Owner’s Manual
For
Spark-Ignited Stationary Emergency Generators
Residential and Commercial
22 kW 2.4L
25 kW 1.5L
27 kW 2.4L
30 kW 1.5L
32 kW 2.4L
36 kW 2.4L
38 kW 2.4L
45 kW 2.4L
48 kW 5.4L
60 kW 2.4L
NOT INTENDED FOR USE IN CRITICAL
LIFE SUPPORT APPLICATIONS.
*
*
ONLY QUALIFIED ELECTRICIANS OR
CONTRACTORS SHOULD ATTEMPT
INSTALLATION!
DEADLY EXHAUST FUMES! OUTDOOR
INSTALLATION ONLY!
*
This manual should remain with the unit.
This manual must be used in conjunction
with the appropriate installation manual.
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Table of Contents
Section 1 Safety
1.1 Introduction .......................................................................................................................... 1
1.2 Safety Information ................................................................................................................ 2
1.3 General Hazards ................................................................................................................... 2
1.4 Exhaust Hazards .................................................................................................................. 3
1.5 Electrical Hazards ................................................................................................................ 3
1.6 Fire Hazards .......................................................................................................................... 3
1.7 Explosion Hazards ............................................................................................................... 3
Section 2 Specifications
2.1 Emission Information .......................................................................................................... 5
2.1.1 Emissions Data Plate ....................................................................................................................5
2.2 Specifications ....................................................................................................................... 6
2.3 Engine Oil Recommendations ............................................................................................ 7
2.4 Weather and Maintenance Kits ........................................................................................... 8
2.5 Coolant Water Treatment .................................................................................................... 8
2.6 Fuel Requirements ............................................................................................................... 8
2.7 Reconfiguring the Fuel System .......................................................................................... 9
2.7.1 Fuel Conversion Procedure from NG to LPV ................................................................................9
2.7.2 Change Fuel Selection ...............................................................................................................10
2.8 Battery Requirements ........................................................................................................ 10
2.8.1 Battery Charger ..........................................................................................................................10
2.9 Corrosion Protection ......................................................................................................... 10
Section 3 Activation and Startup
3.1 Orientation .......................................................................................................................... 11
3.2 Remove Side Access Panels ............................................................................................ 11
3.3 Install Battery ..................................................................................................................... 12
3.4 Open Viewing Window ....................................................................................................... 12
3.5 Activate Unit ...................................................................................................................... 13
3.6 Start and Run Engine ......................................................................................................... 14
3.7 Operational Checks ........................................................................................................... 15
3.7.1 Self Test ......................................................................................................................................15
3.7.2 Check Manual Transfer Switch Operation ..................................................................................15
3.7.3 Electrical Checks ........................................................................................................................15
3.7.4 Test Generator Under Load ........................................................................................................16
3.7.5 Check Automatic Operation ........................................................................................................16
3.8 Final Instructions ............................................................................................................... 17
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Table of Contents
Section 4 Operation
4.1 Control Panel ......................................................................................................................19
4.2 Auto/Manual/Off ..................................................................................................................19
4.3 Menu Navigation .................................................................................................................20
4.4 Alarm/Warning Conditions ................................................................................................23
4.5 Change Time and Date .......................................................................................................23
4.6 Programmable Timers ........................................................................................................23
4.6.1 Dealer Programmable ................................................................................................................23
4.6.1.1 Exercise Time ..................................................................................................................... 23
4.6.2 User Programmable ...................................................................................................................24
4.6.2.1 Start-Up Delay Timer .......................................................................................................... 24
4.6.2.2 Warm-Up Delay Timer ........................................................................................................ 24
4.7 USB Port for Firmware Updates ........................................................................................24
4.8 Battery Charger ..................................................................................................................24
4.9 Transfer Switch Automatic Operation ..............................................................................24
4.9.1 Automatic Sequence of Operation ..............................................................................................25
4.9.1.1 Utility Failure ....................................................................................................................... 25
4.9.1.2 Cranking.............................................................................................................................. 25
4.9.1.3 Load Transfer...................................................................................................................... 25
4.10 Transfer Switch Manual Operation .................................................................................25
4.10.1 Transfer to Generator Power ....................................................................................................26
4.10.2 Transfer Back to Utility Power ..................................................................................................26
Section 5 Maintenance
5.1 Component Locations ........................................................................................................27
5.2 Access Panels ....................................................................................................................28
5.2.1 Removal .....................................................................................................................................28
5.2.2 Installation ..................................................................................................................................28
5.3 Service Maintenance Intervals ..........................................................................................29
5.4 Remove From Service ........................................................................................................30
5.5 30 Hour Break-In .................................................................................................................30
5.6 Daily Maintenance ..............................................................................................................30
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Table of Contents
5.7 Schedule A Maintenance ................................................................................................... 31
5.7.1 Schedule A Maintenance Item Locations ...................................................................................31
5.7.2 Preliminary Instructions ..............................................................................................................31
5.7.3 Check Enclosure Louvers ...........................................................................................................31
5.7.4 Check Fuel Lines ........................................................................................................................31
5.7.5 Check Coolant Level and Hoses ................................................................................................32
5.7.6 Check Radiator for Clogging .......................................................................................................32
5.7.7 Check Lubricating Oil Level and Drain Hose ..............................................................................32
5.7.8 Replace Lubricating Oil and Oil Filter .........................................................................................33
5.7.9 Check Battery Condition/Fluid Level ...........................................................................................37
5.7.9.1 Check Condition and Clean ................................................................................................ 37
5.7.9.2 Check Fluid Level ............................................................................................................... 37
5.7.9.3 Check State of Charge........................................................................................................ 37
5.7.9.4 Battery Replacement .......................................................................................................... 37
5.7.10 Check and Adjust Accessory/Drive Belt ...................................................................................38
5.7.10.1 Check................................................................................................................................ 38
5.7.10.2 Adjust................................................................................................................................ 38
5.7.11 Replace Air Filter Element ........................................................................................................39
5.7.12 Final Instructions .......................................................................................................................40
5.8 Schedule B Maintenance ................................................................................................... 41
5.8.1 Schedule B Maintenance Item Locations ...................................................................................41
5.8.2 Drain/Flush Coolant System .......................................................................................................41
5.8.3 Clean/Gap/Replace Spark Plugs ................................................................................................42
5.8.4 Final Instructions .........................................................................................................................43
5.9 Schedule C Maintenance ................................................................................................... 44
5.10 Return To Service ............................................................................................................ 44
5.11 Lube Oil Maintainer System ............................................................................................ 45
5.11.1 Description ................................................................................................................................45
5.11.2 Fill Oil Supply Tank ...................................................................................................................45
5.11.3 Test Functionality ......................................................................................................................46
5.11.4 Shutoff Valve ............................................................................................................................46
Section 6 Troubleshooting
6.1 Engine Troubleshooting .................................................................................................... 47
6.2 Controller Troubleshooting ............................................................................................... 48
6.3 Removal From Service During Utility Outages ............................................................... 49
6.4 Storage ................................................................................................................................ 49
6.4.1 Prepare For Storage ...................................................................................................................49
6.4.2 Return From Storage ..................................................................................................................50
6.5 Attention After Submersion .............................................................................................. 51
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Table of Contents
WARNING
California Proposition 65. Engine exhaust and some of
its constituents are known to the state of California to
cause cancer, birth defects, and other reproductive
harm.
(000004)
WARNING
California Proposition 65. This product contains or
emits chemicals known to the state of California to
cause cancer, birth defects, and other reproductive
harm.
(000005)
vi
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Section 1
Safety
1.1 — Introduction
Thank you for purchasing this stationary automatic standby generator set. Every effort was made to ensure that the
information in this manual was both accurate and complete at the time it was released. However, the manufacturer
reserves the right to change, alter or otherwise improve this product at any time without prior notice.
This generator is designed to automatically supply electrical power to operate critical loads during a utility power failure.
The unit is factory installed in an all-weather metal enclosure and is intended exclusively for outdoor installation
using either Natural gas (NG) or Liquid Propane vapor (LPV).
NOTE: All 22-48 kW units are field convertible between NG or LPV, while 60 kW units are built per fuel require-
ments and are not field convertible.
When properly sized, the generator is suitable for supplying typical residential/commercial loads, such as induction
motors (sump pumps, refrigerators, freezers, air conditioners, furnaces, etc.), electronic components (computers, mon-
itors, televisions, etc.), lighting, microwaves, and other residential and business loads.
READ THIS MANUAL THOROUGHLY: The operator is responsible for proper and safe use of this equipment. Read
and thoroughly understand the contents of this manual before attempting to use the equipment. If any portion of this
manual is not fully understood, contact the nearest Independent Authorized Service Dealer for assistance.
SAVE THESE INSTRUCTIONS: The manufacturer suggests that this manual and the rules for safe operation be cop-
ied and posted near the generator installation site. Safety should be stressed to all operators and potential operators of
this equipment.
SAFETY: Throughout this manual, and on tags and decals affixed to the unit, DANGER, WARNING, CAUTION and
NOTE blocks are used to alert personnel to special instructions about a particular operation, function or service that
may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS
INJURY.
Indicates a hazardous situation or action which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTE: Notes contain additional information important to an operation or procedure.
Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of informa-
tion each indicates is as follows:
This symbol points out important Safety Information that, if not followed, could endanger personal safety and/or
property of others.
*
$
This symbol points out a potential Explosion Hazard.
This symbol points out a potential Fire Hazard.
!
+
This symbol points out a potential Electrical Shock Hazard.
These “Safety Alerts” cannot eliminate the hazards that they signal. Strict compliance with these special instructions,
plus common sense, are major accident prevention measures.
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Safety
1.2 — Safety Information
Study these safety rules carefully before operating or servicing this equipment. Become familiar with this Owner’s Man-
ual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated
and maintained. Many accidents are caused by failing to follow simple rules or precautions.
The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this
manual, and on tags and decals affixed to the unit are not all-inclusive. If using a procedure, work method or operating
technique the manufacturer does not specifically recommend, ensure that it is safe for personnel. Also make sure the
procedure, work method or operating technique used does not render the generator unsafe.
Despite the safe design of this generator, operating this equipment imprudently, neglecting its mainte-
nance or being careless can cause possible injury or death. Permit only responsible and capable per-
sons to install, operate and maintain this equipment.
*
Potentially lethal voltages are generated by these machines. Ensure steps are taken to make the
machine safe before attempting to work on the generator.
*
*
Parts of the generator are rotating and/or hot during operation. Exercise care near a running generator.
The installation of this generator must always comply with applicable codes, standards, laws and regu-
lations.
*
A running generator gives off DEADLY carbon monoxide, an odorless, colorless, poisonous gas.
Breathing carbon monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, head-
ache, vomiting, weakness, sleepiness, inability to think clearly, fainting, unconsciousness or even
death.
*
The control panel for this unit is intended to be operated by qualified service personnel only.
*
1.3 — General Hazards
• For safety reasons, this equipment should only be installed, serviced and repaired by a Service Dealer or other
competent, qualified electrician or installation technician who is familiar with applicable codes, standards, regula-
tions and product Installation Manual guidelines. The operator also must comply with all such codes, standards,
regulations and product Installation Manual guidelines.
• The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if breathed in
sufficient concentrations, can cause unconsciousness or even death. DO NOT alter or add to the exhaust system
or do anything that might render the system unsafe or in noncompliance with applicable codes and standards.
• Install a carbon monoxide alarm indoors, according to manufacturer’s instructions/recommendations.
• Adequate, unobstructed flow of cooling and ventilating air is critical for correct generator operation. Do not alter
the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation
of the generator. The generator MUST be installed and operated outdoors only.
• Keep hands, feet, clothing, etc. away from drive belts, fans, and other moving or hot parts. Never remove any
drive belt or fan guard while the unit is operating.
• When working on this equipment, remain alert at all times. Never work on the equipment when physically or men-
tally fatigued.
• Inspect the generator regularly, and contact the nearest Dealer for parts needing repair or replacement.
• Before performing any maintenance on the generator, remove the control panel fuse and disconnect the Nega-
tive (-) battery cable to prevent accidental startup. When disconnecting battery cables always remove the NEGA-
TIVE (-) cable first. When reconnecting the cables, connect the POSITIVE (+) cable first.
• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may
result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.
2
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Safety
1.4 — Exhaust Hazards
• Generator engine exhaust contains DEADLY carbon monoxide, an odorless, colorless, poisonous gas. Breathing
carbon monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting,
weakness, sleepiness, inability to think clearly, fainting, unconsciousness or even death. If any carbon monoxide
poisoning symptom is experienced, move into fresh air and immediately seek medical attention.
• This generator is designed for OUTDOOR installation ONLY. Never operate the generator inside any garage or
other enclosed space.
1.5 — Electrical Hazards
• All generators covered by this manual produce dangerous electrical voltages that can cause fatal electrical
shock. Utility power delivers extremely high and dangerous voltages to the transfer switch, as does the standby
generator when it is in operation. Avoid contact with bare wires, terminals, connections, etc. while the unit is run-
ning. Ensure all appropriate covers, guards and barriers are in place, secured and/or locked before operating the
generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce potential
shock hazard.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
• The generator may crank and start at any time when utility power is lost. When this occurs, load circuits are
transferred to the STANDBY (generator) power source. Before working on the generator, always move the Main
Circuit Breaker switch on the control panel down to the OFF (Open) position, press the OFF key on the control
panel keypad, remove the 7.5 amp fuse, and disconnect the battery negative cable (black) from the battery neg-
ative (-) terminal.
• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not
possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use
a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is
unconscious, apply first aid and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock,
or may get caught in moving parts resulting in injury.
1.6 — Fire Hazards
• For fire safety, the generator must be installed and maintained properly. Installation MUST always comply with
applicable codes, standards, laws, regulations and product Installation Manual guidelines. Adhere strictly to
local, state, and national electrical and building codes. Comply with regulations of the Occupational Safety and
Health Administration (OSHA). Also, ensure that the generator is installed in accordance with the manufacturer’s
instructions and recommendations. Following proper installation, do nothing that might alter a safe installation
and render the unit in noncompliance with the aforementioned codes, standards, laws and regulations.
• Keep a fire extinguisher near the generator at all times. Extinguishers rated “ABC” by the National Fire Protection
Association are appropriate for use on the standby generator. Keep the extinguisher properly charged and be
familiar with its use. Consult the local fire department with any questions pertaining to fire extinguishers.
1.7 — Explosion Hazards
• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible mate-
rials are left in the generator compartment, or on or near the generator as FIRE or EXPLOSION may result. Keep
the area surrounding the generator clean and free from debris.
If this generator is used to power electrical load circuits normally powered by a utility power source,
it is required by code to install a transfer switch. The transfer switch must effectively isolate the elec-
+
trical system from the utility distribution system when the generator is operating (NEC 702). Failure to
isolate an electrical system by such means will result in damage to the generator and also may result
in injury or death to utility power workers due to backfeed of electrical energy.
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Safety
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Section 2
Specifications
2.1 — Emission Information
The U.S. Environmental Protection Agency (EPA) requires that the generator comply with exhaust emission standards.
The generator is certified to meet the applicable EPA emission levels, and is certified for use as a stationary engine for
standby power generation. Any other use may be a violation of federal and/or local laws. To ensure that the engine
complies with the applicable emission standards for the duration of the engine’s life, it is important to follow the mainte-
nance specifications in Section 5.
2.1.1— Emissions Data Plate
A data plate is attached to the valve cover to verify compliance with EPA emissions regulations.
Figure 2-1. Emissions Data Plate (Sample)
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Specifications
2.2 — Specifications
Model
22 kW
2.4L
25 kW
1.5L
27 kW
2.4L
30 kW
1.5L
32 kW
2.4L
36 kW
2.4L
38 kW
2.4L
45 kW
2.4L
48 kW
5.4L
60 kW
2.4L
Engine
Generator Set
Rotor Insulation
Class H
Class F
Class H
Class F
Class H
Class F
Class H
Stator Insulation
Class H
Dimensions L x W x H
62.2 x 30.6 x 38.6
76.8 x 35 x 46.1
Product Weight W/ Steel
Enclosure (lbs)
865
895
807
961
873
1255
1202
1355
1283
1230
1383
1330
–
–
–
–
–
Product Weight W/ Aluminum
Enclosure (lbs)
900
–
777
931
843
940
–
1225
1325
1235
1335
1555
–
Shipping Weight W/ Steel
Enclosure (lbs)
Shipping Weight W/ Aluminum
Enclosure (lbs)
966
1006
1302
1302
1655
Engine System
Type
In-Line
V-type
527
In-Line
287
Dry Weight (lbs)
Bore (in/mm)
Stroke (in/mm)
Displacement (liters)
287
3.41/86.5
3.94/100
2.4
243
3.05/77.4
3.13/79.5
1.5
287
3.41/86.5
3.94/100
2.4
243
3.05/77.4
3.13/79.5
1.5
287
3.41/86.5
3.94/100
2.4
3.55/90.2
3.41/86.5
4.17/105.9 3.94/100
5.4
2.4
1-3-7-2-
6-5-4-8
Firing Order
1-3-4-2
CW From Flywheel
1-3-4-2
Direction or Rotation
Compression Ratio
Spark Plug Gap (mm)
Cooling System
Water Pump
9.5:1
11:1
0.9
9.5:1
11:1
0.9
9.5:1
9:1
9.5:1
0.71
1.07-1.17
1.07-1.17
0.71
1.07-1.17
0.71
1.07-1.17 1.29-1.45
Belt Driven
Fan Speed (rpm)
Fan Diameter (inches)
Fan Mode
1980
18.1
2484
17.7
1980
18.1
2484
17.7
1500
2200
1865
1500
1865
2725
1954
2100
22.0
Pusher
Puller
Air Flow (ft3/min.)
2400
2490
2400
2490
2725
2200
4350
3280
Coolant Capacity (gallons/
liters)
2.5/9.5
2.0/7.6
2.5/9.5
2.0/7.6
2.5/9.5
193,000 145,000
3.0/11.4
2.5/9.5
Heat Rejection
to Coolant (Btu/h)
99,000
112,000
105,000
135,000
145,000
193,000
186,000
270,000
Max Operating Air Temp on
Radiator
150° F (60° C)
Max Ambient Temp
Thermostat (Full Open)
Lubricating System
Oil Pump Type
140° F (50° C)
190° F (88° C)
Gear
Oil Filter Type
Full Flow Spin-On Cartridge
Crankcase Oil Capacity
(quarts/liters)
4/3.8
6/5.7
4/3.8
Lubricating Oil Type
5W-30
Air Intake System
Turbo/
Naturally
Turbo/
Turbo/
Aftercooled
Type
Naturally Aspirated
Naturally Aspirated
Aftercooled Aspirated Aftercooled
Exhaust System
6
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Specifications
Model
22 kW
2.4L
25 kW
1.5L
27 kW
2.4L
30 kW
1.5L
32 kW
2.4L
36 kW
2.4L
38 kW
2.4L
45 kW
2.4L
48 kW
5.4L
60 kW
2.4L
Engine
Breather
Closed
Open
Closed
Open
Closed
420 cfm
1100° F
Open
Exhaust Flow at
Rated Output 60 Hz
165 cfm
900° F
203 cfm
1100° F
180 cfm
1000° F
237 cfm
1130° F
300 cfm
1075° F
420 cfm
1100° F
300 cfm
1075° F
414 cfm
1025° F
494 cfm
1050° F
Exhaust Temperature at Rated
Output
Electrical System
Battery Charge
Alternator
12V,
30 Amp
12V,
15 Amp
12V,
30 Amp
12V,
15 Amp
12V, 30 Amp
Recommended Battery
Static Battery Charger
Governor System
Type
Group 26
Group24F Group 26
2.5 Amp
Electronic
Frequency Regulation
Isochronous
Steady State
Regulation
+/- 0.25%
Voltage Regulator
Type
Electronic
Single
Sensing Phase
Regulation
+/- 1%
Fuel System
Operating Pressure
5-14” WC
A complete specification sheet is included in the documentation provided with the unit at the time of purchase. For
additional copies, consult your local Independent Authorized Service Dealer.
2.3 — Engine Oil Recommendations
To maintain the product warranty, use only genuine Generac replacement parts. Generac maintenance kits include
both the oil filter and air filter, and can be obtained through any Authorized Dealer.
Although the unit is filled at the factory with 5W-20 engine oil, replace with 5W-30 engine oil at the first oil change which
is due at 30 hours break-in. Select a high-quality detergent oil classified “SJ or SH.” Detergent oils keep the engine
cleaner and reduce carbon deposits. After break-in, a synthetic oil that meets or exceeds SAE specifications is recom-
mended. Once synthetic oil is used, it should be used for the life of the generator. It is not recommended to go back to
a mineral oil. Do not use special additives.
NOTE: If not already equipped, it is strongly recommended to use the optional Cold Weather Start Kit for tem-
peratures below 32°F. The oil grade for temperatures below 32°F is 5W-30 synthetic oil.
º C
º F
- 30 - 20 - 10
- 22 - 4 14
0
32
10
50
20
68
30
40
50
- 40
- 40
86 104 122
5W-30
All Seasons
Arctic Conditions
º C
5W-30 w/ Block Heater
- 30 - 20 - 10
0
32
10
50
20
68
30
40
50
- 40
- 40
º F
- 22 - 4
14
86 104 122
Figure 2-2. Lubricating Oil Recommendations
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Specifications
2.4 — Weather and Maintenance Kits
To keep the generator running at its peak, the following kits are offered:
• Cold Weather Kit
– Recommended for climates with temperatures below 32°F
• Extreme Cold Weather Kit
– Recommended Block Heater Kit for protection in temperatures below 32°F
• Scheduled Maintenance Kit
– Kit includes the recommended parts to maintain the generator. Refer to the Service Schedule for regular main-
tenance intervals.
For additional information, or to order any of these kits, please contact an Independent Authorized Service Dealer or
Customer Service Representative.
2.5 — Coolant Water Treatment
Use of improper coolants can damage the engine cooling system. Use demineralized water or distilled water for best
results. Hard water causes scale deposits, which reduces cooling efficiency and raises internal temperatures, possibly
leading to engine damage. Use an anti-corrosive to prevent rot in summer and anti-freeze to prevent freezing in winter.
Dilute the anti-freeze based on a theoretical temperature that is 9-18°F (5-10°C) below the lowest temperature
expected in the area. A ratio of 40-60% is most common range.
Freezing Point °F (°C)
Coolant (% Volume)
Water (% Volume)
-13 (-25)
40
-31 (-35)
50
-58 (-50)
60
60
50
40
NOTE: Use only Peak Fleet-Charge® 50/50 ethylene glycol type coolant (available from any authorized
dealer).
Do not use propylene glycol type coolant. Using the wrong coolant, mixing different types of coolant,
or even mixing different brands of the correct type of coolant, can produce unsatisfactory results, pos-
sibly leading to engine damage.
*
2.6 — Fuel Requirements
The Stationary Emergency Generator may be equipped with one of the following fuel systems:
• Natural Gas Fuel System
• Propane Vapor (LPV) fuel system
Recommended fuels must have a BTU content of at least 1,000 BTUs per cubic foot (37.26 megajoules per cubic
meter) for NG, or at least 2,520 BTUs per cubic foot (93.8 megajoules per cubic meter) for LPV. If converting to LPV
from NG, a minimum LP tank size of 250 gallons (946 liters) is recommended. See the Installation Manual for complete
details and procedures.
8
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Specifications
2.7 — Reconfiguring the Fuel System
While some models are created fuel specific for either Natural gas (NG) or Liquid Propane vapor (LPV) and are not fuel
convertible, others are configured at the factory for NG, but are field convertible to LPV. Units fitted with a dual fuel car-
buretion system are generally configured for the selected fuel source during installation.
To reconfigure the fuel system, change the jet in the demand regulator, and then navigate to the appropriate menu to
assign the new fuel type. Before proceeding, be aware that the fuel conversion software is password protected.
NOTE: Generac recommends that fuel conversion be done by an authorized dealer or a qualified, competent
installation contractor or electrician who is familiar with applicable codes, standards and regulations.
2.7.1— Fuel Conversion Procedure from NG to LPV
1. Turn off the main gas supply.
2. Remove battery negative cable (black) from battery negative (-) terminal.
3. Remove carburetor fuel hose from outlet port. See Figure 2-3.
4. Remove screw at front of power wire connector and pull connector from fuel solenoid.
5. Expand spring clamp on fuel enrichment hose and remove from hose barb.
NOTE: On 5.4L (48 kW) units, remove two screws (with flat washers, lock washers and hex nuts) to release fuel
inlet flange from frame rail. This will provide adequate access to the regulator for jet conversion.
6. Remove black pipe assembly from outlet port. If clearance is not sufficient, first remove fuel solenoid assembly.
7. Rotate NG fuel jet counterclockwise to remove
from the outlet port.
Carburetor
Fuel Hose
NOTE: Both the NG and LP fuel jets are slotted, so
that they may be removed and installed using an
ordinary flat blade screwdriver.
Solenoid Body
Black
Pipe
Assembly
Connector
Screw
8. Rotate LP fuel jet counterclockwise to remove
from the jet keeper port.
NOTE: The orifice size is stamped on each jet. The
jet with the larger orifice is used for running on NG.
Spring
Clamp
9. Rotate LP fuel jet clockwise to install in the outlet
port.
Fuel Jet
10. Rotate NG fuel jet clockwise to install in the jet
keeper port.
Outlet Port
11. Install fuel solenoid assembly, if removed.
NOTE: Solenoid must be installed with flow arrow
pointed toward black pipe assembly. See inset of
Figure 2-3.
Jet Keeper
Port
Fuel
Enrichment
Hose
12. Apply appropriate pipe sealant to threads of black
pipe assembly and install into outlet port.
NOTE: On 5.4L (48 kW) units, install two screws
(with flat washers, lock washers and hex nuts) to
fasten fuel inlet flange to frame rail.
13. Expand spring clamp on fuel enrichment hose
and install onto hose barb.
14. Push power wire connector onto fuel solenoid and
install screw.
15. Install carburetor fuel hose onto outlet port.
16. Install battery negative cable (black) onto battery
negative (-) terminal.
Figure 2-3. Demand Regulator Assembly
17. Turn on the main gas supply.
18. See Subsection 2.7.2—Change Fuel Selection.
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Specifications
Serious injury, including death, or damage will occur if not configured properly. Consult an Authorized
Dealer with any questions.
*
2.7.2— Change Fuel Selection
Failure to convert both the hardware and software will result in decreased performance and an increase in
emissions, which is a violation of Environmental Protection Agency (EPA) regulations. It is the responsibility
of the installer to make sure that only the correct recommended fuel is supplied to the generator fuel system.
Thereafter, the owner/operator must ensure that only the proper fuel is supplied.
1. Once fuel regulator is converted to desired fuel type call 888-9ACTIVATE for the control panel password. This
fuel selection conversion is required to be password protected by EPA regulations.
2. Access the control panel located behind the viewing window at the rear of the unit.
3. From the Home screen, press ESCAPE to display the Main Menu.
4. Navigate the software using UP ARROW, DOWN ARROW, ENTER and ESCAPE. For more detailed informa-
tion, see Subsection 4.3 —Menu Navigation.
2.8 — Battery Requirements
Group 26, 12 Volt
1.5L, 2.4L Engines: For areas where temperatures regularly drop below 32° F (0° C).
NOTE: Battery dimensions (L x W x H) for Group 26 battery must not exceed 8-3/16" x 6-13/16" x 7-3/4"
(208mm x 173mm x 197mm).
Group 24F, 12 Volt
5.4L Engine: For areas where temperatures regularly drop below 32° F (0° C).
NOTE: Battery dimensions (L x W x H) for Group 24F battery must not exceed 10-3/4" x 6-13/16" x 9"
(273mm x 173mm x 229mm).
2.8.1— Battery Charger
A 2.5 amp battery charger is integrated into the control panel module. It operates as a “Smart Charger” which ensures
output charging levels are safe and continuously optimized to promote maximum battery life.
2.9 — Corrosion Protection
Periodically wash and wax the enclosure using automotive type products. Frequent washing is recommended in salt
water/coastal areas.
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Section 3
Activation and Startup
3.1 — Orientation
NOTE: The 2.4L (32 kW) unit is depicted in the artwork used in this manual. The location and appearance of
some components may vary between engine models.
The side of the enclosure with the viewing window is identified as the rear of the generator set. The right and left sides
are identified by standing at the rear and looking towards the front of the unit.
Viewing
Window
Battery
Figure 3-1. Enclosure (Rear Left View)
3.2 — Remove Side Access Panels
NOTE: Access panels are located at both the left and right sides of the enclosure.
1. Remove key from bag attached to door of unit.
2. Insert key into latch and rotate counterclockwise 1/2 turn. See Figure 3-2.
3. Raise panel using thumb latch.
Key
Thumb Latch
Figure 3-2. Access Panel Key
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Activation and Startup
3.3 — Install Battery
CAUTION: Always connect the positive battery
$
cable first. If the positive cable should contact
ground with the negative cable installed, the result-
ing sparks may cause a battery explosion which
could result in serious injury.
1. Loosen two screws with nylon washers to release hold-
down clamp from battery tray.
2. Install battery onto tray.
3. Install two screws with nylon washers to secure hold-
down clamp to battery tray.
4. Install battery positive cable (red) to battery positive (+)
terminal.
5. Install battery negative cable (black) to battery negative
Red Lead
From Starter
(-) terminal.
Black Lead
To Frame
Battery
Figure 3-3. Battery Cable Connections
3.4 — Open Viewing Window
1. Remove plastic film from both sides of viewing window.
2. Rotate viewing window upward to access control panel.
3. To hold viewing window in the open position, remove rod
from clip at back of window and insert into hole in frame.
See Figure 3-4.
Figure 3-4. Viewing Window
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Activation and Startup
3.5 — Activate Unit
Display Reads:
Generator Active is displayed on the
LCD screen when the unit is first
powered up. After displaying firmware
and hardware version codes, as well as
other system information, the Installation
Wizard is launched, and the Language
screen is displayed.
If the wrong language is selected, it may be changed
later using the Edit menu.
Up Arrow = (+)
Language
-
English
+
Use UP ARROW or DOWN ARROW to
scroll to desired language.
Press ENTER.
Down Arrow = (-)
Display Reads:
Press ENTER.
Press ESCAPE to abort the activation sequence. NOT
ACTIVATED is displayed and the generator will run in
manual mode only. Disconnect and reconnect the
negative battery cable to restart the activation routine.
If power is removed after a successful activation, no
data is lost, but the time and date must be updated.
Activate me (ENT) or
ESC to run in manual
888-9ACTIVATE (922-8482, US & Can-
ada only) if activation passcode is not
available.
Display Reads:
To Activate go to
If activation pass code is available, wait a
few seconds for the next display.
Display Reads:
Use UP ARROW or DOWN ARROW to
increment or decrement the digit to
correspond to the first number of the
pass code.
Press ESCAPE to return to preceding digits if a
correction becomes necessary.
SN 1234567890
If attempts to enter the activation code are
PASS CODE XXXXX
unsuccessful, check the number against the code
given on activategen.com. If it is correct, contact 1-888-
9ACTIVATE (922-8482, US & Canada only).
Press ENTER.
Repeat step to enter remaining digits.
Display Reads:
Use UP ARROW or DOWN ARROW to
increment or decrement the hour. Press
ENTER.
Select Hour (0-23)
- 6 +
Use UP ARROW or DOWN ARROW to
increment or decrement the minute.
Press ENTER.
Use UP ARROW or DOWN ARROW to
select the month. Press ENTER.
Use UP ARROW or DOWN ARROW to
increment or decrement the date. Press
ENTER.
Use UP ARROW or DOWN ARROW to
increment or decrement the year. Press
ENTER.
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Activation and Startup
Display Reads:
Use UP ARROW or DOWN ARROW to
select either Yes or No.
Select YES to perform exercise at low speed. Select
NO to perform exercise at normal operating speed.
Quiet Test Mode?
Yes No
Press ENTER.
Display Reads:
Set Exercise Time.
In the AUTO mode, the engine starts and runs once
each week at the time and day specified. During the
exercise cycle, the unit runs approximately 12 minutes
and then shuts down. Transfer of loads to the generator
does not occur unless utility power fails.
Use UP ARROW or DOWN ARROW to
increment or decrement the hour. Press
ENTER.
Select Hour (0-23)
- 1 +
Use UP ARROW or DOWN ARROW to
increment or decrement the minute.
Press ENTER.
Use UP ARROW or DOWN ARROW to
scroll to the day of the week. Press
ENTER.
3.6 — Start and Run Engine
1. Pull up rubber flap covering fuse holder and verify installation of 7.5 amp fuse. See A of Figure 3-5.
2. Move the Main Circuit Breaker switch down to the OFF (Open) position. See B of Figure 3-5.
3. Press MANUAL on the control panel to start the engine. A blue LED illuminates to confirm that the system is in
the MANUAL mode. See C of Figure 3-5.
4. Allow the engine to run until it reaches normal operating temperature.
5. Press OFF on the control panel to stop the engine. A red LED illuminates to confirm that the system is in the OFF
mode.
7.5 Amp Fuse
and USB Port
A
B
LCD Screen
o
OFF
PUSH TO TRIP
Main Circuit Breaker
Control Panel
C
Figure 3-5. Generator Control Panel
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Activation and Startup
3.7 — Operational Checks
The following procedures require special tools and skills. Contact an authorized service provider to
perform these tasks.
+
3.7.1— Self Test
Upon power up, the controller goes through a system self test which checks for the presence of utility voltage on the
DC circuits. This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the
DC terminal block. If utility voltage is detected, the controller displays a warning message and locks out the generator,
thereby preventing damage to the controller. Remove power to the controller to clear this warning.
Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test
to be performed and pass.
Before starting, complete the following:
1. Verify that the generator is OFF. A red LED on the control panel illuminates to confirm that the system is in the
OFF mode.
2. Verify that the Main Circuit Breaker switch on the generator control panel is in the OFF (Open) position.
3. Turn off all circuit breakers/electrical loads that will be powered by the generator.
4. Check the coolant and engine lubricating oil levels. See Subsections 5.7.5 and 5.7.7, respectively.
During initial start up only, the generator may exceed the normal number of start attempts and experience an “over
crank” fault. This is due to accumulated air in the fuel system during installation. Reset the control board and restart up
to two more times, if necessary. If unit fails to start, contact the local dealer for assistance.
3.7.2— Check Manual Transfer Switch Operation
Refer to the manufacturer’s instructions.
Do not attempt manual transfer switch operation until all power voltage supplies to the transfer switch
have been positively turned off. Failure to turn off all power voltage supplies will result in extremely
hazardous and possibly fatal electrical shock.
+
3.7.3— Electrical Checks
Complete electrical checks as follows:
1. Verify that the generator is OFF. A red LED on the control panel illuminates to confirm that the system is in the
OFF mode.
2. Verify that the Main Circuit Breaker switch on the generator control panel is in the OFF (Open) position.
3. Turn OFF all circuit breakers/electrical loads that will be powered by the generator.
4. Turn on the utility power supply to the transfer switch using the means provided (such as a utility main line circuit
breaker).
The transfer switch is now electrically “hot.” Contact with “hot” parts will result in extremely hazard-
ous and possibly fatal electrical shock.
+
5. Use an accurate AC voltmeter to check utility power source voltage across transfer switch terminals N1, N2, and
N3 (if three phase). Normal line-to-line voltage should be equivalent to rated unit voltage.
6. Check utility power source voltage across terminals N1, N2, and N3 (if three phase) and the transfer switch neu-
tral lug.
7. When certain that utility supply voltage is compatible with transfer switch and load circuit ratings, turn OFF the
utility power supply to the transfer switch.
8. Press MANUAL on the control panel to crank and start the engine.
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Activation and Startup
9. Allow the engine to warm up for about five minutes. Move the Main Circuit Breaker switch on the generator con-
trol panel up to the ON (or closed) position.
Generator power voltage is now supplied to the transfer switch. Contact with live transfer switch parts
will result in dangerous and possibly fatal electrical shock.
+
10. Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1, E2, and E3 (if
three phase).
11. Successively connect the AC voltmeter test leads across terminal lugs E1, E2, and E3 (if three phase) and neu-
tral; then across E2 and neutral. Voltage reading in each case should match utility voltage reading. If system is
three phase, verify that generator phase rotation matches utility phase rotation.
12. Move the Main Circuit Breaker switch on the generator control panel down to the OFF (Open) position.
13. Press OFF on the control panel to shut the engine down.
Do not proceed unless certain that generator AC voltage and frequency are correct and within the
stated limits.
+
3.7.4— Test Generator Under Load
To test the generator set with electrical loads applied, proceed as follows:
1. Verify that the generator is OFF. A red LED on the control panel illuminates to confirm that the system is in the
OFF mode.
2. Turn OFF all breakers/electrical loads that will be powered by the generator.
3. Turn OFF the utility power supply to the transfer switch, using the means provided (such as a utility main line cir-
cuit breaker).
Do not attempt manual transfer switch operation until all power voltage supplies to the transfer switch
have been positively turned off. Failure to turn off all power voltage supplies will result in extremely
hazardous and possibly fatal electrical shock.
+
4. Manually set the transfer switch to the STANDBY position, i.e., load terminals connected to the generator’s E1,
E2, and E3 (if three phase) terminals.
5. Press MANUAL on the control panel. The engine will crank and start.
6. Allow the engine to warm up for a few minutes.
7. Move the Main Circuit Breaker switch on the generator control panel up to the ON (or closed) position. The
switch is now powered by the standby generator.
8. Turn ON the circuit breaker/electrical loads powered by the generator.
9. Connect a calibrated AC voltmeter and a frequency meter across terminal lugs E1, E2, and E3 (if three phase).
Voltage should be approximately unit rated voltage. Check with clamp on amp meter to ensure unit is not over-
loaded.
10. Let the generator run at full rated load for 20-30 minutes. Listen for unusual noises, vibration or other indications
of abnormal operation. Check for oil leaks, evidence of overheating, etc.
11. When testing under load is complete, turn OFF electrical loads.
12. Move the Main Circuit Breaker switch on the generator control panel up to the OFF (or open) position.
13. Allow the engine to run at no-load for 2-5 minutes.
14. Press OFF on the control panel to shut the engine down. A red LED illuminates to confirm that the system is in
the OFF mode.
3.7.5— Check Automatic Operation
To check the system for proper automatic operation, proceed as follows:
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Activation and Startup
1. Verify that the generator is OFF. A red LED on the control panel illuminates to confirm that the system is in the
OFF mode.
2. Install front cover of the transfer switch.
3. Turn ON the utility power supply to the transfer switch, using the means provided (such as a utility main line cir-
cuit breaker).
NOTE: Transfer Switch will transfer back to utility position.
4. Move the Main Circuit Breaker switch on the generator control panel up to the ON (or closed) position.
5. Press AUTO on the control panel. The system is now ready for automatic operation.
6. Turn OFF the utility power supply to the transfer switch.
With the generator ready for automatic operation, the engine will crank and start when the utility source power is turned
OFF after a 10 second delay (factory default setting). After starting, the transfer switch connects load circuits to the
standby side. Let the system operate through its entire automatic sequence of operation.
With the generator running and loads powered by generator AC output, turn ON the utility power supply to the transfer
switch. The system transfers back to the utility position and then runs through the cool down cycle and shuts down.
3.8 — Final Instructions
1. Use key to install left and right side access panels.
2. Close viewing window.
NOTE: Obtain viewing window hasp, if not installed. See
Figure 3-6. With the retaining tab at the bottom, insert
square end of hasp into slot below viewing window.
Push on hasp until it snaps in place. Gently pull on hasp
to verify that it will not come free.
3. Install customer supplied padlock into hasp.
Figure 3-6. Install Viewing Window Hasp
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Activation and Startup
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Section 4
Operation
4.1 — Control Panel
NOTE: The control panel is intended for use by qualified service personnel only.
The control panel is located behind the viewing window at the rear of the unit.
With the control panel set to AUTO, the engine may crank and start at any time without warning. Such
*
automatic starting occurs during the programmed exercise cycle or when utility power source voltage
drops below the configured level. To prevent possible injury that might occur during sudden starts,
always set the control panel to OFF, remove the negative battery cable from the negative battery post,
and remove the 7.5 amp fuse before working on or around the generator or transfer switch. For added
security, place a DO NOT OPERATE tag or placard on both the control panel and transfer switch.
7.5 Amp Fuse
and USB Port
LCD Screen
o
OFF
PUSH TO TRIP
AUTO
MANUAL
OFF
Main Circuit Breaker
ENTER
Control Panel
ESCAPE
Figure 4-1. Generator Control Panel
4.2 — Auto/Manual/Off
Feature
Description
Press to activate fully automatic operation. Green LED illuminates to confirm that system is in AUTO mode.
Transfer to standby power occurs if utility power fails.
AUTO
Functionality of exercise timer is enabled, if set.
Press to crank and start engine. Blue LED illuminates to confirm that system is in MANUAL mode.
Transfer to standby power occurs if utility power fails.
Functionality of exercise timer is disabled.
MANUAL
OFF
Press to shut down engine, if running. Red LED illuminates to confirm that system is in OFF mode.
Transfer to standby power does not occur if utility power fails.
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Operation
LCD Screen
UP ARROW
Green
LED
Blue
LED
Red
LED
ENTER
AUTO
MANUAL
OFF
DOWN ARROW
ESCAPE
Figure 4-2. Control Panel and LCD Screen
4.3 — Menu Navigation
See Figure 4-3.
Feature
Description
System Menus
The system returns to the Home screen if the control panel is not used for five minutes. The screen nor-
mally displays a Status message, such as Ready to Run (Auto mode) or Switched to OFF (Off mode), and
the total Hours of Protection. If an active alarm/warning condition occurs, the associated Alarm/Warning
message is displayed. To clear the Alarm/Warning message, press OFF on the control panel followed by
ENTER. In the event of multiple Alarms/Warnings, the next message is then displayed. The highest priority
alarm is always displayed first.
HOME Screen
Normally off. If the operator presses any button, the backlight will automatically light and remain on for 30
seconds.
Display Backlight
MAIN MENU
Enables the operator to navigate the software using UP ARROW, DOWN ARROW, ENTER and ESCAPE.
The Main Menu can be accessed from any sub menu by consecutively pressing ESCAPE. Each time
ESCAPE is pressed, the preceding menu is displayed. The Main Menu is reached when the System,
Date/Time, Battery, and Sub Menus are displayed.
SUB-MENUS
HISTORY
The Sub-Menus screen includes HISTORY, MAINT, EDIT, AND DEALER menus.
The HISTORY screen includes an Alarm Log and Run Log. The Alarm Log displays the last 50 alarm
events. The Run Log displays the last 50 operational events.
Includes Run Hours, Maintenance Log, and Scheduled. Run Hours displays cumulative hours on
engine. Maintenance Log displays the last service warnings and service completions. Scheduled
displays when the next scheduled maintenance interval warning will occur.
MAINTENANCE
MENU
Includes Language, Current Date/Time, Exercise Settings, Firmware Update, Startup Delay, and
Warmup Time. All of these settings are adjustable without a password.
EDIT MENU
Includes settings that are password protected and can be adjusted by an Independent Autho-
rized Service Dealer during installation or a service visit.
DEALER MENU
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Operation
Feature
Description
Navigation
ESCAPE
ENTER
Used to abort a routine or back up to the preceding menu.
Used to make a selection or save an entry.
UP ARROW
DOWN ARROW
Used to move forward or backward from menu to menu or to scroll forward or backward (increment or dec-
rement) through available selections.
NOTE: Pressing the control panel illuminates the backlight for 30 seconds. The backlight also illuminates for 30 seconds when-
ever an active Alarm/Warning message is displayed.
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Operation
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Operation
Figure 4-3. Navigation Menu
4.4 — Alarm/Warning Conditions
The owner/operator is alerted to Alarm and/or Warning conditions via the control panel LCD screen. All Alarm condi-
tions cause the generator to shut down. The Warning messages alert the operator to conditions that do not disable the
unit or require immediate correction.
The possible Alarm/Warning messages are listed below.
Alarm Messages
Warning Messages
• High Engine Temperature
• Low Oil Pressure
• Overcrank
• Low Battery
• Exercise Set Error
• Schedule A Maintenance
• Schedule B Maintenance
• Schedule C Maintenance
• Battery Problem
• Overspeed
• RPM Sense Loss
• Underspeed
• Controller Fault
• Ignition Fault Code
• WIRING ERROR
• Over Voltage
• Charger Warning
• Charger Missing AC
• USB Warning
• Download Failure
• Check Engine
• Under Voltage
• Overload
• Canbus Error
• Missing Cam Pulse
• Missing Crank Pulse
• Low Fuel Pressure
• E-Stop
NOTE: Unless properly trained to correct and clear Alarm/Warning conditions, contact an Authorized Dealer or trained
service technician.
4.5 — Change Time and Date
To change the time and date after activation, see the Navigation Menu in Figure 4-3. If power is lost (battery is discon-
nected/reconnected, control panel fuse is removed/installed, etc.), the display automatically prompts the user for the
Time and Date. All other information is retained in memory.
4.6 — Programmable Timers
4.6.1— Dealer Programmable
4.6.1.1—Exercise Time
A programmable exercise time is provided. In the AUTO mode, the engine starts and runs once each week at the time
and day specified. During the exercise cycle, the unit runs approximately 12 minutes and then shuts down. Transfer of
loads to the generator does not occur unless utility power fails.
NOTE: A Dealer password is required to change the duration of Exercise Cycle.
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Operation
4.6.2— User Programmable
4.6.2.1—Start-Up Delay Timer
A programmable line interrupt delay (or Start-Up Delay) timer is provided. When utility voltage fails (falls below 60% of
nominal), the start-up delay timer is started. If the voltage rises above the Utility Volts Low threshold, the timer is reset.
If the utility voltage remains below the threshold during the duration of the timer, the unit cranks and starts.
NOTE: The factory default setting is five seconds, but is adjustable from 2 to 1500 seconds.
4.6.2.2—Warm-Up Delay Timer
A programmable Warm-Up Delay timer is provided. As soon as the generator starts, the warm-up timer is started.
When the warm-up timer expires, the control transfers load to the generator (through the transfer switch) if the utility
voltage is less than 80% of nominal. If utility voltage is greater than the threshold at expiration of the warm-up time, the
load is not transferred to the generator and a cool-down period begins. At the end of the cool-down period, the gener-
ator stops.
NOTE: The factory default setting is five seconds, but is adjustable from 5 to 1500 seconds.
4.7 — USB Port for Firmware Updates
A USB port is located beneath the rubber flap on the control panel, and is provided for firmware updates. Firmware
updates must be performed by an Independent Authorized Service Dealer.
NOTE: The USB port is intended for use with a USB thumb drive only. The USB port is not intended for charging
devices such as phones or laptops. Do not connect any consumer electronics to the USB port.
4.8 — Battery Charger
NOTE: The battery charger is integrated into the control panel module.
The battery charger ensures:
• Output is continually optimized to promote maximum battery life.
• Charging levels are safe.
NOTE: A warning message is displayed on the LCD screen when the battery requires service.
4.9 — Transfer Switch Automatic Operation
In AUTO, the generator starts automatically when utility source voltage drops below the preset level. Once the unit
starts, loads are transferred to the standby power source.
To select automatic operation:
1. Verify that the transfer switch main contacts are set to the UTILITY position (loads connected to the utility power
source).
2. Verify that normal UTILITY power source voltage is available to transfer switch terminal lugs N1, N2 and N3 (if
three phase).
3. Move the Main Circuit Breaker switch on the control panel up to the ON (Closed) position.
4. Press AUTO on the control panel. A green LED illuminates to confirm that the system is in the AUTO mode.
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Operation
4.9.1— Automatic Sequence of Operation
4.9.1.1—Utility Failure
If the control panel is set to AUTO when the utility power fails, a ten second Start-Up Delay timer is started (user pro-
grammable). If utility power is still absent when the time expires, the engine cranks and starts.
Once started, a five second engine Warm-Up Delay timer starts (user programmable). When the time has elapsed, the
load is transferred to the generator. If utility power is restored (above 90% of nominal, dealer programmable) between
the time the engine is first started and expiration of the warm-up time, the controller completes the start cycle and then
runs through its normal cool-down cycle (while the load remains on the utility source throughout the episode).
4.9.1.2—Cranking
The cyclic cranking is controlled as follows:
Fifteen (15) seconds crank, seven (7) seconds rest, seven (7) seconds crank, seven (7) seconds rest; this sequence is
repeated for a total of six (6) crank cycles.
4.9.1.3—Load Transfer
With the generator running, the transfer of load is dependent upon the operating mode as follows:
• Starts and runs if utility power fails (falls below 60% of nominal) for five consecutive sec-
onds (adjustable).
• Starts a five second (adjustable) engine warm-up timer.
• Does not execute transfer if utility power returns before expiration of warm-up timer (but
finishes the warm-up and cool-down cycles).
• Transfers back to utility once utility power returns (above 80% of nominal) for fifteen
consecutive seconds.
• Only shuts down if OFF is pressed or an alarm shutdown occurs.
AUTO
• Once utility power returns, starts a cool-down cycle before it shuts down.
NOTE: Cool-down cycle is five minutes if turbocharger equipped, one minute if naturally
aspirated.
EXERCISE
• Only works in AUTO mode.
• Does not exercise if generator is already running in AUTO.
• During exercise cycle, transfers only if utility power fails for ten consecutive seconds.
• Engine cranks and runs even if utility power is present, but does not transfer to generator.
• Transfers to generator if utility fails (falls below 60% of nominal) for ten consecutive sec-
MANUAL
onds.
• Transfers back to utility when utility returns for fifteen consecutive seconds. The engine
continues to run until the AUTO or OFF key is pressed.
4.10 — Transfer Switch Manual Operation
DO NOT attempt to activate the transfer switch manually until all power voltage supplies to the switch
have been completely turned off. Failure to turn off all power voltage supplies may result in extremely
hazardous and possibly fatal electrical shock.
Prior to automatic operation, manually exercise the transfer switch to verify that there is no binding or interference with
proper operation of the mechanism. Manual operation of the transfer switch is required if automatic operation fails.
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Operation
IMPORTANT NOTE: Always use the applicable transfer switch owner's manual for actual manual transfer
switch operation instructions. The information presented here describes a transfer switch, which is not used
for three phase applications. See specific manual for three phase transfer switch.
4.10.1— Transfer to Generator Power
When utility power fails, manually transfer to standby power and start the generator as follows:
1. Press OFF on the control panel. A red LED illuminates to confirm that the system is in the OFF mode.
2. Move the Main Circuit Breaker switch down to the OFF (Open) position.
3. Turn off the utility power supply to the transfer switch using the means provided (such as a utility main line circuit
breaker).
4. Use the manual transfer handle inside the transfer switch to move the main contacts to the STANDBY position
(loads connected to the standby power source).
5. Press MANUAL on the control panel. The engine cranks and starts.
6. Allow the engine to run for two minutes to bring it up to normal operating temperature.
7. Move the Main Circuit Breaker switch up to the ON (Closed) position.
Manual Transfer
Handle
Load Connected to Utility
Load Connected to Standby
Transfer Switch
Operating Lever
NOTE: V-style transfer switch not used for three phase applications.
Figure 4-4. Manual Transfer Switch Operation (Typical)
4.10.2— Transfer Back to Utility Power
When utility power is restored, manually transfer back to utility power and shut down the generator as follows:
NOTE: Verify that utility voltage has returned and is at the proper value.
1. Move the Main Circuit Breaker switch down to the OFF (Open) position.
2. Allow the engine to run for two minutes at no-load to bring it up to normal operating temperature.
3. Press OFF on the control panel to shut down the engine.
4. Verify that utility power supply to the transfer switch is turned off.
5. Use the manual transfer handle inside the transfer switch to move the main contacts to the UTILITY position
(loads connected to the utility power source).
6. Turn on the utility power supply to the transfer switch using the means provided.
7. Press AUTO on the control panel. A green LED illuminates to confirm that the system is in the AUTO mode.
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Section 5
Maintenance
5.1 — Component Locations
The side of the enclosure with the viewing window is identified as the rear of the generator set. The right and left sides
are identified by standing at the rear and looking towards the front of the unit.
NOTE: The 2.4L (32 kW) unit is depicted in the artwork used in this manual. The location and appearance of
some components may vary between engine models.
Viewing
Window
7.5 Amp Fuse
and USB Port
Main Circuit Breaker
Control Panel
and LCD Screen
Left Side
Right Side
Figure 5-1. Rear View
Oil Fill Cap
Air Filter Element
Timing Belt
Oil Level
Dipstick
Oil Filter
Figure 5-2. Right Side View
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Maintenance
Coolant Overflow
Reservoir
Spark Plugs
Coolant Drain
Oil
Drain Hose
Battery
Figure 5-3. Left Side View
NOTE: All normal maintenance and service items are easily accessible for consumer convenience. Wherever
possible, touch points are colored orange to provide for quick and easy recognition.
5.2 — Access Panels
Access panels are located at both the left and right sides of the enclosure.
5.2.1— Removal
1. Insert key into latch and rotate counterclockwise 1/2 turn. See Figure 5-4.
2. Raise panel using thumb latch.
Key
Thumb Latch
Figure 5-4. Access Panel Key
5.2.2— Installation
1. Lower panel into position using thumb latch.
2. Insert key into latch and rotate clockwise 1/2 turn.
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Maintenance
5.3 — Service Maintenance Intervals
NOTE: Use only Genuine Generac parts to ensure warranty coverage.
All generator service must be performed by an authorized service provider or a qualified service person-
nel only.
*
It is important to perform all maintenance at the interval specified in the Service Maintenance Schedule. This ensures
safe and proper operation, as well as compliance with applicable emissions standards. Critical emissions maintenance
must be performed for the Emissions Warranty to remain valid. Service and repairs may be performed by an authorized
service provider, any qualified service technician, or repair shop.
Observe the maintenance tasks and intervals shown in the table below.
Schedule A
Every
Schedule B Schedule C
Daily If Running
Continuously
30 Hours
Engine Break In
Every
Every
Service
Year or
2 Years or
250 Hours
1000 Hours
125 Hours
Check Enclosure Louvers
Check Fuel Lines
Check Coolant Level and Hoses
Check Radiator for Clogging
Check Lubricating Oil Level and Drain Hose
Replace Lubricating Oil and Oil Filter
Check Battery Condition/Fluid Level
Check/Adjust Accessory/Drive Belt Tension
Replace Air Filter Element
Drain/Flush Coolant System
Clean/Gap/Replace Spark Plugs
Replace Timing Belt (2.4L Engines Only)
Tighten Critical Fasteners
NOTE: If the unit reaches a Schedule A or Schedule B maintenance interval with 900 to 999 total hours, have
an authorized service provider perform the Schedule C maintenance tasks as well (and reset the A-B-C/Year
maintenance schedule counter).
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Maintenance
5.4 — Remove From Service
To ensure safety, follow the steps below prior to inspection, maintenance or service.
IMPORTANT NOTE: If currently experiencing a utility outage, see Subsection 6.3 —Removal From Service
During Utility Outages for special instructions.
1. Open the viewing window. See Subsection 3.4 —Open Viewing Window.
2. Move the Main Circuit Breaker switch down to the OFF (Open) position. See A of Figure 5-5.
3. Press OFF on the control panel. A red LED illuminates to confirm that the system is in the OFF mode. See B of
Figure 5-5.
4. Remove T1 fuse from transfer switch.
5. Pull up rubber flap covering fuse holder and remove 7.5 amp fuse. See C of Figure 5-5.
6. Disconnect NEGATIVE battery cable.
7. Place a DO NOT OPERATE tag or placard on both the control panel and transfer switch.
8. If the unit has been running, wait five minutes for the engine to cool.
C
7.5 Amp Fuse
and USB Port
A
LCD Screen
o
OFF
PUSH TO TRIP
Main Circuit Breaker
Control Panel
B
Figure 5-5. Generator Control Panel
5.5 — 30 Hour Break-In
Perform the following task:
• Replace Lubricating Oil and Oil Filter
NOTE: See Subsection 5.7.8 under Schedule A Maintenance.
5.6 — Daily Maintenance
Perform the following tasks:
• Check Enclosure Louvers
• Check Fuel Lines
• Check Radiator for Clogging
• Check Lubricating Oil Level and Drain Hose
• Check Coolant Level and Hoses
NOTE: See Subsection 5.7.3 through Subsection 5.7.7 under Schedule A Maintenance.
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Maintenance
5.7 — Schedule A Maintenance
NOTE: Perform Schedule A maintenance once each year or after 125 hours of service, whichever comes first.
NOTE: The 2.4L (32 kW) unit is depicted in the artwork used in this manual. For the general location of compo-
nents in all other models, see Subsection 5.7.1—Schedule A Maintenance Item Locations.
5.7.1— Schedule A Maintenance Item Locations
NOTE: The side of the enclosure with the viewing window is identified as the rear of the generator set. The
right and left sides are identified by standing at the rear and looking towards the front of the unit.
Model
22/27 kW
2.4L
25/30 kW
1.5L
32/38 kW
2.4L
36/45 kW
2.4L
48 kW
5.4L
60 kW
2.4L
Engine
Coolant Overflow Reservoir
Oil Dipstick
L
L
L
L
L
L
L
R
R
R
R
R
L
R
E
R
R
E
L
R
E
L
R
E
R
L
L
R
E
Oil Drain Hose
Oil Filter
R
Oil Fill Cap
Oil Supply Tank Fill Cap
Battery
-
-
-
TL
L
-
TL
L
L
E
R
E
L
E
R
E
E
E
Fan Belt
L
R
L
L
E
L
Air Filter Element
R = Right Side
L = Left Side
E = Either Side
T = Top
- = Not Applicable
5.7.2— Preliminary Instructions
1. See Subsection 5.4 —Remove From Service.
2. Remove left and right side access panels. See Subsection 5.2 —Access Panels.
3. Remove battery negative cable (black) from battery negative (-) terminal.
5.7.3— Check Enclosure Louvers
1. Verify that intake and exhaust louvers and openings are clean and unobstructed. Keep clear of leaves, grass,
snow, and debris.
2. Wipe exterior surfaces clean using a damp cloth.
3. Loosen dirt, oil, etc. with a soft bristle brush.
4. Remove loose dirt and debris using a vacuum cleaner, or low pressure compressed air (not exceeding 25 psi).
NOTE: Periodically wash and wax enclosure using automotive type products. Frequent washing is recom-
mended in salt water/coastal areas.
5.7.4— Check Fuel Lines
1. Check fuel lines for leaks. Tighten fittings and clamps, if necessary.
2. Check fuel lines for nicks, dents, kinks or other damage. Replace as necessary.
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Maintenance
5.7.5— Check Coolant Level and Hoses
Do not add coolant when the engine is hot. Steam and scalding fluids can cause severe burns.
*
1. Verify that the coolant level is between the HOT and COLD marks on the overflow reservoir. See Figure 5-6.
NOTE: Coolant expands when hot, so the level may be higher than the HOT mark. Do not add coolant higher
than the HOT mark.
2. If the coolant level is below the COLD mark, remove fill cap from overflow reservoir and add coolant. See Sub-
section 2.5 —Coolant Water Treatment.
3. Check coolant hoses for leaks. Tighten hose clamps, if necessary.
4. Check hoses for nicks, cuts, tears or general deterioration. Replace as necessary.
Figure 5-6. Coolant Overflow Reservoir
5.7.6— Check Radiator for Clogging
1. Direct beam of flashlight into enclosure to inspect the radiator fins.
2. Look for debris, accumulations of dirt or other deposits.
3. Carefully remove any debris from radiator fins. Use warm soapy water and a soft bristled brush to remove dirt
and other deposits, if necessary.
5.7.7— Check Lubricating Oil Level and Drain Hose
NOTE: If changing engine lubricating oil and filter, see Subsection 5.7.8—Replace Lubricating Oil and Oil Fil-
ter.
1. If the engine was running, allow at least 10 minutes to elapse to ensure that the oil has fully drained into the oil
pan.
NOTE: The most accurate oil level readings are obtained when the engine is cold.
2. Remove the dipstick and wipe dry with a clean, lint free cloth. See B of Figure 5-7
3. Slowly insert the dipstick into the dipstick tube.
4. Verify that the dipstick is fully seated in the dipstick tube.
NOTE: Some dipsticks require more effort to fully seat than others.
5. Allow at least 10 seconds to elapse.
6. Slowly remove the dipstick.
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Maintenance
7. Verify that the oil level is at or near the FULL mark. Add oil as necessary. See A of Figure 5-7
NOTE: Observe the oil level on both sides of the dipstick. The lower of the two readings is the correct oil level
measurement.
8. If necessary, remove the oil fill cap and slowly add oil. Do not fill above “FULL” mark on dipstick.
9. Install dipstick and oil fill cap.
10. Install battery negative cable (black) onto battery negative (-) terminal.
11. Pull up rubber flap covering fuse holder and install 7.5 amp fuse.
12. Press MANUAL on the control panel to start the engine.
13. Allow the engine to run for one minute.
14. Press OFF on the control panel to shut down the engine. A red LED illuminates to confirm that the system is in
the OFF mode.
15. Return to step 1.
NOTE: The most common reasons for inaccurate oil level readings are:
• Reading the dipstick before the oil has fully drained into the oil pan.
• Inserting and removing the dipstick too quickly.
• Reading the dipstick when it has not been fully seated in the dipstick tube.
• Reading only the high level side of the dipstick.
16. Check oil drain hose for leaks. Check hose for nicks, cuts, tears or general deterioration. Replace as necessary.
17. Pull up rubber flap covering fuse holder and remove 7.5 amp fuse.
18. Remove battery negative cable (black) from battery negative (-) terminal.
NOTE: On 36 kW, 45 kW, and 60 kW models, check the level of oil in the clean oil supply tank. Add clean oil as
necessary. For more information, see Subsection 5.11 —Lube Oil Maintainer System.
A
B
FULL
1.5L
5.4L
2.4L
Figure 5-7. Oil Level Dipstick and Oil Fill Cap
5.7.8— Replace Lubricating Oil and Oil Filter
NOTE: On 36 kW, 45 kW, and 60 kW models, close shutoff valve to avoid draining the oil supply tank with the
crankcase oil. For more information, see Subsection 5.11 —Lube Oil Maintainer System.
1. Remove oil drain hose from holding clamp. See A of Figure 5-8
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Maintenance
2. Use one wrench to hold hex on hose fitting (to prevent rotation), and use second wrench to remove drain plug.
Hot oil may cause burns. Allow engine to cool before draining oil. Avoid prolonged or repeated skin
exposure with used oil. Thoroughly wash exposed areas with soap
*
3. Drain oil into a suitable container.
4. Install drain plug onto end of oil drain hose.
5. Install oil drain hose into holding clamp.
6. Rotate oil filter counterclockwise to remove from oil filter adapter. See B of Figure 5-8
7. Apply a light coat of clean engine oil to gasket of new oil filter.
8. Install oil filter by hand until gasket just contacts oil filter adapter. Tighten oil filter an additional 3/4 to one full turn.
9. Remove fill cap and fill engine with the recommended quantity and type of oil. See Subsection 2.3 —Engine Oil
Recommendations. Crankcase oil capacity is listed below:
Lubrication System Capacity (Oil Pan Including Oil Filter)
Model
22/27 kW
2.4L
25-30 kW
1.5L
32/38 kW
2.4L
36/45 kW
2.4L
48 kW
5.4L
60 kW
2.4L
Engine
4.0 quarts (3.8 liters)
6.0 quarts (5.7 liters)
5.25 quarts (5 liters)
10. Install fill cap.
11. Install battery negative cable (black) onto battery negative (-) terminal.
12. Pull up rubber flap covering fuse holder and install 7.5 amp fuse.
13. Press MANUAL on the control panel to start the engine.
14. Allow the engine to run for one minute. Check for leaks while the engine is running.
15. Press OFF on the control panel. A red LED illuminates to confirm that the system is in the OFF mode.
16. Wait ten minutes for the engine to cool and to allow oil to drain back to the oil pan.
17. Check oil level and add oil as necessary. See Subsection 5.7.7—Check Lubricating Oil Level and Drain Hose.
18. Install fill cap.
NOTE: On 36 kW, 45 kW, and 60 kW models, open shutoff valve to enable Lube Oil Maintainer System.
NOTE: Dispose of used oil and oil filter at a proper collection center.
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Maintenance
A
B
Figure 5-8. Oil Drain Hose, Fill Cap, Dipstick and Filter
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Maintenance
Oil Fill Cap
Air Cleaner
Air Cleaner
Oil Fill Cap
Oil Filter
Oil Filter
Oil Level
Oil Level
Dipstick
Dipstick
2.4L: 22/27/36/45 kW
2.4L: 32/38 kW
Oil Fill Cap
Oil Fill Cap
Air Cleaner
Air Cleaner
Oil Filter
Oil Filter
Oil Level
Dipstick
Oil Level
Dipstick
2.4L: 60 kW
1.5L: 25/30 kW
Oil Fill Cap
Oil Level
Dipstick
Air Cleaner
Oil Filter
5.4L: 48 kW
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Maintenance
Figure 5-9. Engine Oil and Air Cleaner Maintenance (All Models)
5.7.9— Check Battery Condition/Fluid Level
5.7.9.1— Check Condition and Clean
1. Verify that top of battery is clean and dry. Dirt and electro-
lyte on top of the battery can cause battery to self-dis-
charge. Clean battery top with a solution of baking soda
(sodium bicarbonate) and water (5 teaspoons baking
soda per quart or liter of water). When solution stops bub-
bling, rinse off the battery with clean water.
2. Clean cable clamps and battery terminals using a wire
brush or sandpaper to remove any oxidation.
3. Inspect battery screws, clamps and cables for breakage,
loose connections and corrosion. Tighten and clean as
necessary.
4. Check the battery posts for melting or damage caused by
over tightening.
Red Lead
From Starter
5. Inspect battery for discoloration, raised top or a warped
or distorted case, which might indicate that the battery
has been frozen, overheated or overcharged.
6. Inspect the battery case for cracks or leaks.
7. Check the battery fluid level of unsealed batteries. See
Subsection 5.7.9.2—Check Fluid Level.
8. Check the battery state of charge. See Subsection
Black Lead
To Frame
5.7.9.3—Check State of Charge.
9. Replace battery if necessary. See Subsection 5.7.9.4—
Battery
Battery Replacement.
5.7.9.2— Check Fluid Level
Figure 5-10. Battery Cable Connections
Check the fluid level of unsealed batteries. If necessary, fill with
distilled water only. DO NOT use tap water.
5.7.9.3— Check State of Charge
Check the state of charge using a Digital Multimeter. Recharge and retest if state of charge is below manufacturer's
recommendations. Replace battery if necessary.
5.7.9.4— Battery Replacement
Removal
Always disconnect the negative battery cable first. If the positive cable should contact ground with the
negative cable installed, the resulting sparks may cause a battery explosion which could result in seri-
ous injury.
$
1. Remove battery negative cable (black) from battery negative (-) terminal.
2. Remove battery positive cable (red) from battery positive (+) terminal.
3. Install rubber protective cover over battery positive (+) terminal. See A of Figure 5-11
4. Loosen two screws with nylon washers to release battery hold-down clamp from battery tray.
5. Grasp battery strap, and lift battery from battery tray. See B of Figure 5-11
6. Remove rubber protective cover from battery positive (+) terminal.
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Maintenance
Installation
Always connect the positive battery cable first. If the positive cable should contact ground with the
negative cable installed, the resulting sparks may cause a battery explosion which could result in seri-
ous injury.
$
1. Install rubber protective cover over battery posi-
tive (+) terminal. See A of Figure 5-11
2. Grasp battery strap and lift battery. See B of
Figure 5-11
3. Set battery onto battery tray.
4. Tighten two screws with nylon washers to
A
B
secure hold-down clamp to battery tray.
5. Remove rubber protective cover from battery
positive (+) terminal.
6. Install battery positive cable (red) to battery
positive (+) terminal.
7. Install battery negative cable (black) to battery
negative (-) terminal.
NOTE: If continuing with Schedule A maintenance
procedures, leave the battery negative cable
(black) disconnected.
5.7.10— Check and Adjust Accessory/
Drive Belt
A = Protective Cover
B = Battery Strap
5.7.10.1— Check
Check the accessory/drive belt condition.
1. Perform visual inspection as follows:
Figure 5-11. Remove/Install Battery
• Inspect belt for cracks, fraying, excessive wear
or other damage.
• Verify that belt is free of grease and oil. Replace belt if contaminated.
NOTE: Use a solution of soap and warm water to clean pulleys, if necessary. Avoid use of solvents, but if
used, always follow by a soap and water wash.
2. Check the fan belt deflection. Adjust the belt deflection as follows:
• Using a suitable gauge, apply 22 Ibs (10 kgf) force midway between the water pump and alternator pulleys. See
Figure 5-12
NOTE: 5.4L (48 kW) units are provided with an automatic belt tensioner and do not need adjustment.
• Take note of gauge reading. If belt deflection is not within specification, see Subsection 5.7.10.2—Adjust.
English
Metric
Belt Deflection
3/8 - 5/8 Inches
7.6 - 12.7 cm
5.7.10.2— Adjust
1. Loosen DC alternator tension bracket screw. Rotate alternator outward to reduce belt deflection, rotate inward to
increase belt deflection.
2. Tighten DC alternator tension bracket screw to 17-22 ft-lbs (23-30 N-m).
3. Recheck belt deflection and repeat steps as necessary.
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Maintenance
Water Pump Pulley
Belt Deflection Gauge
Alternator Pulley
2.4L: Manual Adjustment
Automatic Tensioner
1.5L: Manual Adjustment
5.4L: Automatic Adjustment
Figure 5-12. Check Accessory/Drive Belt Deflection
5.7.11— Replace Air Filter Element
1. Remove wing nut, lock washer and flat washer from threaded rod to release air cleaner cover. See Figure 5-13
2. Remove the air filter element and discard.
3. Thoroughly clean air cleaner cover of any dust, dirt, or debris.
4. Place new air filter element against adapter flange.
NOTE: The air filter element is not directional.
5. Install air cleaner cover over threaded rod. Install flat washer, lock washer and wing nut. Tighten wing nut until
snug.
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Maintenance
Element
Cover
Wing Nut
Flat Washer
Lock Washer
Figure 5-13. Air Cleaner Cover and Filter Element
NOTE: Service kits are available from Independent Authorized Service Dealers.
5.7.12— Final Instructions
If only performing Schedule A maintenance procedures, proceed as follows:
1. Install battery negative cable (black) onto battery negative (-) terminal.
2. Install left and right side access panels. See Subsection 5.2 —Access Panels.
3. See Subsection 5.10 —Return To Service.
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Maintenance
5.8 — Schedule B Maintenance
NOTE: Perform Schedule B maintenance every two years or after 250 hours of service, whichever comes first.
Before proceeding below, first perform all tasks listed under Schedule A Maintenance.
NOTE: The 2.4L (32 kW) unit is depicted in the artwork used in this manual. For the general location of compo-
nents in all other models, see Subsection 5.8.1—Schedule B Maintenance Item Locations.
5.8.1— Schedule B Maintenance Item Locations
NOTE: The side of the enclosure with the viewing window is identified as the rear of the generator set. The
right and left sides are identified by standing at the rear and looking towards the front of the unit.
Model
22/27 kW
2.4L
25/30 kW
1.5L
32/38 kW
2.4L
36/45 kW
2.4L
48 kW
5.4L
R
60 kW
2.4L
L
Engine
L
R
L
L
Coolant Drain Hose
T
T
T
T
T
T
Radiator Fill Cap
Coolant Overflow Reservoir
Spark Plugs
L
L
L
L
L
L
L
L
L
L
R
B
R = Right Side
L = Left Side
B = Both Sides
T = Top
5.8.2— Drain/Flush Coolant System
1. Disconnect and empty coolant overflow reservoir.
2. Install and connect coolant overflow reservoir.
Verify that the engine is cool before removing the radiator cap. The cooling system is under pressure,
so steam and hot liquid can come out forcefully when the cap is loosened.
*
3. Rotate and remove plastic cover at top of enclosure.
4. Slowly unscrew radiator cap.
5. Locate drain cock at bottom left side of radiator.
NOTE: If unit is not equipped with drain hose, install suitable length of rubber hose to drain cock.
6. Rotate hex fitting to open drain cock. See A of Figure 5-14
7. Remove coolant drain hose from holding clamp.
8. Use wrench to hold hex on hose fitting (to prevent rotation), and use second wrench to remove drain plug.
9. Drain coolant into a suitable container.
10. Install plug at end of drain hose.
11. Install drain hose in holding clamp.
12. Rotate hex fitting to close radiator drain cock.
13. Obtain the recommended quantity and type of coolant. See Subsection 2.5 —Coolant Water Treatment.
System Coolant Capacity
Model
22/27 kW
2.4L
25/30 kW
1.5L
32/38 kW
2.4L
36/45 kW
2.4L
48 kW
5.4L
60 kW
2.4L
Engine
2.0 gallons (7.6 liters)
2.5 gallons (9.5 liters)
3.0 gallons (11.4 liters)
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Maintenance
14. Insert funnel into filler neck of radiator. See B of Figure 5-14
15. Slowly pour coolant into filler neck until radiator is full.
16. Install radiator cap.
17. Press MANUAL on the control panel to start the engine. A blue LED illuminates to confirm that the system is in
the MANUAL mode.
18. Allow engine to run until the thermostat opens, as indicated by heating of the top radiator hose.
19. Check coolant hoses for leaks. Tighten clamps, if necessary.
20. Press OFF on the control panel to shut the engine down.
21. Wait for the engine to cool.
22. Repeat steps 4-21 to drain and refill cooling system.
23. Slowly unscrew radiator cap. Slowly pour coolant into filler neck until radiator is full.
24. Add coolant to the overflow reservoir. See Subsection 5.7.5—Check Coolant Level and Hoses.
25. Install plastic cover at top of enclosure and rotate until tight.
26. Check hoses for nicks, cuts, tears or general deterioration. Replace as necessary.
A
B
NOTE: Drain hose removed for
illustration purposes.
Figure 5-14. Drain/Fill Coolant System
5.8.3— Clean/Gap/Replace Spark Plugs
Clean, gap or replace spark plugs as follows:
Never disconnect a spark plug with the engine running. Doing so will result in an electric shock that
could result in death or serious injury.
+
1. Remove battery negative cable (black) from battery negative (-) terminal.
2. Remove spark plug cables from spark plug terminals. See A of Figure 5-15
NOTE: When disconnecting spark plug cable from spark plug terminal, always grasp and pull on the boot at
the terminal end of the cable. Pulling on cable portion can result in parts damage.
3. Thoroughly clean area around spark plugs.
4. Remove spark plugs from cylinder head using a 5/8 inch spark plug socket.
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Maintenance
A
B
Figure 5-15. Adjust Spark Plug Gap
5. Check condition of threads in cylinder head and on spark plugs. If necessary, soften deposits with penetrating oil
and clean out with a thread chaser.
6. Clean spark plugs using a wire brush and commercial solvent. Do not blast spark plugs. Use new spark plugs if
necessary.
7. See B of Figure 5-15 Check spark plug gap using a wire feeler gauge. Adjust gap by carefully bending ground
electrode as follows:
Spark Plug Gap
Model
22/27 kW
2.4L
25/30 kW
1.5L
32/38 kW
2.4L
36/45 kW
2.4L
48 kW
5.4L
60 kW
2.4L
Engine
0.71 mm (0.028 in.)
0.9 mm (0.035 in.)
1.07-1.17 mm (0.042-0.046 in.)
1.29-1.45 mm (0.051-0.057 in.)
8. Finger tighten spark plugs into cylinder head, and then using a spark plug socket, tighten as follows:
Spark Plug Torque
Engine
1.5L, 2.4L
5.4L
ft-lbs
18
N-m
25
13
18
9. Install spark plug cables onto spark plug terminals.
10. Verify that spark plug cables are captured in cable clips at top of valve cover.
5.8.4— Final Instructions
If only performing Schedule A and Schedule B maintenance procedures, proceed as follows:
1. Install battery negative cable (black) onto battery negative (-) terminal.
2. Install left and right side access panels. See Subsection 5.2 —Access Panels.
3. See Subsection 5.10 —Return To Service.
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Maintenance
5.9 — Schedule C Maintenance
NOTE: Perform Schedule C maintenance after 1000 hours of service. Before proceeding below, first perform all
tasks listed under Schedule A Maintenance and Schedule B Maintenance.
The following procedures require special tools and skills. Contact an authorized service provider to
perform these tasks.
*
1. Remove battery negative cable (black) from battery negative (-) terminal.
2. Proceed as follows:
• Replace Timing Belt (2.4L engines only)
• Tighten Critical Fasteners
NOTE: Reset the A-B-C/Year time maintenance schedule counter using the Dealer Sub Menu (password
required).
3. Install battery negative cable (black) onto battery negative (-) terminal.
4. Install front access panel. Install left and right side access panels. See Subsection 5.2 —Access Panels.
5. See Subsection 5.10 —Return To Service.
5.10 — Return To Service
After inspection, maintenance or service of the generator, return the unit to service as follows:
1. Pull up rubber flap covering fuse holder and install 7.5 amp fuse. See A of Figure 5-16.
2. Install T1 fuse in transfer switch.
3. Press AUTO on the control panel. A green LED illuminates to confirm that the system is in the AUTO mode. See
B of Figure 5-16.
4. Move the Main Circuit Breaker switch up to the ON (Closed) position. See C of Figure 5-16.
5. Close the viewing window.
6. Remove the DO NOT OPERATE tag or placard from both the control panel and transfer switch.
7. Reset the time and date.
7.5 Amp Fuse Holder
A
C
LCD Screen
o
OFF
PUSH TO TRIP
Main Circuit Breaker
Control Panel
B
Figure 5-16. Generator Control Panel
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Maintenance
5.11 — Lube Oil Maintainer System
5.11.1— Description
NOTE: Oil reservoir is empty when shipped from factory. Fill with clean engine oil to activate the system.
The 36 kW, 45 kW, and 60 kW models are equipped with a Lube Oil Maintainer System. The system is installed at the
factory and calibrated at the factory to the correct engine-running crankcase oil level. As needed, the system keeps the
engine lubricating oil full by automatically adding clean oil from the oil supply tank.
See A of Figure 5-17. The green bar observed through the viewing lens shows the normal oil level operating range of
the Lube Oil Maintainer Regulator during engine running operation. When the oil level is within the green bar, the inter-
nal float holds the inlet valve closed to keep the crankcase oil at the current level.
As the engine uses oil, the float drops to open the inlet valve and allow clean oil to be supplied to the crankcase,
replenishing engine oil to the full mark indicated on the oil dipstick. The float then rises with the crankcase oil level until
it reaches a point where the inlet valve closes.
When the oil level as observed through the viewing lens is below the normal operating range green bar, it is an indica-
tion that the oil supply tank is low or the oil inlet screen is clogged. See B of Figure 5-17.
NOTE: It is normal for the oil level to be above the normal operating range green bar when engine is not run-
ning.
A
B
Oil Inlet
Screen
Test
Button
Normal
Operating
Range
Low Zone
Viewing Lens
Green Bar
Figure 5-17. Lube Oil Maintainer Regulator
NOTE: When changing engine oil, always close the shutoff
valve to avoid draining the clean oil in the oil supply tank with
the crankcase oil. See Figure 5-19.
5.11.2— Fill Oil Supply Tank
1. Rotate plastic cover counter-clockwise and remove from top
of enclosure. See Figure 5-18.
2. Remove fill cap at top of oil supply tank (Figure 5-20.).
3. Add clean engine oil to oil supply tank (2-1/2 gallons [9.46
liters] capacity).
4. Install fill cap at top of oil supply tank.
5. Install plastic cover at top of enclosure and rotate clockwise
until tight.
Figure 5-18. Access Oil Supply Tank
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Maintenance
5.11.3— Test Functionality
See A of Figure 5-17. Momentarily press the test button to confirm that the float is operating correctly.
Do not hold the test button down for a prolonged period of time or the crankcase can be over filled. Over
filling the crankcase can result in engine damage.
*
5.11.4— Shutoff Valve
See Figure 5-19 and Figure 5-20. When draining engine crank-
case oil, always close shutoff valve to avoid draining clean oil from
supply tank.
After filling crankcase with clean oil, remember to open shutoff
valve to enable operation of Lube Oil Maintainer System.
Figure 5-19. Shutoff Valve
(Shown in Open Position)
FILL CAP
Oil Supply
Tank
Oil Inlet
Hose
Test
Button
2 1/2 GALLON OIL
SUPPLY TANK
Viewing
Lens
Running
Engine
Crankcase
Oil
Level
SHUTOFF VALVE
TEST BUTTON
Center of
Green Bar
Crankcase
Hose
REGULATOR
ENGINE CRANKCASE
OIL PAN
REGULATOR VIEWING
LENS
OIL DRAIN
HOSE
Figure 5-20. Lube Oil Maintainer Assembly
and Function Diagram
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Section 6
Troubleshooting
6.1 — Engine Troubleshooting
Problem
Cause
Correction
Replace 7.5 amp fuse in generator con-
trol panel. Correct short circuit condi-
tion if fuse blows again.
Fuse blown.
Loose, corroded or defective bat-
tery cables.
Tighten, clean or replace as neces-
sary.*
The engine will not crank.
Tighten, clean or replace as neces-
sary.*
Defective starter contact.
Defective starter motor.
Tighten, clean or replace as neces-
sary.*
Dead Battery.
Charge or replace battery.
Out of fuel.
Replenish fuel. Turn on fuel valve.
*
Defective fuel solenoid.
Replace F1 7.5 amp fuse if fuse blows
again.*
Open F1 7.5 amp fuse.
Open F2 15 amp fuse.
The engine cranks but will not
start.
Replace F2 15 amp fuse if fuse blows
again.*
Defective fuel system.
No fuel supply.
*
Turn on fuel supply.*
The engine starts hard and runs
rough.
Air cleaner plugged or damaged.
Check/replace air cleaner.
Defective keypad.
*
*
The generator is set to OFF, but
the engine continues to run.
Defective control board.
Main line circuit breaker is in the
OFF (OPEN) position.
Reset circuit breaker to ON (CLOSED)
position.
There is no AC output from the
generator.
Generator internal failure.
Defective transfer switch coil.
Defective transfer relay.
*
*
*
There is no transfer to standby
after utility source failure.
Transfer relay circuit open.
Defective control logic board.
Engine over filled with oil.
Engine breather defective.
Incorrect oil type or viscosity.
Damaged gasket, seal or hose.
*
*
Adjust oil to correct level.
*
Unit consumes large amounts of
oil.
See Engine Oil Recommendations.
Check for oil leaks.
* Contact an Independent Authorized Service Dealer for assistance.
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Troubleshooting
6.2 — Controller Troubleshooting
Active Alarm
Problem
Solution
NOT ACTIVATED
Unit will not start in AUTO with utility loss.
Refer to activation section in Owner’s Manual.
Check MLCB. Contact servicing dealer if MLCB is in the ON
position.
NONE
NONE
Unit running in AUTO but no power in house.
Unit will not start in AUTO with utility loss.
Check screen for start delay countdown. If the start up delay is
greater than expected, contact servicing dealer to adjust from 2
to 1500 seconds.
HIGH
TEMPERATURE
Check ventilation around the intake, exhaust and rear of gener-
ator. Contact serving dealer if no obstruction is found.
Unit shuts down during operation.
Unit shuts down during operation.
Clear alarm and remove loads from the generator. Put back in
AUTO and restart.
OVERLOAD
Clear alarm and remove loads from the generator. Put back in
AUTO and restart. If problem returns, contact servicing dealer to
investigate possible fuel issue.
Unit was running and shuts down, attempts to
restart.
RPM SENSE LOSS
LOW OIL
PRESSURE
Check oil level. Add oil per Owner’s Manual. Contact servicing
dealer if oil level is correct.
Unit will not start in AUTO with utility loss.
Unit will not start in AUTO with utility loss.
Clear alarm. From the MAIN menu on the control panel, navi-
gate to the BATTERY MENU. Contact servicing dealer if battery
is GOOD. Replace battery If CHECK BATTERY is displayed.
RPM SENSE LOSS
Clear alarm. Attempt to start the unit in MANUAL. If it does not
start or starts and runs rough, contact servicing dealer.
OVERCRANK
OVERSPEED
Unit will not start in AUTO with utility loss.
Unit will not start in AUTO with utility loss.
Unit will not start in AUTO with utility loss.
Contact servicing dealer.
Contact servicing dealer.
UNDER
VOLTAGE
UNDERSPEED
MISWIRE
Unit will not start in AUTO with utility loss.
Unit will not start in AUTO with utility loss.
Unit will not start in AUTO with utility loss.
Contact servicing dealer.
Contact servicing dealer.
Contact servicing dealer.
OVERVOLTAGE
Clear alarm. From the MAIN menu on the control panel, navi-
gate to the BATTERY MENU. Contact servicing dealer if battery
is GOOD. Replace battery If CHECK BATTERY is displayed.
LOW BATTERY
Warning active.
BATTERY PROBLEM
CHARGER WARNING
Warning active.
Warning active.
Contact servicing dealer.
Contact servicing dealer
Perform SERVICE SCHEDULE A maintenance; press ENTER
to clear.
SERVICE SCHEDULE A
SERVICE SCHEDULE B
SERVICE SCHEDULE C
Warning active.
Warning active.
Warning active.
Perform SERVICE SCHEDULE B maintenance; press ENTER
to clear.
Perform SERVICE SCHEDULE C maintenance; press ENTER
to clear.
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Troubleshooting
6.3 — Removal From Service During Utility Outages
If, during prolonged utility outages, the user wishes to remove the unit from service to conserve fuel, reduce run hours,
or to perform maintenance tasks, then complete the steps listed below.
IMPORTANT NOTE: Failure to abide by this procedure can result in equipment damage.
To remove the generator from service while running in AUTO and online, proceed as follows:
1. Turn the main utility disconnect to OFF (Open).
2. Open the viewing window. See Subsection 3.4 —Open Viewing Window.
3. Move the Main Circuit Breaker switch down to the OFF (Open) position.
4. Press OFF on the control panel. A red LED illuminates to confirm that the system is in the OFF mode.
NOTE: If inspection and/or maintenance tasks are to be performed, complete the additional steps listed below.
5. Remove T1 fuse from transfer switch.
6. Pull up rubber flap covering fuse holder and remove 7.5 amp fuse.
7. Remove battery negative cable (black) from battery negative (-) terminal.
8. Place a DO NOT OPERATE tag or placard on both the control panel and transfer switch.
To return the generator to service, proceed as follows:
NOTE: If inspection and/or maintenance tasks were performed, start with step 1. If the unit was just shut down
to conserve fuel or to reduce run hours, start at step 5.
1. Install battery negative cable (black) onto battery negative (-) terminal.
2. Pull up rubber flap covering fuse holder and install 7.5 amp fuse.
3. Install T1 fuse in transfer switch.
4. Remove the DO NOT OPERATE tag or placard from both the control panel and transfer switch.
5. Press AUTO on the control panel. A green LED illuminates to confirm that the system is in the AUTO mode.
Allow the generator to start and run for a few minutes.
6. Move the Main Circuit Breaker switch up to the ON (Closed) position.
7. Turn the main utility disconnect to ON (Closed).
8. Close the viewing window.
6.4 — Storage
6.4.1— Prepare For Storage
If the generator cannot be exercised every seven days and will be out of service longer than 90 days, prepare for stor-
age as follows:
1. Open the viewing window. See Subsection 3.4 —Open Viewing Window.
2. Press MANUAL on the control panel to start the engine. A blue LED illuminates to confirm that the system is in
the MANUAL mode.
3. Allow the engine to run until it reaches normal operating temperature.
4. Press OFF on the control panel. A red LED illuminates to confirm that the system is in the OFF mode.
5. Move the Main Circuit Breaker switch on the control panel down to the OFF (Open) position.
6. Pull up rubber flap covering fuse holder and remove 7.5 amp fuse.
7. Turn off utility power to the transfer switch.
8. Place a DO NOT OPERATE tag or placard on both the control panel and transfer switch.
9. Wait five minutes for the engine to cool.
10. Remove left and right side access panels. See Subsection 5.2 —Access Panels.
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Troubleshooting
NOTE: On 36 kW, 45 kW, and 60 kW models, close shutoff valve to avoid draining the oil supply tank with the
crankcase oil. For more information, see Subsection 5.11 —Lube Oil Maintainer System.
11. Remove oil drain hose from holding clamp.
12. Use one wrench to hold hex on hose fitting (to prevent rotation), and use second wrench to remove drain plug.
13. Drain oil into a suitable container.
14. Install drain plug onto end of oil drain hose.
15. Install oil drain hose into holding clamp.
16. Rotate oil filter counterclockwise to remove from oil filter adapter.
17. Apply a light coat of clean engine oil to gasket of new oil filter.
18. Install oil filter by hand until gasket just contacts oil filter adapter. Tighten oil filter an additional 3/4 to one full turn.
19. Remove oil fill cap and fill engine with the recommended oil. See Subsection 2.3 —Engine Oil Recommenda-
tions.
20. Install oil fill cap.
NOTE: Dispose of used oil and oil filter at a proper collection center.
Always disconnect the negative battery cable first. If the positive cable should contact ground with the
negative cable installed, the resulting sparks may cause a battery explosion which could result in seri-
ous injury.
$
21. Remove battery negative cable (black) from battery negative (-) terminal.
22. Remove battery positive cable (red) from battery positive (+) terminal.
23. Remove two screws to release battery hold-down clamp from platform.
24. Remove battery and store on a wooden board in a cool, dry room. Do not store the battery on a concrete or
earthen floor.
25. Install left and right side access panels. See Subsection 5.2 —Access Panels.
26. Thoroughly clean and wipe down the generator. See Subsection 2.9 —Corrosion Protection.
6.4.2— Return From Storage
To return the unit to service after storage, proceed as follows:
1. Thoroughly clean and wipe down the generator. See Subsection 2.9 —Corrosion Protection.
2. Remove left and right side access panels. See Subsection 5.2 —Access Panels.
3. Install battery onto tray oriented with the negative (-) post toward the front of the enclosure.
4. Install two screws with nylon washers to secure battery hold-down clamp to tray.
5. Check battery. See Subsection 5.7.9—Check Battery Condition/Fluid Level..
Always connect the positive battery cable first. If the positive cable should contact ground with the
negative cable installed, the resulting sparks may cause a battery explosion which could result in seri-
ous injury.
$
6. Install battery positive cable (red) onto battery positive (+) terminal.
7. Install battery negative cable (black) onto battery negative (-) terminal.
8. Check oil level and add oil as necessary. DO NOT OVERFILL.
NOTE: On 36 kW, 45 kW, and 60 kW models, open shutoff valve to enable Lube Oil Maintainer System.
9. Open the viewing window. See Subsection 3.4 —Open Viewing Window.
10. Pull up rubber flap covering fuse holder and install 7.5 amp fuse.
11. Move the Main Circuit Breaker switch up to the ON (Closed) position.
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Troubleshooting
12. Press MANUAL on the control panel to start the engine. A blue LED illuminates to confirm that the system is in
the MANUAL mode.
13. Allow the engine to run until it is reaches normal operating temperature. Check for leaks while the engine is run-
ning.
14. Press OFF on the control panel. A red LED illuminates to confirm that the system is in the OFF mode.
15. Install left and right side access panels. See Subsection 5.2 —Access Panels.
16. Turn on utility power to the transfer switch.
17. Press AUTO on the control panel. A green LED illuminates to confirm that the system is in the AUTO mode.
18. Reset the time and date.
19. Close the viewing window.
6.5 — Attention After Submersion
Do NOT start and operate the generator if it has been submerged in water. Have a Dealer thoroughly clean, dry, and
inspect the generator following any submersion. If the structure (home) has been flooded, it should be inspected by a
certified electrician to ensure there won’t be any electrical problems during generator operation or when utility power is
returned.
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Troubleshooting
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Part No. 0K8185 Rev. A 02/16/2015 Printed in USA
©2015 Generac Power Systems, Inc. All rights reserved
Specifications are subject to change without notice.
No reproduction allowed in any form without prior written
consent from Generac Power Systems, Inc.
Generac Power Systems, Inc.
S45 W29290 Hwy. 59
Waukesha, WI 53189
1-888-GENERAC (1-888-436-3722)
generac.com
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