GENERAC XG03245 (01) PDF Document

Read and understand the manual completely before using the product. If any section of this manual is not understood, contact an Independent Authorized Service Dealer (IASD) or Generac Customer Service for starting, operating, and servicing procedures. The owner is responsible for proper maintenance and safe use of the unit.

SAVE THESE INSTRUCTIONS for future reference. This manual contains important instructions that must be followed during placement, operation, and maintenance of the unit and its components. Always supply this manual to any individual that will use this unit, and instruct them on how to correctly start, operate, and stop the unit in case of emergency.

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. If using a procedure, work method, or operating technique that the manufacturer does not specifically recommend, verify that it is safe for others and does not render the equipment unsafe.

Throughout this publication, and on tags and decals affixed to the unit, DANGER, WARNING, CAUTION, and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Alert definitions are as follows:

• DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

These safety alerts cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

To maintain the product warranty, engine oil should be serviced in accordance with the recommendations of this manual. Maintenance kits designed and intended for use on this product are available from the manufacturer which include engine oil, oil filter, air filter, spark plug(s), a shop towel, and funnel.

The unit is filled at the factory with 5W-20 engine oil. After the initial 25 hour break in period, replace the oil with Generac proprietary 5W-20 Synthetic oil. After break-in, a synthetic oil which meets or exceeds SAE specifications is recommended. Once synthetic oil is used, it should be used for the life of the generator. It is not recommended to go back to a mineral oil. Do not use special additives.

The following kits are offered to keep the GENERAC XG03245 running at its peak:

Cold Weather Operation

• Battery Heater Kit: Recommended for operating environments where the temperature drops below 32 °F (0 °C); externally powered by 120 VAC 60 Hz.
• Engine Block Heater Kit: Recommended for operating environments where the temperature drops below 0 °F (-18 °C); externally powered by 120 VAC 60 Hz.

Scheduled Maintenance Kit

• Kit includes the recommended parts to maintain the GENERAC XG03245. See Service Maintenance Schedule for regular maintenance intervals.

Use approved coolant only. Use of incorrect coolants can damage the engine cooling system. Use demineralized water or distilled water for best results. Hard water causes scale deposits, which reduces cooling efficiency and raises internal temperatures, possibly leading to engine damage. Use an anti-corrosive to prevent rot in summer and anti-freeze to prevent freezing in winter.

Dilute the anti-freeze based on a theoretical temperature that is 9–18 °F (5–10 °C) below the lowest temperature expected in the area. A ratio of 40-60% is most common range. Use only Generac brand 50/50 ethylene glycol type coolant. Do not use propylene glycol type coolant. Using the wrong coolant, mixing different types of coolant, or even mixing different brands of the correct type of coolant, can produce unsatisfactory results, possibly leading to engine damage.

Coolant dilution based on lowest expected temperature:

The GENERAC XG03245 may be equipped with one of the following fuel systems:

• Liquid Propane (LP) Vapor Fuel System
• Natural Gas (NG) Fuel System

Recommended fuels must have an energy density of at least 91,420 BTU/US gal (25.5 MJ/L) for LP or at least 1,036 BTU/ft³ (38.6 MJ/m³) for NG. If using LP, a minimum LP tank size of 250 US gal (946 L) is recommended.

All generator models are capable of using either Liquid Propane (LP) Vapor or Natural Gas (NG). The fuel type is configured using only the Power Zone 410 controller.

The fuel type is configured using only the Power Zone 410 controller. Navigate to the appropriate menu in the controller to select the fuel type to configure the fuel system. The fuel selection software is password protected.

Selecting the correct fuel type occurs during the Install Wizard Process. Navigate the software using UP arrow, DOWN arrow, ENTER, and ESCAPE. The user selects the fuel type when the display reads:

Display Reads:

Fuel Selection

– LP +

– NG +

Action:

Fuel Type Selection.

Use UP or DOWN arrow to index the correct fuel type.

Press ENTER.

Select the correct fuel based on the fuel connected at the installation site.

The GENERAC XG03245 engine requires a Group 27, 12 volt battery for operating environments where temperatures regularly drop below 24 °F (-4 °C).

Battery dimensions (L x W x H) for Group 27 battery must not exceed 6-9/16 x 12 x 8-11/16 in (16.7 x 30.5 x 22 cm).

An upgrade option is available for a Group 31, 12 volt battery for operating environments where temperatures regularly drop below 24 °F (-4 °C). Battery dimensions (L x W x H) for Group 31 battery must not exceed 13 x 6-13/16 x 9-7/16 in (33 x 17.3 x 24 cm).

A five amp battery charger is integrated into the Power Zone 410 controller. It operates as a “smart charger” which verifies output charging levels are safe and continuously optimized to promote maximum battery life.

• Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.
• Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.
• Explosion hazard. Never add acid to a battery. Add distilled water only. Failure to do so could result in death, serious injury, or equipment damage.
• Risk of burn. Do not open or mutilate batteries. Batteries contain electrolyte solution which can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.
• Never charge a battery in wet conditions. Doing so could result in death, serious injury, equipment or property damage.
• Electrical shock. Disconnect battery ground terminal before working on battery or battery wires. Failure to do so could result in death or serious injury.
• 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.
• Stationary emergency generators installed with automatic transfer switches will crank and start automatically when NORMAL (UTILITY) source voltage is removed or is below an acceptable preset level. Do not connect battery cables until NORMAL (UTILITY) source voltage at transfer switch is correct and system is ready to be placed into operation to prevent automatic startup and possible injury to personnel.
• Only use tools with insulated handles when working on the battery. Do not lay tools or metal parts on top of the battery.
• Discharge static electricity from the body before touching the battery by first touching a grounded metal surface.
• Immediately wash down spilled electrolyte with an acid neutralizing agent. Use a solution of 1 lb/US gal (125 g/L) of bicarbonate of soda to water. Add the bicarbonate of soda solution until evidence of reaction (foaming) has ceased. Flush the resulting liquid with water.

Proceed as follows to remove the front access panel:

1. Remove the key from the bag attached to the door of the unit.

2. Insert the key into the latch and rotate counterclockwise one half turn.

3. Raise the panel using the thumb latch.

Proceed as follows to install the battery:

1. Loosen the nylon strap on the battery tray.

2. Install the battery onto the tray.

3. Secure the nylon strap over the top of the battery and tighten.

4. Install the positive battery cable (red) to the positive (+) battery terminal.

5. Install the negative battery cable (black) to the negative (-) battery terminal.

Proceed as follows to open the viewing window:

1. Remove the protective film from the exterior surface of the viewing window.

2. Lift the viewing window to access the controls.

3. To hold the viewing window open, rotate the prop up and insert into the stop in the cover.

Proceed as follows to attach the radio harness to the cellular accessory:

1. Align the key in the radio harness with the slot in the mating connector on the cellular accessory. Press the connectors together.

2. Finger-tighten the nut on the radio harness.

3. Turn the nut on the radio harness clockwise until fully seated.

Proceed as follows to attach the cellular accessory to the mounting plate:

1. Align the arrow on the cellular accessory with the arrow on the mounting plate.

2. Press the cellular accessory flush with the mounting plate.

3. Turn the cellular accessory clockwise to attach to the mounting plate until there is an audible click.

The functionality of the Cellular Accessory is verified as follows:

• The Green LED on the cellular accessory face will illuminate once the radio harness is fully connected.
• The LED will slowly pulse while the cellular accessory attempts to connect to the generator and to the cellular network.
• The LED will be solid green when connected successfully. If the cellular accessory encounters an error, it will begin blinking.

The activation process starts after initial startup of the GENERAC XG03245. The sequence of displays and actions are as follows:

Display Reads: Language English +

Action: Use Up arrow or Down arrow to scroll to desired language. Press ENTER. If the wrong language is selected, it may be changed later using the Edit menu.

Display Reads: Activate me (ENT) or ESC to run in manual

Action: Press ENTER. Press ESCAPE to abort the activation sequence. NOT ACTIVATED is displayed and the unit will run in MANUAL only. Disconnect and reconnect the negative battery cable to restart the activation routine. If power is removed after a successful activation, no data is lost, but time and date must be updated.

Display Reads: To Activate go to www. activategen. com

Action: Go to www. activategen. com or call 1-888-9ACTIVATE (922-8482, US & Canada only) if activation passcode is not available. If activation pass code is available, wait a few seconds for the next display.

Display Reads: SN 1234567890 PASS CODE XXXXX

Action: Use Up arrow or Down arrow to increment or decrement the digit to correspond to the first number of the pass code. Press ENTER. Repeat step to enter remaining digits. Press ESCAPE to return to preceding digits if a correction becomes necessary.

Display Reads: Select Hour (0-23) – 6 +

Action: Use Up arrow or Down arrow to increment or decrement the hour. Press ENTER. Use Up arrow or Down arrow to increment or decrement the minute. Press ENTER. Use Up arrow or Down arrow to select the month. Press ENTER. Use Up arrow or Down arrow to increment or decrement the date. Press ENTER. Use Up arrow or Down arrow to increment or decrement the year. Press ENTER. With the GGCAC device successfully installed and connected, the date and time on the generator will be set automatically.

Display Reads: Fuel Selection – LP + – NG +

Action: Fuel Type Selection. Use UP or DOWN arrow to index the correct fuel type. Press ENTER. Select the correct fuel based on the fuel connected at the installation site.

Proceed as follows to start and run the engine:

1. Pull up the rubber flap covering the fuse holder and verify the installation of the 7.5 amp fuse.

2. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

3. Verify both emergency shutdown switches are ON (I).

4. Press MANUAL on the controller to start the engine. A blue LED illuminates to verify the system is in MANUAL.

5. Allow the engine to run until it reaches normal operating temperature. Press OFF on the controller to stop the engine. A red LED illuminates to verify the system is OFF.

The controller goes through a system self test upon startup, which checks for utility voltage on the DC circuits. This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block. If utility voltage is detected, the controller displays a warning message and locks out the generator, preventing damage to the controller. Remove power to the controller to clear this warning.

Utility voltage must be turned on and present at N1 and N2 terminals inside the generator controller for this test to be performed and pass.

Complete the following before starting the Self Test:

1. Verify the GENERAC XG03245 is OFF. A red LED on the controller illuminates to verify the system is off.

2. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

3. Turn off all circuit breakers/electrical loads to be powered by the generator.

4. Verify both emergency shutdown switches are ON (I).

Proceed as follows to complete electrical checks:

1. Verify the generator is in OFF mode. A red LED on the controller illuminates to verify the system is OFF.

2. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

3. Turn off all circuit breakers/electrical loads to be supplied by the generator.

4. Turn on utility power supply to the transfer switch using the means provided (such as a utility MLCB).

5. Use an accurate AC voltmeter to verify utility power source voltage across transfer switch terminals N1, N2, and N3 (if three-phase). Normal line-to-line voltage should be equivalent to rated unit voltage.

6. Verify utility power source voltage across terminals N1, N2, and N3 (if three-phase) and the transfer switch neutral lug.

7. Turn off utility power supply to the transfer switch when utility supply voltage is compatible with transfer switch and load circuit ratings.

8. Press MANUAL on the controller to crank and start the engine.

9. Allow the engine to warm up for approximately five minutes. Set the generator MLCB (generator disconnect) to ON (CLOSED), if equipped.

10. Connect an accurate AC frequency meter across transfer switch terminal lugs E1, E2, and E3 (if three-phase) and verify the correct rated frequency (50 Hz or 60 Hz).

11. Use an accurate AC voltmeter to verify generator output voltage across transfer switch terminals E1 to E2, (E2 to E3 and E3 to E1 if three-phase). Normal line-to-line voltage should be equivalent to site specific utility voltage.

12. Successively connect the AC voltmeter test leads across terminal lugs E1 and Neutral, then E2 and Neutral (and E3 and Neutral if three-phase). Line-to-neutral reading in each case should match utility voltage reading. Verify generator phase rotation matches utility phase rotation if the system is three-phase.

13. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

14. Press OFF on the controller to shut the engine down.

IMPORTANT NOTE: Do not proceed unless generator AC voltage and frequency are correct and within stated limits.

The GENERAC XG03245 is equipped with an independent means of shutting down the prime mover (engine) for use in emergency situations. The shutdown mechanism, when activated, requires a mechanical reset.

Proceed as follows to test auxiliary emergency switches after installation to verify correct operation:

1. Verify emergency shutdown switches are ON (I).

2. Press MANUAL on the controller to start the engine.

3. With the engine running, set one emergency shutdown switch to OFF (O). The engine should shut down immediately.

• If the engine stops, set the emergency shutdown switch to ON (I), clear the alarm on the controller, and restart the engine to verify the generator is operating normally. After verifying normal operation of the first emergency switch, verify the operation of the second emergency switch.
• If the engine does not stop, the emergency shutdown switch is not functioning correctly. Contact an IASD.

NOTE: Generator emergency shutdown switches are not intended to be a primary means to shut down the generator under normal operating conditions. Accidental activation of an emergency shutdown switch will prevent the generator from operating during a power outage.

Proceed as follows to test the GENERAC XG03245 set with electrical loads applied:

1. Verify the generator is in OFF mode. A red LED on the controller illuminates to verify the system is off.

2. Turn off all breakers/electrical loads to be supplied by the generator.

3. Turn off utility power supply to the transfer switch, using the means provided (such as a utility MLCB).

4. Manually set the transfer switch to STANDBY, i.e., load terminals connected to the generator’s E1, E2, and E3 (if three-phase) terminals.

5. Press MANUAL on the controller. The engine will crank and start.

6. Allow the engine to warm up for a few minutes.

7. Set the generator MLCB (generator disconnect) to ON (CLOSED), if equipped. The transfer switch is now powered by the standby generator.

8. Turn on the circuit breaker/electrical loads supplied by the generator.

9. Connect a calibrated AC voltmeter and a frequency meter across terminal lugs E1, E2, and E3 (if three-phase). Voltage should be approximately unit rated voltage. Verify with a clamp-on amp meter to verify the unit is not overloaded.

10. Allow the generator to run at full rated load for 20-30 minutes. Listen for unusual noises, vibration, or other indications of abnormal operation. Inspect for oil leaks, evidence of overheating, etc.

11. Turn off electrical loads when testing under load is complete.

12. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

13. Allow the engine to run at no-load for 2-5 minutes.

14. Press OFF on the controller to shut the engine down. A red LED illuminates to verify the system is OFF.

Proceed as follows to check the system for correct automatic operation:

1. Verify the generator is in OFF mode. A red LED on the controller illuminates to verify the system is OFF.

2. Install the front cover of the transfer switch.

3. Turn on the utility power supply to the transfer switch, using the means provided (such as a utility MLCB). The transfer switch will transfer to UTILITY.

4. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

5. Press AUTO on the controller. The system is now ready for automatic operation.

6. Turn off the utility power supply to the transfer switch.

With the generator ready for automatic operation, the engine will crank and start when the utility source power is turned off after a 10 second delay (factory default setting). After starting, the transfer switch connects the load circuits to the standby side. Allow the system to operate through its entire automatic sequence of operation.

With the generator running and loads powered by the generator AC output, turn on the utility power supply to the transfer switch. The system transfers back to the utility position and then runs through a cool-down cycle and shuts down.

Proceed as follows to secure the GENERAC XG03245:

1. Use the key to install the side access panel.

2. Close the viewing window.

3. Obtain the viewing window hasp, if not installed. From the backside (interior) of the panel, remove the fastener as shown. Install the hasp and secure with the removed fastener.

4. Install the customer supplied padlock into the viewing window hasp.

The GENERAC XG03245 has three modes of operation:

With the controller set to AUTO, the engine may crank and start at any time without warning. Such automatic starting occurs during the programmed exercise cycle or when utility power source voltage drops below the configured level. To prevent possible injury that might occur during sudden starts, always set the controller to OFF and remove the 7.5 amp fuse before working on or around the generator or transfer switch. For added security, place a DO NOT OPERATE tag or placard on both the control panel and transfer switch. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

The menu navigation is as follows:

NOTE: Pressing the controller illuminates the backlight for five minutes. The backlight also illuminates for 30 seconds whenever an active Alarm/Warning message is displayed.

The owner/operator is alerted to Alarm and/or Warning conditions via the controller screen. All Alarm conditions cause the GENERAC XG03245 generator to shut down. The Warning messages alert the operator to conditions that do not disable the unit or require immediate correction.

The possible Alarm/Warning messages are listed below:

Alarm Messages

• High Engine Temperature
• Low Oil Pressure
• Overcrank
• Overspeed
• RPM Sense Loss
• Underspeed
• Controller Fault
• Ignition Fault Code
• Emergency Shutdown
• WIRING ERROR
• Over Voltage
• Under Voltage
• Overload
• Canbus Error
• Missing Cam Pulse
• Missing Crank Pulse
• Low Fuel Pressure
• E-Stop
• Configuration Mismatch

Warning Messages

• Low Battery
• Exercise Set Error
• Schedule A Maintenance
• Schedule B Maintenance
• Schedule C Maintenance
• Battery Problem
• Charger Warning
• Charger Missing AC
• USB Warning
• Download Failure
• Check Engine

NOTE: Unless correctly trained to correct and clear Alarm/Warning conditions, contact an IASD or trained service technician.

See Navigation Menu to change date/time after activation. If power is lost (battery is disconnected/reconnected, controller fuse is removed/installed, etc.), the display automatically prompts the user for Date/Time. All other information is retained in memory.

A programmable exercise time is provided. In AUTO, the engine starts and runs once each week at the time and day specified. During the exercise cycle, the unit runs approximately five minutes and then shuts down. Transfer of loads to the generator does not occur unless utility power fails.

NOTE: A dealer password is required to change the duration of the exercise cycle.

A programmable line interrupt delay (or startup delay) timer is provided. When utility voltage fails (falls below 60% of nominal), the startup delay timer is started. If voltage rises above the utility volts low threshold, the timer is reset. If utility voltage remains below the utility volts low threshold during the duration of the timer, the unit cranks and starts.

NOTE: The Factory default setting is five seconds, but is adjustable from 2 to 1,500 seconds.

A programmable warm-up delay timer is provided. As soon as the generator starts, the warm-up timer starts. When the warm-up timer expires, the controller transfers the load to the generator (through the transfer switch) if the utility voltage is less than 80% of nominal. If the utility voltage is greater than the threshold at the expiration of the warm-up timer, the load is not transferred to the generator and a cool-down period begins. At the end of the cool-down period, the generator stops.

NOTE: The factory default setting is five seconds, but is adjustable from 5 to 1,500 seconds.

The GENERAC XG03245 includes cellular connectivity standard. This capability will enable over-the-air firmware updates to be completed. No effort is required by the generator owner. Firmware updates will be automatic with the reliability of a cellular connection. An announcement will be made when this capability is fully functional.

A USB port is located beneath the rubber flap on the controller, and is provided for firmware updates. Firmware updates must be performed by an IASD.

IMPORTANT NOTE: The USB port is intended for use with a USB thumb drive only. The USB port is not intended for charging devices such as phones or laptops. Do not connect any consumer electronics to the USB port. Contact an IASD for any firmware updates.

The battery charger is integrated into the Power Zone 410 controller.

The battery charger verifies:

• Output is continually optimized to promote maximum battery life.
• Charging levels are safe.

NOTE: A warning message is displayed on the LCD when the battery requires service.

In AUTO, the GENERAC XG03245 starts automatically when the utility source voltage drops below the preset level. Loads are transferred to the standby power source once the unit starts.

Proceed as follows to select automatic operation:

1. Verify the transfer switch main contacts are set to UTILITY (loads connected to utility power source).

2. Verify normal utility power source voltage is available to the transfer switch terminal lugs N1, N2, and N3 (if three-phase).

3. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

4. Press AUTO on the controller. A green LED illuminates to verify the system is in AUTO.

If the controller is set to AUTO when utility power fails, a ten second startup delay timer is started (user programmable). If utility power is still absent when the time expires, the engine cranks and starts.

Once started, a (default five second) engine warm-up delay timer starts (user programmable). When time has elapsed, the load is transferred to the generator. If utility power is restored (above 90% of nominal, dealer programmable) between the time the engine is first started and expiration of the warm-up time, the controller completes the start cycle and then runs through its normal cool-down cycle (while the load remains on the utility source throughout the episode).

The cyclic cranking is controlled as follows: 15 seconds crank, seven seconds rest, seven seconds crank, seven seconds rest; this sequence is repeated for a total of six crank cycles.

When the GENERAC XG03245 is running, the transfer of load in Auto mode is dependent upon the operating mode as follows:

• Starts and runs if utility power fails (falls below 60% of nominal) for five consecutive seconds (adjustable).
• Starts a five second (adjustable) engine warm-up timer.
• Does not execute transfer if utility power returns before expiration of warm-up timer (but finishes warm-up and cool-down cycles).
• Transfers back to utility once utility power returns (above 80% of nominal) for 15 consecutive seconds.
• Only shuts down if OFF is pressed or an alarm shutdown occurs.
• Once utility power returns, starts a cool-down cycle before it shuts down.
• The GENERAC XG03245 has a belt-driven cooling fan. The electric fans turn on when the coolant temperature reaches 194 °F (90 °C).

NOTE: The cool-down cycle is five minutes if turbocharger equipped, one minute if naturally aspirated.

When the GENERAC XG03245 is running, the transfer of load in Exercise mode is dependent upon the operating mode as follows:

• Only works in AUTO.
• Does not exercise if the generator is already running in AUTO.
• During the exercise cycle, transfers only if utility power fails for ten consecutive seconds.
• The GENERAC XG03245 has a belt-driven cooling fan and is therefore always ON.

When the GENERAC XG03245 is running, the transfer of load in Manual mode is dependent upon the operating mode as follows:

• The engine cranks and runs even if utility power is present, but does not transfer to the generator.
• Transfers to the generator if utility fails (falls below 60% of nominal) for ten consecutive seconds.
• Transfers back to utility when utility returns for 15 consecutive seconds. The engine continues to run until AUTO or OFF is pressed.
• The GENERAC XG03245 has a belt-driven cooling fan and is therefore always ON. They stay ON in manual mode for diagnostic purposes.

Proceed as follows to manually transfer to standby power and start the GENERAC XG03245 when utility power fails:

1. Press OFF on the controller. A red LED illuminates to verify the system is OFF.

2. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

3. Turn off the utility power supply to the transfer switch using the means provided (such as a utility MLCB).

4. Use the manual transfer handle inside the transfer switch to set the main contacts to STANDBY (loads connected to standby power source).

5. Press MANUAL on the controller. The engine cranks and starts.

6. Allow the engine to run for two minutes to bring it up to normal operating temperature.

7. Set the generator MLCB (generator disconnect) to ON (CLOSED).

Proceed as follows to manually transfer back to utility power and shut down the GENERAC XG03245 when utility power is restored:

NOTE: Verify utility voltage has returned and is at the correct value.

1. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

2. Allow the engine to run for two minutes at no-load to bring it up to normal operating temperature.

3. Press OFF on the controller to shut down the engine. A red LED illuminates to verify the system is OFF.

4. Verify the utility power supply to the transfer switch is turned off.

5. Use the manual transfer handle inside the transfer switch to set the main contacts to UTILITY (loads connected to utility power source).

6. Turn on the utility power supply to the transfer switch using the means provided (such as a utility MLCB).

7. Press AUTO on the controller. A green LED illuminates to verify the system is in AUTO.

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. To obtain emissions control warranty service free of charge, the work must be performed by an IASD. See the emissions warranty.

It is important to perform all maintenance at the interval specified in the Service Maintenance Schedule. This verifies safe and correct operation, as well as compliance with applicable emissions standards.

Regular maintenance service points include:

• Oil level check: See Checking Lubricating Oil Level and Drain Hose.
• Oil drain: See Replacing Lubricating Oil and Oil Filter.
• Oil filter change: See Replacing Lubricating Oil and Oil Filter.
• Oil fill: See Replacing Lubricating Oil and Oil Filter.
• Air filter change: See Replacing Air Filter Element.
• Spark plug change: See Clean/Gap/Replace Spark Plugs.
• Coolant drain: See Draining and Flushing Coolant System.
• Coolant fill: See Draining and Flushing Coolant System.

The maintenance tasks and intervals are shown in the table below:

* Replace the battery every two years in extreme conditions.

NOTE: If the unit reaches a Schedule A or Schedule B maintenance interval with 900 to 999 total hours, have an IASD perform the Schedule C maintenance tasks as well (and reset the A-B-C / Year maintenance schedule counter).

For safety, follow the steps below prior to inspection, maintenance, or service:

1. Open the viewing window.

2. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

3. Verify both emergency shutdown switches are OFF (OPEN).

4. Press OFF on the controller. A red LED illuminates to verify the system is OFF.

5. Remove the T1 fuse from the transfer switch.

6. Pull up the rubber flap covering the fuse holder and remove the 7.5 amp fuse.

7. Disconnect the negative battery cable.

8. Place a DO NOT OPERATE tag or placard on both the control panel and transfer switch.

9. If the unit has been running, wait five minutes for the engine to cool.

Perform the following task:

• Replace the lubricating oil and oil filter. After the break-in period, it is recommended to use Generac’s propriety 5W-20 oil for continuous use. It is specifically formulated for use in gaseous powered Generac generators.

Perform the following tasks:

• Inspect enclosure slots.
• Inspect fuel lines.
• Inspect coolant level and hoses.
• Inspect radiator for clogging.
• Inspect lubricating oil level and drain hose.

Perform Schedule A maintenance once each year or after 150 hours of service, whichever comes first.

Preliminary Instructions:

1. See Remove From Service.

2. Remove maintenance access panel.

3. Remove the negative battery cable (black) from the negative (-) battery terminal.

Inspecting the Enclosure Slots:

1. Verify intake and exhaust slots and openings are clean and unobstructed. Keep clear of leaves, grass, snow, and debris.

2. Wipe exterior surfaces clean using a damp cloth.

3. Loosen dirt, oil, etc. with a soft bristled brush.

4. Remove loose dirt and debris using a vacuum cleaner, or low pressure compressed air (not exceeding 25 psi (172 kPa).

Inspecting the Fuel Lines:

1. Inspect fuel lines for leaks. Tighten fittings and clamps if necessary.

2. Inspect fuel lines for nicks, dents, kinks, or other damage. Replace as necessary.

Inspecting Coolant Level and Hoses:

1. Verify the coolant level is between HOT and COLD marks on the overflow reservoir.

2. If the coolant level is below the COLD mark, remove the fill cap from the overflow reservoir and add coolant.

3. Inspect the coolant hoses for leaks. Tighten hose clamps, if necessary.

4. Inspect hoses for nicks, cuts, tears, or general deterioration. Replace as necessary.

Inspecting Radiator for Clogging:

1. Use a flashlight to inspect the radiator fins.

2. Inspect for debris, accumulations of dirt, or other deposits.

3. Carefully remove any debris from radiator fins. Use warm soapy water and a soft bristled brush to remove dirt and other deposits, if necessary.

Checking Lubricating Oil Level and Drain Hose:

1. If the engine was running, wait at least ten minutes to verify the oil has fully drained into the oil pan.

2. Remove the oil dipstick and wipe dry with a clean, lint-free cloth.

3. Slowly insert the oil dipstick into the oil dipstick tube.

4. Verify the oil dipstick is fully seated in the oil dipstick tube.

5. Allow at least 10 seconds to elapse.

6. Slowly remove the oil dipstick.

7. Verify the oil level is at or near the FULL mark. Add oil as necessary.

8. If necessary, remove the oil fill cap and slowly add oil. Do not fill above the “FULL” mark on the oil dipstick.

9. Install the oil dipstick and oil fill cap.

10. Install the negative battery cable (black) onto the negative battery (-) terminal.

11. Pull up the rubber flap covering the fuse holder and install the 7.5 amp fuse.

12. Press MANUAL on the controller to start the engine.

13. Allow the engine to run for one minute.

14. Press OFF on the controller to shut down the engine. A red LED illuminates to verify the system is OFF.

15. Return to step 1.

16. Inspect the oil drain hose for leaks. Inspect the oil drain hose for nicks, cuts, tears, or general deterioration. Replace as necessary.

17. Pull up the rubber flap covering the fuse holder and remove the 7.5 amp fuse.

18. Remove the negative battery cable (black) from the negative battery (-) terminal.

Replacing Lubricating Oil and Oil Filter:

1. Remove the oil drain hose from the holding clamp.

2. Use one wrench to hold the hex on the oil drain hose fitting (to prevent rotation), and use the second wrench to remove the oil drain plug.

3. Drain oil into a suitable container.

4. Install the oil drain plug onto the end of the oil drain hose.

5. Install the oil drain hose into the holding clamp.

6. Turn the oil filter counterclockwise to remove it from the oil filter adapter.

7. Apply a light coat of clean engine oil to the gasket of the new oil filter.

8. Install the oil filter by hand until the gasket just contacts the oil filter adapter. Tighten the oil filter an additional three-quarters to one full turn.

9. Remove the oil fill cap and fill the engine with the recommended quantity and type of oil. The crankcase oil capacity is 11.6 qt (11 L) for the GENERAC XG03245.

10. Install the oil fill cap.

11. Install the negative battery cable (black) onto the negative (-) battery terminal.

12. Pull up the rubber flap covering the fuse holder and install the 7.5 amp fuse.

13. Press MANUAL on the controller to start the engine.

14. Allow the engine to run for one minute. Inspect for leaks while the engine is running.

15. Press OFF on the controller. A red LED illuminates to verify the system is OFF.

16. Wait 10 minutes for the engine to cool and to allow oil to drain back to the oil pan.

17. Check the oil level and add oil as necessary.

18. Install the oil fill cap.

Checking Battery Condition/Fluid Level (if applicable):

1. Verify the top of the battery is clean and dry. Clean the battery top with a solution of baking soda (sodium bicarbonate) and water (5 tsp baking soda per 1 L or 1 qt of water). When the solution stops bubbling, rinse off the battery with clean water.

2. Clean the cable clamps and battery terminals using a wire brush or sandpaper to remove any oxidation.

3. Inspect battery screws, clamps, and cables for breakage, loose connections, and corrosion. Tighten and clean as necessary.

4. Inspect battery posts for melting or damage caused by over tightening.

5. Inspect the battery for discoloration, a raised top, or a warped or distorted case, which might indicate the battery has been frozen, overheated, or overcharged.

6. Inspect the battery case for cracks or leaks.

7. Check the battery fluid level of unsealed batteries. Fill with distilled water only if necessary. DO NOT use tap water.

8. Verify the battery state of charge using a digital multimeter (DM). Recharge and retest if the state of charge is below the manufacturer’s recommendations. Replace the battery if necessary.

Battery Replacement – Removal:

1. Remove the negative battery cable (black) from the negative battery (-) terminal.

2. Remove the positive battery cable (red) from the positive battery (+) terminal.

3. Install the rubber protective cover over the positive (+) battery terminal.

4. Release the buckle on the nylon strap securing the battery to the generator frame.

5. Grasp the battery strap, and lift the battery from the battery tray.

6. Remove the rubber protective cover from the positive (+) battery terminal.

Battery Replacement – Installation:

1. Install the rubber protective cover over the positive (+) battery terminal.

2. Grasp the battery strap and lift the battery.

3. Set the battery onto the battery tray.

4. Tighten two screws with nylon washers to secure the hold-down clamp to the battery tray.

5. Remove the rubber protective cover from the positive (+) battery terminal.

6. Install the positive battery cable (red) to the positive (+) battery terminal.

7. Install the negative battery cable (black) to the negative (-) battery terminal.

Inspecting Accessory/Drive Belt:

1. Perform a visual inspection as follows:

• Inspect the belt for cracks, fraying, excessive wear, or other damage.
• Verify the belt is free of grease and oil.
• Replace the belt if contaminated, damaged, frayed, or worn.

2. Verify the fan belt deflection.

Replacing Air Filter Element:

1. Remove the nut and bolt from the air filter clamp, and loosen the elbow clamp to release the air cleaner.

2. Remove the air filter element and discard it.

3. Thoroughly clean the elbow of any dust, dirt, or debris.

4. Place the new air filter element into the elbow clamp.

5. Install the elbow clamp over the clamping surfaces and tighten. Install the nut and bolt from the air filter clamp, and tighten until snug.

Final Instructions (if only performing Schedule A maintenance):

1. Install the negative battery cable (black) onto the negative battery (-) terminal.

2. Install the left and right side access panels.

3. Return To Service.

The maintenance access panel side is identified as the front (service left). The control panel is therefore on the right (service rear) side of the generator. The exhaust is on the left (service front) side of the generator.

Proceed as follows to drain and flush the coolant system:

1. Disconnect and empty the coolant overflow reservoir.

2. Install and connect the coolant overflow reservoir.

3. Rotate and remove the plastic cover at the top of the enclosure.

4. Slowly unscrew the radiator cap.

5. Locate the drain screw at the bottom left side of the radiator.

6. Rotate the hex fitting to open the drain screw.

7. Remove the coolant drain hose from the holding clamp.

8. Use a wrench to hold the hex on the coolant hose fitting (to prevent rotation), and use a second wrench to remove the drain plug.

9. Drain the coolant into a suitable container.

10. Install the drain plug at the end of the coolant drain hose.

11. Install the coolant drain hose in the holding clamp.

12. Rotate the hex fitting to close the radiator drain screw.

13. Fill the radiator with de-ionized or distilled water (tap water contains minerals which can affect internal engine and cooling system components) and a commercially available cooling system flushing or cleaning product as required.

14. Install the radiator cap.

15. Press MANUAL on the controller to start the engine. A blue LED illuminates to verify the system is in MANUAL.

16. Allow the engine to run until the thermostat opens, as indicated by the heating of the top radiator hose.

17. Inspect coolant hoses for leaks. Tighten clamps, if necessary.

18. Press OFF on the controller to shut the engine down.

19. Allow the engine to cool.

20. Repeat steps 4 – 21 to drain and refill the cooling system.

21. Obtain the recommended quantity and type of coolant. Slowly unscrew the radiator cap. Slowly pour the coolant into the filler neck until the radiator is full.

22. Add coolant to the overflow reservoir.

Proceed as follows to clean, gap, or replace spark plugs:

1. Remove the negative battery cable (black) from the negative battery (-) terminal.

2. Remove the spark plug cables from the spark plug terminals. Always grasp and pull on the boot at the terminal end of the cable when disconnecting the spark plug cable from the spark plug terminal. Pulling on the cable portion can result in parts damage.

3. Thoroughly clean the area around the spark plugs.

4. Remove the spark plugs from the cylinder head using an appropriate spark plug socket wrench.

5. Inspect the condition of the threads in the cylinder head and on the spark plugs. If necessary, soften deposits with penetrating oil and clean out with a thread chaser.

6. Clean the spark plugs using a wire brush and commercial solvent. Do not blast spark plugs. Use new spark plugs if necessary.

7. Inspect the spark plug gap using a wire feeler gauge. Adjust the gap by carefully bending the ground electrode. The spark plug gap should be 0.012-0.017 in (0.31-0.45 mm).

8. Finger tighten the spark plugs into the cylinder head, and then using a spark plug socket, tighten as follows:

9. Install the spark plug cables onto the spark plug terminals.

10. Verify the spark plug cables are captured in the spark plug cable clips at the top of the valve cover.

Final Instructions (if only performing Schedule A and Schedule B maintenance procedures):

1. Install the negative battery cable (black) onto the negative battery (-) terminal.

2. Install the front (service left) access panels.

3. Return To Service.

Perform Schedule C maintenance after 1,000 hours of service. First perform all tasks listed under Schedule A Maintenance and Schedule B Maintenance before proceeding.

IMPORTANT NOTE: The following procedures require special tools and skills. Contact an IASD to perform these tasks.

1. Remove the negative battery cable (black) from the negative battery (-) terminal.

2. Proceed as follows:

• Tighten critical fasteners.
• Replace upper and lower radiator hoses.
• Replace engine coolant bypass hoses.
• Replace block heater hoses.

NOTE: Reset the A-B-C / Year time maintenance schedule counter using the Dealer Sub Menu (password required).

3. Install the negative battery cable (black) onto the negative battery (-) terminal.

4. Install the front access panel. Install the left and right side access panels.

5. Return To Service.

Proceed as follows to return the GENERAC XG03245 unit to service after inspection, maintenance, or service of the generator:

1. Pull up the rubber flap covering the fuse holder and install the 7.5 amp fuse.

2. Install the T1 fuse in the transfer switch.

3. Verify both emergency shutdown switches are ON (B).

4. Press AUTO on the controller. A green LED illuminates to verify the system is in AUTO.

5. Set the generator MLCB (generator disconnect) to ON (CLOSED), if equipped.

6. Close the viewing window.

7. Remove the DO NOT OPERATE tag or placard from both the control panel and transfer switch.

8. Reset the date/time.

If, during prolonged utility outages, the user wishes to remove the unit from service to conserve fuel, reduce run hours, or to perform maintenance tasks, then complete the steps listed below.

Proceed as follows to remove the generator from service while running in AUTO and online:

1. Turn the main utility disconnect to OFF (OPEN).

2. Open the viewing window.

3. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

4. Press OFF on the controller. A red LED illuminates to verify the system is in OFF mode.

NOTE: Complete the additional steps listed below if inspection and/or maintenance tasks are to be performed.

5. Remove the T1 fuse from the transfer switch.

6. Pull up the rubber flap covering the fuse holder and remove the 7.5 amp fuse.

7. Remove the negative battery cable (black) from the negative battery (-) terminal.

8. Place a DO NOT OPERATE tag or placard on both the control panel and transfer switch.

Proceed as follows to return the GENERAC XG03245 generator to service:

NOTE: Start with step 1 if inspection and/or maintenance tasks were performed. Start at step 5 if the unit was only shut down to conserve fuel or to reduce run hours.

1. Install the negative battery cable (black) onto the negative battery (-) terminal.

2. Pull up the rubber flap covering the fuse holder and install the 7.5 amp fuse.

3. Install the T1 fuse in the transfer switch.

4. Remove the DO NOT OPERATE tag or placard from both the control panel and transfer switch.

5. Press AUTO on the controller. A green LED illuminates to verify the system is in AUTO mode. Allow the generator to start and run for a few minutes.

6. Set the generator MLCB (generator disconnect) to ON (CLOSED), if equipped.

7. Set the utility MLCB to ON (CLOSED).

8. Close the viewing window.

Proceed as follows to prepare the GENERAC XG03245 for storage if the generator cannot be exercised every seven days and will be out of service longer than 90 days:

1. Open the viewing window.

2. Press MANUAL on the controller to start the engine. A blue LED illuminates to verify the system is in MANUAL.

3. Allow the engine to run until it reaches normal operating temperature.

4. Press OFF on the controller. A red LED illuminates to verify the system is OFF.

5. Set the generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

6. Pull up the rubber flap covering the fuse holder and remove the 7.5 amp fuse.

7. Turn off the utility power to the transfer switch.

8. Place a DO NOT OPERATE tag or placard on both the control panel and transfer switch.

9. Wait five minutes for the engine to cool.

10. Remove the front (service left) access panel.

11. Remove the oil drain hose from the holding clamp.

12. Use one wrench to hold the hex on the oil drain hose fitting (to prevent rotation), and use a second wrench to remove the oil drain plug.

13. Drain the oil into a suitable container.

14. Install the oil drain plug onto the end of the oil drain hose.

15. Install the oil drain hose into the holding clamp.

16. Turn the oil filter counterclockwise to remove it from the oil filter adapter.

17. Apply a light coat of clean engine oil to the gasket of the new oil filter.

18. Install the oil filter by hand until the gasket just contacts the oil filter adapter. Tighten the oil filter an additional three-quarters to one full turn.

19. Remove the oil fill cap and fill the engine with the recommended oil.

20. Install the oil fill cap.

Proceed as follows to remove the battery:

1. Remove the negative battery cable (black) from the negative battery (-) terminal.

2. Remove the positive battery cable (red) from the positive battery (+) terminal.

3. Remove two screws to release the battery hold-down clamp from the platform.

4. Remove the battery and store in a cool, dry room.

5. Install the left and right side access panels.

6. Thoroughly clean and wipe down the generator.

Proceed as follows to return the GENERAC XG03245 unit to service after storage:

1. Thoroughly clean and wipe down the generator.

2. Remove the left and right side access panels.

3. Install the battery onto the tray oriented with the negative (-) battery post toward the front of the enclosure.

4. Install two screws with nylon washers to secure the battery hold-down clamp to the tray.

5. Check the battery.

6. Install the positive battery cable (red) onto the positive battery (+) terminal.

7. Install the negative battery cable (black) onto the negative battery (-) terminal.

8. Check the oil level and add oil as necessary. DO NOT OVERFILL.

9. Open the viewing window.

10. Pull up the rubber flap covering the fuse holder and install the 7.5 amp fuse.

11. If the generator has a circuit breaker, set the MLCB (generator disconnect) to ON (CLOSED).

12. Press MANUAL on the controller to start the engine. A blue LED illuminates to verify the system is in MANUAL.

13. Allow the engine to run until it reaches normal operating temperature. Inspect for leaks while the engine is running.

14. Press OFF on the controller. A red LED illuminates to verify the system is OFF.

15. Install the front and rear access panels.

16. Turn on the utility power to the transfer switch.

17. Press AUTO on the controller. A green LED illuminates to verify the system is in AUTO.

18. Reset the date/time.

19. Close the viewing window.

Do NOT start and operate the generator if it has been submerged in water. Have an IASD thoroughly clean, dry, and inspect the generator following any submersion. If the structure (home) has been flooded, it should be inspected by a certified electrician to verify there won’t be any electrical problems during generator operation or when utility power is returned.

* It may take up to 15 minutes to establish a cellular connection.