® Owner’s Manual Spark-Ignited Stationary Generators Residential and Commercial 22 kW 25 kW 27 kW 30 kW 2.4L 1.5L 2.4L 1.5L 32 kW 36 kW 38 kW 45 kW 48 kW 60 kW 2.4L 2.4L 2.4L 2.4L 5.4L 2.4L 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. (000209b) Register your Generac product at: WWW.GENERAC.COM 1-888-GENERAC (888-436-3722) Para español , visita: http://www.generac.
Use this page to record important information about the generator set. For quick and easy reference, copy the information printed on the Unit Identification Label onto the sample label printed here. The Unit Identification Label is located on the base frame adjacent to the front engine mount on all models. When contacting an Independent Authorized Service Dealer (IASD) about parts and/or service, always provide the complete model number and serial number.
Table of Contents Section 1: Safety Electrical Checks .......................................................17 Introduction ..........................................................1 Test Generator Under Load ......................................17 Read This Manual Thoroughly ....................................1 Safety Rules .........................................................1 How to Obtain Service .........................................2 General Hazards ....................................
Table of Contents Check Lubricating Oil Level and Drain Hose ............ 34 Replace Lubricating Oil and Oil Filter ....................... 35 Check Battery Condition/Fluid Level ......................... 38 Check and Adjust Accessory/Drive Belt .................... 39 Replace Air Filter Element ........................................ 41 Final Instructions ....................................................... 41 Schedule B Maintenance ..................................
Safety Section 1: Safety 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.
Safety How to Obtain Service When the unit requires servicing or repairs, contact Generac Customer Service at 1-888-GENERAC (1-888-4363722) 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. WARNING Risk of injury.
Safety Exhaust Hazards DANGER Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. (000103) 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. (000178a) WARNING Equipment and property damage.
Safety Battery Hazards DANGER Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) WARNING Explosion. Do not dispose of batteries in a fire. Batteries are explosive. Electrolyte solution can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention. (000162) WARNING Explosion. Batteries emit explosive gases while charging. Keep fire and spark away.
General Information Section 2: General Information 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 emissions compliance decal on the engine to determine applicable standards. See the included emissions warranty for emissions warranty information.
General Information Specifications Model 22 kW 25 kW 27 kW 30 kW 32 kW 36 kW 38 kW 45 kW 48 kW 60 kW Engine 2.4L 1.5L 2.4L 1.5L 2.4L 2.4L 2.4L 2.4L 5.4L 2.4L Class F Class H Class F Class H Class F Class H 1255 (569) – 1283 (582) 1202 (545) 1555 (705) 1230 (558) 1355 (615) – 1383 (627) 1655 (751) 1330 (603) V-type In-Line Generator Set Rotor Insulation Class H Stator Insulation Class H Dimensions L x W x H Product Weight W/ Enclosure—lbs (kg) 62.2 x 30.6 x 38.
General Information Model 22 kW 25 kW 27 kW 30 kW 32 kW 36 kW 38 kW 45 kW 48 kW 60 kW Engine 2.4L 1.5L 2.4L 1.5L 2.4L 2.4L 2.4L 2.4L 5.4L 2.4L 6/5.7 4/3.8 Thermostat (Full Open) 190° F (88° C) Lubricating System Oil Pump Type Gear Oil Filter Type Full Flow Spin-On Cartridge Crankcase Oil (quarts/liters) Capacity 4/3.
General Information Engine Oil Recommendations Coolant Water Treatment To maintain the product warranty, the engine oil should be serviced in accordance with the recommendations of this manual. For your convenience, Generac Maintenance Kits are available that include engine oil, oil filter, air filter, spark plug(s), a shop towel and funnel. These kits can be obtained from an Independent Authorized Service Dealer (IASD). Use of improper coolants can damage the engine cooling system.
General Information Reconfiguring the Fuel System A 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 carburetion system are generally configured for the selected fuel source during installation.
General Information NOTE: Solenoid must be installed with flow arrow pointed toward black pipe assembly. See inset of Figure 2-3. 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.
General Information • Discharge static electricity from the body before touching the battery by first touching a grounded metal surface. • Wear full eye protection, protective clothing, and gloves when handling a battery. • Immediately wash down spilled electrolyte with an acid neutralizing agent. Use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) of water. Add the bicarbonate of soda solution until evidence of reaction (foaming) has ceased.
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Activation and Startup Section 3: Activation and Startup Orientation Install Battery 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 (A) 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. The battery is located on the side of the unit (B).
Activation and Startup Open Viewing Window 1. See Figure 3-4. 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 (A). A 006373 Figure 3-4.
Activation and Startup Activate Unit Display Reads: Up Arrow = (+) Language - English + 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. Use UP ARROW or DOWN ARROW to scroll to desired language. Press ENTER.
Activation and Startup Display Reads: Use UP ARROW or DOWN ARROW to select either Yes or No. Quiet Test Mode? Yes No Display Reads: Press ENTER. Set Exercise Time. Select Hour (0-23) -1+ Select YES to perform exercise at low speed. Select NO to perform exercise at normal operating speed. Use UP ARROW or DOWN ARROW to increment or decrement the hour. Press ENTER. In the AUTO mode, the engine starts and runs once each week at the time and day specified.
Activation and Startup 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 an IASD for assistance. Check Manual Transfer Switch Operation Refer to the manufacturer’s instructions. DANGER Electrocution. Do not manually transfer under load.
Activation and Startup position. The switch is now powered by the standby generator. 8. Turn ON the circuit breaker/electrical powered by the generator. loads 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 overloaded. 10. Let the generator run at full rated load for 20-30 minutes.
Activation and Startup Securing the Generator 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 3-7 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. 006376 Figure 3-7.
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Operation Section 4: Operation Control Panel DANGER NOTE: The control panel is intended for use by qualified service personnel only. 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. The control panel is located behind the viewing window at the rear of the unit. See Figure 3-5 and Figure 4-1.
Operation Menu Navigation See Figure 4-2. Feature Description System Menus HOME Screen The system returns to the Home screen if the control panel is not used for five minutes. The screen normally 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.
Owner’s Manual for Stationary Generators *Note: E-Codes Not Shown ALARM MESSAGE(S)* "High Engine Temp.
Operation Alarm/Warning Conditions The owner/operator is alerted to Alarm and/or Warning conditions via the control panel LCD screen. All Alarm conditions 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.
Operation 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. Transfer Switch Automatic Operation In AUTO, the generator starts automatically when utility source voltage drops below the preset level.
Operation 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 seconds (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).
Operation Transfer Back to Utility Power When utility power is restored, manually transfer back to utility power and shut down the generator as follows: A B 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. C 3. Press OFF on the control panel to shut down the engine. 006375 Figure 4-3.
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Maintenance Section 5: Maintenance 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. A D C B E F 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. A 7.
Maintenance A E D A Spark Plugs B Battery C Oil Drain Hose D Coolant Drain E Coolant Overflow Reservoir B C 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. Access Panels Access panels are located at both the left and right sides of the enclosure. Removal 1. Insert key (B) into latch and rotate counterclockwise 1/2 turn.
Maintenance Service Maintenance Schedule Observe the maintenance tasks and intervals shown in the table below.
Maintenance 30 Hour Break-In Perform the following task: • Replace Lubricating Oil and Oil Filter NOTE: See Replace Lubricating Oil and Oil Filter under Schedule A Maintenance. Daily Maintenance Perform the following tasks: • • • • • Check Enclosure Louvers Check Fuel Lines Check Coolant Level and Hoses Check Radiator for Clogging Check Lubricating Oil Level and Drain Hose NOTE: See Check Enclosure Louvers through Check Coolant Level and Hoses under Schedule A Maintenance.
Maintenance 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 25/30 kW 32/38 kW 36/45 kW 48 kW 60 kW Engine 2.4L 1.5L 2.4L 2.4L 5.4L 2.
Maintenance Figure 5-6. Coolant Overflow Reservoir Check Radiator for Clogging 1. Use a flashlight 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. Check Lubricating Oil Level and Drain Hose 12. Press MANUAL on the control panel to start the engine. 13. Allow the engine to run for one minute. 14.
Maintenance C A FULL B 1.5L 5.4L 2.4L Figure 5-7. Oil Level Dipstick and Oil Fill Cap 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 Lube Oil Maintainer System. 1. Remove oil drain hose from holding clamp (A). See Figure 5-8. 2. Use one wrench to hold hex on hose fitting (to prevent rotation), and use second wrench to remove drain plug. WARNING Skin irritation.
Maintenance 13. Press MANUAL on the control panel to start the engine. 17. Check oil level and add oil as necessary. See Check Lubricating Oil Level and Drain Hose. 14. Allow the engine to run for one minute. Check for leaks while the engine is running. 18. Install fill cap. 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.
Maintenance A D D A B B C C 2.4L: 22/27/36/45 kW 2.4L: 32/38 kW A A D D B C B C 2.4L: 60 kW 1.5L: 25/30 kW A C D B 5.4L: 48 kW Figure 5-9.
Maintenance Check Battery Condition/Fluid Level WARNING Check Condition and Clean 1. See Figure 3-3 for illustration. Verify top of battery is clean and dry. Dirt and electrolyte on top of the battery can cause battery to self-discharge. 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 bubbling, rinse off the battery with clean water. 1.
Maintenance 3. Recheck belt deflection and repeat steps as necessary. B A 001499 Figure 5-10. Remove/Install Battery Check and Adjust Accessory/Drive Belt Check Check the accessory/drive belt condition. 1. Perform visual inspection as follows: • Inspect belt for cracks, fraying, excessive wear or other damage. • Verify belt is free of grease and oil. • Replace belt if contaminated, damaged, frayed or worn. NOTE: Use a solution of soap and warm water to clean pulleys, if necessary.
Maintenance B A C 2.4L: Manual Adjustment D A 1.5L: Manual Adjustment 5.4L: Automatic Adjustment Figure 5-11.
Maintenance Replace Air Filter Element 4. Place new air filter element against adapter flange. 1. Remove wing nut (B), lock washer (C), and flat washer (D) from threaded rod to release air cleaner cover. See Figure 5-12. NOTE: The air filter element is not directional. 5. Install air cleaner cover (E) over threaded rod. Install flat washer, lock washer and wing nut. Tighten wing nut until snug. 2. Remove the air filter element (A) and discard. 3.
Maintenance Drain/Flush Coolant System NOTE: If unit is not equipped with drain hose, install suitable length of rubber hose to drain cock. 1. Disconnect and empty coolant overflow reservoir. 6. Rotate hex fitting to open drain cock (A). See Figure 5-13 2. Install and connect coolant overflow reservoir. 7. Remove coolant drain hose from holding clamp. WARNING Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (000139) 8.
Maintenance Clean/Gap/Replace Spark Plugs 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. Clean, gap or replace spark plugs as follows: 3. Thoroughly clean area around spark plugs. WARNING Electric shock. Do not disconnect spark plug wires with engine running. Doing so could result in death or serious injury. (000140a) 1.
Maintenance 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. IMPORTANT NOTE: The following procedures require special tools and skills. Contact an Independent Authorized Service Dealer to perform these tasks. 1. Remove battery negative cable (black) from battery negative (-) terminal. 2. Proceed as follows: • • • • • Replace timing belt (2.
Maintenance 009678 Figure 5-16. Access Oil Supply Tank 009681 Test Functionality Figure 5-17. Shutoff Valve (Shown in Open Position) SeeFigure 5-15. Momentarily press the test button (E) to confirm that the float is operating correctly. Shutoff Valve NOTE: 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. See Figure 5-17 and Figure 5-18.
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Troubleshooting Section 6: Troubleshooting Engine Troubleshooting Problem The engine will not crank. The engine cranks but will not start. The engine starts hard and runs rough. The generator is set to OFF, but the engine continues to run. There is no AC output from the generator. There is no transfer to standby after utility source failure. Unit consumes large amounts of oil. Cause Correction Fuse blown. Replace 7.5 amp fuse in generator control panel.
Troubleshooting Controller Troubleshooting Active Alarm NOT ACTIVATED 48 Solution Unit will not start in AUTO with utility loss. Refer to activation section in Owner’s Manual. NONE Unit running in AUTO but no power in house. Check MLCB. Contact Independent Authorized Service Dealer (IASD) if MLCB is in the ON position. NONE Unit will not start in AUTO with utility loss. Check screen for start delay countdown.
Troubleshooting Removal From Service During Utility Outages Storage 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. Prepare For Storage If the generator cannot be exercised every seven days and will be out of service longer than 90 days, prepare for storage as follows: this 1. Open the viewing window. See Open Viewing Window.
Troubleshooting WARNING Explosion. Batteries emit explosive gases. Always disconnect negative battery cable first to avoid spark. Failure to do so could result in death or serious injury. (000238) 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 in a cool, dry room. 25.
® Part No. 0K8185 Rev. D 05/28/2019 ©2019 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) www.generac.
