1. Introduction
This manual provides instructions for the installation, operation, and maintenance of the Generac 5630 Cold Weather Kit. This kit is designed to enhance the performance and reliability of Generac liquid-cooled standby generators with 2.4L engines in cold weather conditions by maintaining optimal battery and engine temperatures.
The Generac 5630 Cold Weather Kit includes a battery warmer with an integrated thermostat and an engine block heater. These components work together to ensure your generator starts reliably when ambient temperatures drop.
2. Safety Information
WARNING: Read and understand all safety precautions before installation or operation. Failure to follow these instructions may result in serious injury, death, or property damage.
- Always disconnect power to the generator before performing any installation or maintenance.
- Ensure the generator is completely shut down and cooled before working on it.
- Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
- Installation should be performed by a qualified technician if you are unsure about any steps.
- Do not modify the components of the cold weather kit.
3. Kit Components
The Generac 5630 Cold Weather Kit typically includes the following items:
- Battery Warmer with Integrated Thermostat
- Engine Block Heater
- Associated Wiring and Mounting Hardware
Image 1: Components of the Generac 5630 Cold Weather Kit. Shown are the battery warmer (black wrap) with its power cord and an oil filter (white cylinder), which may be included for maintenance or as a visual reference for the generator type.
4. Compatibility
This kit is specifically designed for Generac 22, 27, 36, 45, and 60 kW automatic standby generators equipped with a 2.4L engine. It is also compatible with the Extreme Cold Weather Kit model 5616 for comprehensive cold weather preparedness.
5. Installation
The installation of the Generac 5630 Cold Weather Kit involves installing the battery warmer and the engine block heater. Refer to your generator's main instruction manual for specific access panels and safety procedures.
5.1 Battery Warmer Installation
- Prepare the Generator: Ensure the generator is turned off, disconnected from all power sources, and has cooled down. Open the generator enclosure to access the battery compartment.
- Clean Battery: Clean the battery surface to ensure proper contact for the warmer.
- Position Warmer: Carefully wrap the battery warmer around the battery. Ensure the integrated thermostat is positioned correctly according to the kit's specific instructions (usually on the side or bottom of the battery).
- Secure Warmer: Use any provided fasteners or adhesive to secure the warmer in place, ensuring it does not interfere with other components or moving parts.
- Route Wiring: Route the warmer's power cord safely away from hot surfaces and moving parts, securing it with cable ties as needed.
5.2 Engine Block Heater Installation
The engine block heater typically replaces a freeze plug in the engine block or is installed in a coolant hose. Consult the specific instructions provided with your kit and your generator's service manual for the exact location and procedure.
- Drain Coolant (if applicable): If installing into a freeze plug port, you may need to partially drain the engine coolant.
- Install Heater: Install the engine block heater into the designated port or hose. Ensure a tight, leak-free seal.
- Refill Coolant (if applicable): If coolant was drained, refill to the appropriate level with the recommended coolant type.
- Route Wiring: Route the heater's power cord safely, similar to the battery warmer.
5.3 Electrical Connection
Both the battery warmer and engine block heater require an electrical connection. These are typically connected to a dedicated circuit within the generator's control panel or a separate power source, as specified by the kit's wiring diagram. Ensure all connections are secure and properly insulated.
- Connect the power cords of both components to the designated terminals or outlets.
- Verify all connections are tight and correct according to the wiring diagram.
- Close the generator enclosure and restore power.
6. Operation
The Generac 5630 Cold Weather Kit operates automatically. The integrated thermostat in the battery warmer monitors ambient temperatures. When temperatures fall below a preset threshold (typically around 0°C or 32°F), the thermostat activates the battery warmer and the engine block heater.
- Battery Warmth Optimization: The battery warmer maintains the battery at an optimal temperature, preventing capacity loss and ensuring reliable starting power in cold conditions.
- Engine Pre-heating: The engine block heater warms the engine coolant and oil, reducing engine wear during cold starts and improving starting reliability.
- Automatic Activation: The system is designed to activate and deactivate automatically based on temperature, requiring no manual intervention once installed.
7. Maintenance
Regular maintenance ensures the longevity and proper functioning of your cold weather kit.
- Annual Inspection: Before the cold season, inspect all components of the kit. Check the battery warmer for any signs of damage or wear. Inspect the engine block heater and its connections for leaks or corrosion.
- Wiring Check: Ensure all wiring is secure, free from fraying, and not exposed to excessive heat or sharp edges.
- Cleanliness: Keep the battery and surrounding area clean and free of debris.
- Battery Condition: Regularly check the generator battery's overall condition and charge level as part of your routine generator maintenance.
8. Troubleshooting
If you experience issues with your Generac 5630 Cold Weather Kit, consider the following:
- Kit Not Activating:
- Verify the generator's power supply is active.
- Check all electrical connections for tightness and proper contact.
- Ensure ambient temperature is below the activation threshold of the thermostat.
- Inspect wiring for damage or breaks.
- Generator Still Hard to Start in Cold:
- Confirm the cold weather kit is receiving power and activating.
- Check the condition of the generator's battery; it may need replacement.
- Ensure the engine block heater is functioning (it should feel warm to the touch when active).
- Consult your generator's main manual for general cold-start troubleshooting.
- Visible Damage: If any component shows signs of physical damage, discontinue use and contact Generac customer support or a qualified service technician for replacement.
9. Specifications
| Feature | Detail |
|---|---|
| Model Number | 5630 |
| Manufacturer | Generac Power Systems Inc |
| Item Weight | 2 pounds |
| Product Dimensions | 14.1 x 8.3 x 4.5 inches |
| Power Source | Battery Powered (for activation logic, heaters are AC powered) |
| Voltage | 240 Volts (for heating elements) |
| Compatible Generator Wattage | 22, 27, 36, 45, and 60 kW (for liquid-cooled standby generators) |
| Included Components | Generac 5630 Cold Weather Kit (includes battery warmer, engine block heater) |
| Batteries Included? | No |
| Batteries Required? | No (operates with generator's existing battery and power) |
10. Warranty and Support
Warranty Description: The product specifications indicate "wear item, no warranty." Please refer to the original purchase documentation or contact Generac directly for the most current and accurate warranty information regarding this accessory.
For technical assistance, replacement parts, or further inquiries, please contact Generac customer support or visit the official Generac website. Always provide your product model number (5630) and generator model number when seeking support.
