® Owner’s Manual Spark-Ignited Stationary Generators Residential and Commercial 48 kW 60 kW 80 kW 4.5L 4.5L 4.5L 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.com/service-support/product-support-lookup Pour le français, visiter : http://www.
Use this page to record important information about the generator. 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 GENERATOR UNIT all models. GEN MODEL: Always provide the complete model number and serial MODEL: number when contacting an Independent Authorized SerSERIAL: vice Dealer (IASD) about parts and/or service.
Table of Contents Section 1: Safety Rules & General Information Testing Auxiliary Shutdown Switch Operation ........... 14 Checking Automatic Operation ..................................15 Introduction ..........................................................1 Securing the Generator .................................... 15 Safety Rules .........................................................1 Section 4: Operation How to Obtain Service .................................................
Replacing Air Filter Element ..................................... 31 Final Instructions ....................................................... 31 Schedule B Maintenance ..................................32 Schedule B Maintenance Item Locations .................. 32 Draining and Flushing Coolant System ..................... 32 Clean/Gap/Replace Spark Plugs .............................. 33 Final Instructions ....................................................... 33 Schedule C Maintenance ..............
Safety Rules & General Information Section 1: Safety Rules & General Information Introduction Thank you for purchasing this compact, high performance, liquid-cooled, engine-driven generator. It is designed to automatically supply electrical power to operate critical loads during a utility power failure. This unit is factory installed in an all-weather enclosure intended exclusively for outdoor installation.
Safety Rules & General Information General Hazards 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. (000190) 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) WARNING Equipment damage.
Safety Rules & General Information DANGER WARNING 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. (000219) WARNING Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury.
Safety Rules & General Information 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.
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 Model 48 kW 60 kW 80 kW Engine 4.5L 4.5L 4.5L Air Intake System Type Naturally aspi- Turbocharged / Turbocharged / rated Aftercooled Aftercooled Exhaust System Breather Closed Closed Closed 104 scfm (2.9 cmm) 181scfm (5.1 cmm) 181 scfm (5.
General Information Reconfiguring the Fuel System WARNING Risk of burns. Do not open coolant system until engine has completely cooled. Doing so could result in serious injury. (000154) CAUTION Engine damage. Use approved coolant only. Failure to do so could result in equipment damage. (000323) Use of incorrect coolants can damage the engine cooling system. Use demineralized water or distilled water for best results.
General Information Battery Safety Precautions DANGER Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) 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. (000138a) WARNING Explosion hazard. Never add acid to a battery. Add distilled water only.
Activation and Startup Section 3: Activation and Startup Orientation Installing the Battery NOTE: The 4.5L (48 kW) unit is depicted in the artwork used in this manual. The location and appearance of some components may vary between engine models. See Figure 3-1. The viewing window (A) side of the enclosure 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.
Activation and Startup Opening the Viewing Window Proceed as follows to open the viewing window: 1. Remove plastic film from both sides of viewing window. 2. Lift viewing window up to access control panel. 3. See Figure 3-4. To hold viewing window open, remove rod from clip at back of window and insert into hole in frame (A). A 006373 Figure 3-4.
Activation and Startup Activating the Unit Display Reads: Up Arrow = (+) Language - English + Generator Active is displayed on the LCD during initial startup. After displaying firmware and hardware version codes, as well as other system information, the Install 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: Select YES to perform exercise at low speed. Select NO to perform exercise at normal operating speed. Press ENTER. Set Exercise Time. Select Hour (0-23) -1+ Use Up arrow or Down arrow to increment or decrement the hour. Press ENTER. In AUTO, the engine starts and runs once each week at the time and day specified.
Activation and Startup Operational Checks NOTE: The following procedures require special tools and skills. Contact an IASD to perform these tasks. Self Test Upon startup, controller goes through a system self test which checks for utility voltage on the DC circuits. This is done to prevent damage if installer mistakenly connects AC utility power sense wires into DC terminal block.
Activation and Startup IMPORTANT NOTE: Do not proceed unless generator AC voltage and frequency are correct and within stated limits. Testing Generator Under Load See Figure 3-6. Generators 15 kW and larger are equipped with two auxiliary shutdown switches. One auxiliary shutdown switch (A) is located on the generator roof above and to the right of the viewing window. The second auxiliary shutdown switch (B) is inside the control panel enclosure. DANGER Electrocution. Do not manually transfer under load.
Activation and Startup Checking Automatic Operation Proceed as follows to check system for correct automatic operation: 1. Verify generator is in OFF mode. A red LED on control panel illuminates to verify system is OFF. 2. Install front cover of transfer switch. 3. Turn on utility power supply to transfer switch, using the means provided (such as a utility MLCB). NOTE: Transfer switch will transfer to UTILITY. 4. Set generator MLCB (generator disconnect) to ON (CLOSED). 5. Press AUTO on control panel.
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Operation Section 4: Operation Control Panel 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. (000191) NOTE: The control panel is intended for use by qualified service personnel only. See Figure 4-1. The control panel is located behind the viewing window at the rear of the unit. See Figure 3-5 and Figure 3-6.
Operation AUTO/MANUAL/OFF Feature Description AUTO Activates fully automatic operation. Green LED illuminates to verify system is in AUTO. Transfer to standby power occurs if utility power fails. Functionality of exercise timer is enabled, if set. MANUAL Cranks and starts engine. Blue LED illuminates to verify system is in MANUAL. Transfer to standby power occurs if utility power fails. Functionality of exercise timer is disabled. OFF Shuts down engine, if running.
Alarm/Warning Conditions The owner/operator is alerted to Alarm and/or Warning conditions via the control panel LCD. All Alarm conditions cause the generator to shut down. Owner’s Manual for Spark-Ignited Stationary Generators *Note: E-Codes Not Shown ALARM MESSAGE(S)* "High Coolant Temp.
Operation Alarm Messages • High Engine • • • • • • • • • • • • • • • • • Temperature Low Oil Pressure Overcrank Overspeed RPM Sense Loss Underspeed Controller Fault Ignition Fault Code Auxiliary Shutdown WIRING ERROR Over Voltage Under Voltage Overload Canbus Error Missing Cam Pulse Missing Crank Pulse Low Fuel Pressure E-Stop Warning Messages • Low Battery • Exercise Set Error • Schedule A • • • • • • • • Maintenance Schedule B Maintenance Schedule C Maintenance Battery Problem Charger Warning Charge
Operation Battery Charger Automatic Sequence of Operation NOTE: Battery charger is integrated into control panel module. Utility Failure If control panel is set to AUTO when utility power fails, a 10 second startup delay timer is started (user programmable). If utility power is still absent when time expires, engine cranks and starts. Once started, a five second engine warm-up delay timer starts (user programmable). When time has elapsed, load is transferred to generator.
Operation Transfer Switch Manual Operation DANGER Electrocution. Do not manually transfer under load. Disconnect transfer switch from all power sources prior to manual transfer. Failure to do so will result in death or serious injury, and equipment damage. (000132) Prior to automatic operation, manually exercise transfer switch to verify there is no binding or interference with correct operation of the mechanism. Manual operation of transfer switch is required if automatic operation fails.
Maintenance Section 5: Maintenance Component Locations NOTE: The 4.5L (48 kW) unit is depicted in the artwork used in this manual. The location and appearance of some components may vary between engine models. A D B C E The viewing window side of the enclosure 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 7.
Maintenance A A Spark plugs B Oil drain hose C Coolant drain hose D Coolant overflow reservoir C B D 010076 Figure 5-3. Right 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 Proceed as follows to remove the access panels: 1. See Figure 5-4.
Maintenance Service Maintenance Schedule Observe the maintenance tasks and intervals shown in the table below.
Maintenance Remove From Service 25 Hour Break-In Perform the following task: • Replace lubricating oil and oil filter. WARNING Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury. (000130) For safety, follow the steps below prior to inspection, maintenance, or service.
Maintenance Schedule A Maintenance NOTE: Perform Schedule A maintenance once each year or after 125 hours of service, whichever comes first. NOTE: The 4.5L (48 kW) unit is depicted in the artwork used in this manual. Schedule A Maintenance Item Locations NOTE: The viewing window side of the enclosure with 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 48kW / 60kW / 80 kW Engine 4.
Maintenance Checking Lubricating Oil Level and Drain Hose NOTE: If changing engine lubricating oil and filter, see Replacing Lubricating Oil and Oil Filter. Proceed as follows to check oil level and oil drain hose: 1. If engine was running, wait at least 10 minutes to verify oil has fully drained into oil pan. NOTE: The most accurate oil level readings are obtained when engine is cold. 2. See Figure 5-2. Remove oil dipstick (D) and wipe dry with a clean, lint free cloth. 3.
Maintenance C B 009884 Figure 5-9. Oil Drain Hose Holding Clamp 2. Use one wrench to hold hex on oil drain hose fitting (to prevent rotation), and use second wrench to remove oil drain plug. 3. Drain oil into a suitable container. 4. Install oil drain plug onto end of oil drain hose. 5. Install oil drain hose into holding clamp. 6. See Figure 5-2. Turn oil filter (C) counterclockwise to remove from oil filter adapter. 7. Apply a light coat of clean engine oil to gasket of new oil filter. 8.
Maintenance Checking Fluid Level Check the fluid level of unsealed batteries. If necessary, fill with distilled water only. DO NOT use tap water. Verifying Battery State of Charge Verify the battery state of charge using a digital multimeter (DM). Recharge and retest if state of charge is below manufacturer's recommendations. Replace battery if necessary. Battery Replacement Removal WARNING Electrical shock. Disconnect battery ground terminal before working on battery or battery wires.
Maintenance NOTE: Service kits are available from an IASD. Final Instructions B Proceed as follows if only performing Schedule A maintenance procedures: 1. Install negative battery cable (black) onto negative battery (-) terminal. 2. Install left and right side access panels. See Access Panels. 3. See Return To Service. C A 010060 Figure 5-12.
Maintenance Schedule B Maintenance NOTE: Perform Schedule B maintenance every two years or after 250 hours of service, whichever comes first. Before proceeding below, first perform all tasks listed under Schedule A Maintenance. NOTE: The 2.4L (32 kW) unit is depicted in the artwork used in this manual. For the general location of components in all other models, see Schedule B Maintenance Item Locations.
Maintenance 17. Press MANUAL on control panel to start engine. A blue LED illuminates to verify system is in MANUAL. 18. Allow engine to run until thermostat opens, as indicated by heating of top radiator hose. 19. Inspect coolant hoses for leaks. Tighten clamps, if necessary. 20. Press OFF on control panel to shut engine down. 21. Allow engine to cool. 22. Repeat steps 4–21 to drain and refill cooling system. 23. Slowly unscrew radiator cap. Slowly pour coolant into filler neck until radiator is full. 24.
Maintenance Schedule C Maintenance NOTE: Perform Schedule C maintenance after 1,000 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 IASD to perform these tasks. 1. Remove negative battery cable (black) from negative battery (-) terminal. 2. Proceed as follows: • • • • Tighten critical fasteners. Replace upper and lower radiator hoses.
Troubleshooting Section 6: Troubleshooting Engine Troubleshooting Problem Cause Fuse blown. Engine does not crank Loose, corroded, or faulty battery cables. Faulty starter contact. Correction Replace 7.5 amp fuse in generator control panel. Correct short circuit condition if fuse blows again. Tighten, clean, or replace as necessary. Contact an IASD. Faulty starter motor. Engine cranks but will not start Engine starts hard and runs rough Discharged battery. Charge or replace battery.
Troubleshooting Controller Troubleshooting Active Alarm Problem Solution NOT ACTIVATED Unit will not start in AUTO with utility loss. See activation section in installation manual. NONE Unit running in AUTO but no power in house. Check MLCB (generator disconnect). Contact an IASD if MLCB is set to ON. NONE Unit will not start in AUTO with utility loss. Check LCD for start delay countdown. If startup delay is greater than expected, contact IASD to adjust from 2 to 1,500 seconds.
Troubleshooting Removal From Service During Utility Outage If, during prolonged utility outages, the user wishes to remove unit from service to conserve fuel, reduce run hours, or to perform maintenance tasks, then complete the steps listed below. IMPORTANT NOTE: Failure to abide by this procedure can result in equipment damage. Proceed as follows to remove generator from service while running in AUTO and online: 1. Turn main utility disconnect to OFF (OPEN). 2. Open viewing window.
Troubleshooting Battery Removal 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) Proceed as follows to remove the battery: 1. Remove negative battery cable (black) from negative battery (-) terminal. 2. Remove positive battery cable (red) from positive battery (+) terminal. 3. Remove two screws to release battery hold-down clamp from platform. 4.
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® Part No. A0000253468 Rev. B 07/6/2020 ©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. S45 W29290 Hwy. 59 Waukesha, WI 53189 1-888-GENERAC (1-888-436-3722) www.generac.
