Generac Number Generator Set

⚠ Explosion. Batteries emit explosive gases. Always connect positive battery cable first to avoid spark. Failure to do so could result in death or serious injury. (W000133)

1. Loosen nylon strap on battery tray.
2. Install battery onto tray.
3. Secure nylon strap over top of battery and tighten.
4. Install positive battery cable (red) to positive terminal.
5. Install negative battery cable (black) to negative terminal.

⚠ Electric shock. Do not disconnect spark plug wires with engine running. Doing so could result in death or serious injury. (W000140)

Tools: spark plug socket, wire feeler gauge, wire brush

1. Remove negative battery cable.
2. Remove spark plug cables from terminals.
3. Clean area around spark plugs.
4. Remove spark plugs with spark plug socket.
5. Inspect threads; clean with thread chaser if needed.
6. Clean spark plugs with wire brush and solvent; do not blast.
7. Inspect gap with wire feeler gauge; gap 0.012-0.017 in (0.31-0.45 mm).
8. Adjust gap by bending ground electrode.
9. Finger tighten spark plugs; tighten to 28 ft-lb (38 Nm) with socket.
10. Install spark plug cables; verify captured in clips.

⚠ Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (W000139)

Tools: wrenches, container, funnel

1. Disconnect and empty coolant overflow reservoir.
2. Rotate and remove plastic cover at top of enclosure.
3. Slowly unscrew radiator cap.
4. Locate drain screw at bottom left of radiator; open drain.
5. Remove coolant drain hose from clamp; remove plug; drain coolant.
6. Install drain plug and hose; close radiator drain screw.
7. Fill radiator with de-ionized or distilled water and flushing product; use 2.9 US gal (11 L).
8. Install radiator cap.
9. Press MANUAL to start engine; run until thermostat opens.
10. Inspect hoses for leaks; press OFF; allow engine to cool.
11. Repeat steps 4-19 to drain.
12. Add recommended coolant; top off radiator and overflow bottle.

1. Inspect belt for cracks, fraying, excessive wear, or damage.
2. Verify belt is free of grease and oil.
3. Replace belt if contaminated, damaged, frayed, or worn.
4. Inspect belt and rotating components.

Tools: wrenches, container

1. Open viewing window.
2. Press MANUAL to start engine; blue LED illuminates.
3. Allow engine to reach normal operating temperature.
4. Press OFF; red LED illuminates.
5. Set generator MLCB to OFF (OPEN), if equipped.
6. Remove 7.5 amp fuse.
7. Turn off utility power to transfer switch.
8. Place DO NOT OPERATE tag.
9. Wait five minutes for engine to cool.
10. Remove front access panel.
11. Remove oil drain hose from holding clamp; drain oil.
12. Install oil drain plug and hose.
13. Remove oil filter; coat new filter gasket with oil.
14. Install oil filter; tighten 3/4 to 1 full turn.
15. Fill engine with recommended oil; install oil fill cap.

⚠ Electrical shock. Disconnect battery ground terminal before working on battery or battery wires. Failure to do so could result in death or serious injury. (W000164)

1. Remove negative battery cable from negative terminal.
2. Remove positive battery cable from positive terminal.
3. Install rubber protective cover over positive terminal.
4. Release buckle on nylon strap securing battery.
5. Grasp battery strap and lift battery from tray.
6. Remove rubber protective cover from positive terminal.

Tools: wrenches

1. Remove nut and bolt from air filter clamp; loosen elbow clamp.
2. Remove air filter element and discard.
3. Clean elbow of dust, dirt, or debris.
4. Place new air filter element into elbow clamp.
5. Install elbow clamp and tighten; install nut and bolt; tighten until snug.

⚠ Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (W000139)

Tools: wrenches, container, shop towel

1. Follow Removing From Service; wait at least 10 minutes.
2. Remove oil drain hose from holding clamp.
3. Use two wrenches to remove oil drain plug; drain oil.
4. Install oil drain plug and hose into holding clamp.
5. Turn oil filter counterclockwise to remove; wipe adapter.
6. Apply clean engine oil to gasket of new oil filter.
7. Install oil filter by hand until gasket contacts; tighten 3/4 to 1 full turn.
8. Fill engine with 11.6 qt (11 L) recommended oil for 4.5 L NA.
9. Install oil fill cap.
10. Connect negative battery cable; install 7.5 amp fuse.
11. Press MANUAL to start; run one minute; inspect for leaks.
12. Press OFF; wait 10 minutes; check oil level and add as needed.

1. Install 7.5 amp fuse.
2. Install T1 fuse in transfer switch.
3. Verify both emergency shutdown switches are ON.
4. Press AUTO on controller; green LED illuminates.
5. Set generator MLCB to ON (CLOSED), if equipped.
6. Close viewing window.
7. Remove DO NOT OPERATE tag from control panel and transfer switch.
8. Reset date/time.

⚠ Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury. (D000191)

1. Pull up rubber flap covering fuse holder; verify 7.5 amp fuse.
2. Set generator MLCB to OFF (OPEN), if equipped.
3. Verify both emergency shutdown switches are ON (I).
4. Press MANUAL on controller to start engine; blue LED illuminates.
5. Allow engine to reach normal operating temperature.
6. Press OFF on controller to stop engine; red LED illuminates.