GENERAC XG04045 (01) PDF Document

For quick and easy reference, copy the information printed on the Unit Identification Label onto the sample label printed here. The Unit Identification Label is located on the base frame adjacent to the front engine mount on all models.

Always provide the complete model number and serial number when contacting an Independent Authorized Service Dealer (IASD) about parts and/or service.

The GENERAC XG04045’s GENERATOR UNIT specifications are as follows. Fill in the required fields:

GEN MODEL:

MODEL:

SERIAL:

ALTERNATE NO:

PROD DATE:

COUNTRY OF ORIGIN:

The GENERAC XG04045’s GENERATOR DATA specifications are as follows. Fill in the required fields:

KW

KVA

HZ

PF

UPSIZE ALT

KW

KVA

VOLT

/

AMP

ENG RPM

ALT RPM

X’D

X”D

PHASE

UNBALANCED LOAD CAPACITY

ROTOR

STATOR

CLASS

WINDINGS @

AMBIENT TEMP

MANUF. LOC

The GENERAC XG04045 is designed to automatically supply electrical power to operate critical loads during a utility power failure.

This unit is factory installed in an all-weather enclosure intended exclusively for outdoor installation. This generator will operate using either vapor withdrawn liquid propane (LP gas) or natural gas (NG).

This generator is suitable for supplying typical residential/commercial loads, such as induction motors (sump pumps, refrigerators, freezers, air conditioners, furnaces, etc.), electronic components (computers, monitors, televisions, etc.), lighting, microwaves, and other residential and business loads, when sized correctly.

The GENERAC XG04045’s specifications are as follows:

Engine: 4.5 L NA

Rotor insulation: Class F

Stator insulation: Class H

Dimensions: 79.2 x 33.9 x 45.2 in (2,121 x 862 x 1,147 mm)

Product weight: 1,518 lb (689 kg)

LP fuel pressure: 7-14 in H2O (1.74-3.48 kPa)

NG fuel pressure: 3.5-14 in H2O (0.87-3.48 kPa)

Shipping weight: 1,644 lb (746 kg)

Engine System Type: In-line

Engine System Dry weight: 710 lb (322 kg)

Engine System Bore: 4.5 in (114 mm)

Engine System Stroke: 4.3 in (108 mm)

Engine System Displacement: 4.5 L

Engine System Firing order: 1-3-4-2

Engine System Direction or rotation: CW from flywheel

Engine System Compression ratio: 9.9:1

Engine System Spark plug gap: 0.012-0.017 in (0.31-0.45 mm)

Engine System Exercise Speed: 1,200 rpm

Engine System Operating Speed: 1,800 rpm

Cooling System Water pump: Belt driven

Cooling System Fan Type: Belt driven

Cooling System Fan Mode: Pusher

Cooling System Coolant capacity: 2.9 US gal (11 L)

Cooling System Max ambient air temperature: 122 °F (50 °C)

Lubricating System Oil pump type: Gear

Lubricating System Oil filter type: Full flow spin-on cartridge

Lubricating System Crankcase oil capacity: 2.9 US gal (11 L)

Lubricating System Lubricating oil type: Generac 5W-20

Air Intake System Type: Naturally aspirated

Exhaust System Breather: Closed

Electrical System Battery charge alternator: 12V, 35 amp

Electrical System Recommended battery: Group 27

Electrical System Smart battery charger: 5 Amp

Governor System Type: Electronic

Governor System Frequency regulation: Isochronous

Governor System Steady state regulation: ± 0.25%

Voltage Regulator Type: Electronic

Voltage Regulator Sensing phase: single-phase

Voltage Regulator Regulation: ± 1%

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 XG04045 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 generator. See Service Maintenance Schedule for regular maintenance intervals.

The battery requirements for the GENERAC XG04045 are as follows:

• Group 27, 12 volt: 4.5 L Engine: For operating environment 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).
• Group 31, 12 volt: Upgrade option for 4.5 L Engine: 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).

When working with the GENERAC XG04045, observe the following battery safety precautions:

• 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.
• 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.

Periodically wash and wax the enclosure using automotive type products. Frequent washing is recommended in salt water/coastal areas. Use All Surface Protectant on all vinyl, rubber, and plastics to create a barrier which seals and protects the surface from water and UV rays.

The front (service left) side of the GENERAC XG04045 generator has the service access panel with Generac logo. The control panel is on the right (service rear) side of the generator.

Access panels are located at both the front (service left) and rear (service right) sides of the enclosure. The front access panel requires a key and the rear access panel has bolts.

Proceed as follows to remove the front access panel:

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

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

3. Raise panel using thumb latch.

Proceed as follows to install the battery:

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 (+) battery terminal.

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

Proceed as follows to open the viewing window:

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

2. Lift viewing window to access controls.

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

Proceed as follows to attach radio harness to cellular accessory:

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

2. Finger-tighten nut on the radio harness.

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

Proceed as follows to attach cellular accessory to mounting plate:

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

2. Press cellular accessory flush with mounting plate.

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

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

The unit activation process involves setting the language, activation mode, pass code entry, date/time, fuel type selection, and exercise time.

Language Selection:

• Display Reads: Language – English +
• Use Up arrow or Down arrow to scroll to desired language. Press ENTER.

Activation Mode:

• Display Reads: Activate me (ENT) or ESC to run in manual
• Press ENTER.

Pass Code:

• Display Reads: SN 1234567890 PASS CODE XXXXX
• 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.

Date/Time:

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

Fuel Selection:

• Display Reads: Fuel Selection – LP + – NG +
• Use UP or DOWN arrow to index the correct fuel type. Press ENTER.

Exercise Time:

• Display Reads: Quiet Test Mode? Yes No
• Use Up arrow or Down arrow to select either Yes or No. Press ENTER.
• Display Reads: Select Hour (0-23) – 1 +
• Set Exercise Time. 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 scroll to the day of the week. Press ENTER.

Proceed as follows to start and run the engine:

1. Pull up rubber flap covering fuse holder and verify installation of 7.5 amp fuse (A).

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

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

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

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

Proceed as follows to complete electrical checks:

1. Verify GENERAC XG04045 is in OFF mode. A red LED on the controller illuminates to verify system is OFF.

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

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

4. Turn on utility power supply to 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 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 engine.

9. Allow engine to warm up for approximately five minutes. Set 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 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 system is three-phase.

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

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

The GENERAC XG04045 generator 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. Generators are equipped with two emergency shutdown switches. One emergency shutdown switch is located on the front at the top right corner just below the roof. The second emergency shutdown switch is inside the control panel enclosure on the Power Zone 410 controller.

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 engine running, set one emergency shutdown switch to OFF (O). Engine should shut down immediately.

4. If engine stops, set emergency shutdown switch to ON (I), clear alarm on controller, and restart engine to verify generator is operating normally. After verifying normal operation of the first emergency switch, verify operation of the second emergency switch.

5. If engine does not stop, emergency shutdown switch is not functioning correctly. Contact an IASD.

Proceed as follows to test GENERAC XG04045 generator set with electrical loads applied:

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

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

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

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

5. Press MANUAL on the controller. Engine will crank and start.

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

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

8. Turn on circuit breaker/electrical loads supplied by 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 clamp on amp meter to verify unit is not overloaded.

10. Allow 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 generator MLCB (generator disconnect) to OFF (OPEN), if equipped.

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

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

Proceed as follows to check system for correct automatic operation:

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

2. Install front cover of transfer switch.

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

4. Set 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 utility power supply to transfer switch.

With GENERAC XG04045 generator ready for automatic operation, engine will crank and start when utility source power is turned off after a 10 second delay (factory default setting). After starting, transfer switch connects load circuits to standby side. Allow system to operate through its entire automatic sequence of operation.

With GENERAC XG04045 generator running and loads powered by generator AC output, turn on utility power supply to transfer switch. The system transfers back to utility position and then runs through cool down cycle and shuts down.

Proceed as follows to secure the generator:

1. Use key to install side access panel.

2. Close viewing window.

3. Install customer supplied padlock into viewing window hasp.

The operating modes of the GENERAC XG04045 controller are:

The menu navigation features are:

The GENERAC XG04045 alerts the owner/operator to Alarm and/or Warning conditions via the controller screen. All Alarm conditions cause the 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

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

A programmable exercise time is provided. In AUTO, engine starts and runs once each week at time and day specified. During exercise cycle, unit runs approximately five minutes and then shuts down. Transfer of loads to generator does not occur unless utility power fails. A dealer password is required to change duration of 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 utility volts low threshold, timer is reset. If utility voltage remains below utility volts low threshold during the duration of the timer, unit cranks and starts. 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 generator starts, the warm-up timer starts. When the warm-up timer expires, controller transfers load to generator (through transfer switch) if utility voltage is less than 80% of nominal. If utility voltage is greater than threshold at expiration of warm-up timer, load is not transferred to generator and a cool-down period begins. At the end of the cool-down period, generator stops. Factory default setting is five seconds, but is adjustable from 5 to 1,500 seconds.

In AUTO, the GENERAC XG04045 generator starts automatically when utility source voltage drops below preset level. Loads are transferred to standby power source once unit starts.

Proceed as follows to select automatic operation:

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

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

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

4. Press AUTO on the controller. A green LED illuminates to verify 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 time expires, engine cranks and starts.

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

With the GENERAC XG04045 generator running, transfer of load when set to Auto 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.
• GENERAC XG04045 has a belt-driven cooling fan. The electric fans turn on when the coolant temperature reaches 194 °F (90 °C).

Cool-down cycle is five minutes if turbocharger equipped, one minute if naturally aspirated.

With the GENERAC XG04045 generator running, transfer of load when in Exercise mode is dependent upon the operating mode as follows:

• Only works in AUTO.
• Does not exercise if generator is already running in AUTO.
• During exercise cycle, transfers only if utility power fails for ten consecutive seconds.
• GENERAC XG04045 has a belt-driven cooling fan and is therefore always ON.

With the GENERAC XG04045 generator running, transfer of load when set to Manual is dependent upon the operating mode as follows:

• Engine cranks and runs even if utility power is present, but does not transfer to generator.
• Transfers to generator if utility fails (falls below 60% of nominal) for ten consecutive seconds.
• Transfers back to utility when utility returns for 15 consecutive seconds. Engine continues to run until AUTO or OFF is pressed.
• GENERAC XG04045 has a belt-driven cooling fan and is therefore always ON.

Proceed as follows to manually transfer to standby power and start the GENERAC XG04045 generator when utility power fails:

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

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

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

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

5. Press MANUAL on the controller. Engine cranks and starts.

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

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

Proceed as follows to manually transfer back to utility power and shut down the GENERAC XG04045 generator when utility power is restored:

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

2. Allow 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 engine.

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

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

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

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

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.

The location of maintenance items are:

Proceed as follows to remove the access panels:

1. Insert key (B) into thumb (A) latch and rotate counterclockwise one-half turn.

2. Raise panel using thumb latch.

Proceed as follows to install the access panels:

1. Lower panel into position using thumb latch.

2. Insert key into latch and rotate clockwise one-half turn.

The regular maintenance service points for the GENERAC XG04045 are:

• 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 GENERAC XG04045 Service Maintenance Schedule tasks and intervals are shown in the table below:

* Replace battery every two years in extreme conditions.

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

1. Open viewing window.

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

3. Verify both emergency shutdown switches are OFF (OPEN) and on the control panel.

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

5. Remove T1 fuse from transfer switch.

6. Pull up rubber flap (A) covering fuse holder and remove 7.5 amp fuse.

7. Disconnect negative battery cable.

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

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

Perform the following task:

• Replace lubricating oil and oil filter. After 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.

Preliminary Instructions for Schedule A Maintenance:

1. Remove GENERAC XG04045 from Service.

2. Remove maintenance access panel.

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

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).

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.

Proceed as follows to inspect the coolant level and hoses:

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

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

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

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

Proceed as follows to check 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.

Proceed as follows to check oil level and oil drain hose:

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

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

3. Slowly insert oil dipstick into oil dipstick tube.

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

5. Allow at least 10 seconds to elapse.

6. Slowly remove oil dipstick (A).

7. Verify oil level is at or near FULL mark (A). Add oil as necessary.

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

9. Install oil dipstick and oil fill cap.

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

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

12. Press MANUAL on the controller to start engine.

13. Allow engine to run for one minute.

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

15. Return to step 1.

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

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

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

Complete this procedure once yearly, or every 150 hours of operation, whichever comes first.

Proceed as follows to replace lubricating oil and oil filter:

1. Remove oil drain hose from holding clamp (C).

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

3. Drain oil into a suitable container.

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

5. Install oil drain hose into holding clamp.

6. Turn oil filter (B) counterclockwise to remove from oil filter adapter.

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

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

9. Remove oil fill cap and fill engine with the recommended quantity and type of oil. Crankcase oil capacity is 11.6 qt (11 L) for the GENERAC XG04045.

10. Install oil fill cap.

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

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

13. Press MANUAL on the controller to start engine.

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

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

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

17. Check oil level and add oil as necessary.

18. Install oil fill cap.

1. Verify top of battery is clean and dry. Dirt and electrolyte on top of the battery can cause battery to self-discharge. Clean 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 solution stops bubbling, rinse off the battery with clean water.

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

6. Inspect battery case for cracks or leaks.

7. Check battery fluid level of unsealed batteries.

Check the fluid level of unsealed batteries. If necessary, fill with distilled water only. DO NOT use tap water.

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

Proceed as follows to remove the battery:

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

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

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

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

5. Grasp battery strap (B), and lift battery from battery tray.

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

Proceed as follows to install the battery:

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

2. Grasp battery strap and lift battery.

3. Set battery onto battery tray.

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

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

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

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

The GENERAC XG04045 units are provided with an automatic belt tensioner and do not need adjustment.

Proceed as follows to inspect accessory/drive belt condition:

1. Perform visual inspection as follows:

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

2. Verify fan belt deflection.

Proceed as follows to replace air filter element:

1. Remove nut (B) and bolt (C) from air filter clamp, and loosen elbow clamp (D) to release air cleaner.

2. Remove air filter element (A) and discard.

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

4. Place new air filter element into elbow clamp.

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

Proceed as follows if only performing Schedule A maintenance procedures:

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

2. Install left and right side access panels.

3. Return To Service.

Perform Schedule B maintenance every two years or after 300 hours of service, whichever comes first. Before proceeding below, first perform all tasks listed under Schedule A Maintenance.

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 coolant overflow reservoir.

2. Install and connect coolant overflow reservoir.

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

4. Slowly unscrew radiator cap.

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

6. Rotate hex fitting to open drain screw (A).

7. Remove coolant drain hose from holding clamp.

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

9. Drain coolant into a suitable container.

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

11. Install coolant drain hose in holding clamp.

12. Rotate hex fitting to close radiator drain screw.

13. Fill radiator (B) 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 radiator cap.

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

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

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

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

19. Allow engine to cool.

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

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

22. Add coolant to the overflow reservoir.

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

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

2. Remove spark plug cables (C) from spark plug terminals (D).

3. Thoroughly clean area around spark plugs.

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

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

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

7. Inspect spark plug gap using a wire feeler gauge. Adjust gap by carefully bending ground electrode as follows:

Model: GENERAC XG04045

Engine: 4.5 L

Spark Plug Gap: 0.012-0.017 in (0.31-0.45 mm)

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

Engine: 4.5 L

Torque: 28 ft-lb (38 Nm)

9. Install spark plug cables onto spark plug terminals.

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

Proceed as follows if only performing Schedule A and Schedule B maintenance procedures:

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

2. Install front (service left) access panels.

3. See 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.

1. Remove negative battery cable (black) from 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.

Proceed as follows to return the GENERAC XG04045 unit to service after inspection, maintenance, or service of the generator:

1. Pull up rubber flap (C) covering fuse holder and install 7.5 amp fuse.

2. Install T1 fuse in transfer switch.

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

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

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

6. Close viewing window.

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

8. Reset date/time.

If, during prolonged utility outages, the user wishes to remove 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 generator from service while running in AUTO and online:

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

2. Open viewing window.

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

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

5. Remove T1 fuse from transfer switch.

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

7. Remove negative battery cable (black) from 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 generator to service:

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

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

3. Install T1 fuse in 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 system is in AUTO mode. Allow generator to start and run for a few minutes.

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

7. Set utility MLCB to ON (CLOSED).

8. Close viewing window.

Proceed as follows to prepare for storage if GENERAC XG04045 generator cannot be exercised every seven days and will be out of service longer than 90 days:

1. Open viewing window.

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

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

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

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

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

7. Turn off utility power to transfer switch.

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

9. Wait five minutes for engine to cool.

10. Remove front (service left) access panel.

11. Remove oil drain hose from holding clamp.

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

13. Drain oil into a suitable container.

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

15. Install oil drain hose into holding clamp.

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

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

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

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

20. Install oil fill cap.

Proceed as follows to remove the battery:

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

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

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

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

5. Install left and right side access panels.

6. Thoroughly clean and wipe down generator.

Proceed as follows to return GENERAC XG04045 unit to service after storage:

1. Thoroughly clean and wipe down generator.

2. Remove left and right side access panels.

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

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

5. Check battery.

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

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

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

9. Open viewing window.

10. Pull up rubber flap covering fuse holder and install 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 engine. A blue LED illuminates to verify system is in MANUAL.

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

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

15. Install front and rear access panels.

16. Turn on utility power to transfer switch.

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

18. Reset date/time.

19. Close the viewing window.

Do NOT start and operate the GENERAC XG04045 generator if it has been submerged in water. Have an IASD thoroughly clean, dry, and inspect the generator following any submersion. If 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.

Possible causes and corrections when the GENERAC XG04045 engine does not crank:

Possible causes and corrections when the GENERAC XG04045 engine cranks but will not start:

Possible cause and correction when the GENERAC XG04045 engine starts hard and runs rough:

Possible causes and corrections when the GENERAC XG04045 unit is set to OFF, but engine continues to run:

Possible causes and corrections when the GENERAC XG04045 has No AC output from the generator:

Possible causes and corrections when the GENERAC XG04045 has No transfer to standby after utility source failure:

Possible causes and corrections when the GENERAC XG04045 unit consumes large amounts of oil:

The GENERAC XG04045 Controller Active Alarms troubleshooting:

The Generac Mobile Link™ troubleshooting for the GENERAC XG04045:

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