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Home My WebLink About10kw to 24kw Generac owners manualOwner’s Manual 60 Hz Air-Cooled Generators 10 kW to 24 kW SAVE THIS MANUAL FOR FUTURE REFERENCE ® Para español, visita: http://www.generac.com/service-support/product-support-lookup Pour le français, visiter : http://www.generac.com/service-support/product-support-lookup Register your Generac product at: WWW.GENERAC.COM 1-888-GENERAC (888-436-3722) (000209b) WARNING Loss of life. This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury. ii Owner’s Manual for 60 Hz Air-Cooled Generators Use this page to record important information about this generator. Record the information found on the unit data label on this page. See General Information for the location of the unit data label. The unit has a label plate affixed to the inside par- tition, to the left of the control panel console as shown in Fig- ure 2-1, Figure 2-2, or Figure 2-3. See Operation for directions on how to open the top lid and remove the front panel. Always supply the complete model and serial numbers of the unit when contacting an Independent Authorized Service Dealer (IASD) about parts and service. Operation and Maintenance: Correct maintenance and care of the unit ensures a minimum number of problems, and keeps operating expenses at a minimum. It is the operator’s responsibility to perform all safety inspections, to verify all maintenance for safe operation is performed promptly, and to have the equipment inspected periodically by an IASD. Normal maintenance, service, and replacement of parts are the responsibility of the owner/operator and are not consid- ered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage may con- tribute to the need for additional maintenance or service. When the generator requires servicing or repairs, Generac recommends contacting an IASD for assistance. Authorized service technicians are factory-trained and are capable of handling all service needs. To locate the nearest IASD, please visit the dealer locator at: www.generac.com/Dealer-Locator. Model: Serial: Production Date: Volts: LPV Amps: NG Amps: Hz: Phase: Controller P/N: STA MAC ID: SSID: (000393a) WARNING CANCER AND REPRODUCTIVE HARM www.P65Warnings.ca.gov. Owner’s Manual for 60 Hz Air-Cooled Generators 0 Table of Contents Section 1: Safety Information Introduction ..................................................................1 Read This Manual Thoroughly ....................................1 Safety Rules .................................................................1 How to Obtain Service .................................................1 General Hazards ...........................................................2 Exhaust Hazards ..........................................................3 Electrical Hazards ........................................................3 Fire Hazards .................................................................3 Explosion Hazards .......................................................4 Battery Hazards ............................................................4 Section 2: General Information Generator Components and Control Locations ........7 Data Decals .................................................................10 Specifications .............................................................11 Generator ..................................................................11 Engine .......................................................................11 Protection Systems ...................................................12 Emissions ...................................................................12 Fuel Requirements .....................................................12 Battery Requirements ................................................12 Battery Charger ..........................................................12 Engine Oil Requirements ..........................................12 Activating the Generator ...........................................13 Wi-Fi Module ...............................................................13 Replacement Parts .....................................................13 Accessories ................................................................13 Section 3: Operation Site Prep Verification .................................................15 Generator Enclosure .................................................15 Opening the Lid .........................................................15 Front Access Panel Removal ....................................15 Intake Side Panel Removal .......................................16 Main Line Circuit Breaker (Generator Disconnect) ....16 LED Indicator Lights ..................................................16 Auxiliary Shutdown Switch .......................................17 Control Panel Interface ..............................................17 Using the AUTO/OFF/MANUAL Buttons ..................17 Operating Modes ........................................................18 Interface Menu Displays ............................................18 LCD Panel .................................................................18 Menu System Navigation ..........................................19 Setting the Exercise Timer ........................................21 Battery Charger ..........................................................21 Manual Transfer Operation .......................................21 Transfer to Generator Power Source ........................21 Transfer to Utility Power Source ................................22 Automatic Transfer Operation ..................................22 Automatic Sequence of Operation ...........................22 Utility Failure ..............................................................22 Cranking ....................................................................22 Cold Smart Start ........................................................22 Cleaning Cycle ..........................................................22 Load Transfer ............................................................23 Shutting Generator Down While Under Load or During a Utility Outage ................................23 Section 4: Maintenance Maintenance ...............................................................25 Preparing for Maintenance ........................................25 Performing Scheduled Maintenance ........................25 Service Schedule .......................................................26 Maintenance Log .......................................................26 Checking Engine Oil Level ........................................27 Engine Oil Requirements ..........................................27 Changing the Oil and Oil Filter .................................27 Servicing the Air Cleaner ..........................................28 Spark Plug(s) ..............................................................29 Valve Clearance Adjustment .....................................29 Checking Valve Clearance ........................................29 Adjusting Valve Clearance ........................................30 Battery Maintenance ..................................................30 Inspecting the Battery ................................................31 Cleaning the Sediment Trap .....................................32 Post Maintenance Checks .........................................32 Performing Fuel System Leak Test ...........................33 Attention After Submersion ......................................33 Corrosion Protection .................................................33 Remove From and Return To Service Procedure ...33 Remove From Service ...............................................33 Return to Service .......................................................34 Section 5: Troubleshooting / Quick Reference Guide Generator Troubleshooting ......................................35 Quick Reference Guide .............................................37 Table of Contents i Owner’s Manual for 60 Hz Air-Cooled Generators This page intentionally left blank. Safety Information Owner’s Manual for 60 Hz Air-Cooled Generators 1 Section 1: Safety Information Introduction Thank you for purchasing this compact, high perfor- mance, air-cooled, engine-driven generator. It is designed to automatically supply electrical power to oper- ate critical loads during a utility power failure. This unit is factory installed in an all-weather, metal enclosure intended exclusively for outdoor installation. This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG). NOTE: This generator is suitable for supplying typical residential loads such as induction motors (sump pumps, refrigerators, air conditioners, furnaces, etc.), electronic components (computer, monitor, TV, etc.), lighting loads, and microwaves, when sized correctly. This unit is equipped with a Wi-Fi® module, which allows the genera- tor owner to monitor generator status from anywhere they have Internet access. NOTE: Wi-Fi® is a registered trademark of Wi-Fi Alli- ance®. The information in this manual is accurate based on products produced at the time of publication. The manu- facturer reserves the right to make technical updates, corrections, and product revisions at any time without notice. Read This Manual Thoroughly If any section of this manual is not understood, contact the nearest Independent Authorized Service Dealer (IASD) or Generac Customer Service at 1-888-436-3722 (1-888-GENERAC), or visit www.generac.com for start- ing, operating, and servicing procedures. The owner is responsible for correct maintenance and safe use of the unit. This manual must be used in conjunction with all other supporting product documentation supplied with the product. SAVE THESE INSTRUCTIONS for future reference. This manual contains important instructions that must be fol- lowed during placement, operation, and maintenance of the unit and its components. Always supply this manual to any individual that will use this unit, and instruct them on how to correctly start, operate, and stop the unit in case of emergency. Safety Rules The manufacturer cannot anticipate every possible cir- cumstance that might involve a hazard. The alerts in this manual, and on tags and decals affixed to the unit, are not all inclusive. If using a procedure, work method, or operating technique that the manufacturer does not spe- cifically recommend, verify that it is safe for others and does not render the equipment unsafe. Throughout this publication, and on tags and decals affixed to the unit, DANGER, WARNING, CAUTION, and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be haz- ardous if performed incorrectly or carelessly. Observe them carefully. Alert definitions are as follows: NOTE: Notes contain additional information important to a procedure and will be found within the regular text of this manual. These safety alerts cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents. How to Obtain Service When the unit requires servicing or repairs, contact Gen- erac Customer Service at 1-888-GENERAC (1-888-436- 3722) or visit www.generac.com for assistance. When contacting Generac Customer Service about parts and service, always supply the complete model and serial number of the unit as given on its data decal located on the unit. Record the model and serial numbers in the spaces provided on the front cover of this manual. (000100a) Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury. WARNING (000001) DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. (000002) WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. (000003) CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Safety Information 2 Owner’s Manual for 60 Hz Air-Cooled Generators General Hazards •Inspect generator regularly, and contact the near- est IASD for parts needing repair or replacement. (000190) DANGER Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury. (000191) DANGER Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury. (000209b) WARNING Loss of life. This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury. (000247a) Equipment damage. This unit is not intended for use as a prime power source. It is intended for use as an intermediate power supply in the event of temporary power outage only. Doing so could result in death, serious injury, and equipment damage. WARNING (000130) Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury. WARNING (000182a) WARNING Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage. (000187) WARNING Electrocution. Potentially lethal voltages are generated by this equipment. Render the equipment safe before attempting repairs or maintenance. Failure to do so could result in death or serious injury. (000155a) WARNING Electric shock. Only a trained and licensed electrician should perform wiring and connections to unit. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage. (000115) Moving Parts. Do not wear jewelry when starting or operating this product. Wearing jewelry while starting or operating this product could result in death or serious injury. WARNING (000111) WARNING Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury. (000108) WARNING Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire. (000146) WARNING Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator. Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to operate or service this equipment and could result in death or serious injury.(000215a) WARNING WARNING (000228) Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death, or serious injury. (000216) WARNING Injury and equipment damage. Do not use generator as a step. Doing so could result in falling, damaged parts, unsafe equipment operation, and could result in death or serious injury. Safety Information Owner’s Manual for 60 Hz Air-Cooled Generators 3 Exhaust Hazards Electrical Hazards Fire Hazards (000103) Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. DANGER (000178a) WARNING Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury. (000146) WARNING Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator. WARNING (000281) Fire risk. Fuel and vapors are extremely flammable. Do not operate indoors. Doing so could result in death, serious injury, or property or equipment damage. (000144) DANGER Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury. (000150) Electrocution. Never connect this unit to the electrical system of any building unless a licensed electrician has installed an approved transfer switch. Failure to do so will result in death or serious injury. DANGER (000237) DANGER Electrical backfeed. Use only approved switchgear to isolate generator from the normal power source. Failure to do so will result in death, serious injury, and equipment damage. (000152) DANGER Electrocution. Verify electrical system is properly grounded before applying power. Failure to do so will result in death or serious injury. (000188) DANGER Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000104) DANGER Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury. (000145) DANGER Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury. WARNING (000217) Fire hazard. Do not obstruct cooling and ventilating airflow around the generator. Inadequate ventilation could result in fire hazard, possible equipment damage, death or serious injury. WARNING (000218) Fire and explosion. Installation must comply with all local, state, and national electrical building codes. Noncompliance could result in unsafe operation, equipment damage, death, or serious injury. WARNING (000219) Fire hazard. Use only fully-charged fire extinguishers rated “ABC” by the NFPA. Discharged or improperly rated fire extinguishers will not extinguish electrical fires in automatic standby generators. Safety Information 4 Owner’s Manual for 60 Hz Air-Cooled Generators Comply with regulations the local agency for workplace health and safety has established. Also, verify that the generator is installed in accordance with the manufac- turer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws, and regulations. Explosion Hazards Battery Hazards (000100a) Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury. WARNING WARNING Electrocution. Refer to local codes and standards for safety equipment required when working with a live electrical system. Failure to use required safety equipment could result in death or serious injury. (000257) (000147) WARNING Risk of Fire. Unit must be positioned in a manner that prevents combustible material accumulation underneath. Failure to do so could result in death or serious injury. (000192) DANGER Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury. (000151a) DANGER Explosion and fire. Connection of fuel source must be completed by a qualified professional technician or contractor. Incorrect installation of this unit will result in death, serious injury, and property and equipment damage. (000174) DANGER Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury. (000110) WARNING Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury. (000188) DANGER Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000162) Explosion. Do not dispose of batteries in a fire. Batteries are explosive. Electrolyte solution can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention. WARNING (000137a) WARNING Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury. (000164) WARNING Electrical shock. Disconnect battery ground terminal before working on battery or battery wires. Failure to do so could result in death or serious injury. (000138a) WARNING Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury. (000163a) Risk of burn. Do not open or mutilate batteries. Batteries contain electrolyte solution which can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention. WARNING Safety Information Owner’s Manual for 60 Hz Air-Cooled Generators 5 Always recycle batteries in accordance with local laws and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. For more information on battery recycling, visit the Battery Council International website at: http://batterycouncil.org WARNING (000228) Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death, or serious injury. Safety Information 6 Owner’s Manual for 60 Hz Air-Cooled Generators This page intentionally left blank. General Information Owner’s Manual for 60 Hz Air-Cooled Generators 7 Section 2: General Information Generator Components and Control Locations Figure 2-1. 10 kW—Components and Control Locations A Lock with cover F Oil fill cap/dipstick K Oil drain hose O Fuel inlet B Main line circuit breaker (generator disconnect) G Status LED indicators L Composite base P Wi-Fi module C Control panel H Airbox with air cleaner M Sediment trap Q Data decal location D Battery compartment (battery not supplied) J Oil filter N Fuel regulator R Auxiliary shutdown switch E Exhaust enclosure F 001818 M N O P A Q D C B E L K J H A G R General Information 8 Owner’s Manual for 60 Hz Air-Cooled Generators Figure 2-2. 14 kW–18 kW—Components and Control Locations A Lock with cover F Exhaust enclosure L Composite base Q Data decal location B Main line circuit breaker (generator disconnect) G Status LED indicators M Sediment trap R Auxiliary shutdown switch C Airbox with air cleaner H Oil drain hose N Fuel regulator S Auxiliary shutdown switch D Control panel J Oil fill cap/dipstick O Fuel inlet E Battery compartment (battery not supplied) K Oil filter P Wi-Fi module 009340a C B G F E D A A L K J H P O N M S R Q 009340a General Information Owner’s Manual for 60 Hz Air-Cooled Generators 9 Figure 2-3. 20 kW–24 kW—Components and Control Locations A Lock with cover F Exhaust enclosure L Composite base Q Wi-Fi module B Main line circuit breaker (generator disconnect) G Status LED indicators M Oil dipstick R Data decal location C Airbox with air cleaner H Oil drain hose N Sediment trap S Auxiliary shutdown switch D Control panel J Oil fill cap O Fuel regulator T Auxiliary shutdown switch E Battery compartment (battery not supplied) K Oil filter P Fuel inlet 001786001786 N M O P Q G K J F L R E A D C B A HT S General Information 10 Owner’s Manual for 60 Hz Air-Cooled Generators Data Decals Two decals on the generator provide information about the unit itself and required fuel inlet pressure for correct opera- tion. Model Data Decal Includes important information about the unit including: •model number •serial number •production date •voltage •frequency •amps •country of origin •rated ambient temperature The model data decal also displays certifica- tion symbols by Underwriter’s Laboratory (UL) and the Southwest Research Institute (SwRI). Fuel Inlet Pressure Displays unit serial number, along with mini- mum and maximum inlet pressures for natu- ral gas (NG) and liquid propane (LP) supply. Space is provided for installer to enter maxi- mum flow rates based on installed pipe sizes and lengths. General Information Owner’s Manual for 60 Hz Air-Cooled Generators 11 Specifications Generator Engine A detailed specification sheet for a particular generator is available from a local IASD. Model 10 kW 14 kW 18 kW 20 kW 22 kW 24 kW Rated voltage 240 Rated maximum load current (amps) at rated voltage with LP* 41.7 58.3 75.0 83.3 91.7 100.0 Main line circuit breaker (generator disconnect)45 amp 60 amp 80 amp 90 amp 100 amp Phase 1 Rated AC frequency 60 Hz Battery requirement (field supplied) 12 volts, Group 26R-540CCA Minimum or Group 35AGM-650CCA Minimum (see Replacement Parts) Enclosure Aluminum Weight (lb / kg) (without battery)338 / 153 385 / 175 420 / 191 436 / 198 445 / 202 455 / 206 Normal operating range This unit is tested in accordance to UL 2200 standards with an operating temperature of -20 °F (-29 °C) to 122 °F (50 °C). For areas where temperatures fall below 32 °F (0 °C), a cold weather kit is recommended. When operated above 77 °F (25 °C), there may be a decrease in engine power. See Engine. These generators are rated in accordance with UL 2200, Safety Standard for Stationary Engine Generator Assemblies, and CSA- C22.2 No. 100-04 Standard for Motors and Generators. * NG ratings will depend on specific fuel joules/BTU content. Typical derates are between 10-20% off the LP gas rating. Model 10 kW 14/18 kW 20–24 kW Engine type G-Force™ 400 Series G-Force™ 800 Series G-Force™ 1000 Series Number of cylinders 1 2 2 Displacement 460 cc 816 cc 999 cc Cylinder block Aluminum with cast iron sleeve Recommended spark plug See Replacement Parts Spark plug gap 0.020 in (0.508 mm)0.040 in (1.02 mm) Hydraulic lifters No Yes No Valve clearance 0.002–0.004 in (0.05–0.1 mm)N/A 0.002–0.004 in (0.05–0.1 mm) Starter 12 VDC Oil capacity including filter Approx. 1.1 qt (1.03 L)Approx. 2.2 qt (2.1 L)Approx. 1.9 qt (1.8 L) Recommended oil filter See Replacement Parts Recommended air filter See Replacement Parts Engine power is subject to and limited by such factors as fuel BTU/joules, ambient temperature, and altitude. Engine power decreases approximately 3.5% for each 1,000 ft (304.8 m) above sea level, and also will decrease approximately 1% for each 10 °F (6 °C) above 60 °F (15 °C) ambient temperature. General Information 12 Owner’s Manual for 60 Hz Air-Cooled Generators Protection Systems The generator may need to run for long periods of time with no operator present to monitor engine or generator conditions. The generator is equipped with protection systems to automatically shut down the unit to protect against potentially damaging conditions. Some of these systems include: Alarms: Warnings: The control panel contains a display alerting the operator when a fault condition occurs. The above list is not all- inclusive. See Operation for more information about alarms and control panel operation. NOTE: A warning indicates a condition on the generator which should be addressed, but will not shut down gener- ator. An alarm shuts down the generator to protect sys- tem from any damage. In event of an alarm, an owner can clear the alarm and restart generator prior to contact- ing an IASD. Contact an IASD if the intermittent issue occurs again. Emissions The United States Environmental Protection Agency (US EPA) (and California Air Resources Board (CARB), for engines/equipment certified to California standards) requires this engine/equipment to comply with exhaust and evaporative emissions standards. Locate the emis- sions compliance decal on the engine to determine appli- cable standards. See the included emissions warranty for emissions warranty information. Follow the maintenance specifications in this manual to ensure the engine com- plies with applicable emissions standards for the duration of the product’s life. This generator is certified to operate on liquid propane vapor fuel or pipeline natural gas. The Emission Control System code is EM (Engine Modifi- cation). The Emission Control System on this generator consists of the following: : Fuel Requirements The engine has been fitted with a dual fuel carburetion system. The unit will run on NG or LP gas (vapor), but has been factory-configured to run on NG. The fuel sys- tem will be configured for the available fuel source during installation. Recommended fuels should have a BTU content of at least 1,000 BTUs per ft3 (37.26 megajoules per m3) for natural gas, or at least 2,500 BTUs per ft3 (93.15 mega- joules per m3) for LP gas. NOTE: If converting to LP gas from NG, a minimum LP tank size of 250 gal (946 L) is recommended. See instal- lation manual for complete procedures and details. Battery Requirements 12 volts, Group 26R Wet Cell 540CCA minimum or Group 35 AGM 650CCA minimum (not included with unit). See Battery Maintenance for correct battery main- tenance procedures. Battery Charger The battery charger is integrated into the control panel module in all models. It operates as a smart charger, ver- ifying output charging levels are safe and continuously optimized to promote maximum battery life. A kit is pro- vided to install a fuse in transfer switch for T1 battery charger connection. Follow installation instructions pro- vided with kit. NOTE: Do not use external battery chargers. Engine Oil Requirements See Engine Oil Requirements for correct oil viscosity. •High Temperature •Low Oil Pressure •Overcrank •Overspeed •Overvoltage •Undervoltage •Overload •Underspeed •RPM Sensor Loss •Controller Fault •Wiring Error •Stepper Overcurrent • Charger Warning • Charger Missing AC • Low Battery • Battery Problem •Exercise Set Error •USB Warning •Download Failure System Components Air induction - Intake manifold - Air cleaner Fuel metering - Carburetor and mixer assembly - Fuel regulator Ignition - Spark plug - Ignition module Exhaust - Exhaust manifold - Muffler (000105) Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury. DANGER General Information Owner’s Manual for 60 Hz Air-Cooled Generators 13 Activating the Generator Generator should be activated upon initial startup. See installation manual for complete instructions. Wi-Fi Module Generator is equipped with a Wi-Fi module. See Wi-Fi module owner’s manual for further information. Replacement Parts Accessories NOTE: Performance enhancing accessories are available for air-cooled generators. Contact an IASD or visit www.generac.com for additional information on replacement parts, accessories, and extended warranties. See also http://www.ordertree.com/generac/air-cooled-homestandby-generators/. Description 10 kW 14 kW 18 kW 20 kW 22 kW 24 kW 26R Exide battery 0H3421S Spark plug 0G0767B (RC12YC or equivalent)0G0767A (RC12YC or equivalent) Oil filter 070185E Air filter 0E9371A 0J8478 Control panel fuse 0D7178T Transfer switch fuses See transfer switch manual for part number Accessory Description Cold Weather Accessories*— •Battery Pad Warmer •Oil Warmer •Breather Warmer * each sold separately •Recommended in areas where temperatures fall below 0 °F (-18 °C). (Not necessary for use with AGM-style batteries) •Recommended in areas where temperatures fall below 0 °F (-18 °C). •Recommended in areas where heavy icing occurs. Scheduled Maintenance Kit Includes all items necessary to perform complete routine maintenance on the gener- ator along with oil recommendations (oil not included). Fascia Base Wrap The fascia base wrap snaps together around the bottom of the new air-cooled gener- ators. This offers a sleek, contoured appearance as well as protection from rodents and insects by covering the lifting holes located in the base. Requires use of the mounting pad shipped with the generator. Mobile Link® Cellular Accessories The Mobile Link family of Cellular Accessories allow users to monitor generator sta- tus from anywhere in the world, using a smartphone, tablet, or PC. Easily access information such as the current operating status and maintenance alerts. Users can connect an account with an authorized service dealer for fast, friendly, and proactive service. With Mobile Link, users are taken care of before the next power outage. Touch-Up Paint Kit If the generator enclosure is scratched or damaged, it is important to touch-up the paint to protect from future corrosion. The touch-up paint kit includes the necessary paint to correctly maintain or touch-up a generator enclosure. Extended Warranty Coverage Extend generator warranty coverage by purchasing extended warranty coverage. Covers both parts and labor. Extended coverage can be purchased within 12 months of the end-user’s purchase date. This extended coverage is applicable to registered units and end-user proof of purchase must be available upon request. Available for Generac® and Guardian® products. Not available for Corepower™, PowerPact®, and EcoGen™ products or all interna- tional purchases. Wi-Fi LP Fuel Level Monitor The Wi-Fi enabled LP fuel level monitor provides constant monitoring of a connected LP fuel tank. Monitoring the LP tank’s fuel level is an important step in verifying the generator is ready to run during an unexpected power failure. Status alerts are avail- able through a free application to notify users when the LP tank needs a refill. General Information 14 Owner’s Manual for 60 Hz Air-Cooled Generators Smart Management Module (50 and 100 amps) Smart Management Modules (SMM’s) are used to optimize the performance of a standby generator. They manage large electrical loads upon startup and shed them to aid in recovery when overloaded. In many cases, using SMM’s can reduce the overall size and cost of the system. Ultrasonic Cleaning Solution 1 gal (3.8 L) of ultra concentrated cleaning solution for metal and plastic surfaces. Makes 6 gal (22.7 L) of cleaning solution. All Surface Protectant All surface protectant for vinyl, rubber, and plastics. Creates a barrier to seal and protect surfaces from water and UV rays while renewing the look of the surface. Accessory Description Operation Owner’s Manual for 60 Hz Air-Cooled Generators 15 Section 3: Operation Site Prep Verification Generator must be installed to allow unimpeded airflow into and out of generator. Mechanical and gravity outdoor air intake openings for air distribution and supply systems must be located not less than 10 ft (3.05 m) horizontally from generator enclosure. See Section 401.4 in the ICC Mechanical Code for addi- tional information. Verify all shrubs or tall grasses within 3 ft (0.91 m) of intake and discharge louvers on the sides of the enclo- sure have been removed. Install generator on high ground where water levels will not rise and endanger it. This unit must not operate in or be subjected to standing water. Verify all potential water sources such as water sprinklers, roof run-off, rain gutter downspouts, and sump pump discharges are directed away from unit. Generator Enclosure Enclosure lid is locked prior to shipment. A set of keys is attached to cardboard on top of generator. An additional set of keys is attached to pallet bracket on the front intake end of generator. NOTE: Keys provided with this unit are intended for ser- vice personnel use only. Opening the Lid 1.Use keys to open generator lid. 2.See Figure 3-1. Two locks (A) secure lid; one on each side. Open protective rubber cap to access keyhole. Figure 3-1. Opening the Lid 3.Press down on lid above side lock, and unlock latch to correctly open lid. 4.Repeat for other side. Lid may appear stuck if pres- sure is not applied from the top. NOTE: Always verify side locks are unlocked before attempting to lift lid. Front Access Panel Removal See Figure 3-2. Remove front access panel (A) by lifting straight up and out once lid is open. Figure 3-2. Remove Front Access Panel (000191) DANGER Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury. 009209 A A 009210 A B C D Operation 16 Owner’s Manual for 60 Hz Air-Cooled Generators NOTE: Always lift front access panel straight up before pulling away from enclosure (B and C). Do not pull panel away from the enclosure before lifting up (D). Intake Side Panel Removal See Figure 3-3. Intake side panel (A) must be removed to access battery compartment, fuel regulator, and sedi- ment trap. 1.Raise lid and remove front panel. 2.Use a hex key to remove two mounting screws (B) and L-bracket screw (C). 3.Lift intake panel up and away from generator. NOTE: Always lift intake side panel straight up before pulling away from enclosure. Do not pull panel away from enclosure before lifting up (D). Figure 3-3. Intake Side Panel Removal Main Line Circuit Breaker (Generator Disconnect) See Figure 3-4. This is a 2-pole main line circuit breaker (MLCB) (generator disconnect) (A) rated according to rel- evant specifications. The generator MLCB (generator disconnect) can be locked in OFF (OPEN) for security. Use an appropriately- sized padlock (not included) with a shackle long enough to pass through both lock tabs (B). Figure 3-4. Main Line Circuit Breaker (MLCB) NOTE: DO NOT leave generator MLCB (generator dis- connect) locked in OFF (OPEN) during normal generator operation. Leaving generator MLCB (generator discon- nect) in OFF (OPEN) will prevent generator from power- ing structure during a power outage when placed in AUTO mode. LED Indicator Lights See Figure 3-5. Three LEDs are visible behind a translu- cent lens on the generator side panel. These LEDs indi- cate generator operating status. Figure 3-5. LED Indicator Lights •Green LED “Ready” light (A) illuminates when util- ity is present and control panel is in AUTO. LED flashes when automatic transfer switch converts to generator power during a utility power outage. •Red LED “Alarm” light (B) illuminates when gener- ator is OFF or a fault is detected. Contact an IASD. •Yellow LED “Non-Critical Alert” light (C) illuminates when maintenance is required. NOTE: Yellow LED may be illuminated at the same time as either the red or green LED. 002961 D B A C 001810 BA B 001791 ACB Operation Owner’s Manual for 60 Hz Air-Cooled Generators 17 Auxiliary Shutdown Switch All generators are equipped with an external means of shutting down the generator which complies with the lat- est NEC code requirement. Primary generator shutdown sequence is described in Shutting Generator Down While Under Load or During a Utility Outage. See Figure 3-6. An auxiliary shutdown switch (A) is located on the exterior of the generator back panel. This auxiliary shutdown switch shuts down generator and dis- ables restarts. Figure 3-6. External Auxiliary Shutdown Switch (all models) NOTE: Whenever possible, perform primary shutdown procedure before disabling generator with auxiliary shut- down switch. See Figure 3-7. 14–24 kW generators also have an aux- iliary shutdown switch (A) located inside generator. Figure 3-7. Internal Auxiliary Shutdown Switch (14–24kW) NOTE: Generator will not start if either switch is OPEN (O). Controller displays an “Auxiliary Shutdown” alarm, and red LED “Alarm” light illuminates. To clear this condi- tion, set switch or switches to CLOSED (I). Clear alarm by pressing OFF button, and then ENTER. The generator can then be placed in AUTO or MANUAL. Control Panel Interface See Figure 3-8. The control panel interface (A) is located under the enclosure lid. Verify both left and right side locks are unlocked before attempting to lift lid of enclo- sure. Open lid as directed in Opening the Lid. Figure 3-8. Generator Control Panel The 7.5A fuse is located beneath rubber cover (B) to the right of the control panel. Verify both left and right side locks are securely out of the way before closing unit. All appropriate panels must be in place during any opera- tion of the generator. This includes operation by a servic- ing technician while conducting troubleshooting pro- cedures. Using the AUTO/OFF/MANUAL Buttons NOTE: Damage caused by mis-wiring of interconnect wires is not warrantable. Equipment Damage. The auxiliary shutdown switch is not to be used to power down the unit under normal operating circumstances. Doing so will result in equipment damage.(000399) CAUTION 005492 A 005491 A Button Description of Operation AUTO Activates fully automatic system operation. Allows unit to automatically start and exercise generator according to exercise timer (see Set- ting the Exercise Timer). Green LED flashes when automatic transfer switch converts to generator power during a utility power outage. OFF Shuts down engine and prevents automatic operation of unit. MANUAL Cranks and starts generator. Transfer to stand- by power will not occur unless there is a utility failure. Blue LED flashes when automatic transfer switch converts to generator power during a utility power outage. 001798 A B Operation 18 Owner’s Manual for 60 Hz Air-Cooled Generators Operating Modes Interface Menu Displays LCD PanelModeDescription MANUAL •Will not transfer to standby if utility is present. •Transfers to standby if utility drops below 65% of nominal for five consecutive seconds (dealer programmable) after warm-up. •Transfers back when utility returns for 15 con- secutive seconds (dealer programmable). Engine continues to run until removed from MANUAL. AUTO •Starts and runs if utility drops for five consecu- tive seconds (dealer programmable). •Starts an engine warm-up timer (duration var- ies when Cold Smart Start is enabled). –Will not transfer if utility subsequently returns. –Transfers to standby if utility is not present. •Transfers to utility once utility returns (above 80% of nominal) for 15 consecutive seconds (dealer programmable). •Will not transfer to utility unless utility returns. Unit will shut down if OFF button is pressed or a shutdown alarm is present. •Unit will shut down after one minute cool-down time when utility power returns. EXERCISE •Will not exercise if unit is already running in either AUTO or MANUAL. •During exercise, controller will only transfer if utility drops during exercise for five seconds (dealer programmable), and will switch to AUTO. Feature Description HOME page Default page displayed if no buttons are pressed for 60 seconds. Normally shows cur- rent status message, and current date and time. Highest priority active alarm/warning is automatically posted on this page, as well as flashing the backlight when such a condition is detected. In the case of multiple alarms/ warnings, only first message is displayed. Press OFF button and then ENTER button to clear an alarm or warning. When “Hours of Protection” is displayed, this represents total time generator has been monitoring utility supply and ready to provide backup power if needed. Display Backlight Normally off. The backlight will automatically illuminate and remain on for 30 seconds if operator presses any button. MAIN MENU page Allows operator to navigate to all other pages or sub-menus by using arrow keys and ENTER button. Page can be accessed at any time with several presses of the dedicated ESCAPE button. Each press of the ESCAPE button takes operator to previous menu until MAIN MENU displays. This page contains information for History; Status; Edit; and Debug. Operation Owner’s Manual for 60 Hz Air-Cooled Generators 19 Menu System Navigation Press ESCAPE button from any page to access the MENU. If needed, press ESCAPE button several times to reach the MENU page. Navigate to the desired menu by using the ↑/↓ buttons. Press ENTER button when desired menu is displayed and flashing, Figure 3-9. Navigation MenuEVOLUTION 2.0 / SYNC 3.0 HSB MENU MAPSwitched to “OFF”Hours of Protection0 (H)Note: Menu functions and features may vary depending on unit model and firmware revision.* Hours of Protection and number of hours will flash every 5 seconds when displayed.*Ready to RunHours of Protection0 (H)Utility Loss DelayPausing for 13 sec.CrankingAttempt # 3Running in ExerciseHours of Protection0 (H)RunningCooling DownRunning - Warning“Warning Message”Warning Message(s)Low BatteryExercise Set ErrorService Schedule AService Schedule BInspect BatteryStopping...FIRMWARE ERROR-9Fuel PressureBattery ProblemCharger WarningCharger Missing ACOverload WarningSEEPROM ABUSEUSB WarningDownload FailureOverload WarningNo WIFI ModuleNo WIFI Router CommsNo WIFI Server CommsCranking - Warning“Warning Message”Alarm Message(s)High Engine TempLow Oil PressureOvercrankOverspeedRPM Sense LossUnderspeedController FaultFIRMWARE ERROR-7WIRING ERROROvervoltageUndervoltageOverload Remove LoadLow Volts Remove LoadStepper OvercurrentAuxiliary ShutdownEmergency StopFuse ProblemLoss of Speed SignalLoss of Serial LinkStopped - Warning“Warning Message”CrankingPausing for 13 secRunningHours of Protection0 (H)RunningWarming UpRunning - Alarm“Alarm Message”Cranking - Alarm“Alarm Message”Switched OFFHours of Protection0 (H)UP ARROW = +DOWN ARROW = -006667a Operation 20 Owner’s Manual for 60 Hz Air-Cooled Generators Figure 3-10. Navigation MenuRun LogEXAMPLE: Inspect Battery 200 RnHr or 12/27/18andNext Maintenance 200 RnHr or 12/27/18Exercise TimeÅ HH:MM Day Frequency ÆESC+–++ +–ENTERCurrent Date/TimeÅ 2/12/16 12:22 ÆESCESCESCESCENTERESCENTERESCENTERESCMaint. LogRun HrsScheduledSelect Month (1-12)- 2 +Run Hours (H)0.0Select Date (1-31)- 13 +Select Year (0-99)- 13 +Access Requires PasswordLanguageÅ English ÆFuel SelectionÅ NG or LP ÆAlarm LogENTERESCENTERESCENTERESC"Battery Maintained""Schedule A Serviced""Schedule B Serviced""Maintenance Reset""Inspect Battery""Service Schedule A""Service Schedule B"Warning Message(s)Low BatteryExercise Set ErrorService Schedule AService Schedule BInspect BatteryStopping...FIRMWARE ERROR-9Battery ProblemCharger WarningCharger Missing ACOverload CooldownSEEPROM ABUSEUSB WarningDownload FailureOverload WarningNo WIFIRunning ManualRunning-Utility LostRunning–Remote StartRunning–2 Wire StartRunning–ExerciseSwitched OffStopped - AutoSelect Min (0-59)- 0 +Select Hour (0-23)- 14 +Select Min (0-59)- 0 +Select Hour (0-23)- 14 +Quiet Test Mode ?- YES or NO +Select Frequency- WEEKLY +- BIWEEKLY +- MONTHLY +Language+ English -Fuel Selection+ NG or LP -Cold Smart Start?Å YES or NO ÆCold Smart Start?- YES or NO +Language+ Francais -+ Espanol -+ Português -+ ...... -Battery Condition“Good”, “Inspect Battery” or “Check Battery”Select Day- Wednesday +Generator ActivatedService UnitLanguage Update?Å YES or NO ÆWIFI EnableÅ YES or NO ÆWIFI Enable– YES or NO +<ENT> LOAD LANGUAGE<ESC> TO QUITESCESCESCESCESCESCESCESCCurrent Date/Time10/09/18 07:40ESCESCENTERESCENTERENTERENTERTime ZoneCountry/CityXX - XX/XX/XX XX:XXXXXXXXX - XX/XX/XX XX:XXXXXXXNOTE 1: Last 50 logs displayed for each (Alarm Log, Run Log, Maint. Log).NOTE 2: Date and time displayed for each occurence.NOTE 3: Error code displayed for each Alarm, Error Code and Alarm Message swap every 5 seconds.BatteryNOTE 1: Last 50 maintenance logs displayed.NOTE 2: Date and time displayed for each occurence.(If enabled):Refer to the Wi-Fi manual for flow charts relating to Wi-Fi (If not enabled): Displays SETUP WIFI Only if Wi-Fi is disabled.Date/Time automatically updates if connected to Wi-Fi.Firmware UpdateÅ YES Æ Current: V 1.01 USB: V 1.05Are You Sure?- Yes or No +Update from:Å USB or Wi-Fi ÆSelect YES, then press ENTER to continue or ESCAPE to cancel update. During update process, the Blue “Manual” light flashes, then the Green “Auto” light flashes.Sequence then repeats. When update is complete, the unit returns to Install Wizard menu. When the controller powers up, the first screen briefly displays the version number. When update is complete, remove USB Drive. Then follow the Install Wizard Menu.Firmware Update<- Insert USB ->Possible Message(s):Corrupted FileInvalid FileFile Not FoundUnsupported Device** Re-try using a higher quality USB drive. File names on the USB cannot have more than 8 characters.Refer to the Installation Wizard.Only when WiFi ActivatedSYSTEM WIFIDATE/TIMESUB MENUSHISTORY EDITMAINTDEALERESCENTERESCENTERESCENTERENTERUSBENTERENTERENTERENTERENTERENTERENTERENTERENTERENTER Current: V 1.01 USB: V 1.05Are You Sure?- Yes or No +ENTERENTERENTERENTERENTERENTERENTERESCENTERESCENTERAlarm Message(s)High Engine TempLow Oil PressureOvercrankOverspeedRPM Sense LossUnderspeedInternal FaultFIRMWARE ERROR-7WIRING ERROROvervoltageUndervoltageOverload Remove LoadLow Volts Remove LoadStepper OvercurrentAuxiliary ShutdownEmergency StopDefaults to English. Select desired language by scrolling through list. ESCESCESCESCESCESC006667a Operation Owner’s Manual for 60 Hz Air-Cooled Generators 21 Setting the Exercise Timer This generator is equipped with a configurable exercise timer. Configuration can be performed directly at the con- trol panel or though the Mobile Link® application. There are two settings for the exercise timer: Day/Time: Generator will start and exercise for period defined, on day of week and at time of day specified. During this exercise period, unit runs for approximately five minutes and then shuts down. Exercise frequency: Exercise frequency can be set to Weekly, Biweekly, or Monthly. If Monthly is selected, day of month must be selected from 1–28. Generator will exercise on that day each month. Transfer of loads to generator output does not occur during exercise cycle unless utility power is lost. NOTE: If Wi-Fi is enabled, exercise timer will automati- cally adjust for Daylight Saving Time. NOTE: The exercise feature will operate only when gen- erator is in AUTO, and will not work unless this procedure is performed. If Wi-Fi is NOT enabled, current date/time will need to be reset every time the 12 volt battery is dis- connected and then reconnected, and/or when the fuse is removed. Low Speed Exercise (Quiet-Test™) Profile: Unit will run at operating speed for approximately five seconds, then drop speed to prepare for Quiet-Test. Speed will drop to predetermined Quiet-Test speed after approxi- mately 40 seconds and continue to run until Quiet-Test is complete, a total of five minutes. Table 3-1 details exercise information and programming options for all home standby generators. NOTE: If Quiet-Test is disabled, generator will exercise at the rated rpm. Battery Charger IMPORTANT NOTE: Contact an IASD if controller screen displays “CHARGER MISSING AC.” NOTE: Battery charger is integrated into the control module in all models. The battery charger operates as a smart charger which verifies: •output is continually optimized to promote maxi- mum battery life. •charging levels are safe. NOTE: A warning is displayed on LCD when battery needs service. NOTE: Do not use external battery chargers. Manual Transfer Operation Prior to automatic operation, manually exercise transfer switch to verify there is no interference with correct oper- ation of the mechanism. Manual operation of transfer switch is required if electronic operation should fail. Transfer to Generator Power Source 1.Verify generator is in OFF mode. 2.Set generator MLCB (generator disconnect) to OFF (OPEN). 3.Turn off utility power supply to transfer switch using means provided (such as a utility MLCB). 4.See Figure 3-11. Use manual transfer handle (A) inside transfer switch to move main contacts to STANDBY (loads connected to standby power source). Figure 3-11. Typical Manual Transfer Switch Operation 5.Press MANUAL button on control panel to crank and start engine. 6.Allow engine to stabilize and warm up for a few minutes. Table 3-1. Generator Exercise Characteristics Generator Size 10–24 kW Exercise Frequency Options Weekly/Bi-Weekly/Monthly Exercise Time Length 5 minutes (000132) Electrocution. Do not manually transfer under load. Disconnect transfer switch from all power sources prior to manual transfer. Failure to do so will result in death or serious injury, and equipment damage. DANGER 002565002565 A 002565 Operation 22 Owner’s Manual for 60 Hz Air-Cooled Generators 7.Set generator MLCB (generator disconnect) to ON (CLOSED). Standby power source now powers loads. Transfer to Utility Power Source Shut down generator and transfer to utility source after utility power has been restored. Proceed as follows to manually transfer to utility power and shut down genera- tor: 1.Set generator MLCB (generator disconnect) to OFF (OPEN). 2.Run engine for one minute at no-load to stabilize internal temperature. 3.Press OFF button on control panel. Engine will shut down. 4.Verify utility power supply to transfer switch is turned off. 5.Set main contacts to UTILITY (loads connected to utility power source) using manual transfer handle inside transfer switch. 6.Turn on utility power supply to transfer switch using means provided (such as a utility MLCB). 7.Press AUTO button on control panel. 8.Set generator MLCB (generator disconnect) to ON (CLOSED). 9.Close and lock lid. Automatic Transfer Operation Proceed as follows to select automatic operation: 1.Verify transfer switch main contacts are set to UTILITY (loads connected to utility power source). 2.Verify normal utility power source voltage is avail- able to loads connected to transfer switch. 3.Press AUTO button on control panel. 4.Set generator MLCB (generator disconnect) to ON (CLOSED). Generator will start automatically when utility source volt- age drops below a preset level. Loads are transferred to standby power source after unit starts. Automatic Sequence of Operation Utility Failure If generator is set to AUTO when utility fails (below 65% of nominal), a five second (dealer programmable) line interrupt delay time is started. The engine cranks and starts if utility power is not available when timer expires. An engine warm-up timer will be initiated once engine is started. Timer duration varies depending on whether or not Cold Smart Start is enabled. The controller will transfer load to generator when warm-up time expires. If utility power is restored (above 80% nominal) at any time from initiation of engine start until generator is ready to accept load (warm-up time has not elapsed), the control- ler completes start cycle and runs generator through its normal cool down cycle. However, load will remain on utility source. Cranking The system will control the cyclic cranking as follows: •10 kW Unit: five cranking cycles as follows: 15 seconds cranking, seven seconds resting, followed by four additional cycles of seven seconds crank- ing followed by seven seconds resting. •14–24 kW Units: five cranking cycles as follows: 16 seconds cranking, seven seconds resting, 16 seconds cranking, seven seconds resting, followed by three additional cycles of seven seconds crank- ing followed by seven seconds resting. NOTE: An alarm will be triggered if generator does not start after these five attempts. Cold Smart Start Cold Smart Start is factory-enabled, but can be disabled in the EDIT menu. Generator will monitor ambient tem- perature when Cold Smart Start is enabled. The warm-up delay will be adjusted based on prevailing conditions. See Table 3-2. If ambient temperature is below a fixed temperature (based on model) upon startup in AUTO, generator will warm up for 30 seconds. This allows engine to warm before a load is applied. The generator will startup with normal warm-up delay of five seconds if ambient temperature is at or above the fixed tempera- ture. A check for correct output voltage buildup will be per- formed when generator engine is started. Cleaning Cycle If some condition impedes normal voltage creation, such as frost crystals or dust/dirt preventing a good electrical connection, start sequence will be interrupted so a clean- ing cycle of the internal electrical connections can be attempted. Cleaning cycle is an extended warm up period which lasts for several minutes while normal generator voltage output is determined to be low. During this cycle, genera- tor controller will display “Warming Up” on the display screen. The generator controller display will show “Under Volt- age” if cleaning cycle fails to clear the obstruction. After several minutes, alarm message can be cleared, and the generator restarted. If the problem persists, make no further attempts to start. Contact an IASD. Table 3-2. Cold Smart Start Set Points Generator size 10 kW–20 kW 22/24 kW Fixed temperature 50 °F (10 °C)20 °F (-7 °C) Operation Owner’s Manual for 60 Hz Air-Cooled Generators 23 Load Transfer The transfer of load when generator is running is depen- dent upon operating mode. Shutting Generator Down While Under Load or During a Utility Outage IMPORTANT NOTE: To avoid equipment damage, follow these steps, in order, during utility outages. Shutdowns may be required during utility outages to perform routine maintenance or to conserve fuel. To turn generator OFF: 1.Set utility MLCB to OFF (OPEN). 2.Set generator MLCB (generator disconnect) to OFF (OPEN). 3.Allow generator to run for cool-down for approxi- mately one minute. 4.Set generator to OFF at the controller. 5.Remove 7.5A fuse from controller. To turn generator back ON: 1.Install 7.5A fuse in controller. 2.Verify generator MLCB (generator disconnect) is OFF (OPEN). 3.Set generator to AUTO mode at the controller. 4.Generator will start and run. Allow generator to run and warm up for a few minutes. 5.Set generator MLCB (generator disconnect) to ON (CLOSED). 6.Set utility MLCB to ON (CLOSED). The system now operates in automatic mode. Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury. (000191) DANGER Operation 24 Owner’s Manual for 60 Hz Air-Cooled Generators This page intentionally left blank. Maintenance Owner’s Manual for 60 Hz Air-Cooled Generators 25 Section 4: Maintenance Maintenance Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be per- formed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be per- formed by any repair shop or person of the owner’s choosing. To obtain emissions control warranty service free of charge, the work must be performed by an IASD. See the emissions warranty. Preparing for Maintenance Proceed as follows to prepare unit for maintenance: 1.Set utility MLCB to OFF (OPEN). 2.Lift lid and set generator MLCB (generator discon- nect) to OFF (OPEN). 3.If running during a utility outage, allow generator to run and cool down for one minute with no load. 4.Press OFF button on controller. 5.Remove 7.5A fuse from control panel. 6.Remove front panel and intake side panel. Performing Scheduled Maintenance It is important to perform maintenance as specified in the Service Schedule for correct generator operation. Engine oil and oil filter must be changed, and valve clear- ance adjusted (where applicable, see Engine) after first 25 hours of operation. Emissions-critical maintenance must be performed as scheduled in order for emissions warranty to be valid. Emissions-critical maintenance consists of servicing the air filter and spark plug(s) in accordance with Service Schedule. Controller will prompt for Schedule A or Schedule B maintenance to be performed. Schedule A maintenance consists of oil, oil filter, and battery check. Schedule B maintenance includes oil, oil filter, battery check, air cleaner, spark plug(s), and valve clearance (where appli- cable, see Engine). Since most maintenance alerts occur at the same time (most have two year intervals), only one will appear on control panel display at a time. Once first alert is cleared, the next active alert will be displayed. (000191) DANGER Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury. (000182a) WARNING Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage. Maintenance 26 Owner’s Manual for 60 Hz Air-Cooled Generators Service Schedule NOTE: Contact an IASD or visit www.generac.com for additional information on replacement parts. Maintenance Log Battery Inspection and Charge Check Dates Performed: Oil, Oil Filter, Air Filter, and Spark Plug Replacement Dates Performed: Valve Adjustment NOTE: Not required on 14 or 18 kW units with 816cc engines. Dates Performed: Service Daily If Running Continuously or Before Each Use Every Year Schedule A Every Two Years or 200 Hours Schedule B Every Four Years or 400 Hours Inspect enclosure louvers for dirt and debris *● Inspect lines and connections for fuel or oil leaks ● Check engine oil level ● Inspect for water intrusion **● Perform fuel system leak test ● Check battery condition, electrolyte level, and state of charge ●●● Replace engine oil and oil filter †●● Replace engine air filter ● Clean; inspect spark plug gap; replace if necessary ● Inspect/adjust valve clearance (where applicable) ‡● Inspect/clean sediment trap See local codes and guidelines. Contact the nearest IASD for assistance if necessary. * Remove any shrubs or tall grasses which have grown within 3 ft (0.91 m) of intake and discharge louvers on enclosure sides. Clean any debris (dirt, grass clippings, etc.) which may have accumulated inside enclosure. ** Verify all sources of potential water intrusion such as water sprinklers, roof run-off, rain gutter downspouts, and sump pump discharges are directed away from generator enclosure. † Change engine oil and filter after first 25 hours of operation. In cold weather conditions (ambient below 40 °F [4.4 °C]), or if unit is operated continuously in hot weather conditions (ambient above 85 °F [29.4 °C]), change engine oil and filter every year or 100 hours of operation. ‡ Inspect/adjust valve clearance after first 25 hours of operation. (Excludes units with hydraulic lifters. See Engine.) Maintenance Owner’s Manual for 60 Hz Air-Cooled Generators 27 Checking Engine Oil Level IMPORTANT NOTE: Verify oil level daily when power outages necessitate running generator for extended periods. Generator will shut down if oil level is low. Proceed as follows to check engine oil level: 1.Set utility MLCB to OFF (OPEN). 2.Set generator MLCB (generator disconnect) to OFF (OPEN). 3.Allow generator to run for a cool-down period of approximately one minute, if generator was run- ning during an outage. 4.Press OFF button to turn generator off. Wait five minutes. 5.See Figure 2-1, Figure 2-2, or Figure 2-3. Remove oil dipstick and wipe it dry with a clean cloth. 6.Completely insert oil dipstick into oil dipstick tube and remove. 7.Observe oil level. Oil level should be at FULL mark on oil dipstick. 8.If necessary, remove oil fill cap and add recom- mended oil to engine (with oil dipstick removed) until oil level reaches FULL mark. Insert oil dipstick and install fill cap. See Engine Oil Requirements. To restart generator: 1.Press AUTO button on control panel. 2.Allow generator to start and warm up for a few min- utes. 3.Set generator MLCB (generator disconnect) to ON (CLOSED). The system is now operating in AUTO. The utility MLCB can be turned ON (CLOSED). Engine Oil Requirements Engine oil should be serviced in accordance with the rec- ommendations of this manual to maintain product war- ranty. Generac maintenance kits consisting of engine oil, oil filter, air filter, spark plug(s), a shop towel, and a funnel are available through an IASD. All Generac oil kits meet minimum American Petroleum Institute (API) Service Class SJ, SL, or better. Do not use special additives. Synthetic SAE 5W-30 for all temperature ranges. See Engine. Changing the Oil and Oil Filter Proceed as follows to change oil and oil filter: 1.Lift lid and press MANUAL button on control panel to start engine, and run unit until it is thoroughly warmed up. Press OFF button on control panel to shut down engine. 2.See Figure 4-1, Figure 4-2, or Figure 4-3. Remove front panel when unit has cooled. Pull oil drain hose (A) free of retaining clip. Remove cap from oil drain hose and place free end into a suit- able container. Drain oil. Figure 4-1. Oil Filter and Drain Location (10 kW) (000139) WARNING Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (000210) WARNING Skin irritation. Avoid prolonged or repeated contact with used motor oil. Used motor oil has been shown to cause skin cancer in laboratory animals. Thoroughly wash exposed areas with soap and water. (000135) Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage. CAUTION (000135) Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage. CAUTION 001831 B A Maintenance 28 Owner’s Manual for 60 Hz Air-Cooled Generators Figure 4-2. Oil Filter and Drain Location (14–18 kW) Figure 4-3. Oil Filter and Drain Location (20–24 kW) 3.Install cap on oil drain hose. Position and secure oil drain hose with the retaining clip. 4.Remove oil filter (B) by turning it counterclockwise. 5.Apply a light coating of clean engine oil to gasket of new filter. 6.Screw new filter on by hand until gasket lightly con- tacts oil filter adapter. Tighten filter an additional three-quarter to one full turn. 7.Fill engine with recommended oil. See Engine Oil Requirements. 8.Press MANUAL button on control panel to start engine. Run for one minute, and inspect for leaks. 9.Press OFF button on control panel to stop engine. Wait five minutes. 10.Inspect oil level. Add oil as needed. DO NOT OVERFILL. 11.Insert oil dipstick and/or attach fill cap. 12.Press AUTO button on control panel to return unit to AUTO. 13.Close and lock lid. 14.Dispose of used oil and filter according to local, state, or national codes. Servicing the Air Cleaner Proceed as follows to service air cleaner: 1.Lift lid and press OFF button on control panel to stop generator. 2.Remove front panel. 3.See Figure 4-4 or Figure 4-5. Remove cover clips (A) and air cleaner cover (B). Figure 4-4. Servicing Air Cleaner (10 kW) Figure 4-5. Servicing Air Cleaner (14–24 kW) 4.Remove old air filter element (C) and discard. 5.Thoroughly clean air cleaner enclosure of any dust or debris. 6.Install a new air filter element. 7.Install air cleaner cover and fasten cover clips. 009342009342 B A 009343 B A (000249) WARNING Risk of fire. Never operate engine without the air cleaner installed. Operating engine without the air cleaner could result in death or serious injury. (000580) WARNING Explosion and fire. Never clean air filter element with gasoline or low flash-point detergents. Doing so could result in death, serious injury, or equipment damage. A B C 001820 001814001814 B A C D Maintenance Owner’s Manual for 60 Hz Air-Cooled Generators 29 8.(14–24 kW units only): Verify air inlet duct (D) is correctly connected to air cleaner cover. 9.Press AUTO button on control panel to return unit to AUTO. Spark Plug(s) Proceed as follows to inspect spark plug gap(s) and replace spark plug(s) as necessary: 1.With generator OFF and engine cool, lift lid and remove front panel. 2.Clean area around base of spark plug(s) to keep dirt and debris out of engine. 3.Remove spark plug(s) and inspect. Install new spark plug(s) if existing spark plug(s) is worn, or if reuse is questionable. 4.Clean spark plug(s) by scraping or washing with a wire brush and commercial solvent. Do not blast spark plug(s) to clean. NOTE: Clean spark plug(s) in emergency situations only. Otherwise, replace spark plug(s). 5.See Figure 4-6. Inspect spark plug gap(s) using a wire feeler gauge. Replace spark plug(s) if spark plug gap is out of specification. See General Infor- mation. Figure 4-6. Spark Plug Gap Measurement NOTE: New spark plug(s) should have spark plug gap checked prior to installation. 6.Install spark plug(s), and tighten to 18.4 ft-lbs (25 Nm). 7.Press AUTO button to return unit to AUTO mode. Valve Clearance Adjustment IMPORTANT NOTE: Contact an IASD for service assistance. Correct valve clearance is essential for prolonging the life of the engine. Excludes units equipped with hydraulic lifters. See Engine. IMPORTANT NOTE: Valve lash not required on 14 or 18 kW units with 816cc engine. See Engine. Inspect valve clearance after first 25 hours of operation, then after 400 hour intervals. Adjust if necessary. Checking Valve Clearance NOTE: Engine should be cool before checking valve clearance. Adjustment is not needed if valve clearance is within dimensions provided in Engine. Proceed as follows to check valve clearance. 1.Close fuel valve and disconnect battery to avoid accidental startup. 2.Remove spark plug wire(s), and position spark plug wire(s) away from spark plug(s). 3.Remove spark plug(s). 4.Remove the four screws attaching the valve cover. Remove and discard gasket. (Repeat for second cylinder, if equipped.) 5.Verify piston is at top dead center (TDC) of its com- pression stroke (both valves closed). NOTE: To move piston to TDC, remove intake baffle at front of the engine to access the flywheel nut. Use a large socket and socket wrench to rotate flywheel nut clock- wise, which will rotate the crankshaft. Watch piston through spark plug hole. Piston will move up and down. Piston is at TDC when at its highest point of travel. (000140a) WARNING Electric shock. Do not disconnect spark plug wires with engine running. Doing so could result in death or serious injury. 000211 WARNING (000560) Risk of Burn. Allow the engine to cool before performing the following procedure. Failure to do so could result in serious injury. (000130) Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury. WARNING (000141) WARNING Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury. Maintenance 30 Owner’s Manual for 60 Hz Air-Cooled Generators 6.See Figure 4-7 or Figure 4-8. Verify valve clear- ance between each rocker arm (E) and valve stem (F) with a feeler gauge. . Figure 4-7. Valve Clearance Adjustment (10 kW) Figure 4-8. Valve Clearance Adjustment (20–24 kW) 7.Install replacement valve cover gasket(s). 8.Install valve cover(s). Tighten fasteners in a cross pattern, tightening to: Adjusting Valve Clearance IMPORTANT NOTE: Valve lash not required on 14 or 18 kW units with 816cc engine. See Engine. See Figure 4-7 or Figure 4-8. Proceed as follows to ad- just valve clearance: NOTE: Allow engine to cool before adjusting valve clear- ance. 1.Remove spark plug wire(s) and position spark plug wire(s) away from spark plug(s). 2.Remove spark plug(s). 3.Remove the four screws attaching valve cover. Remove and discard gasket. 4.Verify piston is at TDC of its compression stroke (both valves closed). 5.Loosen rocker jam nut (C) using a 10 mm wrench (10 kW units) or 13 mm wrench (20–24 kW units). 6.Turn pivot ball stud (D) using a 14 mm wrench (10 kW units), or 10 mm hex key (20–24 kW units) while inspecting clearance between rocker arm (E) and valve stem (F) with a feeler gauge. Adjust clearance as per Engine. NOTE: Hold rocker jam nut in place as pivot ball stud is turned. 7.When valve clearance is correct, hold pivot ball stud in place with a wrench and tighten rocker arm jam nut. Tighten jam nut according to: 8.Inspect valve clearance to verify it did not change. 9.Install new valve cover gasket. 10.Install valve cover. Tighten fasteners in a cross pat- tern. Tighten to: NOTE: Start all four screws before tightening, or it will not be possible to get all screws in place. Verify valve cover gasket is in place. 11.Install spark plug(s) and tighten to 18 ft-lbs (25 Nm). 12.Attach spark plug wire(s) to spark plug(s). 13.Repeat process for other cylinder if equipped. Battery Maintenance 10 kW 80 in-lbs (9.0 Nm) 20–24 kW 60 in-lbs (6.8 Nm) 001812 C D F E 002380002380 F C E D WARNING (000560) Risk of Burn. Allow the engine to cool before performing the following procedure. Failure to do so could result in serious injury. 10 kW 53 in-lbs (6.0 Nm) 20–24 kW 174 in-lbs (19.68 Nm) 10 kW 80 in-lbs (9.0 Nm) 20–24 kW 60 in-lbs (6.8 Nm) (000188) DANGER Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000162) Explosion. Do not dispose of batteries in a fire. Batteries are explosive. Electrolyte solution can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention. WARNING Maintenance Owner’s Manual for 60 Hz Air-Cooled Generators 31 Always recycle batteries in accordance with local laws and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. For more information on battery recycling, visit the Battery Council International website at: http://batterycouncil.org Strictly observe the following precautions when working on batteries: •Remove 7.5A fuse from generator control panel. •Disconnect battery charger as directed in Inspect- ing the Battery. •Use tools with insulated handles. •Wear rubber gloves and boots. •Do not place tools or metallic objects on top of bat- tery. •Disconnect charging source prior to connecting or disconnecting battery terminals. •Wear full eye protection and protective clothing. •If electrolyte contacts skin, wash it off immediately with water. •If electrolyte contacts eyes, flush thoroughly with water immediately and seek medical attention. •Wash down spilled electrolyte with an acid neutral- izing agent. A common practice is to use a solution of 1 lb (454 g) bicarbonate of soda to 1 gal (3.8 L) of water. Add bicarbonate of soda solution until evi- dence of reaction (foaming) has ceased. Flush resulting liquid with water and dry area completely. •DO NOT smoke near battery. •DO NOT cause flame or spark in battery area. •Discharge static electricity from the body before touching battery by first touching a grounded metal surface. Battery should be regularly inspected per Service Schedule. Contact an IASD for assistance if necessary. Inspecting the Battery Proceed as follows to inspect battery: 1.Press OFF button to shut down generator, then lift lid and remove front panel. 2.Remove 7.5A fuse from control panel. 3.Remove intake side panel. (See Intake Side Panel Removal.) 4.See Figure 4-9. Disconnect white battery charger cable. Figure 4-9. Disconnecting Battery Charger Cable (000137a) WARNING Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury. (000238) Explosion. Batteries emit explosive gases. Always disconnect negative battery cable first to avoid spark. Failure to do so could result in death or serious injury. WARNING (000164) WARNING Electrical shock. Disconnect battery ground terminal before working on battery or battery wires. Failure to do so could result in death or serious injury. (000138a) WARNING Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury. (000163a) Risk of burn. Do not open or mutilate batteries. Batteries contain electrolyte solution which can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention. WARNING WARNING (000228) Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death, or serious injury. 002389 Maintenance 32 Owner’s Manual for 60 Hz Air-Cooled Generators 5.See Figure 4-10. Inspect battery posts and cables for tightness and corrosion. Tighten and clean as necessary. Figure 4-10. Battery Cables 6.Unsealed batteries only: Completely disconnect battery, removing negative battery cable first. Check battery fluid level and, if necessary, fill with distilled water only. DO NOT use tap water. Have an IASD or a qualified service technician verify state of charge and condition. 7.Connect positive battery cable, then negative bat- tery cable. 8.Connect battery charger cable. 9.Install intake side panel, and install 7.5 A fuse. 10.Press AUTO button on controller. 11.Install front panel and close generator lid. Cleaning the Sediment Trap The sediment trap removes contaminants (moisture and fine particles) from gaseous fuels before they enter the fuel regulator. Accumulated moisture and particles must be emptied from the sediment trap per local codes and guidelines. Proceed as follows to clean sediment trap: 1.Remove intake side panel. See Intake Side Panel Removal. 2.Turn generator fuel supply OFF. 3.See Figure 4-11. Unscrew and remove cap (A). Figure 4-11. Cleaning the Sediment Trap 4.Use a clean-out tool (not provided) to remove accumulated moisture and particles from cap and body (B). 5.Wipe inside of each component with a clean, dry, lint-free cloth. 6.Seal threads of cap with appropriate sealing com- pound. Install cap and hand-tighten. 7.Tighten cap with an appropriately sized pipe wrench. DO NOT overtighten. 8.Turn generator fuel supply ON. Inspect for leaks by spraying all connection points with a non-corrosive gas leak detection fluid. Solution should not be blown away or form bubbles. 9.Install intake side panel. Post Maintenance Checks Proceed as follows to perform post maintenance checks: 1.Perform required maintenance procedure(s). 2.Install intake side panel and front panel if removed. (See Intake Side Panel Removal and Front Access Panel Removal.) 3.Install 7.5A fuse in control panel. 4.Complete Install Wizard information. 5.Press AUTO button on control panel. Allow unit to run for one minute with no load (if running during a utility outage). 6.Set generator MLCB (generator disconnect) to ON (CLOSED). 7.Set utility MLCB to ON (CLOSED). The system is now in AUTO. NOTE: If correct utility is present at this time, generator will perform its usual shutdown process. –+ 001832 001821 A B Maintenance Owner’s Manual for 60 Hz Air-Cooled Generators 33 Performing Fuel System Leak Test All products are factory-tested before shipping to verify the performance and integrity of the fuel system. How- ever, it is important to perform a final fuel system leak test before starting the generator. The entire fuel system should be tested from supply to regulator. See Figure 4-12. Perform a final fuel system leak test after generator installation. The test will identify possible leaks at all connection points (A). It is best practice to perform a fuel system leak test during normally-scheduled maintenance. Figure 4-12. Connection Points to Leak Check Inspect for leaks by spraying all connection points with a non-corrosive gas leak detection fluid. The solution should not be blown away or form bubbles. Attention After Submersion DO NOT start or operate generator if it has been sub- merged in water. Have an IASD thoroughly clean, dry, and inspect generator following any submersion in water. If the structure (home) has been flooded, it should be inspected by a certified electrician to verify there will not be any electrical problems during generator operation or when utility power is returned. Corrosion Protection Regular scheduled maintenance should be conducted to inspect unit for corrosion. Inspect all metal components of generator, including base frame, brackets, alternator can, the entire fuel system (inside and outside of the gen- erator), and fastener locations. If there is corrosion found on generator components (e.g. regulator, engine/alterna- tor mounts, fuel plenum, etc.), replace parts as neces- sary. Periodically wash and wax enclosure using automotive type products. Do not spray unit with a hose or power washer. Use warm, soapy water and a soft cloth. Fre- quent washing is recommended in salt water/coastal areas. Spray engine linkages with a light oil such as WD- 40. Remove From and Return To Service Procedure Remove From Service If generator cannot be exercised monthly, at a minimum, and will be out of service longer than 90 days, proceed as follows to prepare generator for storage: 1.Start engine and allow it to warm up. 2.Close fuel shutoff valve in fuel supply line and allow engine to stop. 3.Set generator MLCB (generator disconnect) to OFF (OPEN) once engine has stopped. 4.Disconnect battery charger AC input T1/Neutral cable (with white sleeve) at controller. 5.Remove 7.5A fuse from generator control panel. 6.Disconnect battery cables. Remove negative bat- tery cable first. 7.Drain oil completely while engine is still warm, and then fill crankcase with oil. See Changing the Oil and Oil Filter. 8.Attach a tag to engine indicating viscosity and clas- sification of the new oil in the crankcase. 9.Remove spark plug(s) and spray a fogging agent into spark plug(s) threaded openings. Install and tighten spark plug(s) to specification. 10.Remove battery and store in a cool, dry place. 11.Clean and wipe down generator enclosure. (000192) DANGER Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury. A A A 004038 (000238) Explosion. Batteries emit explosive gases. Always disconnect negative battery cable first to avoid spark. Failure to do so could result in death or serious injury. WARNING Maintenance 34 Owner’s Manual for 60 Hz Air-Cooled Generators Return to Service Proceed as follows to return unit to service after storage: 1.Inspect engine tag for oil viscosity and classifica- tion. Drain and fill with recommended oil if neces- sary. 2.Verify state of battery. Fill all cells of unsealed bat- teries to correct level with distilled water. DO NOT use tap water. Charge battery to 100% state of charge. Replace battery if faulty. 3.Clean and wipe down generator enclosure. 4.Verify 7.5A fuse is removed from generator control panel. 5.Connect battery. Observe battery polarity. Damage will occur if battery is connected incorrectly. Install positive battery cable first. 6.Connect battery charger AC input T1/Neutral cable (with white sleeve) at controller. 7.Open fuel shutoff valve. 8.Insert 7.5 A fuse into generator control panel. 9.Complete Install Wizard procedure (diagrammed in generator installation manual). 10.Press MANUAL button to start unit. Allow unit to warm up for a few minutes. 11.Press OFF button to stop unit. 12.Set generator MLCB (generator disconnect) to ON (CLOSED). 13.Press AUTO button on control panel. The generator is ready for service. NOTE: Exercise timer and current date and time must be reset if battery is discharged or has been disconnected. (000133) WARNING Explosion. Batteries emit explosive gases. Always connect positive battery cable first to avoid spark. Failure to do so could result in death or serious injury. (000167a) Equipment damage. Do not make battery connections in reverse. Doing so will result in equipment damage. CAUTION Troubleshooting / Quick Reference Guide Owner’s Manual for 60 Hz Air-Cooled Generators 35 Section 5: Troubleshooting / Quick Reference Guide Generator Troubleshooting Problem Cause Correction Engine will not crank Blown fuse. Correct short circuit condition by replacing 7.5 A fuse in generator control panel. Contact an IASD if fuse continues to blow. Loose, corroded, or faulty battery cables. Tighten, clean, or replace as necessary.*Faulty starter contact. Faulty starter motor. Discharged battery.Charge or replace battery. Engine cranks but will not start No fuel.Replenish fuel / turn on fuel valve. Faulty fuel solenoid (FS).Contact an IASD for assistance.Harness/wiring issue. Faulty spark plug(s).Clean; inspect spark plug gap; replace spark plug(s) if necessary. Valve clearance out of adjustment, if applicable. See Engine.Inspect and adjust valve clearance. Engine starts hard and runs rough Plugged or damaged air cleaner.Inspect and clean air cleaner. Faulty spark plug(s).Clean; inspect spark plug gap; replace spark plug(s) if necessary. Incorrect fuel pressure. Verify fuel pressure to regulator is 10–12 in water column (2.49–2.99 kPa) for LP gas, and 3.5–7.0 in water column (0.87–1.74 kPa) for NG. Fuel selector in wrong position.Set fuel conversion valve to correct position and program controller for fuel type. Valve clearance out of adjustment, if applicable. See Engine.Inspect and adjust valve clearance. Internal engine issue.Contact an IASD for assistance. Unit is set to OFF, but engine continues to run Controller wired incorrectly. Contact an IASD for assistance.Faulty control board. No AC output from generator Generator MLCB (generator disconnect) is OFF (OPEN). Set generator MLCB (generator disconnect) to ON (CLOSED). Generator internal failure.Contact an IASD for assistance. Engine may be warming up. See Cold Smart Start.Check the controller screen to verify status. Troubleshooting / Quick Reference Guide 36 Owner’s Manual for 60 Hz Air-Cooled Generators No transfer to standby after utility source failure Generator MLCB (generator disconnect) is OFF (OPEN). Set generator MLCB (generator disconnect) to ON (CLOSED). Faulty transfer switch coil. Contact an IASD for assistance.Faulty transfer relay. Transfer relay circuit open. Faulty control logic board. Engine may be warming up. See Cold Smart Start.Check controller screen to verify status. Unit consumes large amounts of oil Excessive engine oil.Adjust oil to correct level. See Checking Engine Oil Level. Faulty engine breather.Contact an IASD for assistance. Incorrect type or viscosity of oil.See Engine Oil Requirements. Damaged gasket, seal, or hose.Inspect for oil leaks. Restricted air filter.Replace air filter. Wi-Fi network connection broken or intermittent Various.See Wi-Fi module owner’s manual. * Contact an IASD or visit www.generac.com for assistance. Problem Cause Correction Troubleshooting / Quick Reference Guide Owner’s Manual for 60 Hz Air-Cooled Generators 37 Quick Reference Guide To clear an active alarm, press OFF button on the control panel, then the ENTER button, and finally the AUTO button. Contact an IASD if alarm reoccurs. Active Alarm LED Problem Action Solution NONE FLASHING GREEN Unit running in AUTO but no power in house. Check generator MLCB (generator disconnect). Check generator MLCB (generator disconnect). If it is ON, contact an IASD. HIGH TEMPERATURE RED Unit shuts down during operation. Check LEDs / screen for alarms. Inspect ventilation around generator, intake, exhaust, and rear of generator. If no obstructions are present, contact an IASD. OVERLOAD REMOVE LOAD RED Unit shuts down during operation. Check LEDs / screen for alarms. Clear alarm and remove household loads from generator. Put in AUTO and restart. RPM SENSE LOSS RED Unit was running and shut down, attempts to restart. Check LEDs / screen for alarms. Clear alarm and remove household loads from generator. Put into AUTO and restart. If generator does not start, contact an IASD. NOT ACTIVATED NONE Unit will not start in AUTO with utility loss. Check if screen says unit not activated. See Activation section in installation manual. NONE GREEN Unit will not start in AUTO with utility loss. Check screen for start delay countdown. If startup delay is greater than expected, contact an IASD to adjust from 2 to 1500 seconds. LOW OIL PRESSURE RED Unit will not start in AUTO with utility loss. Check LEDs / screen for alarms. Check oil level and add oil as needed. If oil level is correct, contact an IASD. RPM SENSE LOSS RED Unit will not start in AUTO with utility loss. Check LEDs / screen for alarms. Clear alarm. Using control panel, check battery by navigating to BATTERY MENU option from MAIN MENU. If battery condi- tion displays GOOD, contact an IASD. If control panel displays CHECK BATTERY, replace battery. OVERCRANK RED Unit will not start in AUTO with utility loss. Check LEDs / screen for alarms. Verify fuel line shutoff valve is ON. Clear alarm. Start unit in MANUAL. If it does not start, or starts and runs rough, contact an IASD. LOW VOLTS REMOVE LOAD RED Unit will not start in AUTO with utility loss. Check LEDs / screen for alarms. Clear alarm and remove household loads from generator. Put in AUTO and restart. OVERSPEED RED Unit will not start in AUTO with utility loss. Check LEDs / screen for alarms.Contact an IASD. UNDERVOLTAGE RED Unit will not start in AUTO with utility loss. Check LEDs / screen for alarms.Contact an IASD. UNDERSPEED RED Unit will not start in AUTO with utility loss. Check LEDs / screen for alarms.Contact an IASD. STEPPER OVERCURRENT RED Unit will not start in AUTO with utility loss. Check LEDs / screen for alarms.Contact an IASD. WIRING ERROR RED Unit will not start in AUTO with utility loss. Check LEDs / screen for alarms.Contact an IASD. OVERVOLTAGE RED Unit will not start in AUTO with utility loss. Check LEDs / screen for alarms.Contact an IASD. Troubleshooting / Quick Reference Guide 38 Owner’s Manual for 60 Hz Air-Cooled Generators AUXILIARY SHUTDOWN RED Unit will not start.Check auxiliary shutdown switches Set auxiliary shutdown switch(es) to CLOSED (I). Clear alarm. LOW BATTERY YELLOW Yellow LED illuminated in any state. Check screen for additional information. Clear alarm. Using control panel, check battery by navigating to BATTERY MENU option from MAIN MENU. If battery condi- tion displays GOOD, contact an IASD. If control panel displays CHECK BATTERY, replace battery. BATTERY PROBLEM YELLOW Yellow LED illuminated in any state. Check screen for additional information.Contact an IASD. CHARGER WARNING YELLOW Yellow LED illuminated in any state. Check screen for additional information.Contact an IASD. CHARGER MISSING AC YELLOW Yellow LED illuminated in any state. Check screen for additional information.Contact an IASD. SERVICE A YELLOW Yellow LED illuminated in any state. Check screen for additional information. Perform SERVICE A maintenance. Press ENTER to clear. SERVICE B YELLOW Yellow LED illuminated in any state. Check screen for additional information. Perform SERVICE B maintenance. Press ENTER to clear. INSPECT BATTERY YELLOW Yellow LED illuminated in any state. Check screen for additional information.Inspect battery. Press ENTER to clear. Active Alarm LED Problem Action Solution Part No. A0000973303 Rev. A 10/09/2020 ©2020 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. 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