GENERAC XG04845 (01) PDF Document

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 (A).

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.

The following steps verify the Cellular Accessory Functionality:

• 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. See Generac Mobile Link™ Troubleshooting guide.

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.

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 GENERAC XG04845, 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 generator controller for this test to be performed and pass.

Complete the following before starting:

1. Verify generator is OFF. A red LED on the controller illuminates to verify 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).

DANGER: Electrocution. High voltage is present at transfer switch and terminals. Contact with live terminals will result in death or serious injury.

See Manual Transfer Operation section of owner’s manual for procedures.

DANGER: Electrocution. High voltage is present at transfer switch and terminals. Contact with live terminals will result in death or serious injury.

Proceed as follows to complete electrical checks:

1. Verify generator 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.

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

The GENERAC XG04845 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 (A) is located on the front at the top right corner just below the roof. The second emergency shutdown switch (B) 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.

• 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.

• If engine does not stop, 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 generator under normal operating conditions. Accidental activation of an emergency shutdown switch will prevent generator from operating during a power outage.

DANGER: Electrocution. Do not manually transfer under load. Disconnect transfer switch from all power sources prior to manual transfer. Failure to do so will result in death or serious injury, and equipment damage.

Proceed as follows to test GENERAC XG04845 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).

NOTE: Transfer switch will transfer to UTILITY.

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 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 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.

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

3. Install customer supplied padlock into viewing window hasp.

The owner/operator is alerted to Alarm and/or Warning conditions via the controller screen. All Alarm conditions cause the GENERAC XG04845 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:

Use the 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 utility volts low threshold, the timer is reset. If utility voltage remains below utility volts low threshold during the duration of the timer, the unit cranks and starts.

NOTE: 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 load to the generator (through the transfer switch) if utility voltage is less than 80% of nominal. If utility voltage is greater than the threshold at the expiration of the warm-up timer, 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: Factory default setting is five seconds, but is adjustable from 5 to 1,500 seconds.

Over-the-air-Firmware-Updates: The XG series generators include 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.

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

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.

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.

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

DANGER: Electrocution. Do not manually transfer under load. Disconnect transfer switch from all power sources prior to manual transfer. Failure to do so will result in death or serious injury, and equipment damage.

Proceed as follows to manually transfer to standby power and start the 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 generator when utility power is restored:

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

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.

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.

Regular maintenance service points:

• 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.

* Replace 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).

WARNING: Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury.

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

IMPORTANT NOTE: If currently experiencing a utility outage, see Removal From Service During Utility Outage for special instructions.

1. Open viewing window. See Opening the Control Panel Cover-Viewing Window.

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

Perform the following task:

• Replace 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.

NOTE: See Replacing Lubricating Oil and Oil Filter under Schedule A Maintenance.

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.

NOTE: See Inspecting the Enclosure Slots through Inspecting Coolant Level and Hoses under Schedule A Maintenance.

NOTE: 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. See Access Panels.

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).

NOTE: Periodically wash and wax enclosure using automotive type products. Frequent washing is recommended in salt water or coastal areas.

WARNING: Risk of Burn. Allow the engine to cool before performing the following procedure. Failure to do so could result in serious injury.

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.

WARNING: Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury.

Proceed as follows to inspect the coolant level and hoses:

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

NOTE: Coolant expands when hot, so coolant level may be higher than the HOT mark. Do not add coolant higher than the HOT mark.

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

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

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

WARNING: Risk of burns. Do not open coolant system until engine has completely cooled. Doing so could result in serious injury.

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.

NOTE: If changing engine lubricating oil and filter, see Replacing Lubricating Oil and Oil Filter.

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.

NOTE: The most accurate oil level readings are obtained when the engine is cold.

2. Remove oil dipstick (D) 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.

NOTE: Some oil dipsticks require more effort to fully seat than others.

5. Allow at least 10 seconds to elapse.

6. Slowly remove oil dipstick (A).

7. Verify oil level is at or near the 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.

NOTE: The most common reasons for inaccurate oil level readings are:

• Reading oil dipstick before oil has fully drained into oil pan.

• Inserting and removing oil dipstick too quickly.

• Reading oil dipstick when it has not been fully seated in the oil dipstick tube.

• Reading only the high level side of the oil dipstick.

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.

WARNING: Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury.

WARNING: Skin Irritation. Avoid prolonged or repeated contact with used motor oil. Used motor oil has been shown to cause skin cancer in laboratory animals. Thoroughly wash exposed areas with soap and water.

NOTE: 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 the hex on the oil drain hose fitting (to prevent rotation), and use a second wrench to remove the oil drain plug.

3. Drain oil into a suitable container.

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

5. Install oil drain hose into the holding clamp.

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

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

8. Install 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. Crankcase oil capacity is 11.6 qt (11 L).

10. Install the oil fill cap.

11. Install 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. See Checking Lubricating Oil Level and Drain Hose.

18. Install the oil fill cap.

NOTE: Dispose of used oil and oil filter in accordance with local, state, or national laws.

1. Verify the top of the battery is clean and dry. Dirt and electrolyte on top of the battery can cause the battery to self-discharge. 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 the battery screws, clamps, and cables for breakage, loose connections, and corrosion. Tighten and clean as necessary.

4. Inspect the 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. See Checking Fluid Level.

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 multi-meter (DM). Recharge and retest if the state of charge is below the manufacturer’s recommendations. Replace the battery if necessary.

WARNING: Electrical shock. Disconnect battery ground terminal before working on battery or battery wires. Failure to do so could result in death or serious injury.

WARNING: Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury.

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.

WARNING: Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury.

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.

NOTE: If continuing with Schedule A maintenance procedures, leave the negative battery cable (black) disconnected.

NOTE: The GENERAC XG04845 unit is provided with an automatic belt tensioner and does not need adjustment.

Proceed as follows to inspect the 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.

NOTE: Use a solution of soap and warm water to clean pulleys, if necessary. Avoid use of solvents, but if used, always follow by a soap and water wash.

2. Verify fan belt deflection.

Proceed as follows to replace the air filter element:

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

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

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

NOTE: Service kits are available from an IASD.

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. See Access Panels.

3. See Return To Service.

NOTE: 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.

WARNING: Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury.

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.

NOTE: If the unit is not equipped with a drain hose, install a suitable length of rubber hose to the drain screw.

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

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 (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 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 the 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. See Coolant Water Treatment. Slowly unscrew the radiator cap. Slowly pour coolant into the filler neck until the radiator is full.

22. Add coolant to the overflow reservoir. See Inspecting Coolant Level and Hoses.

23. Install the plastic cover at the top of the enclosure and rotate until tight.

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

WARNING: Electric shock. Do not disconnect spark plug wires with engine running. Doing so could result in death or serious injury.

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

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

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

NOTE: 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 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 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 to a torque of 28 ft-lb (38 Nm).

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

10. Verify spark plug cables are captured in the spark plug cable clips at the top of the 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. See Access Panels.

3. See Return To Service.

NOTE: 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 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.

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

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

4. Install front access panel. Install left and right side access panels. See Access Panels.

5. See Return To Service.

Proceed as follows to return the 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 the 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 the unit from service to conserve fuel, reduce run hours, or to perform maintenance tasks, then complete the steps listed below.

IMPORTANT NOTE: Failure to abide by this procedure can result in equipment damage.

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. See Opening the Control Panel Cover-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.

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

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 the 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 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 the transfer switch.

4. Remove the DO NOT OPERATE tag or placard from both the control panel and the 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 generator MLCB (generator disconnect) to ON (CLOSED), if equipped.

7. Set utility MLCB to ON (CLOSED).

8. Close the viewing window.

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

1. Open viewing window. See Opening the Control Panel Cover-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 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 utility power to the transfer switch.

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

9. Wait five minutes for the engine to cool.

10. Remove the front (service left) access panel. See Access Panels.

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. See Engine Oil Recommendations.

20. Install the oil fill cap.

NOTE: Dispose of used oil and oil filter in accordance with local, state, or national laws.

WARNING: Explosion. Batteries emit explosive gases. Always disconnect the negative battery cable first to avoid spark. Failure to do so could result in death or serious injury.

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. See Access Panels.

6. Thoroughly clean and wipe down the generator. See Corrosion Protection.

WARNING: Explosion. Batteries emit explosive gases. Always connect the positive battery cable first to avoid spark. Failure to do so could result in death or serious injury.

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

1. Thoroughly clean and wipe down the generator. See Corrosion Protection.

2. Remove the left and right side access panels. See 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. See Checking Battery Condition/Fluid Level.

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. See Opening the Control Panel Cover-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. See 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 GENERAC XG04845 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.