on each side. Open protective rubber

cap to access keyhole.

Figure 3-1. Opening the Lid

3. Press down on lid above side lock, and

unlock latch to correctly open lid.

4. Repeat for other side. Lid may appear

stuck if pressure is not applied from the

top.

NOTE: Always verify side locks are unlocked

before attempting to lift lid.

Front Access Panel Removal

See Figure 3-2. Remove front access panel

(A) by lifting straight up and out once lid is

open.

Figure 3-2. Remove Front Access Panel

NOTE: Always lift front access panel straight

up before pulling away from enclosure (B and

C). Do not pull panel away from the enclosure

before lifting up (D).

(000191)

DANGER

Automatic start-up. Disconnect utility power and

render unit inoperable before working on unit.

Failure to do so will result in death or serious injury.

009209

009210

Operation

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

Intake Side Panel Removal

See Figure 3-3. Intake side panel (A) must be

removed to access 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 genera-

tor.

NOTE: Always lift intake side panel straight up

before pulling away from enclosure. Do not

pull panel away from enclosure before lifting

up (D).

Figure 3-3. Intake Side Panel Removal

Main Line Circuit Breaker

(Generator Disconnect)

See Figure 3-4. This is a 2-pole main line cir-

cuit breaker (MLCB) (generator disconnect)

(A) rated according to relevant specifications.

The generator MLCB (generator disconnect)

can be locked in OFF (OPEN) for security.

Use an appropriately-sized padlock (not

included) with a shackle long enough to pass

through both lock tabs (B).

Figure 3-4. Main Line Circuit Breaker

(MLCB)

NOTE: DO NOT leave generator MLCB

(generator disconnect) locked in OFF (OPEN)

during normal generator operation. Leaving

generator MLCB (generator disconnect) in

OFF (OPEN) will prevent generator from

powering structure during a power outage

when placed in AUTO mode.

LED Indicator Lights

See Figure 3-5. Three LEDs are visible

behind a translucent lens on the generator

side panel. These LEDs indicate generator

operating status.

Figure 3-5. LED Indicator Lights

• Green LED “Ready” light (A) illuminates

when utility is present and control panel is in

AUTO. LED flashes when automatic transfer

switch converts to generator power during a

utility power outage.

• Red LED “Alarm” light (B) illuminates when

generator is OFF or a fault is detected. Con-

tact an IASD.

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

minates 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

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

Generator Emergency

Shutdown Switch

All generators are equipped with an external

means of shutting down the generator which

complies with the latest NEC code require-

ment. Primary generator shutdown sequence

is described in Shutting Generator Down

While Under Load or During a Utility Outage.

See Figure 3-6. An emergency shutdown

switch (A) is located on the exterior of the

generator back panel. This emergency shut-

down switch shuts down generator and dis-

ables restarts.

Figure 3-6. External Emergency Shutdown

Switch (all models)

NOTE: Whenever possible, perform primary

shutdown procedure before disabling genera-

tor with emergency shutdown switch.

See Figure 3-7. 14–26 kW ge

by pressing OFF button, and then ENTER.

The generator can then be placed in AUTO

or MANUAL.

Control Panel Interface

See Figure 3-7. The control panel interface

(A) is located under the enclosure lid. Verify

both left and right side locks are unlocked

before attempting to lift lid of enclosure.

Open lid as directed in Opening the Lid.

Figure 3-7. Generator Control Panel

The 7.5A fuse is located beneath rubber

cover (B) to the right of the control panel.

Verify both left and right side locks are

securely out of the way before closing unit.

All appropriate panels must be in place

during any operation of the generator. This

includes operation by a servicing technician

while conducting troubleshooting pro-

cedures.

Using the AUTO/OFF/MANUAL

Buttons

NOTE: Damage caused by mis-wiring of

interconnect wires is not warrantable.

Equipment Damage. The emergency shutdown

switch is not to be used to power down the unit

under normal operating circumstances. Doing so

will result in equipment damage.

(000399a)

CAUTION

005492

001798

Button Description of Operation

AUTO Activates fully automatic system

operation. Allows unit to automati-

cally start and exercise generator

according to exercise timer (see

Setting the Exercise Timer).

Green LED flashes when auto-

matic transfer switch converts to

generator power during a utility

power outage.

OFF Shuts down engine and prevents

automatic operation of unit.

MANUAL Cranks and starts generator.

Transfer to stand-by power will not

occur unless there is a utility fail-

ure.

Blue LED flashes when automatic

transfer switch converts to gener-

ator power during a utility power

outage.

Operation

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

Operating Modes Interface Menu Displays

LCD PanelMode Description

MANUAL • Will not transfer to standby if

utility is present.

• Transfers to standby if utility

drops below 65% of nominal

for five consecutive seconds

(dealer programmable) after

warm-up.

• Transfers back when utility

returns for 15 consecutive

seconds (dealer program-

mable). Engine continues to

run until removed from

MANUAL.

AUTO • Starts and runs if utility

drops for five consecutive

seconds (dealer program-

mable).

• Starts an engine warm-up

timer (duration varies when

Cold Smart Start is

enabled).

–Will not transfer if utility

subsequently returns.

–Transfers to standby if util-

ity is not present.

• Transfers to utility once util-

ity returns (above 80% of

nominal) for 15 consecutive

seconds (dealer program-

mable).

• Will not transfer to utility

unless utility returns. Unit

will shut down if OFF button

is pressed or a shutdown

alarm is present.

• Unit will shut down after one

minute cool-down time

when utility power returns.

EXERCISE • Will not exercise if unit is

already running in either

AUTO or MANUAL.

• During exercise, controller

will only transfer if utility

drops during exercise for

five seconds (dealer pro-

grammable), and will switch

to AUTO.

Feature Description

HOME

page

Default page displayed if no but-

tons are pressed for 60 sec-

onds. Normally shows current

status message, and current

date and time. Highest priority

active alarm/warning is auto-

matically posted on this page,

as well as flashing the backlight

when such a condition is

detected. In the case of multiple

alarms/warnings, only first mes-

sage is displayed. Press OFF

button and then ENTER button

to clear an alarm or warning.

When “Hours of Protection” is

displayed, this represents total

time generator has been moni-

toring 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

operator presses any button.

MAIN

page

Allows operator to navigate to

all other pages or sub-menus by

using arrow keys and ENTER

button. Page can be accessed

at any time with several presses

of the dedicated ESCAPE but-

ton. Each press of the ESCAPE

button takes operator to previ-

ous menu until MAIN MENU dis-

plays. This page contains

information for History; Status;

Edit; and Debug.

Operation

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

Menu System Navigation

Press ESCAPE button from any page to access the MENU. If needed, press ESCAPE button

several times to reach the MENU page. Navigate to the desired menu by using the

↑/↓ buttons.

Press ENTER button when 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

Shutdown Switch

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 = -

006667b

Operation

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

Figure 3-9. Navigation Menu

Run Log

EXAMPLE:

Inspect Battery 200 RnHr or 12/27/18

and

Next Maintenance 200 RnHr or 12/27/18

Exercise Time

Å HH:MM Day Frequency Æ

ESC

–

++ +

–

ENTER

Current Date/Time

Å 2/12/16 12:22 Æ

ESCESCESCESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

Maint. Log

Run Hrs

Scheduled

Select Month (1-12)

- 2 +

Run Hours (H)

0.0

Select Date (1-31)

- 13 +

Select Year (0-99)

- 13 +

Access

Requires Password

Language

Å English Æ

Fuel Selection

Å NG or LP Æ

Alarm Log

ENTER

ESC

ENTER

ESC

ENTER

ESC

"Battery Maintained"

"Schedule A Serviced"

"Schedule B Serviced"

"Maintenance Reset"

"Inspect Battery"

"Service Schedule A"

"Service Schedule B"

Warning Message(s)

Low Battery

Exercise Set Error

Service Schedule A

Service Schedule B

Inspect Battery

Stopping...

FIRMWARE ERROR-9

Battery Problem

Charger Warning

Charger Missing AC

Overload Cooldown

SEEPROM ABUSE

USB Warning

Download Failure

Overload Warning

No WIFI

Running Manual

Running-Utility Lost

Running–Remote Start

Running–2 Wire Start

Running–Exercise

Switched Off

Stopped - Auto

Select Min (0-59)

- 0 +

Select Hour (0-23)

- 14 +

Select Min (0-59)

- 0 +

Select Hour (0-23)

- 14 +

Quiet Test Mode ?

- YES or NO +

Select Frequency

- WEEKLY +

- BIWEEKLY +

- MONTHLY +

Language

+ English -

Fuel Selection

+ NG or LP -

Cold Smart Start?

Å YES or NO Æ

Cold Smart Start?

- YES or NO +

Language

+ Francais -

+ Espanol -

+ Português -

+ ...... -

Battery Condition

“Good”, “Inspect Battery” or

“Check Battery”

Select Day

- Wednesday +

Generator Activated

Service Unit

Language Update?

Å YES or NO Æ

WIFI Enable

Å YES or NO Æ

WIFI Enable

– YES or NO +

<ENT> LOAD LANGUAGE

<ESC> TO QUIT

ESC

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

(If not enabled): Displays SETUP WIFI

Only if Wi-Fi is disabled.

Date/Time automatically updates if connected to Wi-Fi.

Firmware Update

Å YES Æ

Current: V 1.01

USB: V 1.05

Are You Sure?

- Yes or No +

Update from:

Å USB or Wi-Fi Æ

Select YES, then press ENTER to continue or ESCAPE to cancel update. During

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

Sequence then repeats. When update is complete, the unit returns to Install Wizard

menu. When the controller powers up, the first screen briefly displays the version number.

When update is complete, remove USB Drive. Then follow the Install Wizard Menu.

Firmware Update

<- Insert USB ->

Possible Message(s):

Corrupted File

Invalid File

File Not Found

Unsupported Device*

* Re-try using a higher quality

USB drive. File names on the USB

cannot have more than 8 characters.

Refer to the Installation Wizard.

Only when WiFi Activated

SYSTEM

WIFI

DATE/TIME

SUB MENUS

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

Shutdown Switch

Emergency Stop

Defaults to English.

Select desired language

by scrolling through list.

ESC

ESCESCESCESC ESC

006667b

Operation

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

Setting the Exercise Timer

This generator is equipped with a configu-

rable 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: Generator will start and exercise

for period defined, on day of week and at

time of day specified. During this exercise

period, unit runs for approximately five min-

utes and then shuts down.

Exercise frequency: Exercise frequency

can be set to Weekly, Biweekly, or Monthly. If

Monthly is selected, day of month must be

selected from 1–28. Generator will exercise

on that day each month. Transfer of loads to

generator output does not occur during exer-

cise cycle unless utility power is lost.

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

automatically adjust for Daylight Saving Time.

NOTE: The exercise feature will operate only

when generator is in AUTO, and will not work

unless this procedure is performed. If Wi-Fi is

NOT enabled, current date/time will need to

be reset every time the 12 volt battery is

disconnected and then reconnected, and/or

when the fuse is removed.

Low Speed Exercise (Quiet-Test™) Pro-

file: Unit will run at operating speed for

approximately five seconds, then drop speed

to prepare for Quiet-Test. Speed will drop to

predetermined Quiet-Test speed after

approximately 40 seconds and continue to

run until Quiet-Test is complete, a total of five

minutes.

Table 3-1 details exercise information and

programming options for all home standby

generators.

NOTE: If Quiet-Test is disabled, generator will

exercise at the rated rpm.

Battery Charger

IMPORTANT NOTE: Contact an IASD if

controller screen displays “CHARGER

MISSING AC.”

NOTE: Battery charger is integrated into the

control module in all models.

The battery charger operates as a smart

charger which verifies:

• output is continually optimized to promote

maximum battery life.

• charging levels are safe.

NOTE: A warning is displayed on LCD when

battery needs service.

NOTE: Do not use external battery chargers.

Manual Transfer Operation

Prior to automatic operation, manually exer-

cise transfer switch to verify there is no inter-

ference with correct operation of the

mechanism. Manual operation of transfer

switch is required if electronic operation

should fail.

Transfer to Generator Power

Source

Proceed as follows to transfer to generator

power:

1. Verify generator is in OFF mode.

2. Set generator MLCB (generator discon-

nect) to OFF (OPEN).

3. Turn off utility power supply to transfer

switch using means provided (such as a

utility MLCB).

4. See Figure 3-10. Use manual transfer han-

dle (A) inside transfer switch to move main

contacts to STANDBY (loads connected to

standby power source).

Figure 3-10. Typical Manual Transfer

Switch Operation

Table 3-1. Generator Exercise

Characteristics

Generator Size 10–26 kW

Exercise Frequency

Options

Weekly/Bi-Weekly/

Monthly

Exercise Time Length 5 minutes

(000132)

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.

DANGER

002565

Operation

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

5. Press MANUAL button on control panel to

crank and start engine.

6. Allow engine to stabilize and warm up for a

few minutes.

7. Set generator MLCB (generator discon-

nect) to ON (CLOSED). Standby power

source now powers loads.

Transfer to Utility Power Source

Shut down generator and transfer to utility

source after utility power has been restored.

Proceed as follows to manually transfer to

utility power and shut down generator:

1. Set generator MLCB (generator discon-

nect) to OFF (OPEN).

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

stabilize internal temperature.

3. Press OFF button on control panel. Engine

will shut down.

4. Verify utility power supply to transfer

switch is turned off.

5. Set main contacts to UTILITY (loads con-

nected to utility power source) using man-

ual transfer handle inside transfer switch.

6. Turn on utility power supply to transfer

switch using means provided (such as a

utility MLCB).

7. Press AUTO button on control panel.

8. Set generator MLCB (generator discon-

nect) to ON (CLOSED).

9. Close and lock lid.

Automatic Transfer Operation

Proceed as follows to select automatic oper-

ation:

1. Verify transfer switch main contacts are set

to UTILITY (loads connected to utility

power source).

2. Verify normal utility power source voltage

is available to loads connected to transfer

switch.

3. Press AUTO button on control panel.

4. Set generator MLCB (generator discon-

nect) to ON (CLOSED).

Generator will start automatically when utility

source voltage drops below a preset level.

Loads are transferred to standby power

source after unit starts.

Automatic Sequence of

Operation

Utility Failure

If generator is set to AUTO when 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 not available when timer

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

ated once engine is started. Timer duration

varies depending on whether or not Cold

Smart Start is enabled. The controller will

transfer load to generator when warm-up

time expires. If utility power is restored

(above 80% nominal) at any time from initia-

tion of engine start until generator is ready to

accept load (warm-up time has not elapsed),

the controller completes start cycle and runs

generator through its normal cool down

cycle. However, load will remain on utility

source.

Cranking

The system will control the cyclic cranking as

follows:

• 10 kW Unit: five cranking cycles as follows:

15 seconds cranking, seven seconds rest-

ing, followed by four additional cycles of

seven seconds cranking followed by seven

seconds resting.

• 14–26 kW Units: five cranking cycles as fol-

lows: 16 seconds cranking, seven seconds

resting, 16 seconds cranking, seven sec-

onds resting, followed by three additional

cycles of seven seconds cranking followed

by seven seconds resting.

NOTE: An alarm will be triggered if generator

does not start after these five attempts.

Cold Smart Start

Cold Smart Start is factory-enabled, but can

be disabled in the EDIT menu. Generator will

monitor ambient temperature when Cold

Smart Start is enabled. The warm-up delay

will be adjusted based on prevailing condi-

tions.

See Table 3-2. If ambient temperature is

below a fixed temperature (based on model)

upon startup in AUTO, generator will warm

up for 30 seconds. This allows engine to

warm before a load is applied. The generator

will startup with normal warm-up delay of five

seconds if ambient temperature is at or

above the fixed temperature.

A check for correct output voltage buildup will

be performed when generator engine is

started.

Table 3-2. Cold Smart Start Set Points

Generator size 10–20 kW 22–26 kW

Fixed

temperature

50 °F

(10 °C)

20 °F

(-7 °C)

Operation

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

Cleaning Cycle

If some condition impedes normal voltage

creation, such as frost crystals or dust/dirt

preventing a good electrical connection, start

sequence will be interrupted so a cleaning

cycle of the internal electrical connections

can be attempted.

Cleaning cycle is an extended warm up

period which lasts for several minutes while

normal generator voltage output is deter-

mined to be low. During this cycle, generator

controller will display “Warming Up” on the

display screen.

The generator controller display will show

“Under Voltage” if cleaning cycle fails to clear

the obstruction. After several minutes, alarm

message can be cleared, and the generator

restarted.

If the problem persists, make no further

attempts to start. Contact an IASD.

Load Transfer

The transfer of load when generator is run-

ning is dependent upon operating mode.

Shutting Generator Down While

Under Load or During a Utility

Outage

IMPORTANT NOTE: To avoid equipment

damage, follow these steps, in order,

during utility outages. Shutdowns may be

required during utility outages to perform

routine maintenance or to conserve fuel.

To turn generator OFF:

1. Set utility MLCB to OFF (OPEN).

2. Set generator MLCB (generator discon-

nect) to OFF (OPEN).

3. Allow generator to run for cool-down for

approximately one minute.

4. Set generator to OFF at the controller.

5. Remove 7.5A fuse from controller.

To turn generator back ON:

1. Install 7.5A fuse in controller.

2. Verify generator MLCB (generator discon-

nect) is OFF (OPEN).

3. Set generator to AUTO mode at the con-

troller.

4. Generator will start and run. Allow genera-

tor to run and warm up for a few minutes.

5. Set generator MLCB (generator discon-

nect) to ON (CLOSED).

6. Set utility MLCB to ON (CLOSED).

The system now operates in automatic

mode.

Automatic start-up. Disconnect utility power and

render unit inoperable before working on unit.

Failure to do so will result in death or serious injury.

(000191)

DANGER

Maintenance

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

Section 4: Maintenance

Maintenance

Regular maintenance will improve perfor-

mance 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

Proceed as follows to prepare unit for main-

tenance:

1. Set utility MLCB to OFF (OPEN).

2. Lift lid and set generator MLCB (generator

disconnect) to OFF (OPEN).

3. If running during a utility outage, allow

generator to run and cool down for one

minute with no load.

4. Press OFF button on controller.

5. Remove 7.5A fuse from control panel.

6. Remove front panel and intake side panel.

Performing Scheduled

Maintenance

It is important to perform maintenance as

specified in the Service Schedule for correct

generator operation. Engine oil and oil filter

must be changed, and valve clearance

adjusted (where applicable, see Engine) after

first 25 hours of operation.

Emissions-critical maintenance must be per-

formed as scheduled in order for emissions

warranty to be valid. Emissions-critical main-

tenance consists of servicing the air filter and

spark plug(s) in accordance with Service

Schedule.

Controller will prompt for Schedule A or

Schedule B maintenance to be performed.

Schedule A maintenance consists of oil, oil

filter, and battery check. Schedule B mainte-

nance includes oil, oil filter, battery check, air

cleaner, spark plug(s), and valve clearance

(where applicable, see Engine).

Since most maintenance alerts occur at the

same time (most have two year intervals),

only one will appear on control panel display

at a time. Once first alert is cleared, the next

active alert will be displayed.

(000191)

DANGER

Automatic start-up. Disconnect utility power and

render unit inoperable before working on unit.

Failure to do so will result in death or serious injury.

(000182a)

WARNING

Equipment damage. Only qualified service personnel may

install, operate, and maintain this equipment. Failure to

follow proper installation requirements could result in death,

serious injury, and equipment or property damage.

Maintenance

23 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:

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

●

Check engine oil level ●

Inspect for water intrusion ** ●

Perform fuel system leak test ●

Check battery condition ●

Replace engine oil and oil filter † ● ●

Replace engine air filter ●

Replace spark plug(s) ●

Inspect/adjust valve clearance (where

applicable) ‡

●

Inspect/clean sediment trap See local codes and guidelines.

Contact the nearest IASD for assistance if necessary.

* Remove any shrubs or tall grasses which have grown within 3 ft (0.91 m) of intake and discharge lou-

vers on enclosure sides. Clean any debris (dirt, grass clippings, etc.) which may have accumulated

inside enclosure.

** Verify all sources of potential water intrusion such as water sprinklers, roof run-off, rain gutter down-

spouts, and sump pump discharges are directed away from generator enclosure.

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

40 °F [4.4 °C]), or if unit is operated continuously in hot weather conditions (ambient above 85 °F [29.4

°C]), change engine oil and filter every year or 100 hours of operation.

‡ Inspect/adjust valve clearance after first 25 hours of operation. (Excludes units with hydraulic lifters.

See Engine.)

Maintenance

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

Valve Adjustment

NOTE: Not required on 14 or 18 kW units with 816cc engines.

Dates Performed:

Checking Engine Oil Level

IMPORTANT NOTE:

Verify oil level daily

when power outages necessitate running

generator for extended periods. Generator

will shut down if oil level is low

Proceed as follows to check engine oil level:

1. Set utility MLCB to OFF (OPEN).

2. Set generator MLCB (generator discon-

nect) to OFF (OPEN).

3. Allow generator to run for a cool-down

period of approximately one minute, if

generator was running during an outage.

4. Press OFF button to turn generator off.

Wait five minutes.

5. See Figure 2-1, Figure 2-2, or Figure 2-3.

Remove oil dipstick and wipe it dry with a

clean cloth.

6. Completely insert oil dipstick into oil dip-

stick tube and remove.

7. Observe oil level. Oil level should be at

FULL mark on oil dipstick.

8. If necessary, remove oil fill cap and add

recommended oil to engine (with oil dip-

stick removed) until oil level reaches FULL

mark. Insert oil dipstick and install fill cap.

See Engine Oil Requirements.

To restart generator:

1. Press AUTO button on control panel.

2. Allow generator to start and warm up for a

few minutes.

3. Set generator MLCB (generator discon-

nect) to ON (CLOSED).

The system is now operating in AUTO. The

utility MLCB can be turned ON (CLOSED).

Engine Oil Requirements

Engine oil should be serviced in accordance

with the recommendations of this manual to

maintain product warranty. Generac mainte-

nance kits consisting of engine oil, oil filter,

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

funnel are available through an IASD.

All Generac oil kits meet minimum American

Petroleum Institute (API) Service Class SJ,

SL, or better. Do not use special additives.

After the 25 hour break-in period (and at

every interval there-after), it is recommended

to use Generac’s proprietary 5W-20 gaseous

engine oil (GEO) for continuous use. It is

specifically formulated for use in gaseous

powered Generac generators.

Changing the Oil and Oil Filter

Proceed as follows to change oil and oil filter:

1. Lift lid and press MANUAL button on con-

trol panel to start engine, and run unit until

it is thoroughly warmed up. Press OFF

button on control panel to shut down

engine.

2. See Figure 4-1, Figure 4-2, or Figure 4-3.

Remove front panel when unit has cooled.

Pull oil drain hose (A) free of retaining clip.

Remove cap from oil drain hose and place

free end into a suitable container. Drain

oil.

(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)

Engine damage. Verify proper type and quantity of

engine oil prior to starting engine. Failure to do so

could result in engine damage.

CAUTION

(000135)

Engine damage. Verify proper type and quantity of

engine oil prior to starting engine. Failure to do so

could result in engine damage.

CAUTION

Maintenance

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

Figure 4-1. Oil Filter and Drain Location

(10 kW)

Figure 4-2. Oil Filter and Drain Location

(14–18 kW)

Figure 4-3. Oil Filter and Drain Location

(20–26 kW)

3. Install cap on oil drain hose. Position and

secure oil drain hose with the retaining

clip.

4. Remove oil filter (B) by turning it counter-

clockwise.

5. Apply a light coating of clean engine oil to

gasket of new filter.

6. Screw new filter on by hand until gasket

lightly contacts oil filter adapter. Tighten fil-

ter an additional three-quarter to one full

turn.

7. Fill engine with recommended oil. See

Engine Oil Requirements.

8. Press MANUAL button on control panel to

start engine. Run for one minute, and

inspect for leaks.

9. Press OFF button on control panel to stop

engine. Wait five minutes.

10.Inspect oil level. Add oil as needed. DO

NOT OVERFILL.

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

12.Press AUTO button on control panel to

return unit to AUTO.

13.Close and lock lid.

14.Dispose of used oil and filter according to

local, state, or national codes.

Servicing the Air Cleaner

Proceed as follows to service air cleaner:

1. Lift lid and press OFF button on control

panel to stop generator.

2. Remove front panel.

3. See Figure 4-4 or Figure 4-5. Remove

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

Figure 4-4. Servicing Air Cleaner (10 kW)

Figure 4-5. Servicing Air Cleaner

(14–26 kW)

4. Remove old air filter element (C) and dis-

card.

5. Thoroughly clean air cleaner enclosure of

any dust or debris.

001831

009342

009343

(000249)

WARNING

Risk of fire. Never operate engine without the

air cleaner installed. Operating engine without

the air cleaner could result in death or serious

injury.

(000580)

WARNING

Explosion and fire. Never clean air filter element

with gasoline or low flash-point detergents. Doing

so could result in death, serious injury, or

equipment damage.

001820

001814

Maintenance

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

6. Install a new air filter element.

7. Install air cleaner cover and fasten cover

clips.

8. (14–26 kW units only): Verify air inlet

duct (D) is correctly connected to air

cleaner cover.

9. Press AUTO button on control panel to

return unit to AUTO.

Spark Plug(s)

Proceed as follows to inspect spark plug

gap(s) and replace spark plug(s):

1. With generator OFF and engine cool, lift lid

and remove front panel.

2. Clean area around base of spark plug(s) to

keep dirt and debris out of engine.

NOTE: Clean and re-gap spark plug(s) in

emergency situations only. Otherwise, replace

spark plug(s).

3. Remove spark plug(s) and inspect spark

plug gap(s) using a wire feeler gauge.

Replace spark plug(s) if spark plug gap is

out of specification. See Engine.

NOTE: See Figure 4-6. New spark plug(s)

should have spark plug gap checked prior to

installation.

Figure 4-6. Spark Plug Gap Measurement

4. Install spark plug(s), and tighten to 18.4 ft-

lbs (25 Nm).

5. Press AUTO button to return unit to AUTO

mode.

Valve Clearance Adjustment

IMPORTANT NOTE: Contact an IASD for

service assistance. Correct valve clear-

ance is essential for prolonging the life of

the engine. Excludes units equipped with

hydraulic lifters. See Engine.

IMPORTANT NOTE: Valve lash not

required on 14 or 18 kW units with 816cc

engine. See Engine.

Inspect valve clearance after first 25 hours of

operation, then after 400 hour intervals.

Adjust if necessary.

Checking Valve Clearance

NOTE: Engine should be cool before checking

valve clearance. Adjustment is not needed if

valve clearance is within dimensions provided

in Engine.

Proceed as follows to check valve clearance.

1. Close fuel valve and disconnect battery to

avoid accidental startup.

2. Remove spark plug wire(s), and position

spark plug wire(s) away from spark

plug(s).

3. Remove spark plug(s).

4. Remove the four screws attaching the

valve cover. Remove and discard gasket.

(Repeat for second cylinder, if equipped.)

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

its compression stroke (both valves

closed).

NOTE: To move piston to TDC, remove intake

baffle at front of the engine to access the

flywheel nut. Use a large socket and socket

wrench to rotate flywheel nut clockwise, which

will rotate the crankshaft. Watch piston

through spark plug hole. Piston will move up

and down. Piston is at TDC when at its

highest point of travel.

(000140a)

WARNING

Electric shock. Do not disconnect spark

plug wires with engine running. Doing so

could result in death or serious injury.

000211

WARNING

(000560)

Risk of Burn. Allow the engine to cool before

performing the following procedure. Failure

to do so could result in serious injury.

(000130)

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.

WARNING

(000141)

WARNING

Accidental start-up. Disconnect spark plug wires when

working on unit. Failure to do so could result in death

or serious injury.

Maintenance

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

6. See Figure 4-7 or Figure 4-8. Verify valve

clearance between each rocker arm (A)

and valve stem (B) with a feeler gauge.

Figure 4-7. Valve Clearance Adjustment

(10 kW)

Figure 4-8. Valve Clearance Adjustment

(20–26 kW)

7. Install replacement valve cover gasket(s).

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

a cross pattern, tightening to:

Adjusting Valve Clearance

IMPORTANT NOTE: Valve lash not

required on 14 or 18 kW units with 816cc

engine. See Engine.

See Figure 4-7 or Figure 4-8. Proceed as fol-

lows to ad-just valve clearance:

NOTE: Allow engine to cool before adjusting

valve clearance.

1. Remove spark plug wire(s) and position

spark plug wire(s) away from spark

plug(s).

2. Remove spark plug(s).

3. Remove the four screws attaching valve

cover. Remove and discard gasket.

4. Verify piston is at TDC of its compression

stroke (both valves closed).

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

wrench (10 kW units) or 13 mm wrench

(20–26 kW units).

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

wrench (10 kW units), or 10 mm hex key

(20–26 kW units) while inspecting clear-

ance between rocker arm (A) and valve

stem (B) with a feeler gauge. Adjust clear-

ance as per Engine.

NOTE: Hold rocker jam nut in place as pivot

ball stud is turned.

7. When valve clearance is correct, hold

pivot ball stud in place with a wrench and

tighten rocker arm jam nut. Tighten jam

nut according to:

8. Inspect valve clearance to verify it did not

change.

9. Install new valve cover gasket.

10.Install valve cover. Tighten fasteners in a

cross pattern. Tighten to:

NOTE: Start all four screws before tightening,

or it will not be possible to get all screws in

place. Verify valve cover gasket is in place.

11. Install spark plug(s) and tighten to 18 ft-lbs

(25 Nm).

12.Attach spark plug wire(s) to spark plug(s).

13.Repeat process for other cylinder if

equipped.

Battery Maintenance

10 kW 0K8946

14–18 kW 10000014927

20–26 kW 0C2979

10 kW 80 in-lbs (9.0 Nm)

20–26 kW 60 in-lbs (6.8 Nm)

001812

002380

WARNING

(000560)

Risk of Burn. Allow the engine to cool before

performing the following procedure. Failure

to do so could result in serious injury.

10 kW 53 in-lbs (6.0 Nm)

20–26 kW 174 in-lbs (19.68 Nm)

10 kW 80 in-lbs (9.0 Nm)

20–26 kW 60 in-lbs (6.8 Nm)

(000188)

DANGER

Electrocution. Do not wear jewelry while

working on this equipment. Doing so will

result in death or serious injury.

Maintenance

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

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 pro-

cesses. For more information on battery

recycling, visit the Battery Council Interna-

tional website at: http://batterycouncil.org.

Strictly observe the following precautions

when working on batteries:

• Remove 7.5A fuse from generator control

panel.

• Disconnect battery charger as directed in

Inspecting the Battery.

• Use tools with insulated handles.

• Wear rubber gloves and boots.

• Do not place tools or metallic objects on top

of battery.

• Disconnect charging source prior to con-

necting or disconnecting battery terminals.

• Wear full eye protection and protective cloth-

ing.

• If electrolyte contacts skin, wash it off imme-

diately with water.

• If electrolyte contacts eyes, flush thoroughly

with water immediately 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 bicarbon-

ate of soda solution until evidence of reac-

tion (foaming) has ceased. Flush resulting

liquid with water and dry area completely.

• DO NOT smoke near battery.

• DO NOT cause flame or spark in battery

area.

• Discharge static electricity from the body

before touching battery by first touching a

grounded metal surface.

Battery should be regularly inspected per

Service Schedule. Contact an IASD for assis-

tance if necessary.

Inspecting the Battery

Proceed as follows to inspect battery:

1. Press OFF button to shut down generator,

then lift lid and remove front panel.

2. Remove 7.5A fuse from control panel.

3. Remove intake side panel. (See Intake

Side Panel Removal.)

4. See Figure 4-9. Disconnect white battery

charger cable.

Figure 4-9. Disconnecting Battery Charger

Cable

5. See Figure 4-10. Inspect battery posts and

cables for tightness and corrosion. Tighten

and clean as necessary.

(000162)

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.

WARNING

(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.

(000238)

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.

WARNING

(000164)

WARNING

Electrical shock. Disconnect battery ground

terminal before working on battery or battery

wires. Failure to do so could result in death

or serious injury.

(000138a)

WARNING

Risk of burns. Batteries contain sulfuric acid and can

cause severe chemical burns. Wear protective gear

when working with batteries. Failure to do so could

result in death or serious injury.

(000163a)

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

(000228)

Environmental Hazard. Always recycle batteries at an

official recycling center in accordance with all local

laws and regulations. Failure to do so could result in

environmental damage, death, or serious injury.

002389

Maintenance

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

Figure 4-10. Battery Cables

6. Unsealed batteries only: Completely dis-

connect battery, removing negative battery

cable first. Check battery fluid level and, if

necessary, fill with distilled water only. DO

NOT use tap water. Have an IASD or a

qualified service technician verify state of

charge and condition.

7. Connect positive battery cable, then nega-

tive battery cable.

8. Connect battery charger cable.

9. Install intake side panel, and install 7.5 A

fuse.

10.Press AUTO button on controller.

11. 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 sediment trap:

1. Remove intake side panel. See Intake

Side Panel Removal.

2. Turn generator fuel supply OFF.

3. See Figure 4-11. Unscrew and remove cap

(A).

Figure 4-11. Cleaning the Sediment Trap

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

remove accumulated moisture and parti-

cles from cap and body (B).

5. Wipe inside of each component with a

clean, dry, lint-free cloth.

6. Seal threads of cap with appropriate seal-

ing compound. Install cap and hand-

tighten.

7. Tighten cap with an appropriately sized

pipe wrench. DO NOT overtighten.

8. Turn generator fuel supply ON. Inspect for

leaks by spraying all connection points

with a non-corrosive gas leak detection

fluid. Solution should not be blown away

or form bubbles.

9. Install intake side panel.

Post Maintenance Checks

Proceed as follows to perform post mainte-

nance checks:

1. Perform required maintenance proce-

dure(s).

2. Install intake side panel and front panel if

removed. (See Intake Side Panel Removal

and Front Access Panel Removal.)

3. Install 7.5A fuse in control panel.

4. Complete Install Wizard information.

5. Press AUTO button on control panel.

Allow unit to run for one minute with no

load (if running during a utility outage).

6. Set generator MLCB (generator discon-

nect) to ON (CLOSED).

7. Set utility MLCB to ON (CLOSED).

The system is now in AUTO.

NOTE: If correct utility is present at this time,

generator will perform its usual shutdown

process.

Performing Fuel System Leak Test

All products are factory-tested before ship-

ping to verify 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 4-12. Perform a final fuel system

leak test after generator installation. The test

will identify possible leaks at all connection

points (A).

It is best practice to perform a fuel system

leak test during normally-scheduled mainte-

nance.

–

001832

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.

Maintenance

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

Figure 4-12. Connection Points to Leak

Check

Inspect for leaks by spraying all connection

points with a non-corrosive gas leak detec-

tion fluid. The solution should not be blown

away or form bubbles.

Attention After Submersion

DO NOT start or operate generator if it has

been submerged in water. Have an IASD

thoroughly clean, dry, and inspect generator

following any submersion in water. If the

structure (home) has been flooded, it should

be inspected by a certified electrician to ver-

ify there will not be any electrical problems

during generator operation or when utility

power is returned.

Corrosion Protection

Regular scheduled maintenance should be

conducted to inspect unit for corrosion.

Inspect all metal components of generator,

including base frame, brackets, alternator

can, the entire fuel system (inside and out-

side of the generator), and fastener locations.

If there is corrosion found on generator com-

ponents (e.g. regulator, engine/alternator

mounts, fuel plenum, etc.), replace parts as

necessary.

Periodically wash and wax enclosure using

automotive type products. Do not spray unit

with a hose or power washer. Use warm,

soapy water and a soft cloth. Frequent wash-

ing is recommended in salt water/coastal

areas. Spray engine linkages with a light oil

such as WD-40.

Remove From and Return To

Service Procedure

Remove From Service

If generator cannot be exercised monthly, at

a minimum, and will be out of service longer

than 90 days, proceed as follows to prepare

generator for storage:

1. Start engine and allow it to warm up.

2. Close fuel shutoff valve in fuel supply line

and allow engine to stop.

3. Set generator MLCB (generator discon-

nect) to OFF (OPEN) once engine has

stopped.

4. Disconnect battery charger AC input T1/

Neutral cable (with white sleeve) at con-

troller.

5. Remove 7.5A fuse from generator control

panel.

6. Disconnect battery cables. Remove nega-

tive battery cable first.

7. Drain oil completely while engine is still

warm, and then fill crankcase with oil. See

Changing the Oil and Oil Filter.

8. Attach a tag to engine indicating 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 open-

ings. Install and tighten spark plug(s) to

specification.

10.Remove battery and store in a cool, dry

place.

11. Clean and wipe down generator enclo-

sure.

Return to Service

Proceed as follows to return unit to service

after storage:

004038

(000238)

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.

WARNING

(000133)

WARNING

Explosion. Batteries emit explosive gases.

Always connect positive battery cable first to

avoid spark. Failure to do so could result in

death or serious injury.

(000167a)

Equipment damage. Do not make battery

connections in reverse. Doing so will result

in equipment damage.

CAUTION

Maintenance

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

1. Inspect engine tag for oil viscosity and

classification. Drain and fill with recom-

mended oil if necessary.

2. Verify state of battery. Fill all cells of

unsealed batteries to correct level with dis-

tilled water. DO NOT use tap water.

Charge battery to 100% state of charge.

Replace battery if faulty.

3. Clean and wipe down generator enclo-

sure.

4. Verify 7.5A fuse is removed from genera-

tor control panel.

5. Connect battery. Observe battery polarity.

Damage will occur if battery is connected

incorrectly. Install positive battery cable

first.

6. Connect battery charger AC input T1/Neu-

tral cable (with white sleeve) at controller.

7. Open fuel shutoff valve.

8. Insert 7.5 A fuse into generator control

panel.

9. Complete Install Wizard procedure (dia-

grammed in generator installation man-

ual).

10.Press MANUAL button to start unit. Allow

unit to warm up for a few minutes.

11. Press OFF button to stop unit.

12.Set generator MLCB (generator discon-

nect) to ON (CLOSED).

13.Press AUTO button on control panel.

The generator is ready for service.

NOTE: Exercise timer and current date and

time must be reset if battery is discharged or

has been disconnected.

Troubleshooting / Quick Reference Guide

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

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. Con-

tact an IASD if fuse continues to blow.

Loose, corroded, or faulty battery

cables.

Tighten, clean, or replace as necessary.*

Faulty starter contact.

Faulty starter motor.

Discharged battery. Charge or replace battery.

Engine cranks

but will not start

No fuel. Replenish fuel / turn on fuel valve.

Faulty fuel solenoid (FS).

Contact an IASD for assistance.

Harness/wiring issue.

Faulty spark plug(s).

Inspect spark plug gap; replace spark

plug(s) if out of tolerance.

Valve clearance out of adjust-

ment, if applicable. See Engine.

Inspect and adjust valve clearance.

Engine starts

hard and runs

rough

Plugged or damaged air cleaner. Inspect and clean air cleaner.

Faulty spark plug(s).

Inspect spark plug gap; replace spark

plug(s) if out of tolerance.

Incorrect fuel pressure.

Verify fuel pressure to regulator is 10–12 in

water column (2.49–2.99 kPa) for LP gas,

and 3.5–7.0 in water column (0.87–1.74

kPa) for NG.

Fuel selector in wrong position.

Set fuel conversion valve to correct position

and program controller for fuel type.

Valve clearance out of adjust-

ment, if applicable. See Engine.

Inspect and adjust valve clearance.

Internal engine issue. Contact an IASD for assistance.

Unit is set to

OFF, but

engine contin-

ues to run

Controller wired incorrectly.

Contact an IASD for assistance.

Faulty control board.

No AC output

from generator

Generator MLCB (generator dis-

connect) is OFF (OPEN).

Set generator MLCB (generator discon-

nect) to ON (CLOSED).

Generator internal failure. Contact an IASD for assistance.

Engine may be warming up. See

Cold Smart Start.

Check the controller screen to verify status.

Troubleshooting / Quick Reference Guide

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

NOTE: IASD must have an active Tech ID and be air-cooled certified to perform any warrantable

repairs and submit warranty claims related to air-cooled products.

No transfer to

standby after

utility source

failure

Generator MLCB (generator dis-

connect) is OFF (OPEN).

Set generator MLCB (generator discon-

nect) to ON (CLOSED).

Faulty transfer switch coil.

Contact an IASD for assistance.

Faulty transfer relay.

Transfer relay circuit open.

Faulty control logic board.

Engine may be warming up. See

Cold Smart Start.

Check controller screen to verify status.

Unit consumes

large amounts

of oil

Excessive engine oil.

Adjust oil to correct level. See Checking

Engine Oil Level.

Faulty engine breather. Contact an IASD for assistance.

Incorrect type or viscosity of oil. See Engine Oil Requirements.

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

Restricted air filter. Replace air filter.

Wi-Fi network

connection bro-

ken or intermit-

tent

Various. See Wi-Fi module owner’s manual.

* Contact an IASD or visit www.generac.com for assistance.

Problem Cause Correction

Troubleshooting / Quick Reference Guide

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

Quick Reference Guide

To clear an active alarm, press OFF button on the control panel, then the ENTER button, and

finally the AUTO button. Contact an air-cooled certified IASD if alarm reoccurs.

Active Alarm LED Problem Action Solution

NONE

FLASH-

ING

GREEN

Unit running in

AUTO but no

power in house.

Check genera-

tor MLCB

(generator dis-

connect).

Check generator MLCB (gen-

erator disconnect). If it is ON,

contact an IASD.

HIGH

TEMPERA-

TURE

RED

Unit shuts down

during operation.

Check LEDs /

screen for

alarms.

Inspect ventilation around gen-

erator, intake, exhaust, and

rear of generator. If no obstruc-

tions are present, contact an

IASD.

OVERLOAD

REMOVE

LOAD

RED

Unit shuts down

during operation.

Check LEDs /

screen for

alarms.

Clear alarm and remove

household loads from genera-

tor. Put in AUTO and restart.

RPM SENSE

LOSS

RED

Unit was running

and shut down,

attempts to

restart.

Check LEDs /

screen for

alarms.

Clear alarm and remove

household loads from genera-

tor. Put into AUTO and restart.

If generator does not start, con-

tact an IASD.

NOT

ACTIVATED

NONE

Unit will not start

in AUTO with util-

ity loss.

Check if

screen says

unit not acti-

vated.

See Activation section in instal-

lation manual.

NONE GREEN

Unit will not start

in AUTO with util-

ity loss.

Check screen

for start delay

countdown.

If startup delay is greater than

expected, contact an IASD to

adjust from 2 to 1500 seconds.

LOW OIL

PRESSURE

RED

Unit will not start

in AUTO with util-

ity loss.

Check LEDs /

screen for

alarms.

Check oil level and add oil as

needed. If oil level is correct,

contact an IASD.

RPM SENSE

LOSS

RED

Unit will not start

in AUTO with util-

ity loss.

Check LEDs /

screen for

alarms.

Clear alarm. Using control

panel, check battery by navi-

gating to BATTERY MENU

option from MAIN MENU. If

battery condition displays

GOOD, contact an IASD. If

control panel displays CHECK

BATTERY, replace battery.

OVERCRANK RED

Unit will not start

in AUTO with util-

ity loss.

Check LEDs /

screen for

alarms.

Verify fuel line shutoff valve is

ON. Clear alarm. Start unit in

MANUAL. If it does not start, or

starts and runs rough, contact

an IASD.

LOW VOLTS

REMOVE

LOAD

RED

Unit will not start

in AUTO with util-

ity loss.

Check LEDs /

screen for

alarms.

Clear alarm and remove

household loads from genera-

tor. Put in AUTO and restart.

OVERSPEED RED

Unit will not start

in AUTO with util-

ity loss.

Check LEDs /

screen for

alarms.

Contact an IASD.

UNDER-

VOLTAGE

RED

Unit will not start

in AUTO with util-

ity loss.

Check LEDs /

screen for

alarms.

Contact an IASD.

UNDER-

SPEED

RED

Unit will not start

in AUTO with util-

ity loss.

Check LEDs /

screen for

alarms.

Contact an IASD.

Troubleshooting / Quick Reference Guide

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

STEPPER

OVERCUR-

RENT

RED

Unit will not start

in AUTO with util-

ity loss.

Check LEDs /

screen for

alarms.

Contact an IASD.

WIRING

ERROR

RED

Unit will not start

in AUTO with util-

ity loss.

Check LEDs /

screen for

alarms.

Contact an IASD.

OVER-

VOLTAGE

RED

Unit will not start

in AUTO with util-

ity loss.

Check LEDs /

screen for

alarms.

Contact an IASD.

SHUTDOWN

SWITCH

FLASH-

ING RED

Unit will not start.

Check

emergency

shutdown

switches

Set emergency shutdown

switch(es) to CLOSED (I).

Clear alarm.

LOW

BATTERY

YELLOW

Yellow LED illu-

minated in any

state.

Check screen

for additional

information.

Clear alarm. Using control

panel, check battery by navi-

gating to BATTERY MENU

option from MAIN MENU. If

battery condition displays

GOOD, contact an IASD. If

control panel displays CHECK

BATTERY, replace battery.

BATTERY

PROBLEM

YELLOW

Yellow LED illu-

minated in any

state.

Check screen

for additional

information.

Contact an IASD.

CHARGER

WARNING

YELLOW

Yellow LED illu-

minated in any

state.

Check screen

for additional

information.

Contact an IASD.

CHARGER

MISSING AC

YELLOW

Yellow LED illu-

minated in any

state.

Check screen

for additional

information.

Contact an IASD.

SERVICE A YELLOW

Yellow LED illu-

minated in any

state.

Check screen

for additional

information.

Perform SERVICE A mainte-

nance. Press ENTER to clear.

SERVICE B YELLOW

Yellow LED illu-

minated in any

state.

Check screen

for additional

information.

Perform SERVICE B mainte-

nance. Press ENTER to clear.

INSPECT

BATTERY

YELLOW

Yellow LED illu-

minated in any

state.

Check screen

for additional

information.

Inspect battery. Press ENTER

to clear.

Active Alarm LED Problem Action Solution

Part No. A0001846499 Rev. C 05/12/2023

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 7290 Home Standby Generator WiFi Connectivity and Dual Fuel for Reliable Power Solutions

Product's Documents

User Manual

Specifications

Generac 7290 Questions and Answers