Generac Power Systems XG03245 Owner's Manual

Spark-ignited stationary generators

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Spark-Ignited Stationary Generators

Residential and Commercial

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Owner's Manual

WARNING

Loss of life. This product is not intended to

be used in a critical life support application.

Failure to adhere to this warning could result

in death or serious injury.

WWW.GENERAC.COM

1-888-GENERAC

(888–436–37722)

MODELS:

XG03245

XG04045

XG04845

(W000209)

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Summary of Contents for Generac Power Systems XG03245

Page 1 Owner’s Manual Spark-Ignited Stationary Generators Residential and Commercial MODELS: XG03245 XG04045 XG04845 WARNING Loss of life. This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury.
Page 2 Use this page to record important information about the generator. GENERATOR UNIT For quick and easy reference, copy the information printed on the Unit Identification Label onto the sample la- GEN MODEL: bel printed here. The Unit Identification Label is located MODEL: on the base frame adjacent to the front engine mount on SERIAL:...
Page 3: Table Of Contents
Table of Contents Attaching Cellular Accessory to Mounting Section 1: Safety Rules & General Plate ..............16 Information Verifying Cellular Accessory Functionality ....16 Introduction ............5 Activating the Unit..........17 Read This Manual Thoroughly ........5 Starting and Running Engine......18 Safety Rules ............5 Operational Checks ..........
Page 4 Removal of Front (Service Left Access Battery Removal ............49 Panel) ..............32 Return From Storage ..........49 Installation of Front (Service Left) ......32 Attention After Submersion ....... 49 Maintenance............32 Regular maintenance service points .......32 Service Maintenance Schedule ......34 Remove From Service......... 34 25 Hour Break-In..........
Page 5: Section 1: Safety Rules & General Information
Safety Rules & General Information Section 1: Safety Rules & General Information Introduction specifically recommend, verify that it is safe for others and does not render the equipment unsafe. Thank you for purchasing this compact, high perform- Throughout this publication, and on tags and decals af- ance, liquid-cooled, engine-driven generator.
Page 6: General Hazards
Safety Rules & General Information General Hazards WARNING Injury and equipment damage. Do not use generator as DANGER a step. Doing so could result in falling, damaged parts, Loss of life. Property damage. Installation must always unsafe equipment operation, and could result in death or comply with applicable codes, standards, laws and regu- serious injury.
Page 7: Electrical Hazards
Safety Rules & General Information WARNING DANGER Fire hazard. Use only fully-charged fire extin- Electrocution. In the event of electrical acci- guishers rated “ABC” by the NFPA. Dis- dent, immediately shut power OFF. Use non- charged or improperly rated fire conductive implements to free victim from extinguishers will not extinguish electrical live conductor.
Page 8: Battery Hazards
Safety Rules & General Information Battery Hazards DANGER Electrocution. Do not wear jewelry while working on this equipment. Doing so will re- sult in death or serious injury. (D000188) WARNING Explosion. Do not dispose of batteries in a fire. Batteries are explosive. Electrolyte solu- tion can cause burns and blindness.
Page 9: Section 2: General Information
Figure 2-1. Emissions Data Plate (Sample) Cooling System Specifications Water pump Belt driven Belt driven Belt driven Fan Type Belt driven Belt driven 3X Electric Model XG03245 XG04045 XG04845 Engine Fan Mode Pusher Pusher Pusher 4.5 L NA 4.5 L NA 4.5 L NA Coolant 2.9 US gal...
Page 10: Engine Oil Recommendations
General Information 7-14 in H 7-14 in H 7-14 in H LP fuel (1.74-3.48 (1.74-3.48 (1.74-3.48 pressure Model XG03245 XG04045 XG04845 kPa) kPa) kPa) Engine 4.5 L NA 4.5 L NA 4.5 L NA 3.5-14 in 3.5-14 in 3.5-14 in NG fuel O (0.87-...
Page 11: Voltage Configuration Cartridges
General Information required for the generator function or for the UL listing. WARNING The Power Zone 410 controller provides overcurrent pro- Risk of burns. Do not open coolant system tection for the generator thereby eliminating the need for until engine has completely cooled. Doing so a circuit breaker.
Page 12: Controller Fuel Type Selection
General Information Controller fuel type selection WARNING Risk of burns. Batteries contain sulfuric acid Navigate to the appropriate menu in the controller to se- and can cause severe chemical burns. Wear lect the fuel type to configure the fuel system. The fuel se- protective gear when working with batteries.
Page 13: Corrosion Protection
General Information • Stationary emergency generators installed with au- tomatic transfer switches will crank and start auto- matically 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 cor- rect and system is ready to be placed into operation to prevent automatic startup and possible injury to personnel.
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Page 15: Section 3: Activation And Startup
Activation and Startup Section 3: Activation and Startup Orientation 3. Raise panel using thumb latch. NOTE: The XG04845 unit is depicted in the artwork used Installing the Battery in this manual. The location and appearance of some components may vary between models. WARNING Figure 3-1.
Page 16: Installing Generac Generator Connectivity Accessory Cellular (Ggcac) Device
Activation and Startup Verifying Cellular Accessory Functionality 3. See Figure 3-4. To hold viewing window open, ro- tate prop up and insert into stop in cover (A). • Green LED on cellular accessory face will illumi- Figure 3-4. nate once the radio harness is fully connected. •...
Page 17: Activating The Unit
Activation and Startup Activating the Unit Display Reads: Generator Active is displayed on the If the wrong language is selected, it may LCD during initial startup. After displaying be changed later using the Edit menu. firmware and hardware version codes, as Language AUXILIARY SHUTDOWN well as other system information, the In-...
Page 18: Starting And Running Engine
Activation and Startup Display Reads: Set the Voltage for a three-Phase Unit. Only available three-phase configurations. Select Voltage Use Up arrow or Down arrow to select Set Alternator Node the correct voltage. Press ENTER. The selection must match the installed 120/208 VAC (3P) (VCC) installed in the unit.
Page 19: Checking Manual Transfer Switch Operation
Activation and Startup 5. Check coolant and engine lubricating oil levels. 10. Connect an accurate AC frequency meter across Inspecting Coolant Level and Hoses transfer switch terminal lugs E1, E2, and E3 (if Checking Lubricating Oil Level and Drain Hose. three-phase) and verify correct rated frequency (50 Hz or 60 Hz).
Page 20: Testing Generator Under Load
Activation and Startup 2. Press MANUAL on the controller to start the 10. Allow generator to run at full rated load for 20– 30 engine. minutes. Listen for unusual noises, vibration, or other indications of abnormal operation. Inspect for 3. With engine running, set one emergency shutdown oil leaks, evidence of overheating, etc.
Page 21: Securing The Generator
Activation and Startup Securing the Generator Proceed as follows to secure the generator: 1. Use key to install side access panel. 2. Close viewing window. NOTE: See Figure 3-7. Obtain viewing window hasp (A), if not installed. See Figure 3-8. From backside (interior) of panel, remove fastener (B) as shown.
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Page 23: Section 4: Operation
Operation Section 4: Operation Control Panel IMPORTANT NOTE: With controller set to AUTO, en- gine may crank and start at any time without warning. DANGER Such automatic starting occurs during the pro- grammed exercise cycle or when utility power source Automatic start-up.
Page 24: Auto/Manual/Off
Operation AUTO/MANUAL/OFF Description Feature Activates fully automatic operation. Green LED illuminates to verify system is in AUTO. Transfer to standby AUTO power occurs if utility power fails. Functionality of exercise timer is enabled, if set. Cranks and starts engine. Blue LED illuminates to verify system is in MANUAL. Transfer to standby power MANUAL occurs if utility power fails.
Page 25 Operation Figure 4-2. 019298 Figure 4-2. Navigation Menu Spark-Ignited Stationary Generators Owner’s Manual...
Page 26: Alarm/Warning Conditions
Operation Alarm/Warning Conditions specified. During exercise cycle, unit runs approximately five minutes and then shuts down. Transfer of loads to The owner/operator is alerted to Alarm and/or Warning generator does not occur unless utility power fails. conditions via the controller screen. All Alarm conditions NOTE: A dealer password is required to change duration cause the generator to shut down.
Page 27: Battery Charger
Operation Battery Charger warm-up time, controller completes the start cycle and then runs through its normal cool-down cycle (while load NOTE: Battery charger is integrated into the Power Zone remains on utility source throughout the episode). 410 controller. Cranking The battery charger verifies: •...
Page 28: Load Transfer
Once utility power returns, starts a cool-down cycle before it shuts down. • XG03245 and XG04045 each have a belt-driven cooling fan; XG04845 has three electric cooling fans. Auto The electric fans turn on when the coolant temperature reaches 194 °F (90 °C).
Page 29: Transfer Switch Manual Operation
Operation Transfer Switch Manual Operation Transfer Back to Utility Power Proceed as follows to manually transfer back to utility DANGER power and shut down generator when utility power is Electrocution. Do not manually transfer under restored: load. Disconnect transfer switch from all power sources prior to manual transfer.
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Page 31: Section 5: Maintenance
Maintenance Section 5: Maintenance Component Locations NOTE: The XG04845 unit is depicted in the artwork used in this manual. The location and appearance of some compo- nents may vary between models. The viewing window side of the enclosure is identified as the rear of the generator. The right and left sides are identified by standing at the rear and looking towards the front of the unit.
Page 32: Access Panels
Regular maintenance will improve performance and ex- 1. See Figure 5-4. Insert key (B) into thumb (A) latch tend engine/equipment life. Generac Power Systems, and rotate counterclockwise one-half turn. Inc. recommends that all maintenance work be performed Figure 5-4. by an Independent Authorized Service Dealer (IASD).
Page 33 Maintenance • Air filter change: See Replacing Air Filter Element. • Spark plug change: See Clean/Gap/Replace Spark Plugs. • Coolant drain: See Draining and Flushing Cool- System. • Coolant fill: See Draining and Flushing Coolant System. Spark-Ignited Stationary Generators Owner’s Manual...
Page 34: Service Maintenance Schedule
Maintenance Service Maintenance Schedule Observe the maintenance tasks and intervals shown in the table below. Schedule B Schedule A Schedule C 25 Hours Every 2 Daily If Running Every Year Every Service Engine Break- Years Continuously or 150 1,000 Hours or 300 Hours Hours...
Page 35: 25 Hour Break-In
(service left). The control panel is therefore on the right (service rear) side of the generator. The ex- haust is on the left (service front) side of the generator. 019376 XG03245, XG04045, Model and XG04845 Figure 5-5. Generator Control Panel 3.
Page 36: Inspecting The Enclosure Slots
Maintenance 3. Remove negative battery cable (black) from nega- NOTE: Coolant expands when hot, so coolant level tive (-) battery terminal. may be higher than the HOT mark. Do not add coolant higher than the HOT mark. Inspecting the Enclosure Slots 2.
Page 37: Replacing Lubricating Oil And Oil Filter
Maintenance Figure 5-7. 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.
Page 38: Checking Battery Condition/Fluid Level
See Engine Oil Recommendations. Crankcase oil capacity is listed below: System Engine Model Capacity XG03245, 11.6 qt (11 L) XG04045, and 4.5 L NA XG04845 10. Install oil fill cap. 11. Install negative battery cable (black) onto negative 009884 (-) battery terminal.
Page 39: Checking Fluid Level
Maintenance Figure 5-11. 8. Verify battery state of charge. See Verifying Bat- tery State of Charge. 9. Replace battery necessary. Battery Replacement. Checking Fluid Level Check the fluid level of unsealed batteries. If necessary, fill with distilled water only. DO NOT use tap water. Verifying Battery State of Charge Verify the battery state of charge using a digital multi- meter (DM).
Page 40: Inspecting Accessory/Drive Belt
Maintenance Figure 5-13. Inspecting Accessory/Drive Belt Inspection NOTE: XG03245, XG04045, and XG04845 units are pro- vided 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: •...
Page 41: Schedule B Maintenance Item Locations
(service front) side of the generator. 10. Install drain plug at end of coolant drain hose. 11. Install coolant drain hose in holding clamp. Model XG03245, XG04045, and XG04845 12. Rotate hex fitting to close radiator drain screw. Engine 4.5 L NA...
Page 42: Clean/Gap/Replace Spark Plugs
Doing so could re- sult in death or serious injury. Engine Spark Plug Gap Model (W000140) XG03245, 0.012-0.017 in Proceed as follows to clean, gap, or replace spark plugs XG04045, and 4.5 L (0.31-0.45 mm) as follows: XG04845 1.
Page 43: Return To Service
Maintenance NOTE: Reset A-B-C / Year time maintenance schedule counter using Dealer Sub Menu (pass- word 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.
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Page 45: Section 6: Troubleshooting
Troubleshooting Section 6: Troubleshooting Engine Troubleshooting Problem Cause Correction Replace 7.5 amp fuse in generator con- troller. Correct short circuit condition if Fuse blown. fuse blows again. Loose, corroded, or faulty battery cables. Engine does not crank Tighten, clean, or replace as necessary. Faulty starter contact.
Page 46: Controller Troubleshooting
Troubleshooting Controller Troubleshooting Active Alarm Problem Solution Unit will not start in AUTO with See activation section in installation manual. utility loss. ACTIVATED Unit running in AUTO but no Check generator MLCB (generator disconnect). Contact an IASD if genera- NONE power in house.
Page 47: Generac Mobile Link Troubleshooting
Troubleshooting Unit will not start in AUTO with Figure 3-6 EMERGENCY Verify both emergency shutdown switches are ON (I). See utility loss. SHUTDOWN locations. CONFIGURA- Unit will not start in AUTO with Voltage configuration set in controller does not match voltage configuration TION utility loss.
Page 48: Removal From Service During Utility Outage
Troubleshooting Removal From Service During Utility Storage Outage Prepare For Storage If, during prolonged utility outages, the user wishes to re- move unit from service to conserve fuel, reduce run Proceed as follows to prepare for storage if generator hours, or to perform maintenance tasks, then complete cannot be exercised every seven days and will be out of the steps listed below.
Page 49: Removal Of Front
Troubleshooting Battery Removal 12. Press MANUAL on the controller to start engine. A blue LED illuminates to verify system is in WARNING MANUAL. Explosion. Batteries emit explosive gases. 13. Allow engine to run until it reaches normal operat- Always disconnect negative battery cable ing temperature.
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Page 52 Part No. A0005536684 Rev. A 07/09/2024 Generac Power Systems, Inc. © 2024 Generac Power Systems, Inc. S45 W29290 Hwy. 59 All rights reserved Waukesha, WI 53189 Specifications are subject to change without notice. 1–888–GENERAC (1–888–436–3722) No reproduction allowed in any form without prior written www.generac.com...

This manual is also suitable for:

Xg04045 Xg04845 Xg04045anac