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Cover206 Rev. A 12/11 Part No. 0J7768









1-1

Despite the safe design of this generator,

operating this equipment imprudently, neglect-

ing its maintenance or being careless can cause

possible injury or death. Permit only respon-

sible and capable persons to install, operate or

maintain this equipment.



Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.

Parts of the generator are rotating and/or hot

during operation. Exercise care near running

generators.

1-2

FIRE HAZARDS

EXPLOSION HAZARDS

1-3

IDENTIFICATION RECORD

2-1

General Information

Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.

Do not use any chromate base rust inhibitor

with ethylene glycol base anti-freeze or chro-

mium hydroxide (“green slime”) forms and will

cause overheating. Engines that have been

operated with a chromate base rust inhibitor

must be chemically cleaned before adding eth-

ylene glycol base anti-freeze. Using any high

silicate anti-freeze boosters or additives will

also cause overheating. The manufacturer also

recommends that any soluble oil inhibitor is

NOT used for this equipment.

Do not remove the radiator pressure cap while

the engine is hot or serious burns from boiling

liquid or steam could result.

Ethylene glycol base antifreeze is poisonous.

Do not use mouth to siphon coolant from the

radiator, recovery bottle or any container. Wash

hands thoroughly after handling. Never store

used antifreeze in an open container because

animals are attracted to the smell and taste of

antifreeze even though it is poisonous to them.

3-1

Equip001 Rev. G 05/10

4-1

5-1

Engine Parameters

Exhaust System

Combustion Air Requirements (Natural Gas)

Governor

Engine Lubrication System

Fuel Consumption - ft3/hr (Natural Gas/LPV)

Voltage Regulator

Power Adjustment for Ambient Conditions

Controller ................................................................. Nexus

6-1



6-2

ALTERNATOR AC LEAD

CONNECTIONS

ALTERNATOR POWER WINDING

CONNECTIONS

E3 L - N

L - L

INTERNAL

CONNECTIONS

00 (NEUTRAL)

S12

S11

S10

E3 L - N

L - L

7-1

General Information

E3 E2

00 (NEUTRAL)

INTERNAL CONNECTIONS E1

L-L

L-N

S1 S1

S4 S4

S5 S2

E3 E2

L-L

L-N

S7 S1

S10 S4

S12

S11 S2

E3 L - N

L - L

INTERNAL

CONNECTIONS

00 (NEUTRAL)

0VAC

2VAC

208C

240C

240 VAC

120 VAC 120 VAC

240 VAC

S2 S12

S11

S10

E1 E3

208 VAC

7-2

General Information



8-1

8-2

LOW SPEED EXERCISE

AUTOMATIC TRANSFER OPERATION

8-3

SEQUENCE OF AUTOMATIC OPERATION

Initial Conditions: Generator in Auto ready to run, load being sup-

plied by the Utility Source through the transfer switch.

1. When the utility voltage fails (falls below 60% of nominal), a

10-30 second (programmable) “line interrupt” delay timer is

started. The factory set time delay is 10 seconds. If at the

end of the line interrupt time the utility voltage is above 60%

the engine will not crank. If the utility voltage is still below

the 60% of nominal at the end of the line interrupt time, the

unit will crank and start. If the unit cranks for more than 10

seconds and the utility voltage rises above 80% of nominal

(programmed pickup voltage) and the unit has not started, the

crank cycle will abort.

2. As soon as the unit starts a 5 second “warm-up” timer is initi-

ated. When the warm-up timer expires the control will transfer

the load to the generator (through the RTS switch) if the utility

voltage is less than 80% of nominal. If the utility voltage is

greater than the 80% of nominal at the end of the warm-up

time the load will not be transferred to the generator and a one

minute low-speed cool down period will start. At the end of

the one minute cool down period the generator will stop.

3. Once the unit is running and the switch has transferred the

load to the generator the unit will monitor utility voltage.

When utility voltage returns (above the programmable pickup

voltage, normally 80% of nominal), a 15 second “Return to

Utility” timer will start. At the end of the return to utility time,

if the utility voltage is still above the pickup voltage, the unit

will transfer the load back to the utility source and run the unit

through a one minute cool down period. When the cool down

period is over the unit will shut down and be ready for the next

outage.

4. If during the cool down period utility voltage should fall below

60% of nominal the 5 second warm-up timer is initiated and

the unit will transfer the load back to the generator and con-

tinue to monitor the utility.

CRANK CYCLES AND OVERCRANK SHUTDOWN

If the unit fails to start during a cranking period it will display the

Overcrank Shutdown Alarm. The system will control the cranking

cycles as follows:

The first crank cycle is a 16 second crank time followed by a 7

second rest. The next 5 cycles will be 7 seconds of cranking time

each followed by a 7 second rest time.

If the unit fails to start by the end of the 6 crank/rest cycles

the Overcrank Shutdown Alarm will display and the unit will not

attempt to crank until the alarm is reset.

AUTO START

This unit is designed to automatically start in the event of a util-

ity failure or brown out condition. Brown out is defined as utility

voltage less than 60% nominal, while utility is considered good

when it is restored to at least the pickup value, 80% of nominal.

These levels are fixed. The “Line Interrupt period” is an adjustable

parameter by the dealer. If 2-wire start mode is activated, the unit

will start when 2-wire start is active.

MANUAL START

Allows the user to start and run the generator manually.

Transfer of the load to the generator will occur if utility is lost while

the unit is running in the manual mode (only if activated).

ALARM AND WARNING MESSAGES

Alarms are defined as “Latching” which means they must be

cleared before the alarm message on the screen will clear. They

can be of type “Shutdown” or not and are logged in the alarm log.

Alarms are all annunciated on the display).

Warnings are “Non Latching” meaning the message automati-

cally clears when the warning condition goes away. Warnings can

not be of type “Shutdown” but they are logged in the alarm log.

Warnings are all annunciated on the display.

LOW OIL PRESSURE SHUTDOWN ALARM

There is a 10 second delay before oil pressure is monitored.

HIGH COOLANT TEMPERATURE SHUTDOWN ALARM

There is a 10 second delay before engine temperature is moni-

tored.

Once running there is a 1/4 second delay before shut down. The

limit is set at 125° C or 257° F.

OVERCRANK SHUTDOWN ALARM

Occurs if the engine has not started within the specified crank

cycle.

OVERSPEED SHUTDOWN ALARM

Warning indicator is measured and calculated by the microproces-

sor. Overspeed is defined as +20% of nominal engine speed for 3

seconds, or +25% immediate.

Nominal engine speed = 60.0 Hz

RPM SENSOR FAILURE SHUTDOWN ALARM

During cranking: If the board does not see a valid RPM signal

within four (4) seconds of cranking it will shut down and lock out

on RPM sensor loss.

During running: If the RPM signal is lost for one full second the

board will shut the engine down, wait 15 seconds, then re-crank

the engine if in AUTO, it will not re-crank in MANUAL.

If no RPM signal is detected within the first four (4) seconds of

cranking, the control board will shut the engine down and latch out

on RPM sensor loss.

If the RPM signal is detected the engine will start and run normally.

If the RPM signal is subsequently lost the control board will try

two more re-cranks before latching out and flashing the RPM

Sensor Failure message (if it is in AUTO).

8-4

CntrlNexus001 Rev. E 12/11

Control Panel

8-5

If the generator voltage rises above 110% for >3 seconds, an

alarm will be issued.

If the generator voltage rises above 130% for >0.2 seconds, an

alarm will be issued.

Any internal failure that can be detected such as corrupted

firmware will cause this shutdown alarm. This alarm cannot be

cleared.

Where applicable, if the Canbus communications link fails to com-

municate, a “Canbus Alarm” will be generated. This only applies

to systems with external ignition modules. The alarm may be

generated if:

1. The physical link is broken.

2. The Ignition Module fails or resets.

3. The Nexus Controller fails or resets.

4. Having the Battery Chargers 120 VAC connected without a

battery installed.

5. A blown 10 amp Ignition Module fuse (approximately 12

inches away from the starter).

6. A blown 25 amp system fuse (located approximately 12

inches away from the DC alternator).

When an ignition alarm occurs, a generic message “Ignition Fault”

will be displayed as the fault code.

When a maintenance period expires, a warning message will be

posted. The warning can be reset by hitting the Enter key. Resetting

will clear the warning and reset the maintenance counters for the

condition annunciated. The history log will reflect the maintenance

warning.

When the generator is shut down due to a latching alarm, the Auto

/Off/ Manual switch must be set to the off position and the ENTER

key pressed to unlatch any active fault and clear the corresponding

fault alarm message.

The common alarm relay will be activated if there is a shutdown

alarm. It will not activate on warnings or indicate that the Auto/Off/

Manual switch is in the OFF position. The OFF position will clear

the alarms and the relay. The relay will not be used to indicate a

generator is not activated.

The common alarm connections are wired to a set of potential-

free (dry) contacts on the Nexus controller board. These Normally

Open (N.O.) contacts close when an alarm condition occurs and

are used to activate a remote signaling device. The circuit is rated

for a maximum of 130mA at 24 VDC. The connections are a short

set of free hanging wires that exit the engine harness loom directly

behind the Nexus Control Panel and are labeled numbers 209 and

210.

Maintenance alerts will be provided for these conditions.

Inspect Accessory Drive Alert 1yr / 100hrs*

Coolant Change & Flush 1yr / 100hrs

Inspect Spark Plugs Alert 1yr / 100hrs

Change Oil & Filter Alert 1yr / 100hrs*

Inspect Battery Alert 1yr / 100hrs

Change / Inspect Air Filter Alert 1yr / 100hrs

Clean/Inspect Air Inlet & Exhaust 6mo / 50hrs*

* Items require a 3 month / 30 hour break-in change or check.

Change / Inspect spark plugs alert 2yr/ 250hr

8-6

CntrlNexus001 Rev. E 12/11

8-7

Control Panel

ACTIVATION

RUN LOGALARM LOG

HISTORY STATUS

COMMANDSTATE VERSIONSDISPLAY

GENERATOR

FREQUENCY

ENGINE

HOURS

ENGINE

RPM

BATTERY

VOLTAGE

DEBUG

INPUTS OUTPUTS DISPLAYS

EDIT

LANGUAGE

TIME/DATE

EXERCISE

TIME/SPEED

ESC Press the “ESCAPE” key

to jump back up through

the menu levels.

+ / - Use the “+/-” key

to navigate through

the menu.

ENTER Use the “ENTER” key

to select items or

enter data.

ESC

ESC ESC

RESET

MAINTENANCE

QT TEST

MAIN MENU

MENU SYSTEM

CntrlNexus001 Rev. E 12/11

The Maintenance Disconnect Switch and the

AUTO/OFF/MANUAL switches (if so equipped)

must be set properly, or the generator will

crank and start as soon as the utility power to

the transfer switch is turned off. Refer to appli-

cable control panel and transfer switch manuals

for more information.

Do not proceed until certain that utility source

voltage is available to the transfer switch and

the transfer switch main contacts are set to

UTILITY.



Do not attempt manual operation until all

power supplies to the transfer switch have been

positively turned off, or extremely dangerous -

possibly lethal - electrical shock will result.



Transfer switch enclosure doors should be kept

closed and locked. Only authorized personnel

should be allowed access to the transfer switch

interior. Extremely high and dangerous voltages

are present in the transfer switch.

nDo not crank the engine continuously for lon-

ger than 30 seconds, or the heat may

damage the starter motor.

9-1

 Before working on the Stationary Emergency

Generator, ensure the following:

• The AUTO/OFF/MANUAL switch is in the OFF position.

• The control panel fuse has been removed from the control

box.

• The 120VAC supply to the battery charger is switched OFF.

• The negative battery cable has been removed.

CHECK ENGINE OIL

Check engine crankcase oil level (Figure 10.1) according to the

Service Schedule.

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

• Install oil dipstick, wait approximately 10 seconds, then remove

again.

• Oil should be between FULL and ADD marks.

• If oil level is below the dipstick ADD mark, remove oil fill cap-.

Add the recommended oil to bring oil level up to the FULL

mark. DO NOT FILL ABOVE THE “FULL” MARK. See “Engine Oil

Recommendations” for recommended oils.

Figure 10.1 - Oil Dipstick and Oil Fill Cap

Oil Filter

Oil Fill Oil

Dipstick

Add Oil

Level Mark

Full Oil

Level Mark

CHANGING ENGINE OIL

 Hot oil may cause burns. Allow engine to cool

before draining oil. Avoid prolonged or repeat-

ed skin exposure with used oil. Thoroughly

wash exposed areas with soap.

Refer to the Service Schedule for engine oil and filter change fre-

quencies.

Drain the oil while the engine is still warm from running. This

means warm up the engine, shut it down and drain immediately

as follows:

1. Remove the drain hose from its retaining clip or cut the zip-tie

securing the oil drain hose.

2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil com-

pletely into suitable container.

3. When all oil has drained, install and tighten OIL DRAIN HOSE

CAP and secure drain hose with a new zip-tie, or place the

hose in its retaining clip.

4. Turn OIL FILTER (Figure 10.1) counterclockwise and remove.

Properly dispose of old filter.

5. Apply light coating of new engine oil to seal of new oil fil-

ter. Install FILTER and tighten by hand only. DO NOT OVER

TIGHTEN.

6. Remove OIL FILL CAP and add recommended oil. Crankcase

oil capacity is listed in the "Specifications" section.

 After refilling the crankcase with oil, always

check oil level on dipstick. NEVER OPERATE

ENGINE WITH OIL BELOW THE DIPSTICK “ADD”

MARK.

7. Start engine and check for oil leaks.

8. Shut OFF engine and wait 10 minutes for the oil to settle down

into the oil pan. Recheck oil level on dipstick. DO NOT fill

above the dipstick "FULL" mark.

9. Dispose of used oil at a proper collection center.

COOLING INTAKE/OUTLET

Air intake and outlet openings in the generator compartment must

be open and unobstructed for continued proper operation. This

includes such obstructions as high grass, weeds, brush, leaves

and snow.

Without sufficient cooling and ventilating air flow, the engine/gen-

erator quickly overheats, which causes it to shut down. (See the

installation diagram.)

 The exhaust system parts from this product get

extremely hot and remains hot after shutdown.

High grass, weeds, brush, leaves, etc. must

remain clear of the exhaust. Such materials may

ignite and burn from the heat of the exhaust

system.

INSPECT COOLING SYSTEM

• Inspect engine cooling system. See the Service Schedule.

• Check hoses for damage, deterioration, leaks, etc. Correct any

discrepancies found.

• Check hose clamps for tightness.

10-1

Maint032 Rev. A 12/11

ENGINE COOLANT

COOLANT CHANGE

OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL

SYSTEM

If a circuit breaker opens or a fuse element

melts, find the cause of the overload before

resetting the circuit breaker or replacing the

fuse.

PERFORM VISUAL INSPECTION

INSPECT EXHAUST SYSTEM

CHECK FAN BELT

Figure 10.2 – Fan Belts

CHANGING THE ENGINE AIR FILTER

Figure 10.3 – Engine Air Filter

10-2

11-1

United States Environmental Protection Agency Warranty Statement

(Stationary Emergency Spark-Ignited Generators)

Warranty Rights, Obligations and Coverage

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission

Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or compo-

nent on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replace-

ment parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system may include parts

such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac will warrant

the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect, unapproved modifica-

tion, or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the date of sale to the ulti-

mate purchaser. For engines greater than or equal to 130 HP the warranty period is three years or 2500 hours of operation, whichever

comes first, from the date of the engine being placed into service. For high-cost warranted components, the Emission Control System war-

ranty is valid for 5 years or 3500 hours of operation, whichever comes ﬁrst.

Purchaser's/Owner's Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following: 1) The engine must be installed and conﬁgured in accordance to Gen-

erac's installation specifications. 2) The completion of all maintenance requirements listed in your Owner's Manual. 3) Any engine setting

adjustment must be done in accordance and consistent with the instructions in the Owner's Manual. 4) Any emission control system or com-

ponent must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize

emissions at all times.

Generac may deny any/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system or

component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of

counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting either

your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/owner shall

be responsible for any expenses or other charges incurred for service calls and/or tr spection or ansportation of the product to/from the in

repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being trans-

ported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System Warranty

related information, Generac Power Systems, Inc., PO. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www.generac.com.

Important Note

This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Gen-

erac pursuant to federal law. Note that this warranty shall not apply to any incidental, consequential, or indirect damages caused by defects

in materials or workmanship or any delay in repair or replacement of the defective part(s). This warranty is in place of all other warranties,

expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any

implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states

do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Emission Related Parts Include the Following (if so equipped)

*High-Cost Warranted Component

EmsnWrnty001 Revision F (04/15)

1) Fuel Metering System

1.1) Gasoline Carburetor Assembly and Internal Components

A) Fuel Filter, B) Carburetor, C) Fuel Pump

1.2) Carburetion Assembly and Its Components

A) Fuel Controller, B) Carburetor and Its Gaskets,

C) Mixer and Its Gaskets, D) Primary Gas Regulator,

E) Liquid Vaporizer

1.3) Fuel Regulator

2) Air Induction System Including A) Intake Pipe/Manifold,

B) Air Cleaner

3) Ignition System Including A) Spark Plug, B) Ignition Module,

C) Ignition Coil, D) Spark Plug Wires

4) Exhaust System

A) Catalyst Assembly*, B) Exhaust Manifold, C) Muffler,

D) Exhaust Pipe, E) Muffler Gasket

5) Crankcase Breather Assembly Including

A) Breather Connection Tube, B) PCV Valve

6) Oxygen Sensor

7) Diagnostic Emission-Control System

United States Environmental Protection Agency Compliance Requirements

(Stationary Emergency Spark-Ignited Generators)

Purchaser's/Owner's Record Keeping Responsibilities

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record

keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion

Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains

their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in

this Owner's Manual, you are required to meet the following notification and record keeping requirements to demonstrate compliance: 1)

Maintain documentation that the engine is certified to meet emission standards. 2) Record keeping of maintenance conducted. 3) Record

keeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel

solely during emergency operations provided the engine is not certified to operate on propane. 4) Meet all compliance notifications submitted

to the purchaser/owner and maintain all supporting documentation. 5) Record keeping of hours of operation, including what classified the

operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130

HP, record keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, record keeping of hours of oper-

ation begins January 1, 2009; engines are equipped with non-resettable hour meters to facilitate record keeping.

Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements.

Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air

Quality Management or Air Pollution Control District for specific requirements.

Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing,

provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the

engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emer-

gency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be

used for maintenance checks and readiness testing, but a petition t Federal, is not required if the owner maintains records indicating tha

State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may

operate up to 50 hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for

maintenance and testing.

The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to

an electric grid or otherwise supply power as part of a ﬁnancial arrangement with another entity. For purchaser/owner of emergency engines,

any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year,

as permitted in this section is prohibited.

If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance

to the speciﬁcations and guidelines in this Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be con-

sidered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Igni-

tion Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.

Emission-Related Installation Instructions

Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and

replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States

Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized

Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow t ified engine in a hese instructions when installing a cert

piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.

EmsnWrnty001 Revision F (04/15)