Generac Power Systems 0065510 Owner'S Manual Download

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Table of Contents

Owner’s Manual for 60 Hz Air-Cooled Generators

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 .........................28

Servicing the Air Cleaner ..................................28

Spark Plug(s) ......................................................29

Valve Clearance Adjustment ............................29

Check Valve Clearance ............................................ 29
Adjust Valve Clearance ............................................. 30

Battery Maintenance ..........................................31

Cleaning the Sediment Trap .............................32

Post Maintenance Checks ................................32

Perform Leak Test .............................................33

Attention After Submersion ..............................33

Corrosion Protection .........................................33

Remove From, and Return To Service
Procedure ...........................................................34

Remove From Service .............................................. 34
Return to Service ...................................................... 34

Section 5: Troubleshooting / Quick

Reference Guide

Generator Troubleshooting ..............................35

Quick Reference Guide .....................................37

Summary of Contents for 0065510

Page 1: ...t 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 ...

Page 2: ...e the responsibility of the owner operator and are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage may contribute to the need for additional maintenance or service When the generator requires servicing or repairs Generac recommends contacting an Independent Authorized Service Dealer for assistance Authorized service technici...

Page 3: ... Accessories 12 Section 3 Operation Site Prep Verification 13 Generator Enclosure 13 Opening the Lid 13 Removing the Front Access Panel 13 Intake Side Panel Removal 14 Main Line Circuit Breaker Generator Disconnect 14 LED Indicator Lights 14 Auxiliary Shutdown Switch 15 Control Panel Interface 15 Using the AUTO OFF MANUAL Interface 15 Interface Menu Displays 16 LCD Panel 16 Menu System Navigation ...

Page 4: ...Oil Filter 28 Servicing the Air Cleaner 28 Spark Plug s 29 Valve Clearance Adjustment 29 Check Valve Clearance 29 Adjust Valve Clearance 30 Battery Maintenance 31 Cleaning the Sediment Trap 32 Post Maintenance Checks 32 Perform Leak Test 33 Attention After Submersion 33 Corrosion Protection 33 Remove From and Return To Service Procedure 34 Remove From Service 34 Return to Service 34 Section 5 Trou...

Page 5: ... safe operation be copied and posted near the unit installation site Safety should be stressed to all operators and potential operators of this equipment 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 tech...

Page 6: ... 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 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 E...

Page 7: ... of installation or block ventilation for generator Failure to do so could result in unsafe operation or damage to the generator 000144 DANGER Electrocution Contact with bare wires terminals and connections while generator is running will result in death or serious injury 000150 DANGER Electrocution Never connect this unit to the electrical system of any building unless a licensed electrician has ...

Page 8: ...ors 000100a WARNING 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 to use required safety equipment could result in death or serious injury 000257 Electrocution Refer to local codes and standards for safety equipment required when working with a live electrical system Fail...

Page 9: ...yes flush with water and seek immediate medical attention 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...

Page 10: ...Safety Information 6 Owner s Manual for 60 Hz Air Cooled Generators This page intentionally left blank ...

Page 11: ...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 ...

Page 12: ...n 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 Auxiliary Shutdown Switch 16kW 22kW E Battery Compartment Battery not supplied K Oil Filter P Fuel Inlet 001786 N M O P Q G K J F L R E A D C B A H T S ...

Page 13: ...l 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 Fuel Inlet Pressure Displays unit serial number along with minimum and maximum inlet pressures for natural gas NG and liquid propane LP supply Space is provided for...

Page 14: ... 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 andGenerators Natural gas ratings will depend on specific fuel joules BTU content Typical derates are between 10 20 off the LP gas rating Model 9 kW 11 kW 16 20 22 kW Type of Engine G Force 400 Series G Force 500 Series G Force 100...

Page 15: ...l Requirements The engine has been fitted with a dual fuel carburetion system The unit will run on natural gas or LP gas vapor but it has been factory set to run on natural gas The fuel system will be configured for the available fuel source during installation Recommended fuels should have a BTU content of at least 1000 BTUs per ft3 37 26 megajoules per m3 for natural gas or at least 2500 BTUs pe...

Page 16: ...m of the new air cooled generators 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 Enabled Accessory USA only Provides a personalized web portal displaying generator status maintenance schedule event history and much more This po...

Page 17: ...f 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 NOTE Keys provided with this unit are intended for service personnel use only Opening the Lid Two locks secure the lid one on each side A in Figure 3 1 Open the protective rubber cap to access the keyhole and press down on the lid above th...

Page 18: ...ppropriately sized padlock not included with a shackle long enough to pass through both lock tabs B Figure 3 3 Main Breaker NOTE DO NOT lock out the MLCB during normal generator operation Doing so will compromise automatic standby functionality LED Indicator Lights Figure 3 4 LED Indicator Lights See Figure 3 4 Three LEDs are visible behind a translucent lens on the generator side panel These LEDs...

Page 19: ...lid Verify both the left and right side locks are unlocked before attempting to lift the lid of the enclosure Open the lid as directed in Opening the Lid Figure 3 7 Generator Control Panel The 7 5A fuse is located beneath the 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 the unit All appropriate panels must be in p...

Page 20: ...NTER button to clear an alarm or warning When Hours of Protection is displayed this represents the total time the 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 the operator presses any button MAIN MENU page Allows the operator to navigate to all othe...

Page 21: ...Operation Owner s Manual for 60 Hz Air Cooled Generators 17 This page intentionally left blank ...

Page 22: ...ning Cooling Down Running Warning Warning Message Warning Message s Low Battery Exercise Set Error Service Schedule A Service Schedule B Inspect Battery Stopping FIRMWARE ERROR 9 Fuel Pressure Battery Problem Charger Warning Charger Missing AC Overload Warning SEEPROM ABUSE USB Warning Download Failure Overload Warning No WIFI Module No WIFI Router Comms No WIFI Server Comms Cranking Warning Warni...

Page 23: ...X XX XX XX XX XX XXXXX XX XX XX XX XX XX XXXXX NOTE 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 Battery NOTE 1 Last 50 maintenance logs displayed NOTE 2 Date and time displayed for each occurence If enabled Refer to the Wi Fi manual for fl...

Page 24: ...NOT enabled the current date time will need to be reset every time the 12 volt battery is disconnected and then reconnected and or when the fuse is removed Figure 3 10 illustrates an engine speed profile during a typical exercise cycle Table 3 1 details exercise information and programming options for all home standby generators Figure 3 10 Low Speed Exercise Profile NOTE If Quiet Test is disabled...

Page 25: ... prior to manual transfer Failure to do so will result in death or serious injury and equipment damage 002565 A MANUAL Will not transfer to generator if utility is present Will transfer to generator if utility drops below 65 of nominal for five consecutive seconds dealer programmable after warm up Will transfer back when utility returns for 15 consecutive seconds dealer programmable The engine wil...

Page 26: ...ill start automatically when utility source voltage drops below a preset level Loads are transferred to standby power source after the unit starts Automatic Sequence of Operation Utility Failure If the 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 still unavaila...

Page 27: ... to clear the obstruction After several minutes the alarm message can be cleared and the generator restarted If the problem persists make no further attempts to start Contact an IASD Load Transfer The transfer of load when the generator is running is dependent upon the operating mode Shutting Generator Down While Under Load Or During A Utility Outage IMPORTANT NOTE To avoid equipment damage follow...

Page 28: ...Operation 24 Owner s Manual for 60 Hz Air Cooled Generators This page intentionally left blank ...

Page 29: ...or proper generator operation Engine oil and oil filter must be changed and valve clearance adjusted after the first 25 hours of operation Emissions critical maintenance must be performed as scheduled in order for the emissions warranty to be valid Emissions critical maintenance consists of servicing the air filter and spark plug s in accordance with the Service Schedule The controller will prompt...

Page 30: ...l filter Replace engine air filter Clean inspect spark plug gap replace if necessary Inspect adjust valve clearance Inspect clean sediment trap Consult 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...

Page 31: ...rating in automatic mode The main utility disconnect can be turned ON CLOSED Engine Oil Requirements 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 These kits can be obtained from ...

Page 32: ...recommended oil See Engine Oil Requirements 8 Press the MANUAL mode button on the control panel to start the engine Run for one minute and check for leaks 9 Press the OFF mode button on the control panel to stop the engine Wait five minutes 10 Inspect the oil level Add oil as needed DO NOT OVERFILL 11 Insert oil dipstick and or attach fill cap 12 Press AUTO mode button on the control panel to retu...

Page 33: ...D for service assistance Proper valve clearance is essential for prolonging the life of the engine Check valve clearance after the first 25 hours of operation then after 400 hour intervals Adjust if necessary Check Valve Clearance NOTE The engine should be cool before checking valve clearance Adjustment is not needed if valve clearance is within the dimensions provided in Engine 1 Close fuel valve...

Page 34: ... while checking clearance between rocker arm E and valve stem F with a feeler gauge Adjust clearance as per Engine NOTE Hold the rocker jam nut in place as the pivot ball stud is turned 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 8 After tightening jam nut inspect val...

Page 35: ...grounded metal surface The battery should be regularly inspected per the Service Schedule Contact an IASD for assistance if necessary Proceed as follows to inspect the battery 1 Press the OFF mode button to shut down the generator then lift the lid and remove the front panel 2 Remove the 7 5 A fuse from the control panel 3 Remove the intake side panel See Intake Side Panel Removal 4 See Figure 4 8...

Page 36: ...Trap 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 hand tighten 7 Tighten the cap with an appropriately sized pipe wrench DO NOT overtighten 8 Turn the generator fuel supply on Check for leaks...

Page 37: ...wing 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 perform a visual inspection of the unit for corrosion Inspect all metal components of the gener...

Page 38: ...ill with proper oil if necessary 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 3 Clean and wipe down the generator enclosure 4 Verify 7 5 A fuse is removed from generator control panel 5 Connect battery Observe battery polarity Damage ma...

Page 39: ...Clean inspect gap replace plug s if necessary Valve clearance out of adjustment Reset valve clearance Engine starts hard and runs rough Air cleaner plugged or damaged Inspect and clean air cleaner Defective spark plug s Clean inspect gap replace plug s as needed Incorrect fuel pressure Confirm fuel pressure to regulator is 10 12 in water column 19 22 mm Hg for LP and 3 5 7 0 in water column 9 13 m...

Page 40: ...y circuit open Contact an IASD for assistance Defective control logic board Contact an IASD for assistance Engine may be warming up Refer to Cold Smart Start Check the controller screen to verify status Unit consumes large amounts of oil Excessive engine oil Adjust oil to proper level Defective engine breather Contact an IASD for assistance Improper type or viscosity of oil See Engine Oil Requirem...

Page 41: ...n 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 the 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 the LEDs screen for alarms Clear alarm Using the control panel check the battery by navigat...

Page 42: ...attery BATTERY PROBLEM YELLOW Yellow LED illuminated in any state Check the screen for additional information Contact an IASD CHARGER WARNING YELLOW Yellow LED illuminated in any state Check the screen for additional information Contact an IASD CHARGER MISSING AC YELLOW Yellow LED illuminated in any state Check the screen for additional information Contact an IASD SERVICE A YELLOW Yellow LED illum...

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Page 44: ...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 com ...

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