Generac Power Systems 04758-2, 04759-2, 04760

Installation and

Owner’s Manual

Air-cooled Automatic

Standby Generators

Models:

04758-2 (6 kW NG, 7 kW LP)

04759-2 (12 kW NG, 12 kW LP)

04760-2 (13 kW NG, 15 kW LP)

GENERAC

POWER SYSTEMS, INC.

R

R

!

*This manual should remain with the unit.*

Not intended for use as Primary Power in place of utility or in life-support applications.

!

DANGER

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

INTRODUCTION

Thank you for purchasing this Guardian model by Generac

Power Systems Inc.. This model is a compact, high performance, air-cooled, engine-driven generator designed to automatically supply electrical power to operate critical loads during a utility power failure.

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 This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).

This unit meets the 1998 and later California emissions regulations. To ensure that the engine continues to meet these regulations, refer to the following information and instructions in this owner’s manual.

ENGINE EMISSION COMPLIANCE PERIOD

For nonhandheld engines: The Emissions Compliance

Period referred to on the Emissions Compliance label indicates the number of operating hours for which the engine has been shown to meet federal emission requirements.

For engines less than 225 cc displacement, Category C =

125 hours, B = 250 hours, and A = 500 hours.

For engines 225 cc or more, Category C = 250 hours, B =

500 hours, and A = 1000 hours.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest Generac Authorized Dealer for starting, operating and servicing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAU-

TION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

DANGER

After this heading, read instructions that, if not strictly complied with, will result in serious personal injury, including death, in addition to property damage.

After this heading, read instructions that, if not strictly complied with, may result in serious personal injury or property damage.

After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

NOTE:

After this heading, read explanatory statements that require special emphasis.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type of information each indicates follows:

!

This symbol points out important safety information that, if not followed, could endanger personal safety and/or property of others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

The operator is responsible for proper and safe use of the equipment. We strongly recommend that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. We also strongly recommend instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.

CONTENTS

This manual contains pertinent owner’s information, including warranty, electrical diagrams, exploded views and lists of repair parts, for three different Guardian models:

• 04758-2 – 6 kW NG, 7 kW LP, single-cylinder GH-410

Engine

• 04759-2 – 12 kW NG, 12 kW LP, V-twin GT-990 Engine

• 04760-2 – 13 kW NG, 15 kW LP, V-twin GT-990 Engine

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by a Generac Authorized Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum. See the Generac Authorized Dealer for service aids and accessories.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, simply contact a Generac Authorized Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs.

When contacting a Generac Authorized Dealer or the factory about parts and service, always supply the complete model number and serial number of the unit as given on its data decal, which is located on the generator. See Figure 1.1 or

Figure 1.2 in Section 1.4 for decal location.

Model No. ____________ Serial No. ______________

AUTHORIZED DEALER LOCATION

To locate the GENERAC AUTHORIZED

DEALER nearest you, please call this number:

1-800-333-1322

DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

Table of Contents

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Introduction ........................Inside Front Cover

Read This Manual Thoroughly ........................IFC

Contents ..........................................................IFC

Operation and Maintenance ............................IFC

How to Obtain Service ....................................IFC

Authorized Dealer Locator Number ....................IFC

Safety Rules ........................................................2

Standards Index ..................................................3

Section 1 – General Information ..................4

1.1

Unpacking/Inspection ....................................4

1.2

Protection Systems ........................................4

1.3

System Set LED ............................................4

1.4

The Generator ..............................................5

1.5

Specifications ................................................6

1.5.1 Generator ..........................................6

1.5.2 Engine ................................................6

1.6

Fuel Requirements and Recommendations....7

1.7

Fuel Consumption ........................................7

1.8

Reconfiguring the Fuel System ......................7

1.8.1 7 kW, 410CC ......................................7

1.8.2 12 kW and 15 kW, 990cc Engines ......8

1.9

Location ........................................................8

1.9.1 Generator ..........................................8

1.9.2 Transfer Switch ..................................9

1.10 Battery Installation ........................................9

1.11 The Battery....................................................9

Section 2 – Post Installation Start-up and Adjustments ......................10

2.1

Before Initial Start-up ..................................10

2.2

Check Transfer Switch Operation................10

2.3

Electrical Checks ........................................10

2.4

Generator Tests Under Load ......................11

2.5

Checking Automatic Operation ....................11

2.6

Adjusting the Regulator (Natural Gas Only) ..12

2.7

Engine Governor Adjustment ......................13

2.7.1 7 kW Units ......................................13

2.7.2 12 kW and 15 kW Units ..................13

2.7.3 Additional Corrosion Protection ......14

2.8

Voltage Regulator Adjustment ......................14

Section 3 – Operation ....................................14

3.1

Break-in Procedure......................................14

3.2

Using the Auto/Off/Manual Switch ..............14

3.2.1 “Auto” Position ..................................14

3.2.2 “Off” Position ....................................14

3.2.3 “Manual” Position ............................14

3.3

Automatic Transfer Operation ....................15

3.4

Sequence of Automatic Operation................15

3.5

Manual Transfer Operation ........................15

3.5.1 Transfer to Generator

Power Source......................................15

3.5.2 Transfer Back to Utility

Power Source......................................16

3.6

Setting the Exercise Timer ..........................16

3.7

Protection Systems ......................................16

3.7.1 Low Oil Pressure Switch ..................16

3.7.2 High Temperature Switch ................16

3.7.3 Overcrank ........................................17

3.7.4 Overspeed ........................................17

Section 4 – Maintenance ..............................17

4.1

Fuse ............................................................17

4.2

Checking the Engine Oil Level ....................17

4.3

Changing the Engine Oil ..............................18

4.3.1 Engine Oil Recommendations ..........18

4.3.2 Oil Change Procedure ......................18

4.4

Changing the Oil Filter ................................18

4.5

Changing the Engine Air Cleaner ................18

4.5.1 7 kW, 12 kW and 15 kW

Generators........................................18

4.6

Spark Plug(s) ..............................................19

4.7

Battery Maintenance ....................................19

4.8

Adjusting Valve Clearance ............................20

4.9

Cooling System ............................................20

4.10 Attention After Submersion ........................21

4.11 Corrosion Protection ..................................21

4.12 Out of Service Procedure ............................21

4.12.1 Removal From Service ......................21

4.12.2 Return to Service..............................21

4.13 Service Schedule ........................................22

Section 5 – Troubleshooting ........................23

5.1

Troubleshooting Guide ................................23

Section 6 – Electrical Data ............................24

Section 7 – Exploded Views and

Parts Lists....................................32

Section 8 – Mounting Dimensions..............50

Section 9 – Notes ............................................51

Section 10 – Warranty ....................................52

Generac® Power Systems, Inc.

1

IMPORTANT SAFETY INSTRUCTIONS


!

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to all operators and potential operators of this equipment.

!

!

WARNING:

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

!

!

WARNING:

!

This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before installing, operating or servicing this equipment.

Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

Generac cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If using a procedure, work method or operating technique Generac does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique chosen does not render the generator unsafe.

!

!

DANGER

Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to 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.

!

GENERAL HAZARDS

!

• For safety reasons, Generac recommends that the installation, initial start-up and maintenance of this equipment is carried out by a Generac

Authorized Dealer.

• The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust system must be installed properly, in strict compliance with applicable codes and standards.

Following installation, do nothing that might render the system unsafe or in noncompliance with such codes and standards.

• Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

• Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation.

Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator. The generator MUST be installed outdoors.

• When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.

• Inspect the generator regularly, and contact the nearest Generac Authorized Dealer for parts needing repair or replacement.

• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.

• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

2 Generac ® Power Systems, Inc.

IMPORTANT SAFETY INSTRUCTIONS


ELECTRICAL HAZARDS

• All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in operation. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL

SHOCK MAY RESULT.

• The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. Local electrical codes also may require proper grounding of the generator electrical system.

• After installing this home standby electrical system, the generator may crank and start at any time without warning. When this occurs, load circuits are transferred to the STANDBY (generator) power source. To prevent possible injury if such a start and transfer occur, always set the generator’s

AUTO/OFF/MANUAL switch to its OFF position before working on equipment and remove the 5A and 15A fuses from the generator control panel.

• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH

THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

FIRE HAZARDS

• For fire safety, the generator must be installed and maintained properly. Installation always must comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and

Health Administration (OSHA) has established.

Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regulations.

• Keep a fire extinguisher near the generator at all times. Extinguishers rated “ABC” by the National

Fire Protection Association are appropriate for use on the standby electric system. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department.

EXPLOSION HAZARDS

• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or

EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

• Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE.

Install the fuel supply system according to applicable fuel-gas codes. Before placing the home standby electric system into service, fuel system lines must be properly purged and leak tested according to applicable code. After installation, inspect the fuel system periodically for leaks. No leakage is permitted.

STANDARDS INDEX

In the absence of pertinent standards, codes, regulations and laws, the published information listed below may be used as installation guide for this equipment.

1. NFPA No. 37, STATIONARY COMBUSTION

ENGINES AND GAS TURBINES, available from the National Fire Protection Association, 470

Atlantic Avenue, Boston, MA 02210.

2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-

TEMS FOR HEALTH CARE FACILITIES, available same as Item 1.

3. NFPA No. 54, NATIONAL FUEL GAS CODE, available same as Item 1.

4. NFPA No. 58, AMERICAN NATIONAL STANDARD

FOR STORAGE AND HANDLING OF LIQUEFIED

PETROLEUM GAS, available same as Item 1.

5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL

ELECTRIC CODE, available same as Item 1.

6. Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85

John Street, New York, N.Y. 10038.

7. AGRICULTURAL WIRING HANDBOOK, available from the Food and Energy Council, 909

University Avenue, Columbia, MO 65201.

8. ASAE EP-3634, INSTALLATION AND MAINTE-

NANCE OF FARM STANDBY ELECTRICAL SYS-

TEMS, available from the American Society of

Agricultural Engineers, 2950 Niles Road, St.

Joseph, MI 49085.

9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE

LIQUIDS CODE, available same as Item 1.


3

Section 1 — General Information


!

DANGER

Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations.

1.1

UNPACKING/INSPECTION

After unpacking, carefully inspect the contents for damage.

• This standby generator set has been factory supplied with a weather protective enclosure that is intended for outdoor installation only.

If this generator is used to power electrical load circuits normally powered by a utility power source, it is required by code to install a transfer switch. The transfer switch must effectively isolate the electrical system from the utility distribution system when the generator is operating (NEC 700, 701 and 702). Failure to isolate an electrical system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy.

If any loss or damage is noted at time of delivery, have the person(s) making the delivery note all damage on the freight bill or affix his or her signature under the consignor's memo of loss or damage.

If a loss or damage is noted after delivery, separate the damaged materials and contact the carrier for claim procedures.

“Concealed damage” is understood to mean damage to the contents of a package that is not in evidence at the time of delivery, but is discovered later.

1.2

PROTECTION SYSTEMS

Unlike an automobile engine, the generator may have to run for long periods of time with no operator present to monitor engine conditions. For that reason, the engine is equipped with the following systems that protect it against potentially damaging conditions:

1. Low Oil Pressure Sensor

2. High Temperature Sensor

3. Overcrank

4. Overspeed

There are LED readouts on the control panel to indicate that one of these faults has occurred. There is also a “System Set” LED that is described below.

1.3

SYSTEM SET LED

The “System Set” LED is lit when all of the following conditions are true:

1. The AUTO/OFF/MANUAL switch is set to the

AUTO position.

2. The utility voltage being supplied to the unit is being sensed by the Control PCB. If the utility sense voltage is not connected to the unit or if it is below 168 volts AC, then the system set light will flash rapidly. This indicates that if the

AUTO/OFF/MANUAL switch is placed in the Auto position , the generator will start.

3. The “Not In Auto” dip switch is set to the OFF position on the control board.

4. No alarms are present, for example, low oil pressure, high temperature, etc.




Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine

Oil

Dipstick

Data

Decal

Control

Panel

Exhaust

Enclosure

GFCI

Outlet

Fuel

Regulator

Fuel

Inlet

Oil Filter

Figure 1.2 – 12 kW/15 kW, V-twin GT-990/760 Engine

Battery

Compartment

Exhaust

Enclosure

Oil

Dipstick

Data

Decal

Control

Panel

GFCI

Outlet

Fuel

Regulator

Fuel

Inlet

Oil Filter

Battery

Compartment

Composite Base


5



1.5 SPECIFICATIONS

1.5.1 GENERATOR

Rated Max. Continuous Power Capacity (Watts*)

Rated Voltage

Rated Max. Continuous Load Current (Amps)

120 Volts +

240 Volts

Main Line Circuit Breaker

Phase

Number of Rotor Poles

Rated AC Frequency

Model 04758

6,000 NG/7,000 LP

120/240

50.0 NG/58.3 LP

25.0 NG/29.2 LP

30 Amp

1

2

60 Hz

Model 04759

100.0 NG/100.0 LP

50.0 NG/50.0 LP

50 Amp

1

2

60 Hz

Model 04760

12,000 NG/12,000 LP 13,000 NG/15,000 LP†

120/240 120/240

108.3 NG/125.0 LP

54.2 NG/62.5 LP

70 Amp

1

2

60 Hz

Power Factor

Recommended Air Filter

1 1 1

Generac Part # C8127 Generac Part # C8127 Generac Part # C8127

Battery Requirement at -17.8° C (0° F)

Weight

Output Sound Level @ 23 ft (7m) at full load

Group 26/26R

12 Volts and

350 Cold-cranking

Amperes Minimum

452 Pounds

68 db (A)

Group 26/26R

12 Volts and

525 Cold-cranking

Amperes Minimum

470 Pounds

70.5db (A)

Group 26/26R

12 Volts and

525 Cold-cranking

Amperes Minimum

487 Pounds

71.5 db (A)

Normal Operating Range -20°F (-28.8°C) to 104°F (40°C)

* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F).

+ Total current in TWO separate curcuits. Current in each curcuit must not exceed the value stated for 240V.

1.5.2 ENGINE

Type of Engine

Number of Cylinders

Rated Horsepower

Displacement

Cylinder Block

Valve Arrangement

Ignition System

Recommended Spark Plug

Spark Plug Gap

Compression Ratio

Starter

Oil Capacity Including Filter

Recommended Oil Filter

Recommended Air Filter

Operating RPM

Model 04758 Model 04759 Model 04760

GH-410

1

14.5 @ 3,600 rpm

410cc

Aluminum w/Cast

Iron Sleeve

GT-990

2

30 @ 3,600 rpm

992cc

Aluminum w/Cast

Iron Sleeve

GT-990

2

30 @ 3,600 rpm

992cc

Aluminum w/Cast

Iron Sleeve

Overhead Valves Overhead Valves Overhead Valves

Solid-state w/Magneto Solid-state w/Magneto Solid-state w/Magneto

RC14YC RC12YC RC12YC

0.76 mm (0.030 inch) 0.508 mm (0.020 inch) 0.508 mm (0.020 inch)

8.6:1

12 Vdc

9.5:1

12 Vdc

9.5:1

12Vdc

Approx. 1.5 Qts Approx. 1.7 Qts Approx. 1.7 Qts

Generac Part # 70185 Generac Part # 70185 Generac Part # 70185

Generac Part # 0C8127 Generac Part # 0C8127 Generac Part # 0C8127

3,600 3,600 3,600




1.6

FUEL REQUIREMENTS

AND RECOMMENDATIONS

With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed above the liquid fuel in the storage tank.

The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997

California Air Resources Board for tamper-proof dual fuel systems. The unit will run on natural gas or LP gas, but it has been factory set to run on natural gas.

Should the primary fuel need to be changed to LP gas, the fuel system needs to be reconfigured. See

Section 1.9 for instructions on reconfiguration of the fuel system.

Recommended fuels should have a Btu content of at least 1,000 Btus per cubic foot for natural gas; or at least 2,520 Btus per cubic foot for LP gas. Ask the fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is 5 inches to

7 inches water colum (0.18 to 0.25 psi); and for liquid propane, 11 inches to 14 inches of water column (0.4 to 0.5 psi).

NOTE:

Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below 4 inches water colum for natural gas or 10 inches water column for liquid propane for all load ranges.

1.7

FUEL CONSUMPTION

Model #

04758

04759

04760

Nat. Gas (*) LP Vapor (**)

1/2 Load Full Load 1/2 Load Full Load

66

152

156

119

215

220

0.82/30

1.53/56

1.58/58

1.47/54

2.08/76

2.40/88

*Natural gas is in cubic feet per hour.

**LP is in gallons per hour/cubic feet per hour.

DANGER

Gaseous fuels such as natural gas and liquid propane (LP) gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted.

Natural gas, which is lighter than air, tends to collect in high areas. LP gas is heavier than air and tends to settle in low areas.

1.8

RECONFIGURING THE

FUEL SYSTEM

◆

1.8.1 7 KW, 410CC

To reconfigure the fuel system from NG to LP, follow these steps (Figure 1.3):

NOTE:

The primary regulator for the propane supply is

NOT INCLUDED with the generator. A fuel pressure of 11 to 14 inches of water column (0.4 to 0.5

psi) to the fuel inlet of the generator MUST BE

SUPPLIED.

1. Turn off the main gas supply (if connected).

2. Open the roof and remove the door.

3. Remove the battery (if installed).

4. Disconnect wire #0 and wire #14 from the gas solenoid on top of the demand regulator.

5. Remove the carburetor fuel hose from the outlet port of the demand regulator.

6. Remove the demand regulator by removing the fastener that retains the regulator mounting bracket.

7. Remove the square headed steel pipe plug from outlet port #1 and the brass hose barb fitting from outlet port #2.

8. Refit the brass hose barb fitting to outlet port #1 and the square headed steel pipe plug to outlet port #2.

9. Reverse procedure steps 1-5 to reinstall demand regulator.

10. Reverse the procedure to convert back to natural gas.

Figure 1.3 – Demand Regulator

HOSE & PLUG

SWITCHED SIDES

FUEL HOSE

BRASS HOSE

FITTING

ADJUSTMENT

SCREW

PIPE

PLUG

FUEL HOSE

BRASS HOSE

FITTING

OUTLET

PORT

FUEL JET

NG FUEL SYSTEM

LP FUEL SYSTEM

NOTE:

The natural gas adjustment screw is preset during installation and should not need any further adjustment.


7



◆

1.8.2 12KW AND 15KW, 990CC ENGINES

To reconfigure the fuel system from NG to LP, follow these steps:

NOTE:

The primary regulator for the propane supply is

NOT INCLUDED with the generator. A fuel pressure of 11 to 14 inches of water column (0.4 to 0.5

psi) to the fuel inlet of the generator MUST BE

SUPPLIED.

1. Turn off the gas supply. (if connected)

2. Open the roof and remove the door.

3. Remove the battery. (if installed)

4. Remove the engine air in baffle located on the lefthand side of the battery compartment. Two M6 screws are located on top of the baffle and two

M6 screws are located on the inside of the baffle towards the back.

5. Remove the small hose clamp and hose from the fuel regulator. It may be necessary to pry the hose off of the brass fitting using a screwdriver to gently lift up the hose edge.

6. Remove the small brass hose fitting from the regulator casting.

7. Place the small fuel jet, thread side first, into the threaded hole originally occupied by the brass hose fitting (Figure 1.4).

8. Using a short No. 2 Phillips screw driver, thread the small fuel jet into the regulator casting. Do not over tighten.

9. Apply thread sealant to the threads of the hose fitting and replace it into the regulator body.

10. Re-attach the small hose and hose clamp and tighten as necessary.

11. Replace the engine air in baffle using the four M6 screws.

12. Identify both brass adjustment screws on the regulator.

NOTE:

One adjustment screw can be accessed from the front of the unit and the second can be accessed from the back of the unit enclosure by removing the plastic hole plug. The screw can be turned with a long flat blade screwdriver.

13. To adjust the system to run on LP fuel, turn

BOTH adjuster screws 1/2 TURN CLOCKWISE.

The system should now be set for maximum power and best perfomance. DO NOT, UNDER

ANY CIRCUMSTANCES, REMOVE THE SET

PINS FROM THE REGULATOR HOUSING.

THIS WILL VOID THE WARRANTY.

IDLE CIRCUIT

PORT

Figure 1.4 - Demand Regulator

U

T

1

TAP

1/8 NPT

OUTLET PORTS

FUEL HOSE

BRASS HOSE

FITTING

BRASS HOSE

FITTING

SMALL

FUEL JET

REGULATOR

HOUSING PORT

ADJUSTER

SCREWS

14. It may be necessary to make minor adjustments to the preset adjustment screw settings to achieve maximum power, particularly at higher altitudes.

If experiencing problems with the unit producing maximum power, follow the procedure in Section

2.6 (Adjusting the Fuel Regulator).

1.9

LOCATION

◆

1.9.1 GENERATOR

Install the generator set, in its protective enclosure, outdoors, where adequate cooling and ventilating air is always available. Consider these factors:

• Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or drifting, consider using a windbreak to protect the unit.

• Install the generator on high ground where water levels will not rise and endanger it.

• Allow sufficient room on all sides of the generator for maintenance and servicing. A good rule is to allow three feet of space on all sides.

• Where strong prevailing winds blow from one direction, face the generator air inlet openings to the prevailing winds.

• Install the generator as close as possible to the fuel supply, to reduce the length of piping.

• Install the generator as close as possible to the transfer switch. HOWEVER, REMEMBER THAT

LAWS OR CODES MAY REGULATE THE DIS-

TANCE.




◆

1.9.2 TRANSFER SWITCH

1.9.2.1 7 kW, 12 kW and 15 kW Units

Transfer switches for use with these generators are sold separately and can be purchased from Generac

Authorized Dealers.

• Install the transfer switch on a firm, sturdy supporting structure.

• To prevent switch distortion, level the switch if necessary. This can be done by placing washers between the switch enclosure and mounting surface.

• Never install the switch where water or any corrosive substance might drip onto the enclosure.

• Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and corrosive vapors.

• Failure to utilize a Generac/Guardian transfer switch with this generator will void the warranty.

1.10 BATTERY INSTALLATION

Fill the battery with the proper electrolyte fluid if necessary and have the battery fully charged before installing it.

Before installing and connecting the battery, complete the following steps:

1. Set the generator's AUTO/OFF/MANUAL switch to

OFF.

2. Turn off utility power supply to the transfer switch.

3. Remove the 5 amp and 15 amp fuses from the generator control panel.

If the AUTO/OFF/MANUAL switch is not set to its OFF position, the generator can crank and start as soon as the battery cables are connected. If the utility power supply is not turned off, sparking can occur at the battery posts and cause an explosion.

Battery cables were factory connected at the generator (Figure 1.5). Connect cables to battery posts as follows:

4. Connect the red battery cable (from starter contactor) to the battery post indicated by a positive,

POS or (+).

5. Connect the black battery cable (from frame ground) to the battery post indicated by a negative, NEG or (—).

6. Replace the 5 amp and 15 amp fuses in the generator control panel.

NOTE:

Damage will result if battery connections are made in reverse.

Figure 1.5 – Battery Cable Connections

NOTE:

The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation. With the battery installed and utility power source voltage available to the transfer switch, the battery receives a trickle charge while the engine is not running, to prevent self-discharge. The trickle charger is designed to help extend the life of the battery by maintaining the battery when the unit is not running. The trickle charge feature cannot be used to recharge a discharged battery.

1.11 THE BATTERY

Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

When replacing the battery, use the following type of battery: Group 26/26R 12-volt battery with a rating of

350 cold-cranking amps minimum for 7 kW; 525 cold-cranking amps minimum for 12 and 15 kW at

-17.8º C (0º F) minimum. When using a maintenancefree battery, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in the “Service

Schedule.” A negative ground system is used. Battery connections are shown on the wiring diagrams. Make sure the battery is correctly connected and terminals are tight. Observe battery polarity when connecting the battery to the generator set.

DANGER

Do not dispose of the battery in a fire. The battery is capable of exploding.

A battery presents a risk of electrical shock and high short circuit current. The following precautions are to be observed when working on batteries:


9

Section 2 — Post Installation Start-up and Adjustments


• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

• Do not lay tools or metal parts on top of the battery; and

• Disconnect charging source prior to connecting or disconnecting battery terminals.

!

!

Do not open or mutilate the battery. Released electrolyte has been known to be harmful to the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive.

The following procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off immediately with water;

• Where electrolyte contacts the eyes, immediately flush thoroughly with water and seek medical attention; and

• Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) or water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

Lead-acid batteries present a risk of fire because they generate hydrogen gas. The following procedures are to be followed:

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark in battery area; and

• Discharge static electricity from body before touching the battery by first touching a grounded metal surface.

!

Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.

Be sure the utility power supply is turned off, or sparking may occur at the battery posts as the cables are attached and cause an explosion.

2.1

BEFORE INITIAL START-UP

Before starting, complete the following:

1. Set the generator’s main circuit breaker to its

OFF (or open) position.

2. Set the generator's AUTO/OFF/MANUAL switch to the OFF position.

3. Turn OFF the utility power supply to the transfer switch using the means provided (such as the utility main line circuit breaker).

4. Check the engine crankcase oil level and, if necessary, fill to the dipstick FULL mark with the recommended oil. Do not fill above the FULL mark.

5. Check the fuel supply. Gaseous fuel lines must have been properly purged and leak tested in accordance with applicable fuel-gas codes. All fuel shutoff valves in the fuel supply lines must be open.

!

Never operate the engine with the oil level below the “Add” mark on the dipstick. Doing this could damage the engine.

2.2

CHECK TRANSFER SWITCH

OPERATION

Refer to Section 3.5, of the owner’s manual for manual operation procedures.

DANGER

Do not attempt manual transfer switch operation until all power voltage supplies to the transfer switch have been positively turned off.

Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock.

2.3

ELECTRICAL CHECKS

Complete electrical checks as follows:

1. Turn on the utility power supply to the transfer switch using the means provided (such as a utility main line circuit breaker).

DANGER

The transfer switch is now electrically “hot.”

Contact with “hot” parts will result in extremely hazardous and possibly fatal electrical shock.

Proceed with caution.

2. Use an accurate AC voltmeter to check utility power source voltage across terminals N1 and

N2. Nominal line-to-line voltage should be 240 volts AC.




3. Check utility power source voltage across terminals N1 and the transfer switch neutral lug; then across terminal N2 and neutral. Nominal line-toneutral voltage should be 120 volts AC.

4. When certain that utility supply voltage is compatible with transfer switch and load circuit ratings, turn OFF the utility power supply to the transfer switch.

5. Set the generator's main circuit breaker to its

OFF (or open) position. Initial tests will be conducted at no-load condition.

6. On the generator panel, set the AUTO/OFF/MAN-

UAL switch to MANUAL. The engine should crank and start.

7. Let the engine warm up for about five minutes to allow internal temperatures to stabilize. Then, set the generator’s main circuit breaker to its ON (or closed) position.

DANGER

Proceed with caution! Generator power voltage is now supplied to the transfer switch. Contact with live transfer switch parts will result in dangerous and possibly fatal electrical shock.

8. Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1 and E2. Voltage should be 242-252 volts; frequency should read about 61-63 Hertz.

9. Connect the AC voltmeter test leads across terminal lug E1 and neutral; then across E2 and neutral. In both cases, voltage reading should be 121-

126 volts AC.


OFF (or open) position. Let the engine run at noload for a few minutes to stabilize internal engine generator temperatures.


OFF. The engine should shut down.

NOTE:

It is important not to proceed until certain that generator AC voltage and frequency are correct and within the stated limits. Generally, if both AC frequency and voltage are high or low, the engine governor requires adjustment. If frequency is correct, but voltage is high or low, the generator’s voltage regulator requires adjustment.

2.4

GENERATOR TESTS UNDER LOAD

To test the generator set with electrical loads applied, proceed as follows:

1. Set generator’s main circuit breaker to its OFF

(or open) position.

2. Set the generator's AUTO/OFF/MANUAL switch to OFF.

3. Turn OFF the utility power supply to the transfer switch, using the means provided (such as a utility main line circuit breaker).

Do not attempt manual transfer switch operation until all power voltage supplies to the transfer switch have been positively turned off.

Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock.

4. Manually set the transfer switch to the STANDBY position, i.e., load terminals connected to the generator's E1/E2 terminals. The transfer switch operating lever should be down.


MANUAL. The engine should crank and start immediately.

6. Let the engine stabilize and warm up for a few minutes.

7. Set the generator’s main circuit breaker to its ON

(or closed) position. Loads are now powered by the standby generator.

8. Turn ON electrical loads. Apply an electrical load equal to the full rated wattage/amperage capacity of the installed generator.

9. Connect an accurate AC voltmeter and a frequency meter across terminal lugs E1 and E2. Voltage should be greater than 230 volts; frequency should be greater than 58 Hertz.

10. Let the generator run at full rated load for 20-30 minutes. Listen for unusual noises, vibration or other indications of abnormal operation. Check for oil leaks, evidence of overheating, etc.

11. When testing under load is complete, turn OFF electrical loads.

12. Set the generator's main circuit breakers to their

OFF (or open) positions.

13. Let the engine run at no-load for a few minutes.

14. Set the AUTO/OFF/MANUAL switch to OFF. The engine should shut down.

2.5

CHECKING AUTOMATIC

OPERATION

To check the system for proper automatic operation, proceed as follows:

1. Set the generator’s main circuit breaker to it’s


2. Check that the AUTO/OFF/MANUAL switch is set to OFF.

3. Turn OFF the utility power supply to the transfer switch using the means provided (such as a utility main line circuit breaker).


11



4. Manually set the transfer switch to the UTILITY position, i.e., load terminals connected to the utility power source side.

5. Turn ON the utility power supply to the transfer switch, using the means provided (such as a utility main line circuit breaker).

6. Set the AUTO/OFF/MANUAL switch to AUTO.

Then set the generator’s main circuit breaker to its ON (or closed) position. The system is now ready for automatic operation.

7. Turn OFF the utility power supply to the transfer switch.

With the AUTO/OFF/MANUAL switch at AUTO, the engine should crank and start when the utility source power is turned OFF. After starting, the transfer switch should connect load circuits to the standby side. Let the system go through its entire automatic sequence of operation.

With the generator running and loads powered by generator AC output, turn ON the utility power supply to the transfer switch. The following should occur:

• After about six seconds, the switch should transfer loads back to the utility power source.

• About one minute after retransfer, the engine should shut down.

2.6

ADJUSTING THE REGULATOR

(NATURAL GAS ONLY)

Although the generator has been factory set to provide maximum power, it may be necessary in some areas to adjust this setting. Because natural gas has different BTU or power content across the country the engine may not perform as designed.

If experiencing engine problems at high or full load conditions follow these steps. It will require a frequency meter to perform this procedure.

1. Turn off utility power to the main distribution panel in the house. This can be done by switching the service main breaker to the off or open position.

2. Allow the generator to start before loading the generator. Confirm the no-load frequency with the roof open and door off is set at 63-63.5 Hz.

Transfer load to emergency circuits.

3. Turn on appliances, lights, pumps, etc., that are on the emergency circuits in an attempt to fully load the generator. Be cautious not to overload the generator. Use the following chart as a guide:

Unit

7 kW

12 kW

15 kW

120 Volts

50.0 amps

100.0 amps

108.3 amps

240 Volts

25.0 amps

50.0 amps

54.2 amps


4. When full load has been achieved. Connect a frequency meter to the output lugs of the generator’s main line circuit breaker.

5. The fuel regulator is fitted with one (7 kW), or two

(12 & 15 kW) adjustment screws. While watching the frequency meter, slowly turn the adjustment screw clockwise or counterclockwise one at a time until highest frequency is read on the meter.

Only limited adjustment is available between the set pins. Under no circumstances should any of the pins be removed (Figures 2.1 and 2.2).

Figure 2.1 — Dual Fuel Regulators

V-twin 410

Adjustment

Screw

(Both Sides)

Adjustment

Screw

(One Side

Only)

Set

Pin

Set Pin

(Both Sides)

6. When the highest frequency is reached maximum power has been set. Then turn both adjustment screws 1/4 turn counterclockwise. Regulator is now set.

Figure 2.2 — Placement of Regulator

Adjustment Screw

7. Turn utility power to the main distribution panel back on. This can be done by switching the service main breaker to the on or closed position.

Allow the generator to shut down.

!

Do not make any unnecessary adjustments.

Factory settings are correct for most applications. However, when making adjustments, be careful to avoid overspeeding the engine.



If this procedure or equipment are not available, locate the nearest Generac Guardian Dealer and they can perform the adjustments.

NOTE:

A service fee may be charged for this adjustment.

2.7

ENGINE GOVERNOR ADJUSTMENT

If both AC frequency and voltage are correspondingly high or low, adjust the engine governor as follows:

◆

2.7.1

7 KW UNITS

1. Loosen the governor clamp bolt (Figures 2.3 and

2.4).

2. Hold the governor lever at its wide open throttle position, and rotate the governor shaft clockwise as far as it will go. Then, tighten the governor lever clamp bolt to 70 inch-pounds (8 N-m).

3. Start the generator; let it stabilize and warm up at no-load.

4. Connect a frequency meter across the generators

AC output leads.

5. Turn the speed adjust nut to obtain a frequency reading of 63 Hz.

6. When frequency is correct at no load, check the

AC voltage reading. If voltage is incorrect, the voltage regulator may require adjustment.

Figure 2.3 — Single Cylinder Engine Governor

Adjustment

GOVERNOR

SHAFT

GOVERNOR

CLAMP

BOLT

ADJUST

SCREW

◆

2.7.2

12 KW AND 15 KW UNITS

1. Loosen governor clamp bolt (See Figure 2.4).

Figure 2.4 — V-twin Engine Governor

Adjustment

Governor

Shaft

(Rotate

Clockwise)

Idle Spring

Governor Clamp Bolt

No Load Idle

Adjustment Screw

2. Completely remove the idle spring.

3. With governor arm at wide open throttle position, rotate governor shaft fully clockwise. Tighten clamp bolt to 84 inch-pounds.

4. Start unit and apply full load. Use full load speed adjust screw (Figure 2.5) to adjust frequency to

58 Hz.

5. Remove load, stop engine, loosen the idle adjust screw and reconnect the idle spring.

6. Using a hand, push the governor arm to the closed throttle position. Make sure the idle spring does not stretch at all.

7. Restart the unit.

8. Slowly turn the idle adjust screw to adjust the noload idle frequency to 63-63.5 Hz.

9. The governor is now set.

Figure 2.5 — V-twin Full Load Speed Adjust

Screw

Full Load Speed Adjust Screw


13

Section 3 — Operation


◆

2.7.3

ADDITIONAL CORROSION

PROTECTION

Periodically spray all engine linkage parts and brackets with corrosion inhibiting spray such as WD-40 or a comparable product.

2.8

VOLTAGE REGULATOR

ADJUSTMENT

With the frequency between 62-63.5 Hertz, slowly turn the slotted potentiometer (Figure 2.6) until line voltage reads 244-252 volts.

NOTE:

Remove the access panel on top of the control panel to adjust the voltage regulator.

Figure 2.6 – Voltage Adjustment Potentiometer

NOTE:

The voltage regulator is housed above the generator's control panel. The regulator maintains a voltage in direct proportion to frequency. For example, at 62 Hertz, line-to-neutral voltage will be 124 volts.

3.1

BREAK-IN PROCEDURE

Once the unit has been installed, with utility power connected to the transfer switch, and all electrical checks have been made, it is strongly recommended that the following “Break-in Procedure” be completed to ensure correct generator operation in the future.

1. Set the generator’s AUTO/OFF/MANUAL switch to

AUTO.


3. The unit will start, and the transfer switch will transfer to standby.

4. Run the unit for one hour at 25 percent load.





8. Turn ON the utility power supply to the transfer switch, which will allow the transfer switch to transfer back to utility power. The unit will continue to run for one minute and then shut down.

9. Allow the unit to cool.

10. Drain the oil and remove the oil filter. Replace the oil filter according to Section 4.4, “Changing the

Oil Filter”. Replace the oil with synthetic oil as recommended in Section 4.3, “Changing the

Engine Oil”.

11. The generator is now ready for service.

3.2

USING THE AUTO/OFF/MANUAL

SWITCH (FIGURE 3.1)

3.2.1 “AUTO” POSITION

Selecting this switch position activates fully automatic system operation. It also permits starting and exercising the engine every seven days with the setting of the exercise timer (see Section 3.6). This position also is used for remote starting, when it is set up.

3.2.2 “OFF” POSITION

This switch position shuts down the engine. This position also prevents automatic operation.

3.2.3 “MANUAL” POSITION

Set the switch to MANUAL to crank and start the engine. Transfer to standby power will not occur unless there is a utility failure.

Figure 3.1 – Generator Control Panel

FUSE

5A

FUSE

15A

AUTO OFF MAN.

SET

EXERCISE

TIME

L o c a t e y o u r n e a r e s t

R d e a le r a t :

R

POWER SYSTEMS, INC.

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

F L A S H IN G G R E E N

N O U T IL IT Y

4 F L A S H IN G R E D

L E D =

S E N S E

L E D S =

E X E R C IS E R N O T S E T

!

With the switch set to AUTO, the engine may crank and start at any time without warning.

Such automatic starting normally occurs when utility power source voltage drops below a preset level or during the normal exercise cycle. To prevent possible injury that might be caused by such sudden starts, always set the switch to

OFF and remove both fuses before working on or around the generator or transfer switch.

Then, place a “Do Not Operate” tag on the generator panel and on the transfer switch.



3.3

AUTOMATIC TRANSFER

OPERATION

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts are set to their “Utility” position, i.e., loads connected to the utility power source (Figure 3.2).

2. Be sure that normal utility power source voltage is available to transfer switch terminal lugs N1 and N2.

3. Set the generator’s AUTO/OFF/MANUAL switch to

AUTO.


(or closed) position.

With the preceding steps complete, the generator will start automatically when utility source voltage drops below a preset level. After the unit starts, loads are transferred to the standby power source. Refer to

Section 3.4, “Sequence of Automatic Operation.”

3.4

SEQUENCE OF AUTOMATIC

OPERATION

The generator’s control panel houses a control logic circuit board. This board constantly monitors utility power source voltage. Should that voltage drop below a preset level, circuit board action will signal the engine to crank and start. After the engine starts, the circuit board signals the transfer switch to activate and connect load circuits to the standby power supply (load terminal lugs T1/T2 connect to terminal lugs E1/E2).

Upon restoration of utility source voltage above a preset level, generator circuit board action signals the transfer switch to transfer loads back to that power supply. After retransfer, the engine is signalled to shut down.

The actual sequence of operation is controlled by sensors and timers on a control logic circuit board, as follows:

A. Utility Voltage Dropout Sensor

• This sensor monitors utility source voltage.

• If utility source voltage drops below about 70 percent of the nominal supply voltage, the sensor energizes a 15-second timer.

• Once the timer has expired, the engine will crank and start.

B. Engine Warm-up Time Delay

• This mechanism lets the engine warm up for about 10 seconds before the load is transferred to a standby source.

C.Standby Voltage Sensor

• This sensor monitors generator AC output voltage. When the voltage has reached 50 percent of the nominal rated voltage, transfer to standby can occur.

D.Utility Voltage Pickup Sensor

• This sensor monitors utility power supply voltage. When that voltage is restored to above 70 percent of the nominal source voltage, a retransfer time delay starts timing.

E.Retransfer Time Delay

• This timer runs for about 15 seconds.

• At end of a 15-second delay, circuit board action de-energizes the transfer relay in the transfer switch.

• Retransfer to utility power source then occurs.

F. Engine Cool-down Timer

• When the load is transferred back to utility power source, the engine cool-down timer starts timing.

• The timer will run for about one minute, and the generator will then shut down.

3.5

MANUAL TRANSFER OPERATION

3.5.1 TRANSFER TO GENERATOR

POWER SOURCE

To start the generator and activate the transfer switch manually, proceed as follows:



2. Set the generator’s AUTO/OFF/MANUAL switch to OFF.


DANGER

Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off.

Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock.

4. Use the manual transfer handle inside the transfer switch to move the main contacts to their

“Standby” position, i.e., loads connected to the standby power source (Figure 3.2).

5. To crank and start the engine, set the AUTO/OFF/

MANUAL switch to MANUAL.

6. Let the engine stabilize and warm up for a few minutes.


(or closed) position. The standby power source now powers the loads.


15



Figure 3.2 – Manual Transfer Switch Operation

3.5.2 TRANSFER BACK TO UTILITY POWER

SOURCE

When utility power has been restored, transfer back to that source and shut down the generator. This can be accomplished as follows:



2. Let the engine run for a minute or two at no-load to stabilize the internal temperatures.

3. Set the generator’s AUTO/OFF/MANUAL switch to its OFF (or open) position. The engine should shut down.

4. Check that utility power supply to the transfer switch is turned OFF.

DANGER

Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off.

Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock.

5. Use the manual transfer handle inside the transfer switch to move the main contacts back to their

“Utility” position, i.e., loads connected to the utility power source (Figure 3.2).

6. Turn ON the utility power supply to the transfer switch using the means provided.

7. Set the system to automatic operation as outlined in “Automatic Transfer Operation,” Section 3.3.

3.6

SETTING THE EXERCISE TIMER

The generator is equipped with an exercise timer.

Once it is set, the generator will start and exercise once every seven days, on the day of the week and at the time of day the following sequence is completed.

During this exercise period, the unit runs for approximately 12 minutes and then shuts down. Transfer of loads to the generator output does not occur during the exercise cycle.

A switch on the control panel (see Figure 3.1) permits selection of the day and time for system exercise. To select the desired day and time of day, the following sequence must be performed at that time.

1. Verify that the AUTO/OFF/MANUAL switch is set to AUTO.

2. Hold down the set timer switch until the generator starts (approximately 10 seconds) and then release.

3. The generator will start and run for approximately

12 minutes and then shut down on its own. The exerciser will then be set to run at that time of day every week.

NOTE:

The exerciser will only work in the AUTO mode and will not work unless this procedure is performed. The exerciser will need to be reset every time the 12-volt battery is disconnected and then reconnected. The exerciser WILL NOT work if dip switch 2 (Remote Not Auto) on the controller printed circuit board is ON.

3.7

PROTECTION SYSTEMS

3.7.1

LOW OIL PRESSURE SWITCH

This switch (Figure 3.3) has normally closed contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure drop below the

8 psi range, switch contacts close, and the engine shuts down. The unit should not be restarted until oil is added, and the AUTO/OFF/MANUAL switch must be turned to OFF and then back to AUTO.

3.7.2

HIGH TEMPERATURE SWITCH

This switch’s contacts (Figure 3.3) close if the temperature should exceed approximately 140º C (284º

F), initiating an engine shutdown. The generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level.


Section 4 — Maintenance


Figure 3.3 – Low Oil Pressure and

High Temperature Switches

Low Oil Switch

High Temp Switch

Loose n

Oil

Drain

Hose

Oil Filter

3.7.3

OVERCRANK

This feature prevents the generator from damaging itself when it continually attempts to start and another problem, such as no fuel supply, prevents it from starting. The unit will crank and rest for a preset time limit. Then, it will stop cranking, and the LED will light indicating an overcrank failure. The

AUTO/OFF/MANUAL switch will need to be set to OFF and then back to AUTO to reset the generator control board.

NOTE:

If the fault is not repaired, the overcrank feature will continue to activate.

3.7.3.1 Approximate Crank Cycle Times

• 15 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• Repeat for 45 seconds

Approximately 90 seconds total

3.7.4

OVERSPEED

This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit. This protection also prevents the generator from supplying an output that could potentially damage appliances connected to the generator circuit. Contact the nearest Generac Authorized Dealer if this failure occurs.

4.1

FUSE

The generator panel’s 15 amp fuse (Figure 4.1) protects the DC control circuit against overload. The fuse is wired in series with the battery output lead to the panel.

If the fuse element has melted open, the engine cannot crank or start. Replace the fuse using only an identical

15-amp replacement.

The generator panel’s 5 amp fuse protects the battery charge circuit against overload. If the fuse element has melted open, battery charging capability will not be possible. Replace the fuse using only an identical 5 amp replacement. To remove fuse, push cap down and rotate counterclockwise.

Figure 4.1 – Generator Control Panel

FUSE

L o c a t e y o u r n e a r e s t R d e a le r a t :

5A

FUSE

15A

AUTO OFF MAN.

R

POWER SYSTEMS, INC.

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

F L A S H IN G G R E E N

N O U T IL IT Y

4

L E D =

S E N S E

F L A S H IN G R E D L E D S =

E X E R C IS E R N O T S E T

SET

EXERCISE

TIME

4.2

CHECKING THE ENGINE

OIL LEVEL

For oil capacities, see “Specifications,” Section 1.5.

For engine oil recommendations, see Section 4.3.1.

To check the engine oil level, proceed as follows

(Figure 4.2):

1. Start the generator by moving the Auto/

Off/Manual switch to the MANUAL position. Allow it to run for a short while and then shut it down by moving the switch to the OFF position.

Figure 4.2 — Oil Dipstick and Fill, 7 kW

Oil Dipstick and Fill

2. Remove the dipstick and wipe it dry with a clean cloth.

3. Install the dipstick; then, remove it again. The oil level should be at the dipstick “Full” mark. If necessary, add oil to the “Full” mark only. DO NOT

FILL ABOVE THE “FULL” MARK.

!

Never operate the engine with the oil level below the “Add” mark on the dipstick. Doing this could damage the engine.


17



4. Install the dipstick.

5. Reset the AUTO/OFF/MANUAL switch to its original position.

Figure 4.3 — Oil Dipstick and Fill,

12 kW and 15 kW

Oil Dipstick

4.3

4.3.1 ENGINE OIL RECOMMENDATIONS

Use oil of American Petroleum Institute (API) Service

Class SG, SH or SJ. Use all season SAE 5W-30

Synthetic oil. Organic break-in oil is required before using synthetic oil.

NOTE:

The unit is supplied with “break-in” oil. See the

“Break-in Procedure,” Section 3.1, for the first required oil change.

!

CHANGING THE ENGINE OIL

Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure.

4.3.2 OIL CHANGE PROCEDURE

To change the oil, proceed as follows:

1. Run the engine until it is thoroughly warmed up then shut OFF the engine.

2. Immediately after the engine shuts OFF, pull the oil drain hose (Figure 4.4) free of its retaining clip. Remove the cap from the hose and drain the oil into a suitable container.

3. After the oil has drained, replace the cap onto the end of the oil drain hose. Retain the hose in the clip.

4. Refill with the proper recommended oil (see

Section 4.3.1). See Section 1.5.2 for oil capacities.


Oil Fill

Figure 4.4 – Oil Drain Hose and Filter

Loose n

Oil

Drain

Hose

Oil Filter

4.4

CHANGING THE OIL FILTER

Change the engine oil filter as follows:

1. With the oil drained, remove the old oil filter by turning it counterclockwise.

2. Apply a light coating of clean engine oil to the gasket of the new filter. See Section 1.5.1 for recommended filter.

3. Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter. Then, tighten the filter an additional 3/4 to one turn (Figure 4.4).

4. Refill with the proper recommended oil (see

Section 4.3.1). See Section 1.5.2 for oil capacities.

5. Start the engine and check for leaks.

4.5

CHANGING THE ENGINE

AIR CLEANER

4.5.1 7 KW, 12 KW AND 15 KW

GENERATORS

See Figures 1.1 and 1.2, for the location of the air cleaner. Use the following procedure (Figure 4.6):

1. Turn the two screws counterclockwise to loosen.

2. Remove the cover and air filter.

3. Wipe away dust or debris from inside of the air box and around edges.

4. Install the new air cleaner into the air box.

5. Install the cover. Turn the two cover screws clockwise to tighten.

See the “Service Schedule,” Section 4.13 for air cleaner maintenance. See Section 1.5.1 for air filter replacement part number.



Figure 4.6 — 7 kW, Engine Air Cleaner Location

Air Cleaner

Fuel

Regulator

Figure 4.8 – Setting the Spark Plug Gap

SET PLUG GAP AT 0.76 mm/0.50 mm

(0.030 inch/0.020 inch)

Figure 4.7 — 12 kW and 15 kW Engine

Air Cleaner

Screw

Cover

Filter

4.6

SPARK PLUG(S)

Reset the spark plug(s) gap or replace the spark plug(s) as necessary. See Section 4.13 for maintenance requirements.

1. Clean the area around the base of the spark plug(s) to keep dirt and debris out of the engine.

Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plug(s) to clean.

2. Remove the spark plug(s) and check the condition. Replace the spark plug(s) if worn or if reuse is questionable. See Section 4.13 for recommended inspection.

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.76 mm (0.030 inch) for

7 kW and 0.50 mm (0.020 inch) for 12/15 kW by carefully bending the ground electrode (Figure

4.8).

4.7

BATTERY MAINTENANCE

The battery should be inspected per the “Service

Schedule,” Section 4.13. The following procedure should be followed for inspection:

1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER

ONLY. DO NOT USE TAP WATER IN BATTERIES.

3. Have the state of charge and condition checked.

This should be done with an automotive-type battery hydrometer.

DANGER

Do not dispose of the battery in a fire. The battery is capable of exploding.

A battery presents a risk of electrical shock and high short circuit current. The following precautions are to be observed when working on batteries:

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

• Do not lay tools or metal parts on top of the battery; and

• Disconnect charging source prior to connecting or disconnecting battery terminals.

!

Do not open or mutilate the battery. Released electrolyte has been known to be harmful to the skin and eyes, and to be toxic.

!

The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off immediately with water;


19



• Where electrolyte contacts the eyes, immediately flush thoroughly with water and seek medical attention; and

• Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) or water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

Lead-acid batteries present a risk of fire because they generate hydrogen gas. The following procedures are to be followed:

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark in battery area; and

• Discharge static electricity from body before touching the battery by first touching a grounded metal surface.

!

Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.

Be sure the utility power supply is turned off, and the 5A fuse is removed from the generator control panel, or sparking may occur at the battery posts as the cables are attached, causing an explosion.

4.8

ADJUSTING VALVE CLEARANCE

After the first 50 hours of operation, adjust the valve clearance in the engine.

Important: If feeling uncomfortable about doing this procedure or the proper tools are not available, please contact the Generac Authorized dealer for service assistance. This is a very important step to insure longest life for the engine.

To adjust valve clearance:

• Make sure the engine is at room temperature.

• Make sure that the spark plug wire is removed from the spark plug and out of the way.

• Remove the four screws attaching the valve cover with a #2 or #3 phillips screwdriver.

• Make sure the piston is at Top Dead Center (TDC) of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut.

Use a large socket and socket wrench to rotate the nut and hence the engine. While watching the piston through the spark plug hole. The piston should move up and down. The piston is at TDC when it is up as high as it can go.

• Loosen the rocker jam nut. Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge. Correct clearance is 0.002-0.004

inch (0.05-0.1 mm).

NOTE:

Hold the rocker arm jam nut in place as the pivot ball stud is turned.

When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque.

After tightening the jam nut, recheck valve clearance to make sure it did not change.

Figure 4.10 - Valve Clearance Adjustment

Pivot Ball

Stud

Rocker

Arm

Jam Nut

Valve

Stem

• Install new valve cover gasket.

• Re-attach the valve cover.

NOTE:

Start all four screws before tightening or it will not be possible to get them in place. Make sure the valve cover gasket is in place.

• Re-attach the spark plug wire to the spark plug.

• Repeat the process for the other cylinder.

4.9

COOLING SYSTEM

Air inlet 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/generator quickly overheats, which causes it to quickly shut down. (See Figure 4.9 for vent locations.)

The exhaust from this product gets 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.




Figure 4.9 – Cooling Vent Locations

6. Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase.

7. Remove the spark plug(s) and spray fogging agent into the spark plug(s) threaded openings. Reinstall and tighten the spark plug(s).

8. Remove the battery and store it in a cool, dry room on a wooden board. Never store the battery on any concrete or earthen floor.

9. Clean and wipe the entire generator.

4.12.2 RETURN TO SERVICE

To return the unit to service after storage, proceed as follows:

!

The maximum ambient temperature for the generator is 48.9° C (104° F).

4.10 ATTENTION AFTER SUBMERSION

If the generator has been submerged in water, it MUST NOT be started and operated. Following any submersion in water, have a Generac Authorized Dealer thoroughly clean and dry the generator.

4.11 CORROSION PROTECTION

Periodically wash and wax the enclosure using automotive type products. Frequent washing is recommended in salt water/coastal areas. Spray engine linkages with a light oil such as WD-40.

4.12 OUT OF SERVICE PROCEDURE

4.12.1 REMOVAL FROM SERVICE

If the generator cannot be exercised every seven days, and it is to be out of service longer than 90 days, prepare the generator for storage as follows:

1. Start the engine and let it warm up.

2. Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down.

3. Once the unit has shut down, it will signal a low oil fault.

4. Set the AUTO/OFF/MANUAL switch to OFF and turn off the utility power to the transfer switch. Remove both fuses from the generator control panel.

5. While the engine is still warm from running, drain the oil completely. Refill the crankcase with oil. See

”Engine Oil Recommendations,” Section 4.3.1.

1. Set the generator’s main circuit breaker to its OFF

(or open) position.

2. Verify that utility power is turned off and that the

AUTO/OFF/MANUAL switch is set to OFF.

3. Check the tag on the engine for oil viscosity and classification. Verify that the correct recommended oil is used in the engine (see Section 4.3.1). If necessary, drain and refill with the proper oil.

4. Check the state of the battery. Fill all cells of unsealed batteries to the proper level with distilled water. DO NOT USE TAP WATER IN THE BATTERY.

Recharge the battery to 100 percent state of charge, or, if defective, replace the battery. See

“Specifications,” Section 1.5, for type and size.

5. Clean and wipe the entire generator.

6. Remove both fuses from the generator control panel.

7. Reconnect the battery. Observe battery polarity.

Damage may occur if the battery is connected incorrectly. Replace the fuses in the generator control panel.

8. Open the fuel shutoff valve.

9. Start the unit by moving the AUTO/OFF/MANUAL switch to MANUAL. Allow the unit to warm up thoroughly.

10. Stop the unit and set the AUTO/OFF/MANUAL switch to AUTO. Set the generator’s main circuit breaker to its ON (or closed) position.

11. Turn on the utility power to the transfer switch.

12. The generator is now ready for service.

NOTE:

If the battery was dead or disconnected, the exercise timer must be reset.


21



4.13 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work be performed by the nearest Generac Authorized Dealer.

SYSTEM/COMPONENT

X = Action

R = Replace as Necessary

* = Notify Dealer if Repair is Needed.

FUEL

Fuel lines and connections*

LUBRICATION

Oil level

Oil

Oil filter

COOLING

Enclosure louvers

BATTERY

Remove corrosion, ensure dryness

Clean and tighten battery terminals

Check charge state

Electrolyte level

(unsealed batteries only)*

ENGINE AND MOUNTING

Air cleaner

Spark plug(s)

GENERAL CONDITION

Vibration, Noise, Leakage,

Temperature*

COMPLETE TUNE-UP*

Inspect

X

X

X

X

X

X

X

X

X

PROCEDURE

Change

X

X

R

R

R

R

Clean

X

X

TO BE COMPLETED BY A GENERAC

AUTHORIZED DEALER

X

X

FREQUENCY

W = Weekly

M = Monthly

Y = Yearly

M

M

AFTER BREAK-IN,

AND Y

AFTER BREAK-IN,

AND Y

W

M

M

EVERY 6 M

EVERY 6 M

M

Y

Y

Y


Section 5 — Troubleshooting


PROBLEM

The engine will not crank.

The engine cranks but will not start.

CAUSE CORRECTION

1. Fuse blown 1. Replace 15A fuse on generator control panel.

2. Loose, corroded or defective battery cables

2. Tighten, clean or replace as necessary.

3. Defective starter contactor (7 kW) 3. *

4. Defective starter motor

5. Dead Battery

4. *

5. Charge or replace battery.

1. Out of fuel

2. Defective fuel solenoid (FS)

3. Open #14 wire from engine control board

4. Defective spark plug(s)

5. Valve lash out of adjustment.

1. Replenish fuel.

2. *

3. *

4. Clean, re-gap or replace plug(s).

5. Reset valve lash.

The engine starts hard and runs rough.

1. Air cleaner plugged or damaged

2. Defective spark plug(s)

3. Fuel regulator not set.

4. Fuel pressure incorrect.

1. Check, replace air cleaner.

2. Clean, re-gap or replace plug(s).

3. Set fuel regulator.

4. Confirm fuel pressure is at (0.4-

0.5 psi) for LP, and 5-7” water colum (0.18-0.25 psi) for natural gas.

The AUTO/OFF/MANUAL switch 1. Defective switch is set to OFF, but the engine continues to run.

2. AUTO/OFF/MANUAL switch wired incorrectly

3. Defective control board

There is no AC output from the generator.

1. *

2. *

3. *

1. Main line circuit breaker open 1. Reset circuit breaker to ON (or closed).

2. Generator internal failure 2. *

There is no transfer to standby after utility source failure.

1. Defective transfer switch coil

2. Defective transfer relay

3. Transfer relay circuit open

4. Defective control logic board

1. *

2. *

3. *

4. *

Unit consumes large amounts of oil.

1. Break-in procedure not followed (see Section 3.1)

1. *

*Contact the nearest Generac Authorized Dealer for assistance.


23

Section 6 — Electrical Data


Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-B

SP1

SP2

DIAGRAM KEY

BA - BRUSH ASSEMBLY

BCR - BATTERY CHARGE RELAY

CB1 - MAIN OUTPUT BREAKER

CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION

D - DIODE

DSW - PCB MOUNTED DIP SWITCH

FS - FUEL SOLENOID

F1 - FUSE 15 AMP

F2 - FUSE 5 AMP

GRD - CONTROL PANEL GROUND

HTO - HIGH OIL TEMPERATURE SWITCH

IC - INLINE CONNECTOR

ICT - INTERCONNECTION TERMINALS

IM1 - IGNITION MODULE, CYLINDER #1


LOP - LOW OIL PRESSURE SWITCH

SC - STARTER CONTACTOR

SCR - STARTER CONTACTOR RELAY

SP1, SP2 - SPARK PLUGS

SW1 - AUTO / OFF / MANUAL SWITCH

SW2 - SET EXERCISE SWITCH

SM - STARTER MOTOR

TB - INSULATED TERMINAL BLOCK

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)

ENGINE WIRING

14

FS

0

14

BLACK

HTO

0

LOP

0

-

12V

BATTERY

IM1

IM2

+

CUSTOMER SUPPLIED

D

D

85

86

0

3

2

1

BATTERY

CHARGER

13A

0

2

1

224B

225B

0

14

13A

0

224B

225B

14

0

IC

IC

IC

RED

SM

SC

TB

0 6

18

86

85

4

3

13

1

C1

13

16

13

16

14

13

0

13

13

16

SCR

13

18

351

A B

86

85

56

0

56

351

CONTROL

PRINTED CIRCUIT BOARD

DSW

1 2 3

J2

4 5

14

86

J1

18

56

4

86

23

194

56

18

14

66A

239

15A

17

15

0

224

225

18

56

14

1 - 20 Vac Sense Transformer

2 - Remote Not Auto

3 - 50 Hz Operation

4 - SPARE

L.E.D - ALARM INDICATORS




Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-B

225

224

224A

225A

CONTROL PANEL BOX

0

224B

0

225

224

TX

0

13A

N1 N2

225B

0

66

225B

224B

14

13A

N2

N1

11

22

4

0

6

162

VOLTAGE

REGULATOR

0

66A

4

224A

BCR

1 3

4 6

7 9

A B

225A

77

66

0

11

22

4

0

162

6

4

66A

225

13

13

CB2

162

2

351

13

224

0

77

66

4

11

2

6

22

6

5

55

0

3

2

1

C2

10

9

8

55

GRD

194

23

4

194

23

13

17

15

225

224

0

66A

15A

239

13

N2

N1

13

13A

15A

13

0

351

F2 F1

13

15

17

15

17

SW1

AUTO

239

MANUAL

351

1a

1

1b

SW2

0

CB1

CLOSEST TO BEARING

4

0

2

6 11

22

55

66A

66

77

11

44

11

44

OFF

240V GENERATOR

OUTPUT TO TRANSFER

SWITCH CONTACTOR

CUSTOMER

CONNECTION

33

22

STATOR

33

22

194

23

N2

N1


25



Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-B

11

22

225A

224A

F2

225A

3

2

1

BATTERY

CHARGER

225B

224B

225

224A

13A

2

1

13A

7 7

6 3

9

4

BCR

13

F1

224

11

0

13A

ELECTRONIC

VOLTAGE

REGULATOR

22

0

77

C2-1

11

22

4

0

C2-10

4

6

162

CB2

C2-8

C2-11

2

0

BA

FIELD

C2-7

(STATOR)

6

0

77

BATTERY CHARGE

WINDING

66

0

0

C2-9

0

C2-4

55

ENGINE RUN

WINDING

(STATOR)

C2-3

4

C2-2

HTO

C1-4

66

0

0

SW2

66A

85

C1-6

0 351

1 2 3 4

J2

5

DIAGRAM KEY

BA - BRUSH ASSEMBLY


CB1 - CIRCUIT BREAKER, MAIN OUTPUT

CB2 - CIRCUIT BREAKER, ALT. EXCITATION

D - DIODE

FS - FUEL SOLENOID

F1 - FUSE 15 AMP

F2 - FUSE 5 AMP





SC - STARTER CONTACTER

SCR - STARTER CONTACTOR RELAY

SP1, SP2 - SPARK PLUGS



SM - STARTER MOTOR


CONTROL

PRINTED CIRCUIT

BOARD

0

14

66A

C1-3

4

0

86

LOP

14

J1

9

10

1

2

3

5

7

12

14

23

4

86

23

194

56

18

14

66A

239

15A

17

15

194

0

225

224

16

17

15

0

225

224

14

15

23

194

13

66A

239

15A




Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-B

11

225A

224A

225

56VA

1VA

224

TX

N2

N1

22

C2-6

N2

C2-5

N1

N1

N2

23

194

240VAC

UTILITY

INPUT

12Vdc

TRANSFER

RELAY

COIL

CUSTOMER

CONNECTIONS

13

17

15A

0

15A

13

17

0

23

194

15

239

14

15

13

56

18

17

15

0

0

SCR

13

16

C1-1

16

15

239

SC

0

0

15

0

18

18

SW1

C1-5

194

23

11

22

14

FS

0

D

POWER

WINDING

(STATOR)

C2-1

IM1

SP1

33

44

CB1

11

SM

NEUTRAL

120V

240V

SC

RED

BLACK

120V

D

IM2

SP2

BATTERY

12V

CUSTOMER

SUPPLIED


27



Wiring Diagram – 7 kW – Drawing No. 0D9013-C

DIAGRAM KEY

BA - BRUSH ASSEMBLY


CB1 - MAIN OUTPUT BREAKER

CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION

D - DIODE

DSW - PCB MOUNTED DIP SWITCH

FS - FUEL SOLENOID

F1 - FUSE 15 AMP

F2 - FUSE 5 AMP

GRD - CONTROL PANEL GROUND


IC - INLINE CONNECTOR

ICT - INTERCONNECTION TERMINALS

IM - IGNITION MODULE


SC - STARTER CONTACTOR

SP - SPARK PLUG



SM - STARTER MOTOR

TB - INSULATED TERMINAL BLOCK


ENGINE WIRING

14

14

FS

0

SP

HTO

LOP

BLACK

-

IM

85

+

12V

BATTERY

86

CUSTOMER SUPPLIED

D

0

3

1

BATTERY

CHARGER

(UTILITY)

2

1

224B

225B

13A

0

14

225B

13A

0

14

224B

IC

IC

IC

13

RED

SM

0

0

18

86

14

0

85

13 2

1

C1

4

3

6

5

0

56

SC

16

56

14

13

86

85

56

18

351

56

1 2 3

J2

4 5

J1

CONTROL

PRINTED CIRCUIT BOARD

DSW

ON

1 - 20 Vac Sense Transformer

2 - Remote Not Auto

3 - 50 Hz Operation

4 - SPARE

L.E.D - ALARM INDICATORS

4

0

0

13

4

23

56

14

18

194

17

15

0

224

66A

15A

239

225




Wiring Diagram – 7 kW – Drawing No. 0D9013-C

CONTROL PANEL BOX

225

224

224A

225A

224A

225A

TX

351

CB2

0

4

225

224

13A

0

225B

224B

N1

N2

14

225B

224B

14

66

66

0

77

N1

N2

13A

N2

N1

11

22

4

0

6

162

VOLTAGE

REGULATOR

0

0

66A

4

13

11

22

4

4

0

162

6

4

162

2

4

10

2 8

7

0 77

6

66

11

22

55

0

5

4

2

1

C2

0

66A

55

225

0

GRD

224 0

CLOSEST TO BEARIN

4

0

2

6

11

22

55

66A

66

77

11

44

33

22

194

23

N2

66A

N1

66A

239

15A

15

0

23

194

13A

13

351

0

F2

13

15A

13

F1

15

17

15

AUTO

SW1

239

351

SW2

0

CB1

11

44

OFF

33

22

MANUAL

240V GENERATOR

OUTPUT TO TRANSFER

SWITCH CONTACTOR

CUSTOMER

CONNECTION

STATOR

194

23

N2

N1


29



Electrical Schematic – 7 kW – Drawing No. 0D9014-C

11

11

22

0

13A

3

2

1

BATTERY

CHARGER

13A

2

1

225B

224B

13A

225A

224A

9 9 7

1 6 3

7

4

BCR

F2

13

F1

11

22

225A

225

224A

224

ELECTRONIC

VOLTAGE

REGULATOR

22

0

77

11

22

BA

FIELD

4

0

C2-10

4

0

6

162

CB2

C2-8

6

2

C2-7

2

DPE WINDING

(STATOR)

6

C2-1

77

BATTERY CHARGE

WINDING

66

66

C2-2

0

0

C2-9

0

C2-4

55

ENGINE RUN

WINDING

(STATOR)

C2-3

4

66A

HTO

C1-4

0

0

85

SW2

C2-11

0

351

1 2 3

J2

4 5

DIAGRAM KEY

BA - BRUSH ASSEMBLY


CB1 - CIRCUIT BREAKER, MAIN OUTPUT

CB2 - CIRCUIT BREAKER, ALT. EXCITATION

D - DIODE

FS - FUEL SOLENOID

F1 - FUSE 15 AMP

F2 - FUSE 5 AMP


HM - HOUR RUN METER

IM - IGNITION MODULE


SC - STARTER CONTACTER

SP - SPARK PLUG



SM - STARTER MOTOR


CONTROL

PRINTED CIRCUIT

BOARD

0

14

66A

C1-3

4

0

86

LOP

14

J1

3

4

5

6

1

23

4

86

194

23

194

56

18

8

10

11

12

13

66A

239

15A

17

15

0

225

224 15

16

17

0

15

13

225

224

14

194

15

66A

23

239




Electrical Schematic – 7 kW – Drawing No. 0D9014-C

11

225A

56VA

224A

225

1VA

224

TX

N2

N1

22

C2-6

N2

C2-5

N1

N1

N2

23

194

240VAC

UTILITY

INPUT

12Vdc

TRANSFER

RELAY

COIL

14

56

18

0

17

13

15A

17

15

17

0

0

0

18

0

17

23

194

239

15

15A

SW1

15

239

194

23

11

22

33

POWER

WINDING

(STATOR)

44

CB1

11

15

13

C1-2

SC

RED

14

C1-1

56 14

SM

SC

0

C1-6

FS

0

0 BLACK

C1-5

18

D

IM

SP

NEUTRAL

120V

120V

240V

BATTERY

12V

CUSTOMER

SUPPLIED

CUSTOMER

CONNECTIONS


31

Section 7 — Exploded Views and Parts Lists


Enclosure – Drawing No. 0F0080-B

26

35

49

2

46

43

3

PRE PACKAGED UNITS ONLY

76

4

82

80

77

48

79

80

87

72

86

5

72

49

74

46

8

49

41

40 68

73

52

19

31

11

49

51

50

9

35

49

91

57

27

1

56

5

44

60

12

63

97

6

16

65

22

69

71

49

30

75

55

14

17

1

28

29

47

54

35

25

93

51 3

37

42

39

51

21

34

33

94

10

20

18

52

4

25

35

91

63

92

15

71

69

68




Enclosure – Drawing No. 0F0080-B

0C8284C

0C8285

0C8899A

0D1128

0D1128A

0E4244

0D1605A

0D1606

0D5264

0D1839

0D1840

0D2425

0D2588

0D2588A

0D2676

0D2677

0C6140

0D1901

0C6735

0F0063

0C7062

0C7062A

0F0066

0F0066A

0E9873

0C7065

0C7065A

0C8101A

0C8861

0C8101B

0C8862

0C8283

0C8284A

0C8284B

0D2979B

0D2979B

0D2979C

0D2979D

0D2979E

0E4245

0D3058A

0E4245A

0E4245B

0D3058C

0D3057D

0D3059A

0D3059B

0D3059C

0D7176

0D3059D

0D3059E

0C7781A

0D3037

0F0164

0F0165

0D3037A

0A2115

022097

23

24

25

19

20

21

22

26

27

17

18

40

41

42

43

44

36

37

38

39

31

32

33

34

35

28

29

30

8

9

13

14

15

16

10

11

12

6

7

1

2

3

4

5

ITEM PART NO. QTY. DESCRIPTION

1 ASSEMBLY, ENCLOSURE BASE

1 ASSEMBLY, ENCLOSURE BASE (7KW)

2 SUPPORT, ROOF FOLDING

1 ENCLOSURE, FRONT

1 ENCLOSURE, EXHAUST SIDE

1 ENCLOSURE, EXHAUST SIDE (7KW)

1 ENCLOSURE, SIDE & BACK

1 ENCLOSURE, SIDE & BACK (7KW)

1 ENCLOSURE, ROOF

1 PANEL, ALTERNATOR DIVIDER

1 PANEL, ALTERNATOR DIVIDER (7KW)

1 PANEL, MUFFLER BOX SIDE

1 PANEL, MUFFLER BOX SIDE (7KW)

1 COVER, MUFFLER BOX

1 COVER, MUFFLER BOX (7KW)

1 GASKET, DOOR SEAL

1 FOAM, BACK ENCLOSURE

1 FOAM, ROOF ENCLOSURE

1 FOAM, FRONT ENCLOSURE

1 BRACKET, BATTERY SUPPORT

1 PAD, 24"X48" WITH MOUNTING HOLES

1 PANEL, ENGINE DIVIDER

1 PANEL, ENGINE DIVIDER (7KW)

1 BAFFLE, INTAKE

1 BAFFLE, INTAKE (7KW)

1 HOUSING, FAN

1 BAFFLE, EXHAUST (7KW)

2 BRACKET, TOP SUPPORT

2 BRACKET, BOTTOM SUPPORT

1 DUCT, BASE AIR

1 GASKET, FRONT DIVIDER

1 GASKET, FRONT DIVIDER (7KW)

1 COVER, FRONT EXHAUST ENCLOSURE

1 COVER, BACK EXHAUST ENCLOSURE

2 CLOTH, HARDWARE 266.7mm x 146mm

3 CLOTH, HARDWARE 266.7mm x 146mm (7KW)

1 CLOTH, HARDWARE 543mm x 146mm

1 CLOTH, HARDWARE 266.7mm x 387.4mm

1 CLOTH, HARDWARE (7KW)

1 FOAM, FRONT INTAKE BAFFLE

1 FOAM, FRONT INTAKE BAFFLE (7KW)

1 FOAM, TOP INTAKE BAFFLE

1 FOAM, BACK INTAKE BAFFLE

1 FOAM, BACK INTAKE BAFFLE (7KW)

1 FOAM, BACK ENCL. STRIP

1 FOAM, EXHAUST SIDE ENCLOSURE END

1 FOAM, EXHAUST SIDE ENCLOSURE FRONT

1 FOAM, EXHAUST FAN HOUSING

24 WASHER, SELF LOCKING

22 WASHER, SELF LOCKING (7KW)

1 FOAM, FRONT EXHAUST ENCLSURE COVER

1 FOAM, BACK EXHAUST ENCLOSURE COVER

2 DOOR, PAWL

1 LATCH, QUARTER TURN LOCKING

1 HINGE TYPE A WITH STUDS, PIN

1 HINGE TYPE B WITH STUDS, PIN

1 LATCH, QUARTER TURN NON-LOCKING

4 WASHER NYLON .250"

1 WASHER LOCK M6-1/4"

89

90

91

92

84

85

86

87

79

80

81

82

83

93

94

95

96

97

46

47

48

49

50

51

57

58

59

60

52

54

55

56

61

62

63

64

65

75

76

77

78

71

72

73

74

66

67

68

69

70


0F0710

047411

047411

043116

043116

0D3700

0D3700

0D4662

090388

036937

022152

051713

022158

0D3031

026850

049813

0F0164A

0F0165A

0E2874

043107

022145

045771

0C3906

0E4321

0E1330A

0E9692

042907

092120

0D3167

0A3328

055414

092079

0A1658

0C2937

086729

0388040AJ0

022127

022129

022129

074908

0D2346

0D2345

023484F

022142

0A7836

0A8475

0912970069

0912970070

055450

0E5968

0D3701

0D3472

0C8742

0C8911

0D8442

0D8652

14 RIVET POP 0.125 X 0.337

6 SCREW HHC M6-1.0 X 16 G8.8

4 SCREW HHC M6-1.0 X 16 G8.8 (7KW)

5 SCREW HHC M6-1.0 X 12 G8.8

6 SCREW HHC M6-1.0 X 12 G8.8 (7KW)

26 NUT, LOCKING FLANGE M6-1.0

24 NUT, LOCKING FLANGE M6-1.0 (7KW)

11 SCREW HHTT M8-1.2 X 20 BP

36 SCREW TAPTITE M6-1.0 X 12 BP

24 SCREW TAPTITE M6-1.0 X 12 BP (7KW)

2 NUT LOCK TRIC M6 X 1.0 Y/ZNC

1 GASKET, BATTERY SUPPORT BRACKET

1 PLUG, PLASTIC 0.593

1 LUG SLDLSS #2-#8X17/64 CU

1 SCREW TAPTITE M6-1.0X25 BP

2 L/WASH SPECIAL ¼

1 BRACKET, BATTERY HOLD DOWN (7KW)

1 CONTACTOR, STARTER (7KW)

1 CABLE, #6 RED BATTERY 38.5"

2 NUT HEX 1/4-20 STEEL (7KW)

6 WASHER LOCK 5/16

7 WASHER LOCK 5/16 (7KW)

8 SCREW TAPTITE M5-0.8 X 10 BP

1 HARNESS, ENGINE

1 HARNESS, ENGINE (7KW)

1 BUSHING, SNAP SB-1000-12

1 SCREW HHC 5/16-18 X 3/4 G5 (7KW)

2 RIVET,1/8" X 0.126" - 0.375" LSH POP

2 L/WASH SPECIAL #10

1 ASSEMBLY, ROOF / DOOR GROUND WIRE

2 ASSEMBLY, ROOF / DOOR GROUND WIRE

2 PLUG PLASTIC 1.375

11 GASKET, EXTRUDED TRIM

1 PLATE, "HOT"

1 GROMMET 2.75 X 1/16

1 EXTERNAL CONNECTION BOX

1 POWER BLOCK

1 HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX

1 HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX (7KW)

2 SCREW PPHM #10-32 X 1

5 WASHER LOCK #10

2 WASHER FLAT M5

5 NUT HEX #10-32 STEEL

1 FUEL LINE, 3/4"OUTDOOR (NOT SHOWN)

1 WASHER SHAKPROOF EXT 1/4 STEEL

1 NUT HEX M6-1.0 G8 YELLOW CHROME

1 HINGE TYPE A WITH STUDS, SOCKET

1 HINGE TYPE B WITH STUDS, SOCKET

1 SCREW HHTR 1/4-20 X 3/4

4 SCREW HHC M8-1.25 X 25

8 WASHER FLAT 5/16

4 NUT HEX M8-1.25

2 SELF-ALIGN SCREW M6 HH

1 PANEL, EXHAUST ALIGNMENT

1 GROMMET, 38.1 CROSS SLIT WITH HOLE

1 BRACKET, REGULATOR MOUNTING

2 SCREW HHC M8-1.25 X 16mm


33



Control Panel – Drawing No. 0E7974-G




Control Panel – Drawing No. 0E7974-G

1 0E7886A

0E7886C

0E7886D

0E7886E

0E7886F

0E7886G

2 0A1801

3 083049

4 0C2174

5 075210A

6 0D3062

7 0D8615

0D8615A

8 032300

9 022676

10 0E4494

11 0E7890

12 023484E

13 075476

15 0E6480

17 0C1085

0C1085

18 0D8443

19 054502

053623

20 0E7870

0E7871

21 075235

22 0D5240

23 0D9784

0D9784


1 CIRCUIT BREAKER 30A X 2P 240V (7KW)

1 CIRCUIT BREAKER 40A X 2P 240V (8.5KW)





1 ASSEMBLY, BATTERY CHARGER ENGINE

1 ASSEMBLY, POTTED REGULATOR

1 RELAY, 12V 25A SPST

1 BLOCK 1 POSITION

4 HEX STAND-OFF #6-32 x 3/8"

1 ASSEMBLY, HOME STANDBY CONTROLLER

1 ASSEMBLY, HOME STANDBY CONTROLLER

(7KW)

2 HOLDER, FUSE

1 FUSE, 15AMP X AGC15

1 SWITCH, ROCKER DPDT ON-OFF-ON

1 CIRCUIT BREAKER MOUNTING BRACKET

1 SNAP BUSHING

4 SCREW PPHM M4-0.7 x 16mm

6 NUT HEX LOCK M4-0.7 NYLON INSERT

4 SCREW PPHM M3-0.5 X 8mm

2 SCREW PPHM M3-0.5 X 8mm (7KW)

1 DECAL, CONTROL PANEL (NOT SHOWN)

1 CIRCUIT BREAKER 3 X 1 ETA 46-500-P

1 CIRCUIT BREAKER 2.5 X 1 ETA 46-500-P

(7KW)

1 CONTROL, PANEL BOTTOM

1 CONTROL, PANEL BOTTOM (7KW)

4 SCREW HHC M5-0.8 x 30mm

1 SWITCH, SPST (ON)-ON N/O



(7KW)


24 0D8502

26 0D8441

0E0120

27 074908

29 082025

30 0C3910

31 022507

32 099727

33 046689

34 063617

35 075475

36 043180

37 0D8439

0E0119

38 092036

39 045770

40 0E7866

0E7867

41 0D3700

42 0912970069

43 0E2874

44 0A1658

45 022473

46 038750

47 022097

48 049813

49 031879

031879

50 023897

51 0F4793

1 NEUTRAL CONNECTOR

1 HARNESS, CONTROL PANEL (NOT SHOWN)

1 HARNESS, CONTROL PANEL WIRE (NOT

SHOWN) (7KW)

4 SCREW TAPTITE, M5-0.8 x 10 BP


1 TRANSFORMER

2 SCREW HHC 1/4"-20 x 1/2"

1 FUSE 5A X AGC5

1 BLOCK TERMINAL STRIP 20A 4 X 6 X 1100V

1 RELAY PANEL 12VDC DPDT 10A 240VAC


2 WASHER FLAT M4

1 COVER, CONTROL PANEL COMPONENT

1 COVER, CONTROL PANEL COMPONENT

(7KW)

8 SCREW PPHMS/LW #6-32 x 1/4"

2 SCREW HHC M5-0.8 x10mm

1 COVER, CONTROL PANEL

1 COVER, CONTROL PANEL (7KW)

8 NUT FLANGE M6-1.0 NYLOK

1 ASSEMBLY, ROOF/DOOR GROUND WIRE

1 SCREW HHTR 1/4"-20 X 3/4"

2 WASHER LOCK SPECIAL 1/4"

3 WASHER FLAT 1/4"-M6

1 SCREW HHC M6-1.0 x 30mm

3 WASHER LOCK M6-1/4"

1 NUT HEX M6-1.0

6 WASHER FLAT #4

4 WASHER FLAT #4 (7KW)

2 WASHER FLAT #10



35



GT-990 Engine – Drawing No. 0E8774-J Part 1




GT-990 Engine – Drawing No. 0E8774-J Part 1

1 0C5729

2 0E9843

3 090388

4 0C5372

5 0C3005

6 0E3372B

7 0D8067A

8 071983

9 0C2981C

10 045761A

11 0E2985

12 021533

13 0E1466

14 0D4041

15 0C2983

16A 0C2985A

16B 0C2985B

17 0D4042

18 0A7811

19 0C2977

20 0C5943

21 0E4357E

22 0E3223

23 0D2157

24 0E6098

25 0D4123A

26 078699E

27 0C3011

28 0C3009

29 0C3010

30 093873

31 0C5315

32 0C5998

33 0D1667

34 0C2991

35 0C2988

36 0C2992

1

1

1

1

2

1

2

2

4

2

1

1

1

1

1

4

1

3

1

1

3

1

1

1

1

2

2

1

2

2

1

2

1

2

2

1

2


ASSEMBLY, CRANKCASE HOUSING WITH

SLEEVE

SEAL, 38 I.D. CRANKSHAFT

SCREW, TAPTITE M6-1.0 X 12 YC

ASSEMBLY, BREATHER

GASKET, BREATHER COVER

SEPARATOR, OIL BREATHER

ASSEMBLY, HEAD #1 G&S

RETAINER, PISTON PIN 20

ROCKER, COVER NO OIL FILL

STUD M8-1.25/10MM X 30 G5 ZINC

PISTON, HC

SET, PISTON RING 90MM

PIN PISTON

ASSEMBLY, CAMSHAFT & GEAR

SHAFT, GOVERNOR

ROLLER BEARING, GOVERNOR PLATE

ROLLER BEARING, GOVERNOR

ASSEMBLY,GOVERNOR GEAR

SPOOL, GOVERNOR MACHINED

GASKET, CRANK CASE

SEAL, OIL PASSAGE

ASSEMBLY, CRANKSHAFT HORIZONTAL

DIRECT DRIVE

ASSEMBLY, CONNECTING ROD

SCREW SHC M6-1.0 X 50 G8.8

SCREEN, OIL PICKUP

ASSEMBLY, OIL PUMP

SLEEVE, SEAMED DOWEL 10 DIA.

COVER, OIL RELIEF

SPRING, OIL RELIEF

BALL, 1/2D OIL RELIEF

WASHER, LOCK RIB M6

GEROTOR, OUTER

CLAMP, OIL TUBE

ARM, GOVERNOR

E-RING, GOVERNOR ARM

THRUST WASHER, GOVERNOR

BUSHING, GOVERNOR LOWER

37 0C3971C

38 0C5305

39 0C3027

40 0E9842

41 0C5731

42 0C3006

43 080318

44 093064

45 0C8808

46 0D2723B

47 0C2979

48 086515

49 0D2274

50 0D3867

51 078672

52 0C5371

53 072694

54 0D3998

55 0C3027

56 0D5313

57 0D6024

58 0C2976

59 086516

60 0C2229

61 083897

62 0D8067B

63 0D9853D

64 0C2978

65 043790A

66 0D4010

67 0D4011

68 0D4012

69 0D4013

70 0D8675A

71 0D8675B

72 0D4015

73 0D4016


1

1

1

1

1

4

2

4

1

1

1

1

1

1

1

1

1

1

8

4

1

2

4

1

2

9

8

ASSEMBLY, DIPSTICK WITH HANDLE

TUBE, DIPSTICK

O-RING, OIL CLR 3/8 X 1/2


ASSEMBLY, HOUSING COVER WITH

SLEEVE

SCREW, HHFC M10-1.5 X 55

SCREW HHFC M6-1.0 X 25

ASSEMBLY, OIL FILL CAP

HOOK, LIFTING

4

4

2

4

2

ROCKER, COVER WITH OIL FILL

GASKET, VALVE COVER

KEEPER, VALVE SPRING

RETAINER, VALVE SPRING

SPRING, VALVE

SEAL, VALVE STEM D7

WASHER, VALVE SPRING

STUD, ROCKER ARM PIVOT

NUT HEX M8-1.0 G8 YEL CHR

O-RING, 3/8" X 1/2"

4

2

ROCKER ARM

PLATE, PUSH ROD GUIDE

12 SCREW HHFC M8-1.25 X 65

2 VALVE, EXHAUST

2 VALVE, INTAKE

TAPPET, SOLID

ASSEMBLY, HEAD #2 G&S

PUSHROD, 147

GASKET, HEAD

BARBED ELBOW 90 3/8NPT X 3/8 L0CKTITE

KIT GASKET

KIT PISTON & RINGS

KIT BREATHER ASSEMBLY

KIT GOVERNOR ASSEMBLY

KIT HEAD ASSEMBLY CYLINDER 1

KIT HEAD ASSEMBLY CYLINDER 2

KIT OIL RELIEF

KIT GEAR COVER


37



GT-990/760 Engine – Drawing No. 0E8774-J Part 2

74

81

83

84

79

80

11

76

77

75

78

122

124

124

125

123, 145

125

120

119

143

96

95

130

114

121

118

97

8

99

102

103

105

86

88

85

89

90

89

91

92

99

1

101

107

108

112

138

137

136

126

32

133

139

135

134

127

115

116

142

109

110

8

29

112

113

111




GT-990/760 Engine – Drawing No. 0E8774-J Part 2


101

102

103

104

105

96

97

98

99

100

106

107

108

109

89

90

91

92

93

94

95

79

80

81

82

83

84

85

86

88

74

75

76

77

78

0C7649

0C9806

0C3026

0C9764

0C3043

0C7694

0C7693

0C3041A

070008

070006

040976

0F1170A

0E4997

0C3725B

0C3031

0C3032

0A5992

051754

0C3033

0C3034

0C8549A

0C5136A

0C3024

0C3040

0C8127

0D8564A

0D8564B

0D2595

0D4417

0C3025

0D3083

0C7292

070185B

075281

0F2094

035461A

1

1

1

1

2

4

4

2

4

1

1

1

2

1

2

1

1

4

1

4

2

1

1

1

1

1

2

2

1

4

1

1

4

2

1

1

KNOB, AIR CLEANER

COVER, AIRBOX NG/LP

PRE-CLEANER,

ELEMENT, AIR CLEANER

ASSEMBLY, MIXER/AIRBOX 990

ASSEMBLY, MIXER/AIRBOX 760

SCREW SHOULDER (8MM) M6-1.0 X 18

WASHER,RUBBER 1/4" X 1/8" THICK

SWITCH, OIL PRESS

ASSEMBLY, OIL DRAIN HOSE

NIPPLE, 3/4"-16 UNF

OIL FILTER

SWITCH, THERMAL 284F

SCREW M3-0.5 X 6 SEMS

BARBED STR 1/4NPT X 3/8 WITH VIBRA

SEAL

CLAMP HOSE .38-.87

HOSE, 3/8" I.D. X 6" LONG

COOLER, OIL

PLASTITE,1/4-15 X 3/4

GASKET, MANIFOLD / PORT

MANIFOLD CYLINDER 2

MANIFOLD CYLINDER 1

SLEEVE, RUBBER

WASHER FLAT M8 SS

WASHER LOCK M8 SSTL

SCREW SHC M8-1.25 X 20 G12.9

PLATE, BACKING WITH OIL COOLER

GROUND WIRE CONNECTOR

FLYWHEEL ASSEMBLY

FAN, NYLON

PLATE, FAN

WASHER SHAKEPROOF INT M8 SS

SCREW HHC M8-1.25 X 12 G8.8

WASHER, 25mm I.D.

NUT,HEX M24

SNORKEL, AIR INTAKE

127

128

129

130

131

122

123

124

125

126

117

118

119

120

121

113

114

115

116

132

133

134

135

136

137

138

139

0C9763

0C3036A

022145

022129

0C3018

0C3019

0D1142A

0D1143

0E6043

0F1177

0F1338B

022097

092079

0E4271

0D4529

022129

061906

082774

0E5343

0C8468

0C3048

0D3754

0D3742

0C8482

0E0486

0D3743

0D3705


110

111

112

140

142

143

144

145

0F1169A

0D1131

045756

0C2993

0F5467

0D6147

0E8152

0F1338A

1

1

1

1

7

1

1

1

1

1

2

1

2

2

1

1

1

1

4

4

1

1

1

1

1

1

1

2

1

1

4

1

1

1

HOUSING, BLOWER NG COOLER

GUARD, FAN

25 SCREW TAPTITE M6-1X10 YELLOW

CHROME

NUT, GROMMET 1/4 PLUG

HOSE, BREATHER

WASHER FLAT 5/16-M8 ZINC

WASHER LOCK M8-5/16

WRAPPER, UPPER CYLINDER 1

WRAPPER, LOWER CYLINDER 1

WRAPPER, LOWER CYLINDER 2

WRAPPER, UPPER CYLINDER 2

SCREW TAPTITE M5-0.8 X 8 ZP

ASSEMBLY, GROUND WIRE

ASSY, IGN COIL W/DIODE NO ADV

WASHER LOCK M6-1/4

SCREW TAPTITE M6-1.0 X 25 BP

STARTER

SPARKPLUG

WASHER LOCK M8-5/16


KEY, WOODRFF 4 X 19D

NUT HEX LOCK M10-1.50

SPRING, ANTI-LASH

ROD, GOVERNOR CONTROL

ASSEMBLY, GOVERNOR LEVER

SPRING, GOVERNOR

ASSEMBLY, GOVERNOR ADJUSTER

SCREW SHC M10-1.5 X 75 G10.9

SPRING, GOVERNOR IDLE

ASSEMBLY, GOVERNOR ADJUSTER

BRACKET

SEAL, GOVERNOR SHAFT

NUT HEX M8-1.25 YELLOW ZINC

SCREW HHFC M6-1.0 X 10mm

O-RING 0.49" I.D. X 0.07" THICK

ASSY, IGN COIL W/DIODE NO ADV


39



7 kW Generator – Drawing No. 0D3504-D


PART NO.

022259

059637

048031K

0C9592

057822

040976

0C2824

025145

090239

0C6989

0D1214

0C8127

0C3024

0D2273

055934N

074994

0C5136A

074906

022473

0D4662

0C8290

066849

022237

022511

022131

039287

022145

049820

090388

022129

0C7038B

0C7758

0388050AE0

0C2417A

082121C

066386

029451

049451

0C6934

0C9935H

0C9934H

0C6043A

0C8096

0C9593

0D3220

0C8860

031971

0C3168

056147

0D1847

0C7038C

0D1647

0D2558

ITEM

44

45

46

47

40

41

42

43

36

37

38

39

32

33

34

35

48

49

50

51

52

53

28

29

30

31

24

25

26

27

20

21

22

23

16

17

18

19

12

13

14

15

10

11

8

9

6

7

4

5

1

2

3

QTY.

1

1

1

1

1

1

1

1.25 FT

1

1

2

2

3

1

8

2

4

6

2

4

1

2

12

4

3

13

4

4

4

4

1

1

1.8 FT

1

1

1

1

4

1

1

4

1

3

1

1

1

1

1

1

1

1

1

1



7 kW Generator – Drawing No. 0D3504-D

DESCRIPTION

ADAPTOR, ENGINE

STATOR

ROTOR

CARRIER, REAR BEARING

FAN, 8" CURVED BLADE

MUFFLER

TAIL PIPE, MUFFLER

PANEL, MUFFLER BASE

BEARING #6205-2RS-C3

5/16 SPECIAL L/WASH

BOLT ROTOR HHCS 5/16"-24 X 13-1/2" G5

BOLT STATOR HHCS M8-1.25 x 305mm

BRACKET, ALTERNATOR MOUNTING

DUCT, ALTERNATOR AIR

GASKET, ALTERNATOR AIR DUCT

BRACKET, ENGINE MOUNTING

RUBBER MOUNT

CABLE, #6 40" BLACK BATTERY

EARTH STRAP 3/8X 3/8

CLIP-J VINYL COAT .625 ID

ASSEMBLY BRUSH HOLDER

TAPE ELEC UL FOAM 1/8 X 1/2

WASHER FLAT .406ID X 1.62OD

WASHER LOCK 3/8

BOLT HHC 3/8-16 X 1-1/4 G5

WASHER FLAT 3/8 ZINC



NUT LOCK HEX M8-1.25 NYL INSRT

SCREW TAP M6-1.0X12 BP

WASHER LOCK M8-5/16

NUT HEX 5/16-18 STEEL

SCREW TAPTITE 3/8-16X 3/4" BP

BAND, HOSE CLAMP 35.05 DIA.

BELLOWS

CLAMP HOSE #8 .53 - 1.00

SCREW SHC M8-1.25 X 20 G12.9

SCREW TAPR #10-32 X 9/16

U-BOLT 5/16"-18 X 1.25" W/ SADDLE

GASKET, EXHAUST

STINGER, ENGINE AIR IN

BASE, AIR CLEANER

ELEMENT, AIR CLEANER

COVER, AIR CLEANER NG/LP

TUBE, 1.25"O.D. x 20Ga. x 12.125" LONG

CLAMP VINYL 1.31 X .281 Z

HOSE 1\2ID PETROLEUM

KNOB, AIR CLEANER

SCREW TAPTITE M6-1 X 20 BP


SCREW HHTT M8-1.2 X 20 BP

GASKET, PANEL

SCREW HHTT M5-0.8 X 16


41



12 kW and 15 kW Generator – Drawing No. 0D3417-J


ITEM

1

2

3

32

33

34

35

28

29

30

31

24

25

26

27

20

21

22

23

40

41

42

43

36

37

38

39

16

17

18

19

12

13

14

15

10

11

8

9

6

7

4

5

PART NO.

029451

049451

022237

022511

022131

051731

022145

049820

0D1609

0D2559

0C7038A

0C7758

0388050AD0

0C2417A

082121C

066386

0C6934

0C7930

0D2359

0C7944

0D2356

0C6043

0D2336

0D6634

0D3220

0C8101

056482

0C3168

0D1838

0D1846

0C7038

045756

022129

022259

059637

0D4662

074994

057822

0F0462

0C2824

025145

0C4138

048031C

030340

066849

QTY.

1

1

1

8

2

4

3 FT

12

4

2

10

1

1

2.6 FT

1

4

4

5

4

1

1

4

4

2

2

1.33 FT

2

1

1

1

4

1

1

4

1

3

1

1

1

1

1

1

1



12 kW and 15 kW Generator – Drawing No. 0D3417-J

DESCRIPTION

ADAPTOR, ENGINE

STATOR 12KW

STATOR 13KW / 15KW

ROTOR 12KW

ROTOR 13KW / 15KW

CARRIER, REAR BEARING

FAN, 12" CURVED BLADE

MUFFLER

TAIL PIPE, MUFFLER

PANEL, MUFFLER BASE

BEARING 1.1811-2.8346

5/16 SPECIAL LOCK WASHER

BOLT, HHCS 3/8"-24 x 15.50"

BOLT, HHCS M8-1.25 x 345mm

BRACKET, ALTERNATOR MOUNTING

DUCT, ALTERNATOR AIR

GASKET, ALTERNATOR AIR DUCT

BRACKET, ENGINE MOUNTING

RUBBER MOUNT

CABLE, #6 48" BLACK BATTERY

EARTH STRAP 3/8X 3/8

CLIP-J, VYNL COAT 0.625" ID

ASSEMBLY BRUSH HOLDER

TAPE ELEC UL FOAM 1/8 X 1/2

WASHER FLAT .406ID X 1.62OD

WASHER LOCK 3/8

SCREW HHC 3/8-16 X 1-1/4 G5




NUT LOCK HEX M8-1.25 NYL INSERT

SCREW TAPTITE M6-1.0X10 BP

WASHER LOCK M8-5/16

NUT HEX 5/16-18 STEEL

SCREW TAPTITE 3/8-16 X 3/4 BP

SCREW 5/16-18X3/4" HH THD ROLL

HOSE RES 1/2 LP GAS

CLAMP HOSE #8 .53 - 1.00

NUT HEX W/TOOTH WSHR M8-1.25

SCREW TAP-R #10-32 x 9/16

U-BOLT 5/16"-18 X 1.25" WITH SADDLE

GASKET, EXHAUST PORT

CLAMP HOSE BAND ¼"

HOSE 1/4 ID SAE 30R7

SCREW HHTT M5-0.8 X 16


43



GN410 Engine – Drawing No. 0E9180-B Part 1


PART NO.

077158

0C3150

072694

083907

072696

078694

021742

0D6094

076329

0E0057

0D4788

074908

086515

078606

0A1442

078672

089673

0B2104

078699C

0A7627

043790A

088590

078699B

076701

021713B

078691

0A5771

0A5776

076361

0A8898D

0D2274

0C4391

086025

0E3341

021714

086516

086517

0D9853B

083897

0E3221

0E1466

021533

0E2985

071983

0E8440

0A7628

078658

078659

088261E

0E3812

0E6519

078645

0A7811

0A9877

ITEM

44

45

46

47

40

41

42

43

36

37

38

39

32

33

34

35

52

53

54

48

49

50

51

28

29

30

31

24

25

26

27

20

21

22

23

16

17

18

19

12

13

14

15

10

11

8

9

6

7

4

5

1

2

3

QTY.

8

1

4

4

1

1

1

1

4

1

2

1

2

2

1

1

1

1

1

2

1

2

1

2

2

1

1

1

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

2

1

2

1

1

1

2

1

1

1




DESCRIPTION

ASSEMBLY, CONNECTING ROD

PIN, PISTON D20

SET, PISTON RING 90MM

PISTON, HC

RETAINER, PISTON PIN 20

ASSEMBLY, CRANKSHAFT GH410 SMALL TAPER

ARM, GOVERNOR RC45

PIN, "R" GOVERNOR ARM

WASHER, GOVERNOR ARM THRUST

CRANKCASE, SUBASSEMBLY WITH PLUGS GH410


ASSEMBLY, GOVERNOR GEAR

C-RING, GOVERNOR GEAR RETAINER

SPOOL, GOVERNOR- MACHINE

ASSEMBLY, CAMSHAFT & GEAR

GASKET , CRANKCASE

GASKET, HEAD 410

COVER, OIL PRESSURE RELIEF

SPRING, OIL RELIEF 360

BALL, DIA 11/32 PRESSURE RELIEF

WASHER, THRUST GOVERNOR GEAR

ASSEMBLY, COVER, GEAR TOP CHECK / FILL

RETAINER, VALVE SPRING

VALVE SPRING LF

SET,GEROTOR 12 THK

BALANCER

ASSEMBLY,CYLINDER HEAD SEATS & GUIDES

VALVE, EXHAUST

VALVE, INTAKE

PUSH ROD 174.9

TAPPET

ASSEMBLY, SCREEN OIL PICK-UP

GASKET, ROCKER COVER 410

STUD, D20 PIVOT BALL

ROCKER ARM

NUT, JAM (ROCKER ARM)

PLATE, PUSH ROD GUIDE

SCREW, HHFL M10-1.5 X 105

ASSEMBLY, ROCKER COVER BREATHER

PLUG, OIL FILL PLASTIC

O-RING 17.8 I.D. x 2.4

PLUG, STANDARD PIPE 3/8 STEEL SQUARE HEAD

SCREW, TAPTITE M5-0.8 X 10 BP

KEEPER, VALVE SPRING

SCREW & LOCKWASHER M6-1 X 12

SCREW, HHFC M8-1.25 X 42

SEAL, VALVE STEM D7

WASHER, VALVE SPRING

WASHER, LARGE SPRING

DOWEL, SEAMED SLEEVE

SHAFT, GOVERNOR RC55

BARBED ELBOW 90 3/8NPT X 3/8 LOCKTITE

DOWEL DIA 12 X 18L

DOWEL, SLEEVE SEAMED 12 DIA.


45





PART NO.

072735

0C3978

0C6040

0D9760

092079

073100

083502

082025

0D3083

0E7887C

0D5667A

049821

099236

070185B

082774

091222E

067198N

067890

0E7585

072734

090072

075281

0F2094

0C4373

022717B

0C1069

0D2922

0C8435

0C9997

088434

045756

0C4176A

0D9004A

059985

022129

0C2458A

083512

0D1401A

091039

0C9619

049811

022097

040945

086999

ITEM

35

36

37

38

39

30

31

32

33

34

40

41

43

44

45

25

26

27

28

29

20

21

22

23

24

15

16

17

18

19

10

11

12

13

14

7

8

5

6

9

3

4

1

2

QTY.

1

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

1

1

1

1

2

1

4

2

1

2

1

1

1

2

1

1

1

11

1

1

2

1

1

5

1




DESCRIPTION

SCREW, TAPTITE M6-1.0X8 YELLOW CHROME

HOUSING, BLOWER

TUBE, DIPSTICK

GUARD, FAN

WRAPPER, BOTTOM

SCREW, TAPTITE M6-1X10 YELLOW CHROME

WRAPPER, TOP

ASSY, STARTER

SCREW, SHC M8-1.25 X 45 G12.9

WASHER, LOCK M8-5/16

BACKPLATE, L/F D/F


BREATHER TUBE

GASKET, INTAKE ADAPTER

ASSEMBLY, PLASTIC CARB

WASHER, FLAT M6

WASHER, LOCK M6-1/4

SCREW, SHC M6-1.0 X 20 G12.9

GASKET,OIL FILTR ADAPTER

ADAPTER, OIL FILTER

SCREW, SHC M8-1.25 X 30 G12.9

SWITCH, OIL 8.0 PSI

OIL FILTER

KEY, WOODRFF 4 X 19D

FLYWHEEL WITH RING GEAR 32DEG.

WASHER,BELV-20 X 2.2

NUT, HEX - FLYWHEEL

SPARKPLUG

ASSEMBLY,GOVERNOR LEVER 12 HP

ROD,GOVERNOR CONTROL.

SPRING, ANTI-LASH

ASSEMBLY, WIRE

ASSEMBLY, IGNITION COIL


SPRING GOVERNOR

BOLT, GOVERNOR ADJUST M5

NUT HEX LOCK M5-0.8 NYINS ZINC

ASSEMBLY, OIL DRAIN HOSE

ASSEMBLY, CAP & DIPSTICK

O-RING 9/16 X 3/4 X 3/32

SWITCH, THERMAL

SCREW, M3-0.5 X 6 SEMS

SPACER, ENDFRAME

GROMMET


47



Gas Regulator – Drawing No. 0D8720-F




Gas Regulator – Drawing No. 0D8720-F

28

29

30

31

32

37

21

22

23

24

25

18

19

20

26

27

ITEM

12

13

14

15

16

17

9

10

5

8

11

3

4

1

2

PART NO.

045764

0C6731

0C6067

0C4706

0C6068

0C4643A

026073

026073

0A4032

0D3308

024310

028414A

0D5698A

0D3973

0D5694

0F5022

0C4647

0D4166

0C6070

0F4795

0C5760J

0C6606

097934

0C4645

0C5761

0C5968

0C6066

0C5759

0C5764

0C5764A

070728

0C6069

0C5762

* A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY

QTY.

2

2*

2

1

4

16

2

2

2

2

1

1

1

1

4

2

2

2

2

2

2

2*

2

2

1

2*

1

4

2*

1

1

1

1

DESCRIPTION

CASTING, TWIN REGULATOR HOUSING

SOLENOID COIL, 12VDC

GASKET , SOLENOID

PLUNGER, LP REGULATOR ASSEMBLY

SPRING-SOLENOID, PLUNGER

SCREW PPHM SEMS M4-0.7 X 10

JET, GN 410 ENGINE LP (7KW)

BARBED STRAIGHT 1/2NPT x 1/2

O-RING, CHECK VALVE

ADJUSTER SCREW, TWIN REGULATOR

LEVER, REGULATOR

SUPPORT, INLET SEAL

SEAL, INLET

PIN, PIVOT ARM

SPRING, REGULATOR

SPRING, REGULATOR (7KW)

SCREW, PFHMS M3-0.5 x 5

GASKET, DIAPHRAGM

COVER, TWIN REGULATOR

SCREW, TAPTITE M4X8 BP

RIVET, POP .118 X .125

SUPPORT, DIAPHRAGM

DIAPHRAGM, TWIN REGULATOR

CAP, DIAPHRAGM SUPPORT

INLET, TWIN REGULATOR 11.11 DIA.

PLUG, STANDARD PIPE 1/8" STEEL SQUARE HEAD

PLUG, STANDARD PIPE 1/8" STEEL SQUARE HEAD (7KW)

PIN, LIMITED ADJUSTMENT

WASHER, FLAT M3 X 10mm O.D.

PLUG, STANDARD PIPE 1/2" STEEL SQUARE HEAD (7KW)

BARBED STRAIGHT 1/8"NPT X 1/4"

JET IDLE PRIMER PHILLIPS HD (V-TWIN ONLY)

PLUG, EXPANSION 16mm


49

Section 8 — Mounting Dimensions


Drawing No. 0D3739-B


Section 9 — Notes



51

Section 10 – Warranty


NOTE: This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below.

CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with

Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.*

New (small off road) engines must be designed, built and equipped to meet stringent anti-smog standards for the state of

California and the federal government. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or improper maintenance of your engine.

Your emission control system may include parts such as the carburetor, ignition and exhaust systems. Generac will repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on engines are warranted for two years as hereinafter noted. If, during such warranty period, any emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.

PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:

As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.

As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.

You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a

problem occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility.

To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:

1-800-333-1322

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty

(ECS Warranty), which is provided to you by Generac pursuant to California and federal law. See also the “Generac Limited

Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac.

The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac

Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be presented showing the date of the sale to the original purchaser/owner. The purchaser/owner shall be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297

WHITEWATER, WI 53190

Part 1




EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines:

(a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for

24 consecutive months thereafter.

(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or equipment, and to each subsequent purchaser/owner, that each of its engines is ...

(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to their respective authority, and

(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a warranted emissions-related part to fail to be identical in all material respects to the part as described in the engine manufacturer’s application for certification.

(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:

(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s

Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS

Warranty shall be warranted for the remainder of the ECS Warranty Period.

(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below.

Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the

ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.

(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility.

(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable.

(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission-related part covered by the ECS Warranty.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand for such emission-related parts.

(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS

Warranty maintenance or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce

Generac’s ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or “grey market” part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System:

1.1) Gasoline carburetor assembly and its internal components (if so equipped).

a) Fuel filter (if so equipped) b) Carburetor gaskets c) Fuel pump (if so equipped)

1.2) LPG carburetion assembly and its internal components (if so equipped).

a) Fuel controller (if so equipped) b) Mixer and its gaskets (if so equipped) c) Carburetor and its gaskets (if so equipped) d) Primary gas regulator (if so equipped) e) LP liquid vaporizer (if so equipped)

2) Air Induction System including: a) Intake pipe/manifold b) Air cleaner

3) Ignition System including: a) Spark plug b) Ignition module

4) Catalytic Muffler Assembly (if so equipped) including: a) Muffler gasket b) Exhaust manifold

5) Crankcase Breather Assembly including: a) Breather connection tube

*Generac engine types covered by this warranty statement include the following:

1) Utility

2) Lawn and Garden Equipment

3) Recreational Vehicle (RV) Generator

4) Industrial Mobile (IM) Generator

Part 2


53



GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN®

"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"

For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Guardian

Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac Guardian prepackaged emergency automatic standby generators sold and rated for use in "Standby" applications.

WARRANTY SCHEDULE

YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):

Engine - All Components

Alternator - All Components

Transfer System - All Components

Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty. Nicks, scrapes, dents or scratches to the painted enclosure should be repaired promptly by the owner.

All warranty expense allowances are subject to the conditions defined in Guardian's Warranty Policies, Procedures and Flat Rate

Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Guardian generators that utilize non-Guardian/Generac replacement parts.

• Guardian generators utilizing non-Guardian/Generac automatic transfer switches.

• Repairs performed by individuals other than Guardian/Generac authorized dealers.

• Any Guardian generators used as rental or trailer mounted applications.

• Air-cooled units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist.

• Costs of normal maintenance, adjustments, installation and start-up.

• Steel enclosures that are rusting due to the improper installation, location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised.

• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Damage related to rodent and/or insect infestation.

• Products that are modified or altered in a manner not authorized by Generac in writing.

• 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).

• Failure due to misapplication.

• Telephone, cellular phone, facsimile, internet access or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.

• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.

• Rental equipment used while warranty repairs are being performed.

• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)

• Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

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

GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT

SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A

DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.

This warranty gives you specific legal rights. You also have other rights from state to state.

Part No. 0F0083

GENERAC ® POWER SYSTEMS, INC.

P.O. BOX 297 • WHITEWATER, WI 53190

Revision G (03/02/05)

Revision (10/01/04)

Printed in U.S.A.

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