® Owner’s Manual 60 Hz Air-Cooled Generators 9 kW to 22 kW 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.generac.
Use this page to record important information about your generator set. Model: Serial: Production Date: Volts: LPV Amps: NG Amps: Hz: Phase: Controller P/N: STA MAC ID: Record the information found on your unit data label on this page. See General Information for the location of the unit data label. The unit has a label plate affixed to the inside partition, to the left of the control panel console as shown in Figure 2-1 or Figure 2-2.
Table of Contents Section 1: Safety Information Section 3: Operation Introduction ..........................................................1 Site Prep Verification ........................................ 13 Read This Manual Thoroughly ....................................1 Generator Enclosure ......................................... 13 Safety Rules .........................................................1 Opening the Lid .........................................................
Table of Contents 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 ..........................................
Safety Information Section 1: Safety Information Introduction Safety Rules Thank you for purchasing this compact, high performance, air-cooled, engine-driven generator. It is designed to automatically supply electrical power to operate critical loads during a utility power failure. The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The alerts in this manual, and on tags and decals affixed to the unit, are not all inclusive.
Safety Information How to Obtain Service Contact an IASD for assistance when the generator requires servicing or repairs. Service technicians are factory-trained and are capable of handling all service needs. Please visit the dealer locator at: www.generac.com/Service/ DealerLocator/ to locate the nearest IASD. When contacting a dealer about parts and service, always supply the complete model and serial numbers of the unit as given on its data plate (decal), which is located on the generator.
Safety Information DANGER WARNING 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. (000228) WARNING 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. (000237) DANGER Injury and equipment damage.
Safety Information Fire Hazards Explosion Hazards WARNING DANGER 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. (000217) 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. (000192) DANGER WARNING Fire and explosion.
Safety 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. Keep fire and spark away.
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General Information Section 2: General Information The Generator F E B C D L K J Q R G H A A P O N M 001818 Figure 2-1. 9kW—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.
General Information B F C D E J L A K R H T G S A Q P O N M 001786 Figure 2-2. 11kW–22kW—Components and Control Locations 8 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 N. Sediment Trap S. Auxiliary Shutdown Switch (all models) D. Control Panel J. Oil Fill Cap O. Fuel Regulator T.
General Information Data Decals Two decals on the generator provide information about the unit itself and required fuel inlet pressure for proper operation. Model Data Decal Includes important information about the unit including: • model number • serial number • production date • voltage • frequency • amps • country of origin • rated ambient temperature. The model data decal also displays certification symbols by Underwriter’s Laboratory (UL) and the Southwest Research Institute (SwRI).
General Information Specifications Generator Model 9 kW 11 kW Rated Voltage 16 kW 20 kW 22 kW 240 Rated Maximum Load Current (Amps) at Rated Voltage with LP* 37.5 45.8 66.6 83.3 91.
General Information 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.
General Information Activating the Generator Wi-Fi Module The generator should be activated upon initial start-up. See the installation manual for complete instructions. The generator is equipped with a Wi-Fi module. Refer to the Wi-Fi module owner’s manual for further instruction.
Operation Section 3: Operation Site Prep Verification Generator Enclosure The generator must be installed to allow unimpeded airflow into and out of the generator. Enclosure lid is locked prior to shipment. A set of keys is attached to the cardboard on top of the generator. An additional set of keys is attached to the pallet bracket on the front intake end of the generator. Mechanical and gravity outdoor air intake openings for air distribution and supply systems must be located not less than 10 ft (3.
Operation Intake Side Panel Removal See Figure 3-2. The intake side panel (A) must be removed to access the battery compartment, fuel regulator, and sediment trap. 3. Lift intake panel up and away from the generator. NOTE: Always lift intake side panel straight up before pulling away from enclosure. Do not pull panel away from the enclosure before lifting up (D). 1. Raise lid and remove front panel. 2. Use a hex key to remove two mounting screws (B) and L-bracket screw (C).
Operation Auxiliary Shutdown Switch Control Panel Interface All generators are equipped with an external means of shutting down the generator which complies with the latest NEC code requirement. The primary generator shutdown sequence is described in Shutting Generator Down While Under Load Or During A Utility Outage. See Figure 3-7. The control panel interface (A) is located under the enclosure lid.
Operation Interface Menu Displays LCD Panel Feature Description HOME page Default page displayed if no buttons are pressed for 60 seconds. Normally shows current status message, and current date and time. The 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 the first message is displayed.
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18 Ready to Run Hours of Protection 0 (H) Cranking Attempt # 3 Stopped - Warning “Warning Message” Cranking - Warning “Warning Message” Cranking Pausing for 13 sec Running Warming Up Cranking - Alarm “Alarm Message” * * Hours of Protection and number of hours will flash every 5 seconds when displayed. Switched to “OFF” Hours of Protection 0 (H) Utility Loss Delay Pausing for 13 sec.
Owner’s Manual for 60 Hz Air-Cooled Generators Warning Message(s) Low Battery Exercise Set Error Service Schedule A Service Schedule B Inspect Battery Stopping...
Operation Setting the Exercise Timer Battery Charger This generator is equipped with a configurable exercise timer. Configuration can be performed directly at the control panel or though the Mobile Link™ application. There are two settings for the exercise timer: IMPORTANT NOTE: Contact an IASD if the controller screen displays “CHARGER MISSING AC.” Day/Time: The generator will start and exercise for the period defined, on the day of the week and at the time of day specified.
Operation Manual Transfer Operation DANGER 7. Set MLCB (generator disconnect) to ON (CLOSED). The standby power source now powers the loads. 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 the transfer switch to verify there is no interference with proper operation of the mechanism.
Operation 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 the generator: 1. Set the MLCB (generator disconnect) to OFF (OPEN). 2. Run engine for one minute at no-load to stabilize the internal temperature. 3. Press the OFF mode button on the control panel. The engine will shut down. 4. Verify utility power supply to the transfer switch is turned OFF. 5.
Operation Cold Smart Start The generator will monitor ambient temperature when Cold Smart Start is enabled. The warm-up delay will be adjusted based on prevailing conditions. Cold Smart Start is enabled at the factory, but can be disabled in the EDIT menu. See Table 3-2. If the ambient temperature is below a fixed temperature (based on model) upon startup in AUTO mode, the generator will warm up for 30 seconds. This allows the engine to warm before a load is applied.
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Maintenance Section 4: Maintenance Maintenance Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be performed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner’s choosing.
Maintenance Service Schedule Service Daily If Running Continuously or Before Each Use Inspect enclosure louvers for dirt and debris * ● Inspect lines and connections for fuel or oil leaks ● Inspect engine oil level ● Every Year Check for water intrusion ** ● Perform fuel system leak test ● Check battery condition, electrolyte level, and state of charge ● Replace engine oil and oil filter † Schedule A Every Two Years or 200 Hours Schedule B Every Four Years or 400 Hours ● ● ● ● Replace
Maintenance Checking Engine Oil Level Engine Oil Requirements 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) 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 consisting of engine oil, oil filter, air filter, spark plug(s), a shop towel, and a funnel.
Maintenance Changing the Oil and Oil Filter 10. Inspect the oil level. Add oil as needed. DO NOT OVERFILL. Proceed as follows to change the oil and oil filter: 11. Insert oil dipstick and/or attach fill cap. 1. Lift the lid and press the MANUAL mode button on the control panel to start the engine, and run it until it is thoroughly warmed up. Press the OFF mode button on the control panel to shut down the engine. 2. See Figure 4-1 or Figure 4-2.
Maintenance Spark Plug(s) Valve Clearance Adjustment Proceed as follows to inspect spark plug gap(s) and replace spark plug(s) as necessary: IMPORTANT NOTE: Contact an IASD for service assistance. Proper valve clearance is essential for prolonging the life of the engine. 1. With the generator OFF and the engine cool, lift the lid and remove the front panel. 2. Clean the area around the base of the spark plug(s) to keep dirt and debris out of the engine. 3.
Maintenance 7. When valve clearance is correct, hold pivot ball stud (D) in place with a wrench and tighten rocker arm jam nut. Tighten jam nut according to the following torque specifications: D F E C 9 kW 53 in-lb (6.0 Nm) 11 kW 72 in-lb (8.2 Nm) 16–22kW 174 in-lb (19.68 Nm) 8. After tightening jam nut, inspect valve clearance to verify it did not change. 9. Install new valve cover gasket. 002380 Figure 4-7. Valve Clearance Adjustment (11-22 kW) 7. Install replacement valve cover gasket(s). 8.
Maintenance Battery Maintenance Strictly observe the following precautions when working on batteries: DANGER • Remove the 7.5 A fuse from the generator control 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.
Maintenance 4. Use a clean-out tool (not provided) to remove accumulated moisture and particles from cap and body (B). – 5. Wipe the inside of each component with a clean, dry, lint-free cloth. + 6. Seal the threads of the cap with appropriate sealing compound. Install the cap and handtighten. 7. Tighten the cap with an appropriately sized pipe wrench. DO NOT overtighten. 001832 Figure 4-8. Battery Cables 5. Unsealed batteries only: Completely disconnect the battery.
Maintenance Perform Leak Test Attention After Submersion 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. (000192) All products are tested at the factory before shipping to ensure the performance and integrity of the fuel system. However, it is important to perform a final fuel system leak test before starting the generator.
Maintenance Remove From, and Return To Service Procedure 1. Check the tag on the engine for oil viscosity and classification. Drain and fill with proper oil, if necessary. Remove From Service 2. Check the state of the battery. Fill all cells of unsealed batteries to the proper level with distilled water. DO NOT use tap water. Recharge the battery to 100% state of charge. Replace the battery if defective.
Troubleshooting / Quick Reference Guide Section 5: Troubleshooting / Quick Reference Guide Generator Troubleshooting Problem Engine will not crank. Engine cranks but will not start. Engine starts hard and runs rough. Generator is set to OFF, but the engine continues to run. No AC output from generator. Cause Correction Blown fuse. Correct short circuit condition by replacing 7.5 A fuse in generator control panel. Contact an Independent Authorized Service Dealer (IASD) if fuse continues to blow.
Troubleshooting / Quick Reference Guide Problem No transfer to standby after utility source failure. Unit consumes large amounts of oil. Cause Correction MLCB (generator disconnect) is OFF (OPEN). Reset generator disconnect to ON (CLOSED). Defective transfer switch coi Contact an IASD for assistance Defective transfer relay. Contact an IASD for assistance Transfer relay circuit open. Contact an IASD for assistance Defective control logic board.
Troubleshooting / Quick Reference Guide Quick Reference Guide To clear an active alarm, press the OFF mode button on the control panel, then the ENTER button, and finally the AUTO mode button. Contact an IASD if the alarm reoccurs. Active Alarm LED Problem Things to Check Solution NONE FLASHING GREEN Unit running in AUTO but no power in house. Check MLCB. Check MLCB. If it is ON, contact an IASD. HIGH TEMPERATURE RED Unit shuts down during operation. Check the LEDs / screen for alarms.
Troubleshooting / Quick Reference Guide Active Alarm LED Problem Things to Check Solution OVERVOLTAGE RED Unit will not start in AUTO with utility loss. Check the LEDs / screen for alarms. Contact an IASD. 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. Clear alarm.
Part No. 10000006551 Rev. C 03/16/18 ©2018 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.
