Generac Power Systems 004810-0 User manual

Owner’s Manual
Standby Generator
Models: 004810-0 & 004811-0
POWER SYSTEMS, INC.
®
This manual should remain with the unit.

Generac®Power Systems, Inc.
INTRODUCTION
Thank you for purchasing this model of the standby
generator set product line by Generac Power Systems.
Every effort was expended to make sure that the
information and instructions in this manual were
both accurate and current at the time the manual was
written. However, the manufacturer reserves the right
to change, alter or otherwise improve this product(s)
at any time without prior notice.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, con-
tact Generac or the nearest Generac Authorized
Service Dealer for starting, operating and servicing
procedures.
Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert per-
sonnel to special instruction about a particular serv-
ice or operation that may be hazardous if performed
incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:
After this heading, read instructions that, if not
strictly complied with, will result in personal injury
or property damage.
After this heading, read instructions that, if not
strictly complied with, may result in personal injury
or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compli-
ance with the special instructions while performing the
service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:
This symbol points out important safety informa-
tion that, if not followed, could endanger personal
safety and/or property of others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use
of the equipment. Generac strongly recommends that
the operator read this Owner's Manual and thor-
oughly understand all instructions before using this
equipment. Generac also strongly recommends
instructing other users to properly start and operate
the unit. This prepares them if they need to operate
the equipment in an emergency.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safe-
ty checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by a Generac
Authorized Service Dealer. Normal maintenance serv-
ice and replacement of parts are the responsibility of
the owner/operator and, as such, are not considered
defects in materials or workmanship within the
terms of the warranty. Individual operating habits
and usage contribute to the need for maintenance
service.
Proper maintenance and care of the generator ensure
a minimum number of problems and keep operating
expenses at a minimum. See a Generac Authorized
Service Dealer for service aids and accessories.
Operating instructions presented in this manual
assume that the standby electric system has been
installed by a Generac Authorized Service Dealer or
other competent, qualified contractor. Installation of
this equipment is not a “do-it-yourself” project.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
simply contact a Generac Authorized Service Dealer
for assistance. Service technicians are factory-trained
and are capable of handling all service needs.
When contacting a Generac Authorized Service
Dealer or the factory about parts and service, always
supply the complete model number of the unit as
given on the front cover of this manual or on the
DATA CARD affixed to the unit.
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DANGER
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AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest GENERAC AUTHORIZED
SERVICE DEALER, please call this number:
1-800-333-1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER.

Table of Contents
Generac Standby Generator Sets
Generac®Power Systems, Inc. 1
Introduction ................................Inside Front Cover
Read This Manual Thoroughly..................................IFC
Operation and Maintenance ......................................IFC
How to Obtain Service ..............................................IFC
Authorized Service Dealer Locator Number..................IFC
Safety Rules ................................................................2
Section 1 – General Information ..........................4
1.1 IDENTIFICATION RECORD ....................................4
1.1.1 Data Plate..........................................................4
1.2 EQUIPMENT DESCRIPTION ..................................4
1.2.1 Standard Generator Features............................4
1.3 ENGINE PROTECTIVE DEVICES............................4
1.3.1 High Coolant Temperature Switch ....................4
1.3.2 Low Coolant Level Sensor ................................4
1.3.3 Low Oil Pressure Switch ..................................4
1.3.4 Low Fuel Pressure Switch ................................4
1.3.5 Overspeed Shutdown ........................................4
1.3.6 Overcrank Shutdown ........................................5
1.3.7 RPM Sensor Loss Shutdown ............................5
1.4 DC FUSE ................................................................5
1.5 FUEL SYSTEM ........................................................5
1.5.1 Fuel Requirements ............................................5
1.5.2 Diesel Fuel System ............................................5
1.6 SPECIFICATIONS ....................................................5
1.6.1 Generator..........................................................5
1.6.2 Engine ..............................................................5
1.6.3 Engine Oil Recommendations ..........................6
1.6.4 Coolant..............................................................6
1.6.5 Fuel System Requirements and
Recommendations ............................................6
1.7 GENERATOR AC LEAD CONNECTIONS ................6
1.7.1 Four-lead, Single-phase Stator ..........................6
1.8 GENERATOR AND LOAD COMPATIBILITY ............6
1.9 STARTING AIDS......................................................7
1.9.1 Engine Coolant Heaters ....................................7
1.9.2 Battery Chargers ..............................................7
Section 2 – Installation............................................7
2.1 STANDBY GENERATOR INSTALLATION ................7
2.1.1 NFPA Standards................................................8
2.1.2 Other Published Standards ..............................8
2.2 BASIC STANDBY ELECTRIC SYSTEM....................8
2.3 EMERGENCY CIRCUIT ISOLATION METHOD ......8
2.4 TOTAL CIRCUIT ISOLATION METHOD ..................9
2.5 GROUNDING THE GENERATOR ............................9
2.6 GENERATOR AC NEUTRAL CONNECTIONS..........9
2.7 TRANSFER SWITCH START SIGNAL
CONNECTIONS ......................................................9
2.8 BATTERY INSTALLATION ......................................9
2.8.1 Vented Batteries..............................................10
2.9 PREPARATION BEFORE START-UP ......................10
2.9.1 Prior to Initial Start-up ..................................10
2.9.2 Start-up Inspection ........................................11
Section 3 – Operation............................................12
3.1 GENERATOR CONTROL AND OPERATION ..........12
3.2 OPERATING UNIT WITH MANUAL
TRANSFER SWITCH ............................................12
3.2.1 Engine Start-up and Transfer ........................12
3.2.2 Retransfer and Shutdown ..............................12
3.3 OPERATING UNIT WITH AUTOMATIC
TRANSFER SWITCH ............................................12
Section 4 – Maintenance ......................................13
4.1 SERVICE SCHEDULE ..........................................13
4.1.1 Authorized Operator Maintenance Functions ..13
4.1.2 Authorized Service Technician
Maintenance Functions....................................13
4.2 PERIODIC MAINTENANCE ..................................13
4.2.1 Test Standby Generator System
Operation and Components ............................14
4.2.2 Inspect Battery ................................................14
4.2.3 Battery Replacement ......................................14
4.2.4 Check Fluids ..................................................14
4.2.5 Inspect Exhaust System ..................................14
4.2.6 Inspect/Test Fuel Supply System ....................15
4.3 REPAIR PARTS ......................................................15
4.3.1 How to Order Parts ........................................15
Section 5 – Installation Diagram ..............................16
Section 6 – Electrical Data............................................18
Section 7 – Exploded Views and Parts Lists ......28
Section 8 – Notes ..............................................................49
Section 9 – Warranty........................................................52

2 Generac®Power Systems, Inc.
Study these SAFETY RULES carefully before
installing, operating or servicing this equipment.
Become familiar with this Owner’s Manual and with
the unit. The generator can operate safely, efficiently
and reliably only if it is properly installed, operated
and maintained. Many accidents are caused by failing
to follow simple and fundamental rules or precau-
tions.
Generac cannot possibly anticipate every possible
circumstance that might involve a hazard. The warn-
ings in this manual, and on tags and decals
affixed to the unit are, therefore, not all-inclusive. If
using a procedure, work method or operating tech-
nique that Generac does not specifically recommend,
satisfy yourself that it is safe for others. Also make
sure the procedure, work method or operating tech-
nique choosen does not render the generator unsafe.
Despite the safe design of this generator,
operating this equipment imprudently, neglect-
ing its maintenance or being careless can cause
possible injury or death. Permit only responsi-
ble and capable persons to install, operate or
maintain this equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
GENERAL HAZARDS
• For safety reasons, Generac recommends that this
equipment be installed, serviced and repaired by a
Generac Authorized Service Dealer or other compe-
tent, qualified electrician or installation technician
who is familiar with applicable codes, standards
and regulations. The operator also must comply
with all such codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electri-
cal and building codes. Comply with regulations
the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the gen-
erator is installed, operated and serviced in accor-
dance with the manufacturer’s instructions and
recommendations. Following installation, do noth-
ing that might render the unit unsafe or in non-
compliance with the aforementioned codes, stan-
dards, laws and regulations.
• The engine exhaust fumes contain carbon monox-
ide gas, which can be DEADLY. This dangerous
gas, if breathed in sufficient concentrations, can
cause unconsciousness or even death. For that rea-
son, adequate ventilation must be provided.
Exhaust gases must be piped safely away from any
building or enclosure that houses the generator to
an area where people, animals, etc., will not be
harmed. This exhaust system must be installed
properly, in strict compliance with applicable
codes and standards.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit is
operating.
• Adequate, unobstructed flow of cooling and venti-
lating air is critical in any room or building hous-
ing the generator to prevent buildup of explosive
gases and to ensure correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seri-
ously affect safe operation of the generator.
• Keep the area around the generator clean and
uncluttered. Remove any materials that could
become hazardous.
• When working on this equipment, remain alert at
all times. Never work on the equipment when
physically or mentally fatigued.
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DANGER
Important Safety Instructions
Generac Standby Generator Sets
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas. Safety should be stressed to all
operators, potential operators, and service and repair technicians for this equipment.
!
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
!!
!
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:
!!
SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be
followed during installation and maintenance of the generator and batteries.
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Generac®Power Systems, Inc. 3
• Inspect the generator regularly, and promptly
repair or replace all worn, damaged or defective
parts using only factory-approved parts.
• Before performing any maintenance on the genera-
tor, disconnect its battery cables to prevent acci-
dental start-up. Disconnect the cable from the bat-
tery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating con-
ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
ELECTRICAL HAZARDS
• All generators covered by this manual produce dan-
gerous electrical voltages and can cause fatal elec-
trical shock. Utility power delivers extremely high
and dangerous voltages to the transfer switch as
well as the standby generator. Avoid contact with
bare wires, terminals, connections, etc., on the gen-
erator as well as the transfer switch, if applicable.
Ensure all appropriate covers, guards and barriers
are in place before operating the generator. If work
must be done around an operating unit, stand on
an insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands
or feet are wet. DANGEROUS ELECTRICAL
SHOCK MAY RESULT.
• If people must stand on metal or concrete while
installing, operating, servicing, adjusting or repair-
ing this equipment, place insulative mats over a
dry wooden platform. Work on the equipment only
while standing on such insulative mats.
• The National Electrical Code (NEC), Article 250
requires the frame and external electrically con-
ductive parts of the generator to be connected to an
approved earth ground and/or grounding rods.
This grounding will help prevent dangerous elec-
trical shock that might be caused by a ground fault
condition in the generator set or by static electric-
ity. Never disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and
cord sets must be adequate to handle the maxi-
mum electrical current (ampacity) to which they
will be subjected.
• Before installing or servicing this (and related)
equipment, make sure that all power voltage sup-
plies are positively turned off at their source.
Failure to do so will result in hazardous and pos-
sibly fatal electrical shock.
• Connecting this unit to an electrical system nor-
mally supplied by an electric utility shall be by
means of a transfer switch so as to isolate the gen-
erator electric system from the electric utility dis-
tribution system when the generator is operating.
Failure to isolate the two electric system power
sources from each other by such means will result
in damage to the generator and may also result in
injury or death to utility power workers due to
backfeed of electrical energy.
• Generators installed with an automatic transfer
switch will crank and start automatically when
normal (utility) source voltage is removed or is
below an acceptable preset level. To prevent such
automatic start-up and possible injury to person-
nel, disable the generator’s automatic start circuit
(battery cables, etc.) before working on or around
the unit. Then, place a “Do Not Operate” tag on the
generator control panel and on the transfer switch.
• In case of accident caused by electric shock,
immediately shut down the source of electrical
power. If this is not possible, attempt to free the
victim from the live conductor. AVOID DIRECT
CONTACT WITH THE VICTIM. Use a noncon-
ducting implement, such as a dry rope or board, to
free the victim from the live conductor. If the victim
is unconscious, apply first aid and get immediate
medical help.
• Never wear jewelry when working on this equip-
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com-
ponents causing injury.
FIRE HAZARDS
• Keep a fire extinguisher near the generator at all
times. Do NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid can
deteriorate wiring insulation. Keep the extinguish-
er properly charged and be familiar with its use. If
there are any questions pertaining to fire extin-
guishers, consult the local fire department.
EXPLOSION HAZARDS
• Properly ventilate any room or building housing
the generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no com-
bustible materials are left in the generator com-
partment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround-
ing the generator clean and free from debris.
• Generac generator sets may operate using one of
several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulating
the storage and handling of fuels. Inspect the unit’s
fuel system frequently and correct any leaks
immediately. Fuel supply lines must be properly
installed, purged and leak tested according to
applicable fuel-gas codes before placing this equip-
ment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous flu-
ids such as natural gas and liquid propane (LP)
gas are extremely EXPLOSIVE. Natural gas is
lighter than air, and LP gas is heavier than air;
install leak detectors accordingly.
Important Safety Instructions
Generac Standby Generator Sets

4 Generac®Power Systems, Inc.
1.1 IDENTIFICATION RECORD
1.1.1 DATA PLATE
Every generator set has a metal DATA PLATE that
contains important information pertinent to the gen-
erator. The data plate, which can be found attached to
the generator’s lower connection box, lists the unit’s
serial number and its rated voltage, amps, wattage
capacity, phase, frequency, rpm, power factor, etc.
1.1.1.1 Generator Model Number
This number is the key to numerous engineering and
manufacturing details pertaining to your unit. Always
supply this number when requesting service, order-
ing parts or seeking information.
1.1.1.2 Groups and Assembly Numbers
The data card lists the groups and corresponding
assembly numbers for each unit. The assembly num-
bers refer to exploded view drawing numbers that are
applicable to your specific generator model. These
drawings are located in the back half of this manual.
1.2 EQUIPMENT DESCRIPTION
This equipment is a revolving field, alternating current
generator set. The generator was designed to supply
electrical power for the operation of compatible elec-
trical loads when the UTILITY power supply is not
available or has dropped to an unacceptable level.
The generator’s revolving field is directly connected
to and driven by an engine by means of flexible discs.
Generators with a four-pole rotor are driven at rated
speeds of 1,800 rpm to supply a frequency of 60 Hz.
Refer to the data plate on your specific generator or
to the data card affixed to the unit for rated AC volt-
age, wattage, amperage, number of phases, etc.
1.2.1 STANDARD GENERATOR FEATURES
This generator incorporates the following generator
features:
• The rotor insulation system is Class “H” rated, and
the stator insulation is Class “H” rated as defined
by NEMA MG1-22.4 and NEMA MG1-1.65.
• The generator is self-ventilated and drip-proof
constructed.
• The voltage waveform deviation, total harmonic
content of the AC waveform and “telephone influ-
ence factor” have been evaluated and are accept-
able according to NEMA MG1-22.
• All prototype tested models have passed
three-phase symmetrical short circuit test to
ensure system protection and reliability.
1.3 ENGINE PROTECTIVE DEVICES
The standby generator may be required to operate for
long periods of time without an operator on hand to
monitor such engine conditions as coolant tempera-
ture, oil pressure or rpm. For that reason, the engine
has several devices designed to protect it against
potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too
low, the coolant temperature is too high, the coolant
level is too low, or the engine is running too fast.
NOTE:
Engine protective switches and sensors are men-
tioned here for the reader’s convenience. Also
refer to the applicable control panel manual for
additional automatic engine shutdown informa-
tion.
1.3.1 HIGH COOLANT TEMPERATURE
SWITCH
This normally open (N.O.) switch closes to automati-
cally shut down the engine if the engine coolant tem-
perature rises above a safe level.
1.3.2 LOW COOLANT LEVEL SENSOR
Should the engine coolant level drop below the level
of the high coolant temperature switch, it is possible
for the engine to overheat without automatic shut-
down. To prevent such overheating, the engine has a
low coolant level sensor. If the level of engine coolant
drops below the level of the low coolant level sensor,
the engine automatically shuts down.
1.3.3 LOW OIL PRESSURE SWITCH
This normally closed (N.C.) switch is held open by
engine oil pressure during operation. If oil pressure
drops below a safe level, the switch contacts close,
automatically shutting down the engine.
1.3.4 LOW FUEL PRESSURE SWITCH
This normally closed (N.C.) switch is held open by
fuel pressure during operation. If fuel pressure drops
below a safe level, the switch contacts close, auto-
matically shutting down the engine.
1.3.5 OVERSPEED SHUTDOWN
A speed circuit controls engine cranking, start-up,
operation and shutdown. Engine speed signals are
delivered to the circuit board whenever the unit is
running. Should the engine overspeed above a safe,
preset value, the circuit board initiates an automatic
engine shutdown.
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Section 1 – General Information
Generac Standby Generator Sets

Generac®Power Systems, Inc. 5
Section 1 – General Information
Generac Standby Generator Sets
1.3.6 OVERCRANK SHUTDOWN
After a prespecified duration of cranking, this func-
tion ends the cranking if the engine has failed
to start.
1.3.7 RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine
shutdown will occur.
1.4 DC FUSE
This clearly labeled fuse is located on the front panel
of the control system. It protects the panel wiring and
components from damaging overload. Always remove
this fuse before commencing work on the generator.
The unit will not start or crank if the fuse is blown.
Replace the fuse with one of the same size, type, and
rating. Generac normally uses an AGC fuse rated at
15 amps.
1.5 FUEL SYSTEM
1.5.1 FUEL REQUIREMENTS
NOTE:
It is the responsibility of the installer to make sure
that only the correct recommended fuel is sup-
plied to the generator fuel system. Thereafter, the
owner/operator must make certain that only the
proper fuel is supplied.
For further information on the various types of
fuel systems, refer to Engine-Generator Standby
Electric Power Systems Installer’s Guide and
Reference Manual (part #46622).
1.5.2 DIESEL FUEL SYSTEM
Diesel fuel is supplied to the generator set from a
base-mounted fuel tank.
Diesel fuels are less volatile than gaseous fuels, how-
ever, careless installation can lead to safety hazards
and/or serious problems with engine/generator per-
formance and reliability.
NOTE:
Appropriate care should be taken in applications
where extremely low ambient temperatures are
possible to ensure the temperature of the diesel
fuel is not allowed to fall below levels where
“gelling” could occur.
1.6 SPECIFICATIONS
1.6.1 GENERATOR
Refer to the data plate on your particular generator
for rated watts, amperes, frequency, voltage, phase
and other pertinent information.
1.6.2 ENGINE
General:
Cylinders and Arrangement ......................................................4 in-line
Displacement................................................................3.0 L (182.5 in3)
Bore................................................................................95 mm (3.7 in.)
Stroke ..........................................................................105 mm (4.1 in.)
Compression Ratio ..................................................................21.0-to-1
Number of Main Bearings ....................................................................5
Type of Main Bearing Caps ....................................................Cast Iron
Aspiration....................................................................Turbocharged (T)
Governed Engine Speed ........................................................1800 rpm
Type of Valve Lifters........................................................................Solid
Cylinder Head ........................................Cast Iron with Overhead Valve
Pistons......................................................................4 - Aluminum Alloy
Crankshaft..........................................................................Forged Steel
Number of Flywheel Teeth................................................................138
Engine Lubrication System:
Type of Oil Pump ................................................................Gear Driven
Oil Filter ..................................................................Full Flow, Cartridge
Crankcase Oil Capacity ........................................6 L (6.3 U.S. quarts)
Fuel System:
Type of Fuel................................................#2D Fuel (Min Cetane #40)
Consumption:*
Rated 25% 50% 75% 100%
Freq. Load Load Load Load
60 Hz 0.8 1.4 2.0 2.6
*Given in: gal/h
Cooling System:
Type........................................................Pressurized, Closed Recovery
Coolant Capacity
System..............................................................10.6 L (2.8 U.S. gals.)
Engine ................................................................4.5 L (1.2 U.S. gals.)
Coolant Flow Per Minute ........................................90 L (24 U.S. gals.)
Heat Rejection to Coolant................................................107,452 Btu/h
Cooling Fan ........................................................................Pusher Type
Diameter of Fan ............................................................457 mm (18 in.)
Cooling Airflow Required........................................................4,330 cfm
Recommended Coolant ..................................See “Coolant” on Page 8
Combustion Airflow Required....................................................120 cfm
Exhaust System:
Exhaust Flow at Rated Output ..................................................310 cfm
Exhaust Outlet Size......................................................................2.0 in.
Exhaust Temperature at Rated Output..........................(426° C) 800° F
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6 Generac®Power Systems, Inc.
Section 1 – General Information
Generac Standby Generator Sets
Engine Electrical System:
DC Alternator Output ..............................................42 amps at 12 volts
Starter Motor..........................................................................12-volt DC
Recommended Battery ..................................One 12-volt, 90 Ah, 27 F
Ground Polarity ..................................................................Negative (–)
1.6.3 ENGINE OIL RECOMMENDATIONS
The unit has been filled with 15W-40 engine oil
at the factory. Use a high-quality detergent oil classi-
fied “For Service CC, SD, SE or SF.” Detergent oils
keep the engine cleaner and reduce carbon deposits.
Use oil having the following SAE viscosity rating,
based on the ambient temperature range anticipated
before the next oil change:
1.6.4 COOLANT
Use a mixture of half Propylene glycol base antifreeze
and half soft water. Use only soft water and Propylene
glycol antifreeze. When adding coolant, always add
the recommended 50-50 mixture.
Do not remove the radiator pressure cap while
the engine is hot or serious burns from boiling
liquid or steam could result.
Propylene glycol base antifreeze is poisonous.
Do not use your mouth to siphon coolant from
the radiator, recovery bottle or any container.
Wash your hands thoroughly after handling.
Never store used antifreeze in an open contain-
er because animals are attracted to the smell
and taste of antifreeze even though it is poi-
sonous to them.
Do not use any chromate base rust inhibitor
with propylene glycol base antifreeze. Using
any high silicate antifreeze boosters or addi-
tives also will cause overheating. We also rec-
ommend that you DO NOT use any soluble oil
inhibitor for this equipment.
1.6.5 FUEL SYSTEM REQUIREMENTS
AND RECOMMENDATIONS
•Diesel Fuel System: See Chapter 8 of Engine-
Generator Standby Electric Power Systems
Installer’s Guide and Reference Manual (part
#46622).
1.7 GENERATOR AC LEAD
CONNECTIONS
The electrical wires in the unit’s AC connection
(lower) panel should be installed according to the
number of leads and the voltage/phase required for
your application. If there is any question regarding
lead connection, refer to the wiring diagrams at the
back of this manual.
1.7.1 FOUR-LEAD, SINGLE-PHASE STATOR
Four-lead generators are dual voltage coils or wind-
ings (Figure 1.1). Units may be assigned the following
voltage code:
• “A” units are rated 120/240 volts, single-phase,
60 Hertz.
Each stator winding in this case delivers a 120-volt
AC output; connecting the two windings series results
in a 240-volt AC output.
The neutral line is formed by a junction of stator
leads 22 and 33. Thus, you may connect 120-volt
loads across leads 11 and neutral, or across leads 44
and neutral.
Figure 1.1 – Four-lead, Single-phase Stator
1.8 GENERATOR AND LOAD
COMPATIBILITY
The generator must be fully compatible with the
rated voltage, phase and frequency of the connected
electrical loads. The generator, connected electrical
devices, or both, can be damaged if voltage, phase
and frequency are not compatible.
NOTE:
This manual assumes that the standby generator
has been properly selected, installed and inter-
connected by a competent, qualified electrician or
installation contractor. Once the installation is
complete, you must not do anything that may
result in noncompatibility between the generator
and connected electrical loads.
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DANGER
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Temperature Oil Grade (Recommended)
Above 80º F (27º C) SAE 30W or 15W-40
32º to 80º F (-1º to 27º C) SAE 20W-20 or 15W-40
Below 32º F (0º C) SAE 10W or 15W-40

Generac®Power Systems, Inc. 7
Section 2 – Installation
Generac Standby Generator Sets
1.9 STARTING AIDS
This standby generator is equipped with the following
starting aids that serve to provide quicker, easier
starts under varying climactic conditions.
This generator has been mounted with an engine
coolant heater and a battery charger. These aids are
powered by a normal (utility) power source during
nonoperating periods.
1.9.1 ENGINE COOLANT HEATERS
This unit is equipped with an engine coolant (block)
heater (Figure 1.2), it is powered by a circuit normal-
ly fed by the utility power supply. The heater acts to
heat the engine coolant when the unit is not operat-
ing. This action keeps the engine warm even in cold
weather, thus helping ensure quicker starts. Heated
coolant in the engine rises continuously drawing cold
coolant into the heater, thus making certain of a con-
stant flow of warm coolant through the engine.
Figure 1.2 – Typical Engine Coolant Heater
1.9.2 BATTERY CHARGERS
All UL units will be fitted with a 12V or 24V, 10 amp
charger. This charger is similar to the one shown in
Figure 1.3.
1.9.2.1 Dual-rate Battery Charger
This SCR-controlled, fully automatic battery charger
has a panel-mounted DC ammeter and voltmeter,
fused input and output circuits, and an automatic
current limiter design. The unit is equipped with
automatic float and equalize control and uses an SCR
to maintain proper charge voltage. This type of sys-
tem precisely monitors the charge rate (Figure 1.3 ).
The charger is rated at 10 amps DC.
Figure 1.3 – Typical Dual-rate Battery Charger
2.1 STANDBY GENERATOR
INSTALLATION
Connecting this generator to an electrical sys-
tem normally supplied by an electric utility
shall be by means of a transfer switch (such as
the Generac “GTS” type transfer switch), so as to
isolate the electric system from the utility dis-
tribution system when the generator is oper-
ating. Failure to isolate the electric system by
these means will result in damage to the gen-
erator and may also result in injury or death
to utility workers due to backfeed of electrical
energy.
If an open bottom is used, the engine-genera-
tor is to be installed over non-combustible
materials and should be located such that
combustible materials are not capable of accu-
mulating under the generator set.
Only qualified, competent installation contractors or
electricians thoroughly familiar with applicable
codes, standards and regulations should install this
standby electric power system. The installation must
comply strictly with all codes, standards and regula-
tions pertaining to the installation.
This genset must be installed on a level surface. The
base frame must be level within two (2) inches all
around.
After the system has been installed, you must
not do anything that might render the instal-
lation in noncompliance with such codes,
standards and regulations.
!
DANGER
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OUTPUT

8 Generac®Power Systems, Inc.
Section 2 – Installation
Generac Standby Generator Sets
NOTE:
For more information about the installation of a
standby system, you can order Engine-Generator
Standby Electric Power Systems Installer’s
Guide and Reference Manual (part #46622) from
your Generac Authorized Service Dealer.
2.1.1 NFPA STANDARDS
The following published standards booklets pertain-
ing to standby electric systems are available form the
National Fire Protection Association (NFPA),
Batterymarch Park, Quincy, MA 02269:
• NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES.
• NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-
TEMS FOR HEALTH CARE FACILITIES.
• NFPA No. 220, STANDARD TYPES OF BUILDING
CONSTRUCTION
• NFPA No. 68, GUIDE FOR EXPLOSION VENTING
• NFPA No. 70, NATIONAL ELECTRICAL CODE.
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE.
• NFPA No. 10, INSTALLATION, MAINTENANCE AND
USE OF PORTABLE FIRE EXTINGUISHERS.
2.1.2 OTHER PUBLISHED STANDARDS
In addition to NFPA standards, the following infor-
mation pertaining to the installation and use of
standby electric systems is available:
• Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85 John
Street, New York, N.Y. 10038.
• AGRICULTURAL WIRING HANDBOOK, obtainable
from the Food and Energy Council, 909 University
Avenue, Columbia, MO, 65201.
• ASAE EP-364.2, INSTALLATION AND MAINTE-
NANCE OF FARM STANDBY ELECTRIC POWER,
available from the American Society of Agricultural
Engineers, 2950 Niles Road, St. Joseph, MI 49085.
• A52.1, AMERICAN NATIONAL STANDARD FOR
CHIMNEYS, FIREPLACES AND VENTING SYS-
TEMS, available from the American National
Standard Institute, 1430 Broadway, New York, N.Y.
10018.
2.2 BASIC STANDBY ELECTRIC
SYSTEM
Figure 2.1 shows a schematic diagram of a basic
standby electric system. Both the UTILITY power
supply and the STANDBY (generator) output are con-
nected to an approved transfer switch. The transfer
switch is required by electrical code and serves the
following functions:
• Permits the LOAD circuits to be connected to only
one power supply at a time.
• Prevents electrical backfeed between the generator
and the UTILITY power circuits.
Figure 2.1 – Basic Standby Electric System
Notice that both the STANDBY and the UTILITY
power supplies to the transfer switch are protected
against overload by a main line circuit breaker.
NOTE:
Generac recommends the use of a Generac power
systems “GTS” type transfer switch in conjunction
with this generator.
2.3 EMERGENCY CIRCUIT ISOLATION
METHOD
This prevents overloading the generator by keeping
electrical loads below the wattage/amperage capacity
of the generator. If the generator is powering only crit-
ical loads, within the wattage/amperage capacity, dur-
ing utility power outages, you might consider using
the emergency circuit isolation method.
Critical electrical loads are grouped together and
wired into a separate “Emergency Distribution
Panel.” Load circuits powered by that panel are with-
in the wattage/amperage capacity of the generator set.
When this method is used, it is difficult to overload
the generator. The transfer switch must meet the fol-
lowing requirements:
• It must have an ampere rating equal to the total
amperage rating of the emergency distribution
panel circuit.
• Have it installed between the building’s main dis-
tribution panel and the emergency distribution
panel.
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Generac®Power Systems, Inc. 9
Section 2 – Installation
Generac Standby Generator Sets
2.4 TOTAL CIRCUIT ISOLATION
METHOD
When a generator capable of powering all electrical
loads in the circuit is to be installed, you may use the
“Total Circuit Isolation Method.” It is possible for the
generator to be overloaded when this isolation
method is employed. The following apply to the
transfer switch in this type of system.
• Ampere rating of the transfer switch must equal
the ampere rating of the normal incoming utility
service.
• The transfer switch is installed between the utility
service entrance and the building distribution
panel.
2.5 GROUNDING THE GENERATOR
The National Electrical Code requires the frame and
external electrically conductive parts of this equip-
ment to be properly connected to an approved earth
ground and/or grounding rods. For that purpose, a
GROUND LUG (Figure 2.2) is provided on the gener-
ator mounting base. Consult a qualified electrician
for grounding requirements in your area. Grounding
procedures must meet local regulations.
Do not connect the ground wire to any pipe
that carries a flammable or explosive substance
– FIRE or an EXPLOSION may result.
Proper grounding helps protect personnel against
electrical shock in the event of a ground fault condi-
tion in the generator or in connected electrical
devices. In addition, grounding helps dissipate static
electricity that often builds up in ungrounded
devices.
Figure 2.2 – Generator Grounding Lug (typical)
2.6 GENERATOR AC NEUTRAL
CONNECTIONS
Generac uses an UNGROUNDED AC neutral.
Grounding is recommended only at the main service
entrance. If the neutral wire is grounded and one of
the phase loads becomes grounded, the excessive
current opens the load circuit breaker or collapses
the generator field. The actual result depends on the
electrical characteristics of the particular installed
generator.
2.7 TRANSFER SWITCH START SIGNAL
CONNECTIONS
If your generator is to be installed with an automatic
transfer switch, such as a Generac GTS-type switch,
it will be necessary to connect the two-wire start
control system.
Connect the two-wire start signal from the automatic
transfer switch to the automatic start connection,
which is located in the upper right hand corner of the
AC connection panel (see Figure 2.3). Match wires
178 and 183 in the transfer switch to 178 and 183 on
the terminal strip in the connection box. The con-
ductors for the two-wire start circuit must be in their
own conduit.
Figure 2.3 – Start Signal Connections
2.8 BATTERY INSTALLATION
Standby generators installed with automatic
transfer switches will crank and start automati-
cally when normal (utility) source voltage is
removed or is below an acceptable preset level.
To prevent such automatic start-up and possible
injury to personnel, do not connect battery
cables until you are certain that normal source
voltage at the transfer switch is correct and
you are ready to place the system into opera-
tion.
!
DANGER
AUTOMATIC START
CONNECTION
(WIRES 178 AND 183)
AC CONNECTION PANEL
DANGER

10 Generac®Power Systems, Inc.
Section 2 – Installation
Generac Standby Generator Sets
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the gas
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks or any spark
producing tools or equipment near the battery.
Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If you spill the fluid, flush
the affected area immediately with clear water.
Do not dispose of the battery in a fire. The
battery is capable of exploding.
Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
and eyes.
The battery represents a risk of high short cir-
cuit current. When working on the battery,
always remove watches, rings or other metal
objects, and only use tools that have insulated
handles.
2.8.1 VENTED BATTERIES
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following proce-
dures are to be observed:
• Wear full eye protection and protective clothing,
• Where electrolyte contacts the skin, wash it off
immediately with water,
• Where electrolyte contacts the eyes, flush thor-
oughly and immediately with water and seek med-
ical attention, and
• Spilled electrolyte is to be washed down with an
acid-neutralizing agent. A common practice is to
use a solution of one pound (500 grams) bicarbon-
ate of soda to one gallon (4 liters) of water. The
bicarbonate of soda solution is to be added until
the evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
Lead acid batteries present a risk of fire
because they generate hydrogen gas. The fol-
lowing procedure are to be followed:
• DO NOT SMOKE when near batteries,
• DO NOT cause flame or spark in battery area, and
• Discharge static electricity from body before touch-
ing batteries by first touching a grounded metal
surface.
Servicing of batteries is to be performed or super-
vised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized person-
nel away from batteries.
For recommended batteries, see “Specifications.” All
batteries must be at 100 percent state-of-charge
before they are installed on the generator.
When using maintenance-free batteries, it is not nec-
essary to check the specific gravity or electrolyte level.
Have these procedures performed at the intervals
specified in Section 4, “Maintenance.” A negative
ground system is used. Battery connections are
shown on the wiring diagrams. Make sure all batter-
ies are correctly connected and terminals are tight.
Observe battery polarity when connecting batteries
to the generator set.
NOTE:
Damage will result if the battery connections are
made in reverse.
2.9 PREPARATION BEFORE START-UP
The instructions in this section assume that the
standby generator has been properly installed, serv-
iced, tested, adjusted and otherwise prepared for use
by a competent, qualified installation contractor. Be
sure to read the “Safety Rules” on Pages 2 and 3, as
well as all other safety information in this manual,
before attempting to operate this (and related) equip-
ment.
2.9.1 PRIOR TO INITIAL START-UP
Prior to initially starting the generator, it must
be properly prepared for use. Any attempt to
crank or start the engine before it has been
properly serviced with the recommended types
and quantities of engine fluids (oil, coolant,
fuel, etc.) may result in an engine failure.
Before starting the generator for the first time, the
installer must complete the following procedures. For
follow-up maintenance information and/or service
intervals, please refer to Section 4, “Maintenance,”
and the “Service Schedule” on Page 17.
!
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Generac®Power Systems, Inc. 11
Section 2 – Installation
Generac Standby Generator Sets
2.9.1.1 Transfer Switch
If this generator is used to supply power to any elec-
trical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents elec-
trical backfeed between two different electrical sys-
tems. (For additional information, see the applicable
transfer switch manual for this unit.) The transfer
switch, as well as the generator and other standby
components, must be properly located and mounted
in strict compliance with applicable codes, standards
and regulations.
2.9.1.2 Fuel System
Make sure the fuel supply system to the generator (a)
delivers the correct fuel at the correct pressure and
(b) is properly purged and leak tested according to
code. No fuel leakage is permitted. See
“Specifications” (Page 7) for more information.
If the unit has been idle for a long period of time, or
if the fuel lines or system components have been
removed and reinstalled, the fuel system may require
bleeding to remove air from the system. Air in the
fuel system causes hard starting and rough opera-
tion. All fuel system lines must be installed and must
be tight. A loose line may show no sign of leakage, but
may draw air into the system.
Use a suitable container to catch the fuel that
will spill during system bleeding process. Clean
up all spilled fuel after bleeding.
2.9.1.3 Generator Set Lubrication
Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level
below the dipstick “ADD” mark. See “Specifications”
(Page 7) and “Engine Oil Recommendations” (Page 8).
NOTE:
This engine is shipped from the manufacturer
with 15W-40 oil. This oil should be changed after
30 hours of operation.
The engine is equipped with a mechanical governor.
Make sure the governor is properly lubricated with
clean engine oil.
2.9.1.4 Engine Coolant
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
for leaks and other problems. See “Specifications”
(Page 7) and “Coolant” (Page 8).
2.9.1.5 Belt Tension
Check the engine fan belt tension and condition prior
to placing the unit into service and at recommended
intervals. Belt tension is correct when a force of
approximately 22 pounds (10 kg), applied midway
between pulleys, deflects the belt about 3/8- to 5/8-
inch (10 to 16 mm).
2.9.1.6 Electrical System
Make sure the generator is properly connected to an
approved earth ground.
Make sure the generator battery is fully charged,
properly installed and interconnected, and ready for
use.
Check to ensure that there are no loose electrical con-
nections. Restrain any loose wires to keep them clear
of any moving generator set components.
2.9.1.7 Rodent Protection
Make sure the four 3-inch diameter cap plugs (part #
A8785) are properly installed in the tie-down holes in
the side rails of the unit’s base frame (Figure 2.4).
The cap plugs are shipped in a plastic bag located in
the lower connection box. These plugs are needed to
prevent rodents from accessing the interior of the
generator set. On acoustic units, cap plugs also are
needed to stay within noise specification limits.
Figure 2.4 – Base Frame Cap Plugs
2.9.2 START-UP INSPECTION
A standard three-part form titled “Start-up
Inspection for Standby Power Systems” (part #
67377) should be completed by the installation tech-
nician or engineer. As stated on the form, inspections
are to be accomplished only by factory-trained per-
sonnel. The installer should complete the form and
disseminate copies as follows:
• White copy: Mail to Generac Warranty Department,
P.O. Box 8, Waukesha, WI 53187.
• Pink Copy: For service file of installing dealer.
• Yellow Copy: For the customer’s records.
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12 Generac®Power Systems, Inc.
Section 4 – Maintenance
Generac Standby Generator Sets
3.1 GENERATOR CONTROL AND
OPERATION
Refer to the appropriate control panel operator’s
manual for this unit.
3.3 OPERATING UNIT WITH
AUTOMATIC TRANSFER SWITCH
If your generator has been installed along with an
automatic transfer switch, such as a Generac GTS-
type switch, the engine may be started and stopped
automatically or manually.
NOTE:
Refer to the applicable manual for your transfer
switch and to “Transfer Switch Start Signal
Connections” (Page 13). In addition, please note
the dangers under “Engine Start-up and Transfer.”
4.1 SERVICE SCHEDULE
4.1.1 AUTHORIZED OPERATOR
MAINTENANCE FUNCTIONS
4.1.1.1 Every Month or 100 Hours
(whichever comes first)
• Test standby generator system.
• Inspect battery (batteries) and cables.
• Check engine oil level.
• Check gearbox oil level (if so equipped).
• Check engine coolant level.
• Check generator ground connections.
• Test/inspect starting aids.
4.1.1.2 Every Three Months or Every 120
Hours (whichever comes first)
• Inspect and test fuel system and connections.
• Inspect exhaust system.
• Inspect/test fuel supply system.
4.1.2 AUTHORIZED SERVICE TECHNICIAN
MAINTENANCE FUNCTIONS
4.1.2.1 After First 30 Hours of Operation
• Inspect wiring.
• Change engine crankcase oil and oil filter.
• Inspect engine fan belts.
• Inspect battery (batteries) and cables.
4.1.2.2 Every Six Months or Every 200 Hours
(whichever comes first)
• Change engine oil and filter.
• Lubricate engine controls.
• Service engine air cleaner.
• Service engine fuel filter.
• Inspect AC generator.
• Test engine safety controls.
• Inspect fan belts.
• Check engine coolant level.
• Inspect engine cooling system hoses.
• Check optional starting aids.
• Check battery (batteries).
• Check engine compression.
• Check electrical connections.
• Check/test annunciator panel.
• Perform operational test.
4.1.2.3 Annually or Every 600 Hours
(whichever comes first)
• Check engine valve clearance.
• Test fuel injection nozzles.
• Test injection timing.
• Inspect all wiring.
• Test engine starter operation.
• Drain water from fuel tank.
• Retorque fan bolts.
• Drain and refill gearbox (If so equipped, contact
sales for availability.)
4.1.2.4 Every Two Years
• Replace all rubber hoses.
• Replace engine fan belts.
• Inspect the Standby Generator System.
• Drain, flush, refill cooling system.
4.1.2.5 Every 1,000 Operating Hours
• Inspect engine DC alternator.
• Inspect engine starter.
• Retorque engine mounting brackets.
• Remove/test fuel injection pump.
• Remove/test cooling system thermostat.
4.1.2.6 As Required
• Bleed engine fuel system.
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Generac®Power Systems, Inc. 13
Section 4 – Maintenance
Generac Standby Generator Sets
4.2 PERIODIC MAINTENANCE
A rigorous program of scheduled periodic mainte-
nance should be established and maintained. Such a
program, if adhered to diligently, will provide added
assurance that your power system functions proper-
ly when it is needed.
Keeping a “Maintenance Log” is highly recommended.
Such a log should be a continuous record of repairs,
parts replacements, gauge and instrument readings
during operational tests, etc.
Generac recommends that a “Customer Maintenance
Inspection Agreement” be established between the
user of this equipment and the installing Generac
Authorized Service Dealer. Under this agreement,
(Part No. 53263), a Generac Authorized Service
Technician performs prestart and engine running
tests and checks at six-month and one-year intervals.
Ask your Generac Authorized Service Dealer (or con-
sult the factory) about this agreement.
The tasks listed in the “Service Schedule” (Page 17)
cover the minimum recommended maintenance
requirements for this equipment.
Note that many of the tests and checks listed in the
schedule are to be performed only by a Generac
Authorized Service Technician. Fluid capacities and
recommendations, as well as other applicable speci-
fications, are listed in “Specifications” (Page 7).
4.2.1 TEST STANDBY GENERATOR SYSTEM
OPERATION AND COMPONENTS
An authorized operator should test the operation of
the standby generator system and inspect its compo-
nents monthly (or 100 hours). This should include
inspecting the transfer switch for evidence of arcing,
and pitted or burned contacts; inspecting wiring and
grounding connections (see “Grounding the
Generator,” Page 13); and ensuring that starting
devices are operational. During this operational test,
all instrument and gauge readings should be record-
ed in a “Maintenance Log.” The transfer system also
should be tested at this time; the engine should
be run at least 30 minutes and any discrepancies
corrected immediately.
Every six months (or 200 hours), a Generac
Authorized Service Technician should perform a
system operational test.
4.2.2 INSPECT BATTERY
Standby generators installed with automatic
transfer switches will crank and start automati-
cally when normal (utility) source voltage is
removed or is below an acceptable preset level.
To prevent such automatic start-up and possible
injury to personnel, do not connect battery
cables until you are certain that normal source
voltage at the transfer switch is correct and
you are ready to place the system into opera-
tion.
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the gas
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks or any spark
producing tools or equipment near the battery.
Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If you spill the fluid, flush
the affected area immediately with clear water.
Do not dispose of the battery in a fire. The
battery is capable of exploding.
Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
and eyes.
The battery represents a risk of high short cir-
cuit current. When working on the battery,
always remove watches, rings or other metal
objects, and only use tools that have insulated
handles.
An authorized operator should inspect the engine
battery system monthly (or 100 hours). At this time,
the battery fluid level should be checked and distilled
water added if needed. Battery cables and connec-
tions also should be inspected for cleanliness and
corrosion.
Once every six months (or 200 hours), a Generac
Authorized Service Technician should inspect the
battery system. At this time the battery condition and
state of charge should be checked using a battery
hydrometer. The battery should be recharge or
replaced as required.
!
!
!
DANGER
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Section 4 – Maintenance
Generac Standby Generator Sets
4.2.3 BATTERY REPLACEMENT
When replacing batteries, use the same number and
the following type batteries.
NOTE:
The BCI number should be located directly
on the battery. For more information, see
“Specifications.”
4.2.4 CHECK FLUIDS
An authorized operator should check the levels of
engine oil, and engine coolant monthly (or 100
hours). The oil level should be maintained between
the “FULL” and “ADD” marks on the engine dipstick.
Recommended fluids are listed on page 8 of this
manual.
4.2.5 INSPECT EXHAUST SYSTEM
Every three months (or 120 hours), an authorized
operator should inspect the entire exhaust system.
Abnormal noise levels heard during each operational
test may indicate a defective exhaust pipe or muffler.
Any defective or leaking component should be
repaired or replaced immediately by a Generac
Authorized Service Technician.
4.2.6 INSPECT/TEST FUEL SUPPLY SYSTEM
Every three months (or 120 hours), an authorized
operator should inspect and test the fuel supply sys-
tem, as well as all fuel system connections. All con-
nections must be tight and in good condition. A loose
fuel system line may show no signs of leakage, but
may draw air into the system causing rough opera-
tion and starting difficulties. Any defective or leaking
component should be repaired or replaced immedi-
ately by a Generac Authorized Service Technician.
4.3 REPAIR PARTS
The latter portion of this manual consist of exploded
views, parts lists and electrical data pertaining to this
generator set. The parts lists consist of (a) an item
number, (b) a part number, (c) the quantity required,
and (d) a description of the part. The item number
corresponds to an identical number on the exploded
view drawing.
4.3.1 HOW TO ORDER PARTS
To order a replacement part, locate the part in the
applicable exploded view. Contact your Generac
Authorized Service Dealer (call 800-333-1322 to
locate one in your area) and provide the following
information:
• The generator model number.
• The generator identification code, which indicates
the specific generator assembly for each unit.
• The part number and corresponding description
from the applicable parts list in this manual.
• The applicable exploded view “Group” letter (A-H)
and drawing number (five-digit number), which
can be found on the exploded view drawing.
NOTE:
In most cases, you can obtain repair parts by pro-
viding your Generac Authorized Service Dealer
with the data card information and a description
of the required part. If you are unable to locate
either the data card or the construction document,
simply describe the part you need and provide
your unit’s model number. This number can be
found on the metal DATA PLATE attached to the
generator’s lower connection box.
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14 Generac®Power Systems, Inc.
Generac P/N BCI Group No. CCA
058665 27F 700 @ 0 deg. F

Generac®Power Systems, Inc. 15
Section 5 — Installation
Generac Standby Generator Sets
Installation Diagram – Drawing No. 0E5195

16 Generac®Power Systems, Inc.
Section 6 — Electrical Data
Generac Standby Generator Sets
Wiring Diagram - E Panel – Drawing No. 0D2378V-B
1
2
7
8
9
12
11
10
3
4
2
1
7
8
0
BLA
C
K
/
4
85+
C
LEAR
/
4
85-
BARE
S
2
S3
X
N
O
T
US
E
D
T
S
B
E
F
C
0
0
5
7
58
59
S
1
5
4
2
0
1
590
591
BLA
CK
C
LEA
R
TB4
1
5/
22
0
8
4
85+
LP
C
0
4
85-
1
5
0
5
7
2
4
0
0
0
1
0
1
60
1
1
7
8
0
1
83
0
1
601
0
0
15/
22
0
15/
22
0
0
0
0
0
0
0
0
1
1
2
0
0
3
0
0
1
1
0
0
56
150
1
3/
21
8
0
0
0
0
1
8
1
0
12
0
0
14
/
21
9
14
/
21
9
1
3/
21
8
1
3/
21
8
1
50
13/
21
8
49
1
4
/
21
9
1
4
/
21
9
69
5
2
3
7
9
1
5/
22
0
0
0
56
0
0
4
9
R2 =
C/
A EX
C
ITER RE
S
I
S
T
OR
TB4 = TERMINAL BLOCK
[
8 POS.
]
TB3 = TERMINAL BLOCK
[
12 POS.
]
TB2 = TERMINAL BLOCK
[
14 POS.
]
TB1 = TERMINAL BLOCK
[
20 POS.
]
R1 = FIELD B
OOS
T RE
S
I
S
T
OR
C
A = REM
O
TE ANN
U
N
C
IAT
OR
R
3
6
2
0
1
TB2
13
1
14
590
590
591
591
11
10
0
12
7
8
9
R
8
R7
R
9
R4
R
5
R
6
589
590
6
567
567
A4
A
6
2
1
TB
3
11
12
8
10
0
447
4
6
589
1
5/
22
0
1
5/
22
0
3
4
5
1
R1
R2
0
1
83
17
8
0
0
0
A
3
A2
0
6
13/
21
8
79
5
0
1
4
/
21
9
1
4
/
21
9
7
5
2
3
11
5
2
3
15/
22
0
15/
22
0
15/
22
0
10
0
56
49
13
1
7
6
3
4
0
0
0
0
590
59
1
56
7
16
85
68
69
14
15
150
17
18
TB1
5
7
5
56
7
19
20
S
1
5
0
5
4
4
4
4
D1
AVR
2
3
1
62
89
1
14
/
21
9
0
2
16
2
89
R2
C
B
1
1
62
4
9
D2
2
1
5/
22
0
14
/
21
9
1
5/
22
0
14
/
21
9
4
9
C
ABL
E
1
5/
22
0
14
/
21
9
1
5/
22
0
89
1
3/
21
8
0
0
0
0
AVR = A
U
T
O
MATI
C
V
O
LTA
G
E RE
GU
LAT
OR
EC3 = ENGINE CONNECTOR
[
BASETANK
]
LP
C
= L
O
WER PANEL
CO
NNE
C
T
OR
EC1 = ENGINE CONNECTOR
[
ENGINE1
]
C
B1 = AVR
C
IR
CU
IT BREAKE
R
EC2 = ENGINE CONNECTOR
[
ENGINE2
]
FA = FILTER ASS.
[
LOW FUEL PRES SWH
]
D1 = FIELD B
OOS
T DI
O
D
E
D2 =
C/
A EX
C
ITER DI
O
D
E
CA
1
4
/
21
9
0
79
1
4
/
21
9
13/
21
8
85
85
15/
22
0
5
2
3
49
59
1
1
5
0
68
69
85
0
0
447
4
3
5
7
5
150
56
7
567
5
7
5
5
7
5
56
7
56
7
590
591
1
8
5
7
5
E
C3
590
0
,
1
,R
15
,
59
1
14
,
15
,
219
,
22
0
4
,
13
,
29
,
21
8
WIRE #'
s
56
,
56A
,
57-59
,
67
,
89
2
,
49
,
150
,
A1-8
,
R1-
9
515
,
523
,
567
,
575
,
58
9
S15
,
S16
,
64
,
6
5
68
,
69
,
85
,
502
,
509
,
162
,
178
,
183
,
S1-3
,
59
0
S
I
G
NAL
/S
EN
S
IN
G
L
E
G
EN
D
U
NIT
S
TAT
US
BL
UE
YELL
OW
BLA
CK
A
C/
MI
SC
6
N
O
N-F
US
ED D
C
WIRE
CO
L
OR
WHITE
O
RAN
GE
BR
O
W
N
RED
LE
G
EN
D
F
U
N
C
TI
ON
F
US
ED D
C
NEUTRAL
CO
NTR
OL
PR
G
RLY 1 N
C
F
U
EL
+
PR
G
RLY 2 N
O
PR
G
RLY 2
COM
PR
G
RLY 2 N
C
PR
G
RLY
3
N
O
PR
G
RLY
3
N
C
PR
G
RLY
3
COM
BAT GND
(
-
)
0
BAT GND
(
-
)
0
PR
G
RLY 1
COM
PR
G
RLY 1 N
O
DC FUSED (+
)
(
15/220
)
F
D
SOC
P
F
U
EL
-
M
N
N
L
K
B
H
K
T
T
U
4
85+
0V
0V
0V
PR
G
INPT
4
R
U
PT TAN
K
ML
CB
PR
G
INPT
6
PR
G
INPT
G
N
D
PR
G
INPT
G
N
D
B
/C
FAI
L
LINE P
O
WE
R
G
EN P
O
WE
R
C
ALT W
/
L
M
L
C
B
S
W
PRE
-
HEAT
RU
PT TANK

Generac®Power Systems, Inc. 17
Section 6 — Electrical Data
Generac Standby Generator Sets
Wiring Diagram - E Panel – Drawing No. 0D2378V-B
G
N
D
REM
O
TE
S
TR
T
F
U
EL
S
NDR
-
S
PR INPT
1
S
PD
S
N
S
R
+
O
IL TEM
P
F
U
EL LV
L
COO
L TEM
P
PR
G
INPT
5
PR
G
INPT
1
PR
G
INPT
3
PR
G
INPT
7
M
C
1 = E-PANEL
CO
NTR
O
L A
SS
EMBL
Y
PF
G
= PANEL FR
O
NT
G
R
OU
ND
S
T
UD
VR1 = V
O
LT
S
TRIM P
O
TENTI
O
METE
R
E
S
= EMER
G
EN
C
Y
S
T
O
P
S
WIT
CH
S
W1 = V
O
LT
/
AMMETER
S
WIT
CH
F1 = 1
5
AMP A
GC
TYPE F
USE
HZ = FRE
Q
UENCY METE
R
L1
=
PANEL LAMP
VM = V
O
LT METE
R
AA = A
U
DIBLE ALAR
M
AM
=
AMMETER
LE
G
EN
D
14
/
21
9
S
I
G
NAL
/S
EN
S
IN
G
BL
UE
58
7
0
19
6
4
15
65
3
BLA
CK
YELL
OW
5
7
68
,
69
,
85
,
502
,
509
,
515
,
523
,
567
,
575
,
58
9
S15
,
S16
,
64
,
6
5
S3
18
S
W
1
11
A
C/
MI
SC
U
NIT
S
TAT
US
59
6
0
2
16
12
6
7
14
S
2
S
1
O
RAN
GE
LE
G
EN
D
WIRE
CO
L
OR
BR
O
W
N
RED
1
5/
22
0
C
ABL
E
1
5/
22
0
14
/
21
9
89
1
3/
21
8
0
0
0
0
0
56
WIRE #'
s
4
,
13
,
29
,
21
8
0
,
1
,
R15
,
59
1
14
,
15
,
219
,
22
0
2
,
49
,
150
,
A1-8
,
R1-
9
162
,
178
,
183
,
S1-3
,
59
0
56
,
56A
,
57-59
,
67
,
8
9
F
U
N
C
TI
ON
NE
U
TRA
L
F
US
ED D
C
N
O
N-F
US
ED D
C
CO
NTR
OL
VR1
13/
21
8
1
4
/
21
9
15/
22
0
S
1
6
5
1
5
0
0
0
65
64
67
S
1
5
S
1
6
S
1
6
S
1
6
S
1
5
S
1
6
S
1
6
S
1
6
S
1
5
S
1
5
S
1
5
S
1
5
HZ
6
4
0
0
AA
89
56
A
14A
R
1
5
PF
G
0
591
590
R1
5
1
83
0
7
9
12
14
8
1
0
1
3/
21
8
1
5/
22
0
S
1
6
F1
56
14
/
21
9
0
E
S
56A
R1
5
14A
0
5
2
3
85
68
69
5
7
5
0
A7
A
6
A
8
A
5
A1
A2
A
3
A4
9
4
6
2
7
5
1
3
0
6
7
0
64
65
VM
AM
0
0
67
6
2
1
0
1
5/
22
0
ALT LINE 2
14
/
21
9
L1
ALT LINE 1
BAT -
BAT +
15/
22
0
S
1
6
S
1
6
S
1
5
S
1
5
0
15/
22
0
S
1
6
S
1
5
0
S
1
5
S
1
6
4
2
6
12
8
1
0
14
1
6
S
NDR RLY N
/C
PR
G
RLY
3
N
O
PR
G
RLY
3
N
C
S
NDR RLY
COM
S
NDR RLY N
/O
PR
G
RLY 2 N
C
PR
G
RLY 2 N
O
PR
G
RLY 1 N
C
PR
G
RLY 2
COM
PR
G
RLY
3
COM
PR
G
RLY 1 N
O
PRE-HEAT
COM
PRE-HEAT N
/O
S
TARTER
SOL
PR
G
RLY 1
COM
F
U
EL
SOL
M
C1
1
5/
22
0
5
1
5
14A
1
50
56A
R4
R2
R
6
R
8
FERRITE
BEAD
S

N
/O
G
R
OU
ND FR
O
M EN
G
IN
E
0
B
C3
-1
2
B
C3
-
6
TB4-
5
B
C3
-1
0
P
OS
ITIVE D
C
FR
O
M BATTER
Y
A
U
X. F
US
ED D
C
SU
PPL
Y
P
OS
ITIVE D
C
FR
O
M BATTER
Y
C
HAR
G
E ALT. W
/
L
CO
NN
.
4
9
1
3
1
5
1
3
B
C3
-
7
B
C
2-1
1
B
C
4-
1
B
C
4-
7
B
C
2-1
0
B
C
2-
8
B
C
2-
9
B
C3
-
4
B
C3
-
3
B
C3
-
9
G
R
OU
ND FR
O
M EN
G
IN
E
PRE-HEAT
SO
LEN
O
I
D
S
TARTER
SO
LEN
O
I
D
F
U
EL
SO
LEN
O
I
D
14
0
56
1
50
F
U
EL
S
ENDER
-
F
U
EL
S
ENDER
+
COO
LANT LEVEL DETE
C
T
OR
F
U
EL LEVEL
S
EN
SOR
O
IL TEMP.
S
EN
SOR
O
IL PRE
SSU
RE
S
EN
SOR
COO
LANT TEMP.
S
EN
SOR
68
69
5
7
5
5
2
3
591
590
85
19
15
12
B
C
1-
N
3
L1
CT
57
L
O
WER PANEL
CO
NNE
C
T
OR
B
C
1-
H
S
1
5
B
C
1-
C
FIELD
2
6
S
1
6
AVR
EX
C
ITE
R
P
O
WE
R
AVR
S
EN
S
IN
G
B
C
1-
F
B
C
1-
G
B
C
1-
L
S2
L2 V
O
LT
S
183
1
7
8
S3
S
TAR
T
2-
WIRE
S
I
G
NA
L
L3 V
O
LT
S
B
C
1-
B
B
C
1-
J
BC1-
M
5
8
5
9
L1 V
O
LT
S
L3
CT
L2
CT
B
C
1-
K
B
C
1-
P
B
C
1-
O
16
18
14
11
7
G
R
O
UND RETUR
N
C
T
CO
MM
ON
B
C
1-
S
B
C
1-
A
0
0
ML
C
B
O
PE
N
5
89
B
C
1-
R
PR
OG
. INP
U
T
3
A
3
2
PR
OG
. INP
U
T
2
PR
OG
. INP
U
T
1
G
EN. P
O
WE
R
BATT
C
HR
G
FAI
L
A1
A2
5
4
4
R
U
PT. TAN
K
ML
C
B
O
PE
N
LINE P
O
WE
R
G
R
OU
ND RET
U
R
N
G
R
OU
ND RET
U
R
N
PR
OG
. INP
U
T
8
PR
OG
. INP
U
T
7
PR
OG
. INP
U
T
5
A7
B
C
4-
4
B
C
4-
5
A
5
A4
B
C
4-
2
B
C
4-
6
B
C
4-
3
A
8
567
0
0
PR
OG
. RELAY
2
PR
OG
. RELAY
1
N
/O
COM
R1
R2
N/
C
COM
R
3
R4
R
5
B
C
2-
2
B
C
2-1
2
MA
G
NETI
C
RPM
S
EN
SOR
S
HIEL
D
7
9
0
TB4-
6
TB4-
8
TB4
-
7
PR
OG
. RELAY
3
N
/O
N
/C
COM
R
6
R
7
R
8
N
/C
R
9
PRE
SSU
RE #
601
L
O
W F
U
EL
BA
S
IN # 44
7
G
EN. FL
U
I
D
1
5A
F1
L
1
E
S
-
3
E
S
-
2
S
W
1
VR1
C
B
1
CO
N1-
3
CO
N4-
2
CO
N2-1
0
CO
N4-
4
CO
N4-
6
HZ
CO
N4-
1
VM
AM
CO
N1-
2
CO
N1-
1
S
1
6
S
1
5
CO
N2-
6
CO
N
3
-1
4
CO
N
3
-
4
CO
N
3
-
3
CO
N
3
-
2
CO
N
3
-
1
CO
N2-1
4
CO
N2-1
3
CO
N2-
7
CO
N2-
2
CO
N2-
4
CO
N2-
5
CO
N1-
9
CO
N1-1
0
CO
N1-
6
CO
N1-
7
CO
N1-
8
CO
N1-
5
CO
N1-
4
CO
N
3
-
7
CO
N
3
-
6
CO
N
3
-
5
CO
N
3
-
9
CO
N
3
-
8
ES
-
1
AA
RS232
(
Tx
)
/RS485
-
RS232
(
DSR
)
RS232
(
Rx
)
/RS485+
RS232
(
DTR
)
D
S
UB-
5
CO
N
3
-1
5
CO
N2-1
1
CO
N2-
8
CO
N2-
9
D
S
UB-
4
D
S
UB-
3
D
S
UB-
2
D
S
UB-
1
CO
N
3
-1
0
CO
N
3
-1
3
CO
N
3
-1
2
CO
N
3
-1
1
CO
MM
ON
AUT
O
MATI
C
(
AVR
)
EX
C
ITATI
ON
ALTERNAT
OR
V
O
LTA
GE
RE
G
ULAT
OR
FIELD B
OOST
R1
D1
P
O
WE
R
FIELD
4
1
2
6
D2
R2
S
EN
S
IN
G
5
3
CO
NTR
O
L B
OX
M
C1
'E'
PANEL
18 Generac®Power Systems, Inc.
Section 6 — Electrical Data
Generac Standby Generator Sets
Wiring Schematic - E Panel – Drawing No. 0D2379V-A