Guardian 5241, 5243, 5244, 5281, 5282 Installation And Owner's Manual

C

LISTED

US

Installation and

Owner’s Manual

7, 10, 13 and 16kW Air-cooled,

Automatic Standby Generators

Models: 005240, 005280 (6 kW NG, 7 kW LP)

005241, 005281 (9 kW NG, 10 kW LP)

005242, 005282 (13 kW NG, 13 kW LP)

005243, 005244, (15 kW NG, 16 kW LP)



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 model of the Guardian product line 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This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas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).

READ THIS MANUAL THOROUGHLY

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

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

CAUTION 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. The manufacturer strongly recommends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly recommends 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 these different models:

• 05240 & 05280 – 6 kW NG, 7 kW LP, single-cylinder GH-410 Engine

•

•

05241 & 05281 – 9.0 kW NG, 10 kW LP, V-twin

GT-530 Engine

05242 & 05282 – 13 kW NG, 13 kW LP, V-twin GT-

990 Engine

• 05243, 05244, 05283 & 05284 – 15 kW NG, 16 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 an 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 an Authorized Dealer for service aids and accessories.

HOW TO OBTAIN SERVICE

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

When contacting an Authorized Dealer 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 section

"The Generator" for decal location.

Model No. ____________ Serial No. ______________

AUTHORIZED

DEALER LOCATION

To locate the nearest AUTHORIZED

DEALER, please call this number:

1-800-333-1322

DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER or visit www.guardiangenerators.com.

Table of Contents

Air-cooled Generators

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

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

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

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

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

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

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

Interruption Breaker for Bedrooms .............. 4

Section 3 – Operation ....................................16

3.1 Using the AUTO/OFF/MANUAL Switch ........ 16

3.2 Automatic Transfer Operation ..................... 16

3.3 Sequence of Automatic Operation ............... 17

3.5 Setting the Exercise Timer .......................... 18

Section 4 – Maintenance .............................. 20

4.2 Checking the Engine Oil Level ..................... 20

4.3 Changing the Engine Oil .............................. 21

4.4 Changing the Engine Air Cleaner ................. 21

1.7 Fuel Requirements and Recommendations ... 7

1.9 Reconfiguring the Fuel System ...................... 8

1.10 Location ........................................................ 9

1.12 Battery Installation ...................................... 10

1.13 The Battery ................................................. 11

Section 2 – Post Installation Start-up and Adjustments .......................12

2.2 Check Transfer Switch Operation ............... 12

2.4 Generator Tests Under Load ....................... 13

7kW (Natural Gas Only) ............................... 14

2.8 Voltage Regulator Adjustment ...................... 15

Valve Clearance ............................................ 23

4.10 Corrosion Protection ................................... 25

4.11 Out of Service Procedure ............................. 25

4.12 Service Schedule ......................................... 26

Section 5 – Troubleshooting .........................27

Section 6 – Notes ........................................... 28

Section 7 – Electrical Data ........................... 29

Section 8 – Exploded Views and

Parts Lists ................................... 40

Section 9 – Mounting Dimensions ............. 66

Section 10 – Warranty ................................... 68

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.

The manufacturer cannot 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 the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized 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, the manufacturer recommends that the installation, initial start-up and maintenance of this equipment is carried out by an

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 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, then remove the POSITIVE, POS or (+) cable. When reconnecting the cables, connect the

POSITIVE cable first, the NEGATIVE 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

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, secured and/or locked 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 15A fuse 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 dry 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 must always 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. Consult the local fire department with any questions pertaining to fire extinguishers.



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

SYSTEMS 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.

MAINTENANCE OF FARM STANDBY ELECTRICAL

SYSTEMS, 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 is ready for installation with a factory supplied and pre-mounted base pad and has a weather protective enclosure that is intended for outdoor installation only.

This UL listed standby generator set is packaged with an automatic transfer switch with built in load center. The combination transfer switch and load center is pre-wired with a two foot and 30 foot conduit. Circuit breakers for emergency circuit connections are included (if equipped).

This UL listed, 2-pole switch is rated at 100 AC amperes at 250 volts maximum. This transfer switch is for indoor use only (if equipped).



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 & 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 their 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.

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 4. Overspeed

2. High Temperature Sensor 5. RPM Sensor

3. Overcrank 6. Low Battery

4

There are LED readouts on the control panel to notify personnel that one of these faults has occurred.

There is also a System Set LED that is lit when all of the conditions described in section "System Set

LED" are true. (See the "Protection Systems" section for details.)

NEC REQUIREMENT FOR ARC

FAULT CIRCUIT INTERRUPTION

BREAKER FOR BEDROOMS

In 2001, the National Electric Code (NEC) introduced a requirement for new construction. This new requirement indicates the need for Arc Fault Circuit

Interrupters to be used to protect the complete branch circuit that feeds a dwelling bedroom. The actual NEC requirement is indicated below.

INTERRUPTER PROTECTION

1. Definition: An arc fault circuit interrupter is a device intended to provide protection from the effects of arc faults by recognizing characteristics unique to arcing and by functioning to de-energize the circuit when an arc fault is detected.

2. Dwelling Unit Bedrooms: All branch circuits that supply 125 volt, single-phase, 15 and 20 ampere outlets installed in dwelling unit bedrooms shall be protected by an arc fault circuit interrupter listed to provide protection of the entire branch circuit.

Section 210.12 requires that AFCI protection be provided on branch circuits that supply outlets

(receptacle, lighting, etc.) in dwelling bedrooms. The requirement is limited to 15 and 20 ampere, 125 volt circuits. There is no prohibition against providing AFCI protection on other circuits or in locations other than bedrooms. Because circuits are often shared between a bedroom and other areas such as closets and hallways, providing AFCI protection on the complete circuit would comply with 210.12.

If during the installation of the home standby system the decision is made to provide back up power to a bedroom branch circuit, then the circuit breaker in the transfer switch should be replaced with an Arc

Fault Circuit Interrupter.

It is most important that breakers only be switched like for like. For instance, if replacing a 15A breaker, it MUST be replaced with a 15A AFCI breaker.

Likewise, a 20A breaker MUST be replaced with a

20A AFCI.

These AFCI breakers are available at the nearest hardware store.

Siemens Item #

Q115AF

Q120AF

Description

15A Single Pole AFCI

20A Single Pole AFCI



1.4 THE GENERATOR

Figure 1.1 – 7kW, Single Cylinder GH-410 Engine Figure 1.2 – 10kW, V-twin GT-530 Engine

Oil

Dipstick

Data

Decal

Air Filter

Cover

Control

Panel

Oil

Dipstick

Data

Decal

Control

Panel

Exhaust

Enclosure

Exhaust

Enclosure

Fuel

Inlet

(Back)

Fuel

Regulator

Composite Base Oil Filter Battery Compartment

Figure 1.3 – 13kW and 16kW, V-twin GT-990 Engine


Air Filter

Fuel

Inlet

(Back)

Fuel

Regulator

Oil

Dipstick

Air Filter

Cover

Data

Decal

Control

Panel

Exhaust

Enclosure


Fuel

Inlet

(Back)

Fuel

Regulator

5



1.5 SPECIFICATIONS

1.5.1 GENERATOR

Model

Rated Max. Continuous

Power Capacity (Watts*)

Rated Voltage

Rated Max. Continuous

Load Current (Amps)

120 Volts**

05240 & 05280

6,000 NG/7,000 LP

120/240

05241 & 05281

9,000 NG/10,000 LP 13,000 NG/13,000 LP 15,000 NG/16,000 LP

120/240

05242 & 05282

120/240

05243 & 05244

120/240

240 Volts

Main Line Circuit Breaker

Circuits***

50A, 240V

40A, 240V

30A, 240V

Phase

Number of Rotor Poles

Rated AC Frequency

50.0 NG/58.3 LP

25.0 NG/29.2 LP

30 Amp

-

-

1

2

60 Hz

75.0 NG/83.3 LP

37.5 NG/41.7 LP

45 Amp

-

-

1

2

60 Hz

108.3 NG/108.3 LP

54.1 NG/54.1 LP

55 Amp

-

1

1

125 NG/133.3 LP

62.5 NG/66.6 LP

65 Amp

- 1 - 1

1 3 3 5

5 3 5 5

1 1 1 1

2

60 Hz

1

1

-

2

60 Hz

Power Factor

Recommended Air Filter

Battery Requirement

Battery Warming Blanket

Weight (Unit Only)

Enclosure

1

Part # 0C8127

Group 26

12 Volts and

350 Cold-cranking

Amperes Minimum

336 Pounds

1

Part # 0E9581

Group 26

12 Volts and

525 Cold-cranking

Amperes Minimum

375 Pounds

0F6148DSRV

1

Part # 0C8127

Group 26

12 Volts and

525 Cold-cranking

Amperes Minimum

425.5 Pounds

1

Part # 0C8127

Group 26

12 Volts and

525 Cold-cranking

Amperes Minimum

445 & 414 Pounds

Steel/Aluminum

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) ambient temperature.

** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240 volts.

*** Circuits to be moved must be protected by same size breaker. For example, a 15 amp circuit in main panel must be a 15 amp circuit in transfer switch.

1.5.2 ENGINE

Model

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

6

05240 & 05280 05241 & 05281 05242 & 05282 05243 & 05244

05283 & 05284

GH-410

1

14.5 @ 3,600 rpm

410cc

Aluminum w/Cast

Iron Sleeve

GT-530

2

18 @ 3,600 rpm

530cc

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 Overhead Valves

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

RC14YC BPR6HS RC14YC RC14YC

0.76 mm (0.030 inch) 0.76 mm (0.030 inch) 1.02 mm (0.040 inch) 1.02 mm (0.040 inch)

8.6:1

12 Vdc

9.5:1

12 Vdc

9.5:1

12 Vdc

9.5:1

12 Vdc

Approx. 1.5 Qts

Part # 070185F

Part # 0C8127

3,600

Approx. 1.7 Qts

Part # 070185F

Approx. 1.7 Qts

Part # 070185F

Part # 0E9581 Part # 0C8127

3,600 3,600

Approx. 1.7 Qts

Part # 070185F

Part # 0C8127

3,600



1.6 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 PCB. If the utility sense voltage is not connected to the unit or if it is below approximately 150-160 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. No alarms are present, for example, low oil pressure, high temperature, etc.

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 the

Reconfiguring the Fuel System section 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 column (0.18 to 0.25 psi); and for liquid propane, 10 inches to 12 inches of water column (0.36 to 0.43 psi).

NOTE:

All pipe sizing, construction and layout must comply with NFPA 54 for natural gas applications and

NFPA 58 for liquid propane applications. Once the generator is installed, verify that the fuel pressure

NEVER drops below four (4) inches water column for natural gas or 10 inches water column for liquid propane.

Prior to installation of the generator, the installer should consult local fuel suppliers or the fire marshall to check codes and regulations for proper installation. Local codes will mandate correct routing of gaseous fuel line piping around gardens, shrubs and other landscaping to prevent any damage.

Special considerations should be given when installing the unit where local conditions include flooding, tornados, hurricanes, earthquakes and unstable ground for the flexibility and strength of piping and their connections.

Use an approved pipe sealant or joint compound on all threaded fitting.

All installed gaseous fuel piping must be purged and leak tested prior to initial start-up in accordance with local codes, standards and regulations.

Unit Nat. Gas (*)

Full

LP Vapor (**)

1/2 Load Full Load

6/7 kW 66

9/10 kW 102

119

156

0.82/30

1.25/46

1.47/54

1.93/70

13/13 kW 156

15/16 kW 173

220

245

1.55/57

1.59/59

2.18/80

2.51/92

*Natural gas is in cubic feet per hour.

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

*** Values given are approximate.

NATURAL GAS

BTU flow required for each unit based on 1000 BTU per cubic foot.

•

•

•

•

6kW — 119,000 BTU/Hour

9kW — 156,000 BTU/Hour

13kW — 220,000 BTU/Hour

15kW — 245,000 BTU/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.

NOTE:

A minimum of one approved manual shut-off valve must be installed in the gaseous fuel supply line.

The valve must be easily accessible. Local codes determine the proper location.

7



FUEL SYSTEM

1.9.1 7 KW, 410CC ENGINE

To reconfigure the fuel system from NG to LP, follow these steps (Figure 1.4):

NOTE:

The primary regulator for the propane supply is

NOT INCLUDED with the generator. A fuel pressure of 10 to 12 inches of water column (0.36 to

0.43 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.

Figure 1.4 – Demand Regulator

HOSE & PLUG

SWITCHED SIDES

FUEL HOSE

BRASS HOSE

FITTING

ADJUSTMENT

SCREW

PIPE

PLUG

FUEL HOSE

BRASS HOSE

FITTING

OUTLET

PORT

FUEL JET

NOTE:

Use an approved pipe sealant or joint compound on all threaded fittings to reduce the possibility of leakage.

9. Reverse procedure steps 1-6 to reinstall demand regulator.

10. Take the plastic plug supplied in the poly-bag with the generator and press it into the 3/4” hole on the bottom of the air cleaner base (Figure

4.6).

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

12. Check for gas leakage at the pipe plug, hose connection and fittings.

1.9.2 10, 13 AND 16KW, V-TWIN 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 10 to 12 inches of water column (0.36 to

0.43 psi) to the fuel inlet of the generator MUST

BE SUPPLIED.

2. For 10kW units: Loosen clamp and slide back the air inlet hose.

• Slide fuel selector on carburetor out towards the back of the enclosure (Figures 1.5 and 1.6).

• Return the inlet hose and tighten clamp securely.

For 13 and 16kW units: remove the air cleaner cover.

• Slide the selector lever out towards the back of the enclosure (Figures 1.7 and 1.8).

• Return the air cleaner cover and tighten the two thumb screws.

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

8

NG FUEL SYSTEM

RUNNING

PRESSURE

TAP

LP FUEL SYSTEM

STATIC

PRESSURE

TAP

Figure 1.5 - 10kW, GT-530 (Inlet Hose Slid Back)



Figure 1.8 - 13/16kW, GT-990 (Airbox Cover

Removed)

Fuel Selection Lever - "Out" Position for Liquid Propane

(Vapor) Fuel

Fuel Selection

Lever - "In"

Position for

Natural Gas

Fuel

Figure 1.6 - 10kW, GT-530 (Inlet Hose Slid Back)

Fuel Selection

Lever - "Out"

Position for

Liquid Propane

(Vapor) Fuel

Figure 1.7 - 13/16kW, GT-990 (Airbox Cover

Removed)

Fuel Selection Lever - "In" Position for Natural Gas Fuel

1.10 LOCATION

1.10.1 GENERATOR

Install the generator set, in its protective enclosure, outdoors , where adequate cooling and ventilating air is always available (Figure 1.9). Consider these factors:

•

•

•

•

•

•

•

The installation of the generator must comply strictly with NFPA 37, NFPA 54, NFPA 58, and

NFPA 70 standards.

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. This unit must be installed in accordance with current applicable

NFPA 37 and NFPA 70 standards; as well as any other federal, state and local codes for minimum distances from other structures. DO NOT install under wooden decks or structures.

Install the unit where rain gutter down spouts, roof fun-off, landscape irrigation, water sprinklers or sump pump discharge does not flood the unit or spray the enclosure, including any air inlet or outlet openings.

Install the unit where services will not be affected or obstructed, including concealed, underground or covered services such as electrical, fuel, phone, air conditioning or irrigation.

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

9



•

•

•

•

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. REMEMBER THAT LAWS OR

CODES MAY REGULATE THE DISTANCE AND

LOCATION.

The genset must be installed on a level surface.

The base frame must be level within two (2) inches all around.

The generator is typically placed on pea gravel or crushed stone. Check local codes if a concrete slab is required. If a concrete base slab is required, all federal, state and local codes should be followed.

Special attention should be given to the concrete base slab which should exceed the length and width of the generator by a minimum of six (6) inches (0.152 meters) on all sides.

Figure 1.9 – Generator Clearances



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.

• Operate the generator outdoors ONLY.

• Keep exhaust gases from entering a confined area through windows, doors, ventilation or other openings (Figure 1.9).

1.10.2 TRANSFER SWITCH

1.10.2.1 7, 10, 13, and 16 kW Units (if equipped)

The transfer switch shipped with this generator is enclosed in a NEMA 1 enclosure. This type of enclosure is intended for indoor use only . Follow these rules:

10

•

•

•

•

Install the transfer switch indoors 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.



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.

1.11 BATTERY REQUIREMENTS

See the Specifications section for correct battery size and rating.

1.12 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 15A fuse from the generator control panel.

Battery cables were factory connected at the generator (Figure 1.10). 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 (—).

NOTE:

Dielectric grease should be used on battery posts to aid in the prevention of corrosion.

NOTE:

Damage will result if battery connections are made in reverse.



Figure 1.10 – Battery Cable Connections

NOTE:

In areas where temperatures regularly fall below

10° F (-12° C) it is recommended that a pad type battery heater be installed to aid in cold climate starting (see Specifications).

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.

1.13 THE BATTERY

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 the 15A fuse from the generator control panel.

• 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, flush thoroughly and immediately 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) of 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 15A fuse is removed from the generator control panel, or sparking may occur at the battery posts as the cables are attached and cause an explosion.

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.

See the Specifications section for the correct size and rating when replacing the battery. When using a maintenance-free 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.

11

Section 2 — Post Installation Start-up and Adjustments


INITIAL

NOTE:

START-UP

These units have been run and tested at the factory prior to being shipped and do not require any type of break-in.

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 all breakers on the load center of the transfer box (T1 and T2).

4. Turn OFF all loads connected to the transfer switch terminals T1 and T2.

5. 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.

6. 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.

During initial start up, after installation, it is normal for the generator to exceed the normal number of start attempts and experience an “over crank” fault.

This is due to accumulated air in the fuel system during shipment.

To reduce or eliminate this problem on initial start up, remove the air filter cover and partially cover the fuel mixer inlet while the engine is cranking (Figures

2.1 and 2.2). This will cause an abnormal vacuum in the system and purge the air from the system.

Once fuel reaches the engine, it will begin to run.

Remove the blockage from the mixer inlet as soon as the engine begins to fire. The unit should then be run several minutes to insure that all air is removed from the fuel system. Once the engine is running, this procedure is not required as long as the fuel supply to the generator is not interrupted. This procedure will only be required if the generator becomes disconnected from the fuel system for whatever reason.

NOTE:

This procedure applies to 13kW and 16kW units only and should be performed by trained personnel.



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

Figure 2.1 – Remove Air Filter Cover

Figure 2.2 – Restrict Air Flow During

Inital Start Up

OPERATION

Refer to the "Manual Transfer Operation" section, of the owner’s manual for 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.

12



CHECKS

Complete electrical checks as follows:

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


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


4. 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.

5. Use an accurate AC voltmeter to check utility power source voltage across transfer switch terminals N1 and N2. Nominal line-to-line voltage should be 240 volts AC.

6. 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.

7. 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.

8. On the generator panel, set the AUTO/OFF/

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

9. 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.

10. Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1 and E2. 7kW voltage should be 242-252 volts at a frequency of 61-63 Hertz. 10, 13, and 16kW voltage should be 247-249 volts at a frequency of

57.5-59.5 Hertz.

11. Connect the AC voltmeter test leads across terminal lugs E1 and neutral; then across E2 and neutral. In both cases, voltage reading should be

121-126 volts AC (7kW), and 125-126 volts AC

(10, 13 and 16kW).


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* (*GH410 only). 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.



OFF.

4. 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.

5. 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.

6. Set the generator's AUTO/OFF/MANUAL switch to MANUAL. The engine should crank and start immediately.

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

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

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

9. Turn ON the load center of the transfer switch

(T1 and T2).

10. Connect an accurate AC voltmeter and a frequency meter across terminal lugs E1 and E2.

• 7kW voltage should be greater than 230 volts and frequency should be greater than 58 Hz.

13



• 10, 13 & 16kW voltage should be greater than

240 volts and frequency should be greater than

60 Hz.

11. 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.

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

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


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

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

OPERATION

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

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

(or OPEN) position.

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

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

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 generator's main circuit breaker to its ON

(or CLOSED)) position.

7. Set the AUTO/OFF/MANUAL switch to AUTO. The system is now ready for automatic operation.

8. 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 a 10 second delay. After starting, the transfer switch should connect load circuits to the standby side after a 15 second delay. 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 15 seconds, the switch should transfer loads back to the utility power source.

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

- 7KW (NATURAL GAS ONLY)

NOTE:

All V-twin engine units DO NOT require a fuel regulator adjustment due to the fuel system design.

Although the generator has been factory set to provide maximum power, it may be necessary in some areas to adjust this setting. 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 that the No Load Frequency, with the roof open and door off, is set to 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 50.0 amps 25.0 amps

4. When 3/4 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 adjustment screw. While watching the frequency meter, slowly turn the adjustment screw clockwise or counterclockwise until the highest frequency is read on the meter. Only limited adjustment is available because of the set pin. Under no circumstances should any of the pins be removed (Figure 2.3).

Figure 2.3 — 7kW Fuel Regulator

ngine 410cc Engine

Adjustment

Screw

(One Side

Only)

Set

Pin

14



6. When the highest frequency is reached maximum power has been set. From this point turn the adjustment screw 1/4 turn counterclockwise. The regulator is now set.

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 the test equipment is not available, locate the nearest 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



The engine must be OFF to perform steps 1 and

2.

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

Figure 2.4 — Engine Governor Adjustment

Single Cylinder Engines

SECONDARY

ADJUST SCREW

GOVERNOR

SHAFT

GOVERNOR

CLAMP

BOLT

PRIMARY

ADJUST

SCREW

2. Hold the governor lever at its wide open throttle position (clockwise), 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 primary adjust screw to obtain a frequency reading of 61.5 Hertz. Turn the secondary adjust screw to obtain a frequency of 62.5 Hz.

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

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

Voltage Regulator Adjustment section).

2.7.2 13 KW AND 16 KW UNITS

NOTE:

All V-twin units DO NOT require an engine governor adjustment due to their design.

PROTECTION

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

ADJUSTMENT

With the frequency between 62-63 Hertz at no-load, slowly turn the slotted potentiometer (Figure 2.5) until line voltage reads 248-252 volts.

2.8.2 10, 13, AND 16KW UNITS

With the frequency between 58-59 Hertz at no-load, slowly turn the slotted potentiometer (Figure 2.3) until line voltage reads 247-249 volts.

NOTE:

The access panel on top of the control panel must be removed to adjust the voltage regulator.

NOTE:

The voltage regulator is housed above the generator's control panel. The regulator maintains a voltage in direct proportion to frequency at a 2-to-

1 ratio. For example, at 62 Hertz, line-to-neutral voltage will be 124 volts.

15

Section 3 — Operation


Figure 2.5 – Voltage Adjustment Potentiometer

Turn to adjust voltage.

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



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 the 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.

1. 990 engines have an electric choke in the air box that is automatically controlled by the electronic control board.

2. 530 engines have an electric choke on the divider panel air inlet hose that is automatically controlled by the electronic control board.

3. 410 engines do not have a choke.

SWITCH (FIGURE 3.1)

Selecting this switch position activates fully automatic system operation. It also allows the unit to automatically start and exercise the engine every seven days with the setting of the exercise timer (see the Setting the Exercise Timer section).

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

Figure 3.1 – Generator Control Panel

AUTO.

SYSTEM FUSE

OFF MAN.

15A

ASSY: 0F8418/0F8419

SET

EXERCISE

TIME

CONTROL AND INFORMATION CENTER

SYSTEM SET

LOW BATTERY

LOW OIL

HIGH TEMP

OVER SPEED

NO RPM SENSE IF FLASHING

OVER CRANK

FLASHING GREEN LED=

NO UTILITY SENSE

5 FLASHING RED LEDS=

EXERCISER NOT SET

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 (Refer to the Electrical Data section).

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 the

Sequence of Automatic Operation section.

16



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). Refer to the Electrical Data section.

The generator must run at 50 Hz or greater for the transfer output to be activated. Once activated, it will remain active even if the frequency dips below 50

Hz.

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 65 percent of the nominal supply voltage, the sensor energizes a 10 second timer.

• Once the timer has expired, the engine will crank and start if utility is still low.

B. Engine Warm-up Time Delay

• This mechanism lets the engine warm up for about five (5) seconds before the load is transferred to the 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 above 75 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 transfer relay in the transfer switch if utility is still present.

• 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.

POWER SOURCE

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

1. 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).

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.

Figure 3.2 – Manual Transfer Switch Operation

17



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.

3.5 SETTING THE EXERCISE TIMER

This 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 unless utility power is lost.

A switch on the control panel (see Figure 3.1) permits selection of the day and time for the system to exercise. At the chosen time, perform the following sequence to select the desired day and time of day the system will exercise. Remember seasonal time changes affect the exercise time settings.

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

2. Press and hold the "Set Exercise Time" switch for several seconds, then release. All the red LED's will flash for approximately 10 seconds and then stop.

18

3. Once the red LED's stop flashing, the generator will start and run for approximately 12 minutes and then shut down. The exerciser is now set to run at this time of day each week.

Example: If the "Set Exercise Time" switch is pressed on Saturday afternoon at 2:00 p.m., the generator will start and exercise for approximately 12 minutes every Saturday at 2:00 p.m..

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, and when the 15A fuse is removed.

The 16kW unit has a low speed exercise option. Dip switch 1 on the control board is factory set to OFF.

This allows the engine to run at a slower speed during weekly exercise periods for quieter operation. If this Dip switch is set to ON, the generator will exercise at it's normal speed.

This DIP switch position is only read at board power up. If the DIP switch position is changed, power to the board must be cycled for the micro controller to recognize the new DIP switch position.

Low speed exercise will be handled as follows:

1. The standard start sequence will be initiated.

2. The unit will run at 2,400 RPM.

3. If utility is lost during exercise, the controller will do the following:

• Wait 10 seconds for utility to return.

• If utility returns within 10 seconds, continue to exercise at 2,400 RPM.

• If utility is still lost after 10 seconds, run the engine up to 3600 RPM and transfer the load.

At this time the controller will exit the exercise routine and assume full automatic operation.

3.6.1 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. The AUTO/OFF/MANUAL switch must then be turned to OFF and then back to

AUTO.



3.6.2 HIGH TEMPERATURE SWITCH

This switch’s contacts (Figure 3.3) close if the temperature should exceed approximately 144º C (293º

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

Figure 3.3 – Low Oil Pressure and

High Temperature Switches

Low Oil Switch High Temp Switch

Loose n

Oil Filter

Oil

Drain

Hose

3.6.3 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 on the generator control panel 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

7kW Units:

•

•

•

•

•

15 seconds ON

7 seconds OFF

7 seconds ON

7 seconds OFF

7 seconds ON

•

•

•

•

7 seconds OFF

7 seconds ON

7 seconds OFF

7 seconds ON

•

•

7 seconds OFF

7 seconds ON

If the unit fails to start, the overcrank alarm LED will be illuminated.

10kW, 13kW and 16kW Units:

•

•

•

•

•

•

•

16 seconds ON

7 seconds OFF

16 seconds ON

7 seconds OFF

7 seconds ON

7 seconds OFF

7 seconds ON

•

•

7 seconds OFF

7 seconds ON

• 7 seconds OFF

If the unit fails to start, the overcrank alarm LED will be illuminated.

3.6.4 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 Authorized Dealer if this failure occurs.

3.6.5 RPM SENSOR FAILURE

During cranking, if the board does not see a valid

RPM signal within three (3) seconds, it will shut down and latch out on RPM sensor loss.

During running, if the RPM signal is lost for one full second the board will shut down the engine, wait 15 seconds, then re-crank the engine.

•

•

If an RPM signal is not detected within the first three (3) seconds of cranking, the control board will shut the engine down and latch out on RPM sensor loss.

If the RPM signal is detected the engine will start and run normally. If the RPM signal is subsequently lost again, the control board will try one more re-crank attempt before latching out and flashing the overspeed LED.

The microprocessor will continually monitor the battery voltage and turn on the Low Battery LED if the battery voltage falls below 11.0 volts for one (1) minute. No other action is taken on a low battery condition. Low battery voltage is a non-latching alarm which will automatically clear if the battery voltage rises above 11.0 volts. Battery voltage is NOT monitored during the crank cycle.

19

Section 4 — Maintenance


4.1 FUSES

The 15-amp fuse on the generator panel protects the

DC control circuit against overload (Figure 4.1). This fuse is wired in series with the battery output lead to the panel. If this fuse element has melted open, the engine will not be able to crank or start. Replace this fuse using only an identical 15-amp replacement fuse. To replace the fuse, push the fuse holder cap down and rotate it counterclockwise. Whenever the fuse is removed or replaced, the exercise timer needs to be reset.

Figure 4.1 – Generator Control Panel

AUTO.

SYSTEM FUSE

OFF MAN.

15A

ASSY: 0F8418/0F8419

SET

EXERCISE

TIME

CONTROL AND INFORMATION CENTER

SYSTEM SET

LOW BATTERY

LOW OIL

HIGH TEMP

OVER SPEED

NO RPM SENSE IF FLASHING

OVER CRANK

FLASHING GREEN LED=

NO UTILITY SENSE

5 FLASHING RED LEDS=

EXERCISER NOT SET

OIL LEVEL

For oil capacities, see the Specifications section.

For engine oil recommendations, see the Engine Oil

Recommendations section. To check the engine oil level, proceed as follows (Figures 4.2, 4.3 and 4.4):

1. Move the AUTO/OFF/ MANUAL switch to the OFF position.

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

3. Completely insert 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.

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

Figure 4.2 — Oil Dipstick and Fill, 7kW

Oil Dipstick and Fill

Figure 4.3 — Oil Dipstick and Fill, 10kW

Oil Dipstick

Oil Fill

Figure 4.4 — Oil Dipstick and Fill,

13kW and 16kW

Oil Dipstick

Oil Fill

20



4.3 CHANGING THE ENGINE OIL

4.3.1 OIL CHANGE INTERVALS

See the "Service Schedule" section.

4.3.2 ENGINE OIL RECOMMENDATIONS

All oil should meet minimum American Petroleum

Institute (API) Service Class SJ, SL or better. Use no special additives. Select the oil's viscosity grade according to the expected operating temperature.



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

Figure 4.5 – Oil Drain Hose and Filter

Low Oil Switch High Temp Switch

Loose n

Oil Filter

Oil

Drain

Hose

4. Refill with the proper recommended oil (see the

Engine Oil Recommendations section). See the

Specifications section for oil capacities.

5. Start the engine, run for one (1) minute, and check for leaks.

6. Shutdown and recheck oil level, add as needed.

DO NOT OVER FILL.

7. Reset the AUTO/OFF/MANUAL switch to the

AUTO position.

4.3.3 OIL & OIL FILTER CHANGE PROCEDURE

To change the oil, proceed as follows:

1. Start the engine by moving the AUTO/OFF/

MANUAL switch to MANUAL and run until it is thoroughly warmed up. Then shut OFF the engine by moving the switch to the OFF position.

2. Immediately after the engine shuts OFF, pull the oil drain hose (Figure 4.5) 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.

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 the Specifications section 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).

AIR CLEANER

4.4.1 7, 13, AND 16KW GENERATORS

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

7kW; Figure 4.8, 13/16kW):

1. Lift the roof and remove the door.

2. Turn the two screws counterclockwise to loosen.

3. Remove the cover and air filter.

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

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

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

See the Service Schedule section for air cleaner maintenance. See the Specifications section for air filter replacement part number.

21



Figure 4.6 — 7 kW, Engine Air Cleaner Location Figure 4.8 — 13 kW and 16 kW Engine

Air Cleaner

Screw

Air

Cleaner

Cover

Filter

3/4”

Hole

See Figure 1.2 for the location of the air cleaner. Use the following procedure (Figure 4.7):

1. Lift the roof and remove the door.

2. Turn the worm gear clamp screw counterclockwise to loosen.

3. Pull the old filter off the divider panel hub.

4. Wipe away dust or debris from the panel hub.

5. Install the new air cleaner onto the hub.

6. Turn the worm gear clamp screw clockwise to tighten.

7. Replace door and roof.

Figure 4.7 — 10kW Engine Air Cleaner

Control

Panel

Air Filter

PLUG(S)

Reset the spark plug(s) gap or replace the spark plug(s) as necessary. See the Service Schedule section for maintenance requirements.

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

2. Remove the spark plug(s) and check the condition. Replace the spark plug(s) if worn or if reuse is questionable. See the Service Schedule section for recommended inspection. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plug(s) to clean.

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

7 and 10kW; and 1.02 mm (0.040 inch) for 13/16 kW by carefully bending the ground electrode

(Figure 4.9).

Figure 4.9 – Setting the Spark Plug Gap

SET PLUG GAP AT 0.76 mm (.030 inch) - 7 & 10kW;

1.02 mm (.040 inch) - 13 & 16kW

22



MAINTENANCE

The battery should be inspected per the "Service

Schedule" section. 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 the 15A fuse from the generator control panel.

• 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, flush thoroughly and immediately 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) of 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 15A fuse is removed from the generator control panel, or sparking may occur at the battery posts as the cables are attached and cause an explosion.

VALVE CLEARANCE

After the first six (6) months of operation, check the valve clearance in the engine, adjust if necessary.

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

To check valve clearance:

•

•

•

•

The engine should be cool before checking. If valve clearance is 0.002" - 0.004" (0.05 - 0.1mm), adjustment is not needed.

Remove spark plug wires and position wires away from plugs.

Remove spark plugs.

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 in a clockwise direction. While watching the piston through the spark plug hole. The piston should move up and down.

The piston is at TDC when it is at its highest point of travel.

•

23



To adjust valve clearance (if necessary):

•

•

•

•

Make sure the engine is at 60° to 80° F.

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.

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).

Figure 4.10 - Valve Clearance Adjustment

Jam Nut

Pivot Ball

S tud

Rocker

Arm

Valve

S tem

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 4.11 for vent locations.)

Make sure the doors and roof are in place during operation as running the generator with them removed can effect cooling air movement.

Figure 4.11 – Cooling Vent Locations

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.

•

•

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 all the screws in place. Make sure the valve cover gasket is in place.

•

•

•

Install spark plugs.

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

On the GT-530 and GT-990, repeat the process for the other cylinder.



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.

 The maximum ambient temperature for the generator is 40° C (104° F).

4.9 ATTENTION AFTER SUBMERSION

If the generator has been submerged in water, it must not be started and operated. Following any submersion in water, have an Authorized Dealer thoroughly clean, dry and inspect the generator. If the structure

(ex. home) has been flooded, it should be inspected by a certified electrician to ensure there won't be any electrical problems during generator operation or when utility is returned.

24



4.10 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.

4.11 OUT OF SERVICE PROCEDURE

4.11.1 REMOVAL FROM SERVICE

If the generator cannot be exercised every seven days, and will 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.



5. Set the AUTO/OFF/MANUAL switch to OFF and turn off the utility power to the transfer switch.

Remove the 15A fuse from the generator control panel. Disconnect the battery cables as outlined in “General Hazards”.

6. While the engine is still warm from running, drain the oil completely. Refill the crankcase with oil. See ”Engine Oil Recommendations".

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

8. Remove the spark plug(s) and spray fogging agent into the spark plug(s) threaded openings.

Reinstall and tighten the spark plug(s).

9. 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.

10. Clean and wipe the entire generator.

4.11.2 RETURN TO SERVICE

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

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

AUTO/OFF/MANUAL switch is set to OFF.

2. Check the tag on the engine for oil viscosity and classification. Verify that the correct recommended oil is used in the engine (see the Engine Oil

Recommendations section). If necessary, drain and refill with the proper oil.

3. 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,” for type and size.

4. Clean and wipe the entire generator.

5. Make sure the 15A fuse is removed from the generator control panel. Reconnect the battery.

Observe battery polarity. Damage may occur if the battery is connected incorrectly.

6. Open the fuel shutoff valve.

7. Insert the 15A fuse into the generator control panel. Start the unit by moving the AUTO/OFF/

MANUAL switch to MANUAL. Allow the unit to warm up thoroughly.

8. Stop the unit by setting the AUTO/OFF/MANUAL switch to OFF.

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

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

11. The generator is now ready for service.

NOTE:

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



4.12 SERVICE SCHEDULE

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

SYSTEM/COMPONENT PROCEDURE FREQUENCY

X = Action

R = Replace as Necessary

* = Notify Dealer if Repair is Needed.

FUEL

Inspect Change Clean W = Weekly

M = Monthly

Y = Yearly

Fuel lines and connections* X

LUBRICATION

M

Oil level X

Oil X

M

Every 200 hours**, or 24

hours of continuous use,

Oil filter

COOLING

X Every 200 hours**, or 24

hours of continuous use,

X W Enclosure louvers X

BATTERY

Remove corrosion, X ensure dryness

Clean and tighten X battery terminals

Check charge state

Electrolyte level

(unsealed batteries only)*

ENGINE AND MOUNTING

X

X

R

R

X

X

M

M

EVERY 6 M

EVERY 6 M

Air cleaner

Spark plug(s)

GENERAL CONDITION

X

X

R

R

Vibration, Noise, Leakage, X

Temperature*

COMPLETE TUNE-UP* TO BE COMPLETED BY

2Y or 200 hours

2Y or 200 hours

M

2Y or 200 hours

* Contact the nearest dealer for assistance if necessary.

** Change oil and fi lter after fi rst eight (8) hours of operation and then every 200 hours thereafter, or 2 years, whichever occurs fi rst. Change sooner when operating under a heavy load or in a dusty or dirty environment or in high ambient temperatures.

Section 5 — Troubleshooting


5.1 TROUBLESHOOTING GUIDE

Problem Cause

The engine will not crank. 1. Fuse blown.

The engine cranks but will not start.

2. Loose, corroded or defective

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).

Correction

1. Correct short circuit condition, replace 15A fuse in generator control panel.

2. Tighten, clean or replace

1. Replenish fuel/Turn on fuel valve.

2. *

3. *

The engine starts hard and runs rough. engine control board.

4. Defective spark plug(s).

5. Valve lash out of adjustment.

6. Choke not operating.

1. Air cleaner plugged or damaged.

2. Defective spark plug(s).

3. Fuel regulator not set.

4. Fuel pressure incorrect.

5. Fuel selector in wrong position.

6. Choke remains closed.

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

5. Reset valve lash.

6. Verify choke plate moves freely.

1. Check, replace air cleaner.

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

3. Set Fuel Regulator.

4. Confirm fuel pressure to regulator is 10-12” water column (0.36-0.43 psi) for LP, and 5-7” water column

(0.18-0.25 psi) for natural gas.

5. Move selector to correct position.

6. Verify choke plate moves freely.

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 1. Main line circuit breaker is in the generator. the OFF (or OPEN) position.

2. Generator internal failure.

There is no transfer to standby after utility source failure.

Unit consumes large amounts of oil.

1. Defective transfer switch coil.

2. Defective transfer relay.

3. Transfer relay circuit open.

4. Defective control logic board.

1. Engine over filled with oil.

2. Engine breather defective.

4. Damaged gasket, seal or hose.

1. *

2. *

3. *

1. Reset circuit breaker to ON (or CLOSED).

2. *

1. *

2. *

3. *

4. *

1. Adjust oil to proper level.

2. *

4. Check for oil leaks.

*Contact the nearest Authorized Dealer for assistance.

27

28

Section 6 — Notes


Section 7 — Electrical Data


Electrical Schematic – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9775

E1

N1A

N1A

E1

7

1

7 9

4

9

3 6

194

A

TR

23

B

126 205

N1A

N1A

N2A

194

23

E1

N1A

F2

F1

E1

E2

B

B

N2A

A

NO

126

B

205

N2A

N1A

N2A

NC NC NO

COM

XB XA

COM

VR1

C1

ATS

VR2

C2

T1 T2

E1

E2

N2A

B E2

E2

NEUTRAL

CONNECTION

INSIDE SWITCH

B

LEGEND

E2

ATS-AUTOMATIC TRANSFER SWITCH

C1-UTILITY COIL & RECTIFIER

C2-GENERATOR COIL & RECTIFIER

F1,F2-5A, 600V FUSE

LC-CIRCUIT BREAKER (LOADS)

TR-TRANSFER RELAY

TS-TERMINAL STRIP

XA,XB-LIMIT SWITCHES

T1

T2

CIRCUIT 4

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 15

CIRCUIT 16

CIRCUIT 14

CIRCUIT 13

CIRCUIT 10

CIRCUIT 9

CIRCUIT 6

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

194

23

OPEN

E1

E2

N2

N1

LC

194

23

12Vdc TRANSER

COIL

N2

N1

240VAC

OUTPUT

BLACK

RED

NEUTRAL (WHITE)

NEUTRAL (WHITE)

RED (MAIN 2)

BLACK (MAIN 1)

TS TO

GENERATOR

CONTROL PANEL

TO GENERATOR

OUTPUT

CIRCUIT BREAKER

240VAC TO

MAIN DISTRIBUTION

PANEL

29

30



Wiring Diagram – 10, 13 & 16kW, V-Twin – Drawing No. 0F7822-A



Wiring Diagram – 10, 13 & 16kW, V-Twin – Drawing No. 0F7822-A

31

32



Electrical Schematic – 10, 13 & 16kW, V-Twin – Drawing No. 0F7823-A



Electrical Schematic – 10, 13 & 16kW, V-Twin – Drawing No. 0F7823-A

33

34



Wiring Diagram – 7kW, Single Cylinder – Drawing No. 0F7820-A



Wiring Diagram – 7kW, Single Cylinder – Drawing No. 0F7820-A

35

36



Electrical Schematic – 7kW, Single Cylinder – Drawing No. 0F7821-A



Electrical Schematic – 7kW, Single Cylinder – Drawing No. 0F7821-A

37

38



Wiring Diagram – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9070-A



Wiring Diagram – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9070-A

39

Section 8 — Exploded Views and Parts Lists


Enclosure – Drawing No. 0F9431-D

SHEET METAL PAINT/MATERIAL CODE LEGEND

The following exploded views contain part numbers of various sheet metal components. Only the base part number is listed. When ordering sheet metal, the correct color and material information must be included as a suffi x at the end of the part number as shown below.

Material Color Example: Desc. Part No. Material Color Order As"

S = Steel

A = Aluminum

N = Tan

G = Gray

B = Black

Roof

Door

Divider

0F6522

0F6555

0F6558

S = Steel

A = Aluminum

S = Steel

N = Tan

G = Gray

B = Black

0F6522SN

0F6555AG

0F6558SB

40



Enclosure – Drawing No. 0F9431-D

ITEM PART NO. QTY. DESCRIPTION

24

25

26

27

28

29

30

31

0F6570

0F6571

0D2979B

0D2979C

022097

022097

022473

0F7826

0F0165A

32

33

34

35

0F6550

0F0164A

0E1330A

021267A

36 0E5968

37

38

40

41

0F0165

0F0164

0A8475

0G0400

42 0F6552

43 0F9379

44 0D1839

45 0F8210

0F8209

0F9078

46 0F5458

16

17

18

19

20

21

22

23

10

11

12

13

14

15

1

2

3

4

5

6

0F9653

045771

022129

022129

022145

043107

090388

7 0D3700

0D3700*

022097*

022473*

8

9

049813*

0D4662

0D4662

0F8871

0F8080

0F8246

0F8915

0F6558

092120

0F7825

0F7824

0F6549

0F7824A

0D1840

047411

047411

0F0710

0A2115

0C6735

0D2979D

0D7176

0F7827

1 PAD, 24 X 48” WITH MOUNTING HOLES

4 NUT HEX M8-1.25

4 WASHER LOCK 5/16

5 WASHER LOCK 5/16 (7KW)

8 WASHER FLAT 5/16

4 SCREW HHC M8-1.25 X 25

15 SCREW TAPTITE M6-1.0 X 12

24 NUT, LOCKING FLANGE M6-1.0

14 NUT, LOCKING FLANGE M6-1.0

10 WASHER LOCK M6-1/4

10 WASHER FLAT 1/4-M6 ZINC

10 NUT HEX M6 X 1.0

14 SCREW HHTR 5/16-18 X 3/4" (7KW)

13 SCREW HHTR 5/16-18 X 3/4"

1 SCROLL, FAN (7KW, 10KW)

1 PANEL, ALTERNATOR DIVIDER (7KW)

1 PANEL, ALTERNATOR DIVIDER (10KW)

1 PANEL, ALTERNATOR DIVIDER

4 NUT LOCK TRIC M6 X 1.0

1 FOAM, MUFFLER BOX FRONT

1 FOAM, MUFFLER BOX END

1 ENCLOSURE, EXHAUST SIDE

1 FOAM, MUFFLER BOX END

2 BRACKET, BOTTOM SUPPORT

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

8 SCREW HHC M6-1.0 X 16 G8.8

12 RIVET POP 0.125” X 0.337”

4 WASHER NYLON M6-1/4”

2 SUPPORT, ROOF FOLDING

2 CLOTH HARDWARE 266.7mm X 387.4mm

34 WASHER, SELF LOCKING

2 FOAM, EXHAUST ENCLOSURE COVER

1 COVER, BACK EXHAUST ENCLOSURE

1 COVER, FRONT EXHAUST ENCLOSURE

1 CLOTH, HARDWARE 266.7mm X 146mm

1 CLOTH, HARDWARE 543mm X 146mm

4 WASHER LOCK M6-1/4 (7KW)


2 WASHER FLAT M6-1/4

1 FOAM, MUFFLER BOX BACK

1 HINGE TYPE B WITH STUDS, SOCKET

1 ENCLOSURE, SIDE & BACK

1 HINGE TYPE A WITH STUDS, SOCKET

1 GROMMET, 38.1 CROSS SLIT WITH HOLE

2 PLUG PLASTIC 1.5 BLIND GROMMET

11 GASKET, EXTRUDED TRIM

1 HINGE TYPE B WITH STUDS, PIN

1 HINGE TYPE A WITH STUDS, PIN

1 L/WASH SPECIAL #10

1 WIRE ASSEMBLY, GROUND

1 ENCLOSURE, ROOF

1 FOAM, ROOF ENCLOSURE

2 BRACKET, TOP SUPPORT

1 REGULATOR ASSEMBLY (7KW)

1 REGULATOR ASSEMBLY (10KW)

4 SCREW PLASTITE HI-LOW #10 X 3/8


47

48

49

50

0F5438

0F5434

0F8263

0F7886

0F7885

023484H

0D3058A

0E4245

51 0D3058C

52 0D1605A

0F7798

53

54

55

56

57

0F8380

0D3472

0C8285

0D3167

0E1330

64

65

66

67

68

69

70

71

58 043116

043116

59 086729

60 0F8039

61

62

022127

0388040AJ0

63 0F8847

0F8434

0F9968

0C2937

049813

0A1658

0G0617

092079

055414

0F8234

0F7711

72 0F8257

73 0C3906

74 0F6555

75 0F8555

76 0D3037

77 0D3037A

78 0F9143

79 0F8261

80 0F5440

0F9328

0F5478

81

82

83

84

051713

022152

036937

022158

85 0C8911

86 026850

89

90

0G3540

0G3539

1 HARNESS, ENGINE (7KW)

1 HARNESS ENG V-T HSB

1 PANEL, ENGINE DIVIDER (7KW)

1 PANEL, ENGINE DIVIDER (10KW)

1 PANEL, ENGINE DIVIDER

1 BUSHING SNAP SB-1500-18

1 FOAM, FRONT INTAKE BAFFLE (7KW)

1 FOAM, BACK INTAKE BAFFLE (7KW)

1 BAFFLE, INTAKE (7KW)

1 FOAM, TOP INTAKE BAFFLE

1 GROMMET OVAL 31.75 X 50.8

1 BRACKET, BATTERY SUPPORT

1 GASKET, BATTERY SUPPORT BRACKET

1 GROMMET, 38.1 DIA. CROSS SLIT

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

1 SCREW HHC M6-1.0 X 12 G8.8

1 CONTACTOR, STARTER (7KW)

1 MOUNTING CLIP

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

1 CABLE, #6 RED BATTERY 38.5”

1 GASKET, FRONT DIVIDER

1 GASKET, FRONT DIVIDER (10KW)

1 FUEL LINE, 1/2” OUTDOOR (NOT SHOWN)

1 BRACKET, BATTERY HOLD DOWN (7KW)

1 NUT HEX M6-1.0 G8

1 LOCK WASHER SPECIAL 1/4

1 EXTERNAL CONNECTION BOX

1 SCREW TAPTITE M6-1.0 X 25 BP

1 LUG SLDLSS #2-#8 X 17/64 CU

1 ASSEMBLY, ENCLOSURE BASE (7KW)

1 ASSEMBLY, ENCLOSURE BASE

1 FOAM, FRONT ENCLOSURE

2 SELF-ALIGN SCREW M6 HH

1 ENCLOSURE, FRONT

1 GASKET, DOOR SEAL

1 LATCH, QUARTER TURN LOCKING

1 LATCH, QUARTER TURN NON-LOCKING

2 PAWL, DOOR

1 FOAM, BACK ENCLOSURE

1 HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX (7KW)


CONNECTION BOX (10KW)


CONNECTION BOX

2 WASHER FLAT M5

5 WASHER LOCK #10

2 SCREW PPHM#10-32 X 1

5 NUT HEX #10-32

1 POWER BLOCK

1 WASHER SHAKEPROOF EXT 1/4 STEEL

1 WASHER FLAT .125ID X .375OD

1 RIVET POP .122 X 0.465 STEEL

*ITEM 7 FOR MODELS WITH ALUMINUM ENCLOSURE

41

42



Control Panel – Drawing No. 0F9695-F



Control Panel – Drawing No. 0F9695-F

1 0E7886A

0E7886D

0E7886K

0E7886J

0E7886L

2

3

0A1801

0F9719

4 0C2174

5 075210A

7 0F8992

0F1504

0G5715

8 032300

9 022676

10

11

0E4494

0E7890

12 023484E

13

14

075476

043182

15 0E6480

16 0D4804A

0D4804A

17

18

0C1085

0C1085

058000H

19 023897

20 0F8040

21

0F9282

075235

22 0E3928

23 0D9784

0D9784

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

1 CIRCUIT BREAKER 45A X 2P 240V

(10KW)


(13KW)


(16KW)


(18KW)

1 ASSEMBLY, BATTERY CHARGER ENGINE

1 ASSEMBLY, POTTED REGULATOR

1 RELAY, 12V 25A SPST (NON 7KW)

1 BLOCK

1 ASSEMBLY, HOME STANDBY

CONTROLLER


CONTROLLER (7KW)


CONTROLLER (18KW)

1 HOLDER,

1 FUSE, 15 AMP 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

2 M3 LOCK WASHER (NON 7KW)

6 NUT HEX LOCK M4-0.7 NYLON INSERT

CURRENT TRANSFORMER, IDLE

CONTROL (NON 7KW)

24 0D8502

25 031879

26

031879

0F5433

27

28

29

30

31

32

33

34

35

36

37

0F5437

38 045770

39 0E7866

40

0E7867

0D3700

41

43

022097*

022473*

049813*

0G0400

0A1658

44

45

022473

0E3969

46 0G5454

47 0G5449A

CONTROL (18KW)


8 SCREW PPHM M3-0.5 x 8mm (7KW)

2 M3-0.5 TRIC NUT (NON 7KW)

2 WASHER FLAT #10

1 CONTROL, PANEL BOTTOM

1 CONTROL, PANEL BOTTOM (7KW)

4 SCREW HHC M5-0.8 x 30mm

1 SWITCH, SPST



(7KW)

48

49

50

074908

049813

082025

0G0627

022507

022097

046689

063617

075475

043180

0F8041

0F9283

0G5449B

0D5303

0G6131

*ITEM 40 FOR MODELS WITH ALUMINUM ENCLOSURE

1 NEUTRAL BLOCK

4 WASHER FLAT #4

2 WASHER FLAT #4 (7KW)

1 HARNESS, CONTROL PANEL WIRE (NOT

SHOWN)

1 HARNESS, CONTROL PANEL WIRE (NOT

SHOWN) (7KW)

4 SCREW HHTT, M5-0.8 x 10 BP

4 NUT HEX M6-1.0


1 XFMR 240/16V 1VA&56VA W/PTC

2 SCREW HHC 1/4”-20 x 1/2”

4 WASHER LOCK M6-1/4”

1 TERMINAL STRIP 4 POSITION

1 RELAY PANEL 12VDC DPDT 10A 240VAC


2 WASHER FLAT M4

1 COVER, CONTROL PANEL COMPONENT

1 COVER, CONTROL PANEL COMPONENT

(7KW)

2 SCREW HHC M5-0.8 x10mm

1 COVER, CONTROL PANEL

1 COVER, CONTROL PANEL (7KW)

8 NUT FLANGE M6-1.0 NYLOK


8 WASHER FLAT 1/4-M6

8 NUT HEX M6 X 1.0

1 WIRE ASSEMBLY, GROUND

2 WASHER LOCK SPECIAL 1/4”

6 WASHER FLAT 1/4”-M6

2 SCREW PPH M3-0.5 X 30mm (18KW)

2 SPACER (18KW)

1 JUMPER WIRE, RED (18KW, NOT

SHOWN)

1 JUMPER WIRE, BLACK (18KW, NOT

SHOWN)

2 WASHER FLAT .25” ID X 1"OD ZINC

2 SCREW HHC M6-1.0 x 30mm

43

44



Transfer Switch Assembly – Drawing No. 0F9774-C



Transfer Switch Assembly – Drawing No. 0F9774-C

1 0F8278

2 0D4800

0F5211

0D3092

3

0F8312

0C2237

3A 077220

3B 077220A

3C

3D

082574

084464

4

5

074908

024912

6 0A1658

7 063617

8 0E7889A

0E7889

9

10

11

12

0F9213

0A1495

0A1661

022473

081108

13 0D4684

0D4684A

14 0F8279

15 0F4790

16 022152

17

18

064526

0E6155

19 063378

20 0G0979

0G0980

0G0981

0G0982

1 BOX CENTER

1 COVER, 8 CIRCUIT LOAD CENTER




1 TRANSFER SWITCH HOME STANDBY

100A 2P 250V

1 COIL UTILITY

1 COIL STANDBY

1 INSULATOR-SIDEWALL (NOT SHOWN)

1 LIMIT SWITCH OPERATION (NOT

SHOWN)

6 SCREW HHTT M5-0.8 X 10

1 SCREW HHTT 1/4-20 X 5/8

1 LOCK SPECIAL-1/4”

1 RELAY PANEL 12VDC DPDT 10A@240VAC

1 8 CIRCUIT LOAD CENTER

1 12 CIRCUIT LOAD CENTER (ALSO USED

FOR 10 CIRCUIT)

1 16 CIRCUIT LOAD CENTER


2 RIVET POP .156” X .675”

1 WASHER FLAT 1/4-M6 ZINC

1 PLUG PLASTIC

1 HARNESS ADAPTER PLATE

1 8 CIRCUIT HARNESS ADAPTER PLATE

1 SUBPLATE, LOAD CENTER

10.5” U-CHANNEL

6 WASHER LOCK #10

2 SCREW HWHS #6-25 X 3/8”

1 ARM EXTENDER PIN

4 HOLDER CABLE TIE

1 HARNESS, 8 CIRCUIT LOAD CENTER TO

MAIN PANEL

1 HARNESS, 10 CIRCUIT LOAD CENTER

TO MAIN PANEL


TO MAIN PANEL


TO MAIN PANEL

21

22

23

24

25

26

27

28

036933

077033

048850

028739

0A2110

0D3191

0D3088

29 073591

30 073590A

31 040213B

32

33

34

35

36

0E7888

0E7888A

0E7888B

0E7888C

0E7888D

37

38

39

0E7888E

0D3320

0F5439

40

41

42

074138

0F9327

0F6720

0F6720

074908

066849

0A7215

0E6193

2 LUG QUICK DISCONNECT NI-S 10X45

DEG BRASS / TIN

6 SCREW PPHM #10-32 X 3/8”

6 LUG SLDLSS 1/0-#14X9/16 AL/CU

1 BLOCK TERMINAL 20A 5 X 6 X 1100V

4 TIE WRAP 3.9" X .10"

4 SCREW SWAGE 1/4-20 X 1/2" ZINC

1 COVER, RELAY & TERMINAL BLOCK

1 WIRE HARNESS, LOAD CENTER (NOT

SHOWN)

2 FUSE HOLDER

2 FUSE 5A

4 SUPPORT SNAP-IN 1-3/8"

8 10 12 16 CIR.

A/R CIR BRK 20A 2P 1 1

A/R CIR BRK 30A 2P 1 1 1

A/R CIR BRK 15A 1P 5 3 5 5

A/R CIR BRK 20A 1P 1 3 3 5

A/R CIR BRK 40A 2P 1 1

A/R CIR BRK 50A 2P 1

1 COVER - HARNESS ENTRY

1 HARNESS, 8 CIRCUIT LOAD CENTER TO

EXT CONN BOX


TO EXT CONN BOX


TO EXT CONN BOX


TO EXT CONN BOX

2 SCREW HHTT M5-0.8 X 10 (8 CIRCUIT)

2 SCREW HHTT M5-0.8 X 16 (10, 12, 16

CIRCUIT)

4 SCREW SW 1/4"-20 X 5/8” WITH WASHER

1 BRACKET, ARM EXTENDER

45

46



13 & 16kW, GT-990 Engine – Drawing No. 0G3071-J - Part 1




1

2

0C5729

0E9843A

3 0G0919

4 0C5372

5

6

7

8

9

0C3005

0E3372B

0D8067A

071983

0C2981F

11

12

0G2751

0G2565

13 0E1466

14 0D4041

15 0C2977

16

17

0C5943

0E3791E

18

19

20

21

22

23

24

0E3223

0D2157

0E6098

0D4123B

0E8152

0C3011

0C3009

25

26

27

28

0C3010

093873

0F5458

0C3027

29 0C5998

31 0F2664C

32 0C5305

33 0D6147

1 ASSY, CRANKCASE WITH SLEEVE

1 SEAL, 38 I.D. CRANKSHAFT GREEN

5 SCREW, HHFCS M6-1.0 X 12 G8.8

1 ASSEMBLY,

1 GASKET, BREATHER COVER

1 SEPARATOR, OIL BREATHER

1 ASSEMBLY, HEAD #1 G&S

4 RETAINER, PISTON PIN 20

1 ROCKER, COVER NO OIL FILL

2 PISTON, FLAT TOP DIA 90 COATED

2 RING SET, PISTON DIA 90

2 PIN PISTON

1 ASSEMBLY, CAMSHAFT & GEAR

1 GASKET, CRANK CASE

1 SEAL, OIL PASSAGE

1 ASSY, CRANKSHAFT GTH-990 DIRECT

DRIVE

2 ASSEMBLY, CONNECTING ROD

2 SCREW SHC M6-1.0 X 50 G8.8

1 SCREEN, OIL PICKUP

1 ASSEMBLY, OIL PUMP W/O O-RING

1 O-RING .49 ID X .07 THICK

2 COVER, OIL RELIEF

2 SPRING, OIL RELIEF

2 BALL, 1/2D OIL RELIEF

2 WASHER, LOCK RIB M6

1 SCREW, PLASTITE HI-LOW #10

1 O-RING, 3/8” X 1/2”

1 CLAMP, OIL TUBE

1 ASSEMBLY, DIPSTICK WITH HANDLE

1 TUBE, DIPSTICK

5 SCREW HHFC M6-1.0 X 10mm

34

35

36

37

043790A

0E9842A

0F8054

0C3006

38

39

40

41

080318

093064

0G1839

0D2723D

42 0C2979

43 086515

44 0D2274

45 0D3867

46 078672

47 0C5371

48 072694

49 0D5313

50

51

52

0D3998

0D6024

0C2976

53 086516

54 0C2229

55 083897

56 0D8067B

57 0D9853D

58 0C2978

59 0D4010

60

61

62

0D4012

0D8675A

0D8675B

63

64

65

0D4015

078699C

078699B

1 BARBED ELBOW 90 3/8NPT X 3/8 VS

1 SEAL, 42 I.D. CRANKSHAFT GREEN

1 GEARCOVER / ADAPTOR GTH-990

10 SCREW, HHFC M10-1.5 X 55

8 SCREW HHFC M6-1.0 X 25

1 ASSEMBLY, OIL FILL CAP

2 LIFT HOOK GT990/760

1 ROCKER, COVER WITH OIL FILL

2 GASKET, VALVE COVER

8 KEEPER, VALVE SPRING

4 RETAINER, VALVE SPRING

4 SPRING, VALVE

2 SEAL, VALVE STEM D7

4 WASHER, VALVE SPRING

4 STUD, ROCKER ARM PIVOT

4 ROCKER ARM

4 NUT HEX M8-1.0 G8 YEL CHR

2 PLATE, PUSH ROD GUIDE

12 SCREW HHFC M8-1.25 X 65

2 VALVE, EXHAUST

2 VALVE, INTAKE

4 TAPPET, SOLID

1 ASSEMBLY, HEAD #2 G&S

4 PUSHROD, 147

2 GASKET, HEAD

1 KIT GASKET

1 KIT BREATHER ASSEMBLY

1 KIT HEAD ASSEMBLY CYLINDER 1

1 KIT HEAD ASSEMBLY CYLINDER 2

1 KIT OIL RELIEF

2 SLEEVE DOWEL PIN 14 DIA.

4 SLEEVE DOWEL PIN 12 DIA.

47

48







64

65

022145

0C5136A

66 0C3024

67 0C3040

68

69

70

71

72

0C8127

0F9255

0E9582

0D4417

0E7585A

73

74

75

76

77

0E6043

0D1142A

0C3025

0G0290

070185F

78

79

0D3083

0F2094

80 094090

81 035461

82 0G3662

104

105

106

107

108

109

83 0G0286

84 0E9506

85

86

0C9764

0C3043

87

88

89

90

91

0C7694A

045756

082025

0G3730

090388

92 0E4997

93 0C3033

94

95

0C3034

0C9763

96 0D1131

97

98

99

100

101

102

103

0F1169K

051754

0A5992

0C3032

0C3031

0C3725B

0G4928A

0C7693A

0C3041A

082774

0C3036A

0C3019

0C3018

1 WASHER FLAT M8 – 5/16

2 KNOB, AIR CLEANER

1 COVER, AIRBOX NG/LP

1 PRE-CLEANER,

1 ELEMENT, AIR CLEANER

1 ASSEMBLY, MIXER/AIRBOX 990

4 SCREW SHLDR(8MM) M6-1.0 X 21

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

2 SPARKPLUG, RCY14 GAP: 0.040”

2 SCREW TAPTITE M5 – 0.8 X 8

1 WRAPPER, LOWER CYLINDER 2

1 SWITCH, OIL PRESS

1 HOSE, 3/8” ID X 6-1/2”LG SAE J30R9

1 OIL FILTER, 90mm w/LOGO

1 ASSY, OIL DRAIN HOSE

2 SCREW M3 – 0.5 X 6 SEMS

1 SWITCH, THERMAL 293F

2 BARBED STRAIGHT 1/4NPT X 3/8

5 CLAMP, HOSE OETIKER STEPLESS

17mm

1 HOSE, 3/8” I.D. X 6”LG SAE J30R9

1 COOLER, OIL

4 SCREW PLASTITE 1/4-15 X 3/4

2 GASKET, MANIFOLD / PORT

1 MANIFOLD CYLINDER 2

4 SCREW, HHTT M6-1 x 10 LONG

1 NUT, HEX LOCK M5-0.8 ZINC

4 SCREW SHC M8 – 1.25 X 20 SEMS

13 SCREW TAPTITE M6–1X12 CLEAR ZINC

1 ASSY,GROUND WIRE CONNECTOR

1 WASHER, 25MM I.D.

1 NUT, HEX M24

4 NUT, GROMMET 1/4 PLUG

1 GUARD, FAN

1 HOUSING, BLOWER NG COOLER

2 SCREW HHC M8 – 1.25 X 12 G8.8

2 WASHER SHAKEPROOF INT M8 SS

1 PLATE, FAN

1 FAN, NYLON

1

2

1 FLYWHEEL ASSEMBLY

1 PLATE, BACKING WITH OIL COOLER

ZINC

MANIFOLD CYLINDER 1

SLEEVE, RUBBER

1 KEY, WOODRUFF 4 X 19D

1 HOSE BREATHER

1 WRAPPER, LOWER CYLINDER 1

1 WRAPPER, UPPER CYLINDER 1

0E9348

0E9599

0E9595

090987

0E9403

0E9571

0E9380

0A6345

0E9598

0E9593

0E5108

0D6342

0E9570

0E9577

0E5846

0E9419

0C4760

0F9253

0E9553

0E9554

0E9564

0E9575

0E9357

0A7094

0E9574

0F9273

0F5467

0E9557

0E1644

0E9568

0E9565

074027

0C3044

0C4756

075477

043116

0E1644

0E9572

0D9784

0D1143

0E9323

061906

022129

0F1177

022097

0G3110

0G3224A

0G3224B

139

140

141

142

143

144

145

146

147

148

129

130

131

132

133

134

135

136

137

138

149

150

151

152

153

154

155

156

157

119

120

121

122

123

124

125

126

127

128

110

111

112

113

114

115

116

117

118

1 WRAPPER, UPPER CYLINDER 2

1 STARTER MOTOR HEAR REDUCED 1KW

2 SCREW HHC M8 – 1.25 X 85 G8.8

3 WASHER LOCK M8 – 5/16

1 ASSEMBLY, GROUND WIRE


4 SCREW TAPTITE M6 – 1.0 X 20 ZINC

1 ASSY, IGN COIL W/DIODE, CYLINDER 1

1 ASSY, IGN COIL W/DIODE, CYLINDER 2

1

2

ASSY, THROTTLE SHAFT

THROTTLE VALVE

4 SCREW PPHM M3 – 0.5 X 5

1 COVER, DUST, MIX/AIRBOX

1 SPRING, IDLE ADJUST


2 SCREW HHC M6 – 1.0 X 12

1 SCREW BHSC M6-1.0 X 12 SS

1 BRACKET, STEPPER MOTOR

1 NUT HEX LOCK M3 – 0.5 NYLON INSERT

1

1

1

1

1

ASSY, CONTROLLER

BALL STUD, 10MM

ASSY, THROTTLE ROD

BELLOWS, INTAKE

EXPANSION PLUG

3

1

#10 O-RING

PLUG, MANIFOLD

1 ASSY, AIR BOX BASE

1 PIN, FUEL SELECTOR

1 PIN, FUEL SEL STOP

1

1

SOLENOID COVER

LINKAGE, CHOKE

4 SCREW PPPH HI-LO #6 X 1/2

1 SCREW PHTT M3 – 0.5 X 8

1 RETAINER, CHOKE RETURN SPRING

1 SPRING, CHOKE RETURN

1 WASHER, BELLEVILLE SPRING


1 CHOKE ARM

1 SCREW SHOULDER M3 – 0.5 X 6

1

1

VALVE, CHOKE

SHAFT, CHOKE

1 SEAL, GOVERNOR ARM

2 SCREW PHM #4 – 40 X 1/4

1 BRACKET, SOLENOID

1 SOLENOID, 6VDC

1 NUT HEX M8 – 1.25 YELLOW ZINC

1 SPRING, CHOKE VALVE ADJUST

1 SCREW, BHSC M6-1.0 x 12

49

50



10kW, GT-530 Engine – Drawing No. 0F9429-N - Part 1

0C3592

0C3733

0C4390

088156

084186

0E9368

077168

0E9305

0C3590

0E9351

0A5776

0C5315A

0C5314A

0E9473

073144

0C3027

0E9358

093064

0E9334A

0E9352

0E9428B

0E3812

0C8566

0E9367A

0E9366

0E9304

0E9334C

076390

076389

088057

088411

0E9322A

0E9407A

0E9350

0E9318E

043116

093873

0G0272

0E9482

0C3591

083235

0E9455E

0E9353A

076307

077160

077161

0G0273

0G0274

0G0275

0G0276

0E9502

080318

0E3372C

078699B

0C5943

043790

30

31

32

33

34

35

36

37

38

39

20

21

22

23

24

25

26

27

28

29

10

11

12

13

14

15

16

17

18

19

1

2

3

4

5

6

7

8

9

50

51

52

53

54

55

56

40

41

42

43

44

45

46

47

48

49




2

12

1

2

2

8

4

4

2

4

2

1

1

1

2

1

1

1

1

9

1

3

3

1

1

2

2

2

1

1

1

2

2

1

1

1

1

4

2

1

1

12

1

6

1

1

4

4

1

1

1

2

4

4

2

4

CRANKCASE

SEAL D 35 X 48.2

SCREW HHFC M6 – 1.0 X 20

GASKET BREATHER ASSY

CYLINDER HEAD 1

COVER, ROCKER PLAIN

PISTON PIN RETAINER RING

PISTON

PISTON RING SET

ASSY CONNECTING ROD

ASSY, CAM & GEAR

GASKET CRANKCASE

ASSY CRANKSHAFT W/PLUG

SCREW HHC M6 – 1.0 X 12

WASHER LOCK M6 RIBBED

ASSY GEROTOR

SPRING OIL PRESSURE RELIEF

BALL 11/32 DIA PRESSURE RELIEF

GEROTOR OUTER 9MM THICK

GEROTOR INNER 9MM THICK

GEAR COVER


O-RING 3/8 X 1/2

SCREEN OIL PICK-UP

ASSY, OIL FILL CAP

COVER, ROCKER, W/ FILL

GASKET, VALVE COVER

KEEPER, VALVE SPRING

VALVE RETAINER

SPRING VALVE

SEAL, VALVE STEM

WASHER, VALVE SPRING

SPARKPLUG

SCREW HHC M8 – 1.25 X 56

CYLINDER HEAD 2

VALVE EXHAUST

GASKET CYLINDER HEAD

VALVE INTAKE

TAPPET, SOLID

PUSHROD, ALUMINUM

PLATE, PUSH ROD GUIDE

NUT JAM (ROCKER ARM)

ROCKER ARM

STUD ROCKER ARM PIVOT

GASKET KIT

BREATHER KIT

KIT HEAD ASSY CYLINDER #1

KIT HEAD ASSEMBLY CYLINDER #2

SEPERATOR, OIL, GT530


SEPARATOR, OIL BREATHER GT530

SLEEVE DOWEL PIN 12 DIA.

SEAL, OIL PASSAGE

BARBED EL 90 3/8 NPT X 3/8

51

52







58 022097

59 0E9561

60 0E9472

61 0E9471

62

63

078643B

0D9784

64 0E9584

65 0D6342

66 0E9587

67 0C9997

68 0E9319

69 0E9597

70

71

040976

022129

72 061906

73 0E9323

74 0E9507

75 0E9362

76 0E9337

77

78

0E9339

0G3378

79 0F2664H

80 0E9336F

81 0D6147

82

83

84

0E5139

0E9432

0E9338

85

86

87

88

0E9370

0E9505A

0F5458

045757

89 070185B


1 INTAKE ADAPTER

1 GASKET, AIRBOX TO CARB/MIXER

1 GASKET, MANIFOLD TO CARB/MIXER

4 BOLT, CARB MOUNT M6 – 1.0 X 85

1 NUT HEX LOCK M3 – 0.5

1 ASSY, CONTROLLER

1 BALL STUD, 10 MM

1 ASSY, THROTTLE ROD

1 GUARD, FAN

2 GASKET INTAKE

1 BREATHER HOSE

4 SCREW SHC M8 – 1.25 X 20 G12.9


2 SCREW HHC M8 – 1.25 X 85

1 STARTER MOTOR

6 SCREW HHFC M8 – 1.25 X 14

2 LIFTING HOOK

1 WRAPPER OUTER CYLINDER 1

1 WRAPPER INNER CYLINDER 1

1 TUBE, DIPSTICK GTH 530

1 ASSY, DIPSTICK /TEXT

1 BLOWER HOUSING

6 SCREW HHFC M6-1.0 X 10 G8.8

3 SCREW HHFC M6-1.0 X 8 G8.8

1 WRAPPER INNER CYLINDER 2

1 WRAPPER OUTER CYLINDER 2

1 GASKET, OIL FILTER ADAPTER

1 ASSY, DIRECT OIL COOLER ADAPTER

2 SCREW PLASTITE HI-LOW #10X3/8

3 SCREW HHC M6 – 1.0 X 25

1 OIL FILTER

110

111

112

113

114

115

116

117

118

100

101

102

103

104

105

106

107

108

109

90 094090

91 0F2094

92

93

0G4403

0D9235

94 082774

95 0F1177

96 0G3251A

97

98

99

0G3251B

026850

0E9443

0G3662

0G0286

0G0479

0G4985

0E9525C

0E9486

0A5992

051754

067890

067198N

0C3032

0E4997

0E9406

0G1705

0E9450

0E9376

0E9550

028916

0C8563

0G0919

1 THERMAL SWITCH

2 SCREW PPHM M3-0.5 X 6 SEMS

1 ASSY OIL DRAIN HOSE

1 OIL PRESSURE SWITCH HOBBS 5PSI

1 KEY, WOODRUFF 4 X 19D

1 ASSY, GROUNDING WIRE

1 ASSY IGNITION COIL CYLINDER 1

1 ASSY IGNITION COIL CYLINDER 2

4 WASHER SHAKEPROOF EXT 1/4

1 ASSY, MIXER DUAL FUEL

4 CLAMP, HOSE OETIKER STEPLESS

17mm

1 HOSE 3/8”ID X 6” SAE J30R9

1 HOSE 3/8”ID X 7.25 SAE J30R9

1 BACKING PLATE, GT-530 ZINC

1 ASSY, FLYWHEEL & RING GEAR

1 FAN, FLYWHEEL, 20 FIN, 218.8 OD

2 WASHER LOCK INT M8

2 SCREW HHC M8 – 1.25 X 12

1 NUT HEX M20 – 1.5

1 WASHER BELV – 20 X 2.2

1 PLATE, FAN

1

1

ASSY, GROUND WIRE CONNECTOR

OIL COOLER

13 SCREW HHFC M6 – 1.0 X 14

1 CENTER BAFFLE

1 INTAKE MANIFOLD

1 FRONT COVER

1 ELBOW - 1/8” NPT

2 SCREW, HHFC M6-1.0 x 12

4 SCREW, HHFCS M6-1 x 12 CLEAR ZINC

53

54



7kW, GN-410 Engine – Drawing No. 0F9428-D - Part 1

083897

077158

0C3150

072694

083907

0D3998

078694

021742

0D6094

076329

076361

0A8898D

0D2274

0C4391

086025

0E3341

021714

086516

086517

0D9853B

0E3221

0E1466

021533

0E2985

071983

0E8440

0A7628

078658

078659

088261E

0E3812

0E6519

078645

0A7811

0G3358

076701

021713B

078691

0A5771

0A5776

0E0057

0D4788

074908

086515

078606

0A1442

078672

089673

0B2104

078699C

0A7627

043790A

078699B

31

32

33

34

35

36

37

38

39

40

21

22

23

24

25

26

27

28

29

30

11

12

13

14

15

16

17

18

19

20

1

2

3

4

5

6

7

8

9

10

41

42

43

44

45

46

47

48

49

50

51

52

53

54




2

1

4

1

1

2

1

1

2

2

1

1

1

1

2

1

1

2

2

1

1

1

1

1

1

2

1

1

1

1

1

1

1

2

1

1

1

1

1

2

8

1

2

1

2

1

1

1

4

4

1

1

2

ASSEMBLY, CONNECTING ROD

PIN, PISTON D20

SET, PISTON RING 90MM

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

SEAL, 35 I.D. CRANKSHAFT

ASSEMBLY, GOVERNOR GEAR

C-RING, GOVERNOR GEAR RETAINER

SPOOL, GOVERNOR- MACHINE

ASSEMBLY, CAMSHAFT & GEAR 410HSB

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, SLEEVE SEAMED 12 DIA.

55

56




049821

099236

070185B

082774

091222E

067198N

067890

0E7585

072734

072735

0C3978

0C6040

0D9760

0G3111

0F3800

083502

082025

0G4403

0E7887C

090072

094090

022145

0F2094

0C4373

022717B

0F3865

0F3855

039253

0D3751

0F3921

0C8493

0D8758

0C1069

0D2922

0F8426

0C9997

088434

045756

0C4176A

0D9004A

059985

022129

0C2458A

083512

0D1401A

091039

0C9619

049811

022097

040945

086999

0D5667A

31

32

33

34

35

36

37

38

39

40

21

22

23

24

25

26

27

28

29

30

41

42

43

44

45

46

47

48

49

50

51

52

11

12

13

14

15

16

17

18

19

20

1

2

3

4

5

6

7

8

9

10




1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

2

4

2

1

1

1

1

1

1

1

11

1

1

2

3

5

1

1

1

1

SCREW, TAPTITE M6-1X10 YELLOW CHROME

SCREW, SHC M8-1.25 X 45 G12.9

WASHER, LOCK M8-5/16

BACKPLATE, L/F D/F

SCREW, TAPTITE M8-1.25 X 16 BP

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

SCREW, TAPTITE M6-1.0 X 25 ZINC

SPRING GOVERNOR

BOLT, GOVERNOR ADJUST M5

NUT HEX LOCK M5-0.8 NYINS ZINC

ASSY OIL DRAIN HOSE

ASSEMBLY, CAP & DIPSTICK

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

SWITCH, THERMAL 293F

WASHER FLAT 5/16 - M8

SCREW, M3-0.5 X 6 SEMS

SPACER ENDFRAME

GOMMET

SPRING SECONDARY

BRACKET SECONDARY GOVERNOR SPRING

SCREW HHC M8-1.25 x 20

SPRING, IDLE RETURNING

BARREL GOVERNOR ADJUSTMENT

SCREW SHC M5-0.8 x 30

ENGINE LIFT HOOK

57

58



7kW, GN-410 Engine – Drawing No. 0F9422-C



7kW, GN-410 Engine – Drawing No. 0F9422-C

029451

049451

022237

022511

022131

039287

022145

049820

090388

022129

022259

059637

048031K

0C9592

048031M

040976

0G0414

0D5823

090239

0C6989

0F8186

0F5540H

0C9934H

0F7774A

0C8096

0F6591

0F8078

056482

0C3168

056147

0D1847

0C7038C

0F9445

0F9497

0C7038B

0C7758

0388050AE0

0C2417A

0F6528

066386

0D1214

0C8127

0C3024

0D2273

055934N

0F7065

0C5136A

039253

022473

066849

0F6551

0F8079

0F0710

0F8256

045771

0G0676

074906

32

33

34

35

36

37

38

39

40

41

22

23

24

25

26

27

28

29

30

31

12

13

14

15

16

17

18

19

20

21

1

2

3

4

5

6

7

9

10

11

53

54

55

56

57

58

59

42

43

44

45

46

47

48

49

50

52

2

1

3

1

1

8

2

3

1

2

1.8 FT

1

4

4

4

4

18

4

8

17

4

1

1

1

1

4

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

2

1

4

2

4

1

1

1

1

1

1.25 FT

2

2

4

2

STATOR

ROTOR

CARRIER, REAR BEARING

FAN, 8” CURVED BLADE

MUFFLER

TAIL PIPE, MUFFLER

BEARING

5/16 SPECIAL L/WASH

BOLT ROTOR HHCS 5/16”-24 X 13-1/2” G5

BOLT STATOR IHHCS 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

EXHAUST FLEX

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

SCREW HHC M8-1.25 X 45 G8.8

WASHER FLAT 5/16

NUT LOCK HEX M8-1.25 NYL INSRT

SCREW TAP M6-1.0X12

WASHER LOCK M8-5/16

NUT HEX 5/16-18

SCREW TAPTITE 3/8-16X 3/4”

BAND, HOSE CLAMP 35.05 DIA.

BELLOWS

HOSE CLAMP 3/4"

SCREW SHC M8-1.25 X 20 G12.9

PLATE “HOT”

U-BOLT 5/16”-18 X 1.62” 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 LP 1/2" I.D.

KNOB, AIR CLEANER

SCREW HHC M8-1.25 X 20 G8.8

WASHER FLAT 1/4

SCREW HHTT M5-0.8 X 16

FLEX COVER

BRACKET MUFFLER ACCESS

RIVET POP 0.125” X 0.337”

EXHAUST MANIFOLD

NUT HEX M8-1.25 NY INS

SCREW THTT M6-1.0 X 10

SCREW HHTT M6-1.0 X 20

59

60



10, 13, and 16kW, V-twin Generators – Drawing No. 0G4392-A


1 040976

2 0F6694

0F5538

0F7548

3 0F9795

0F5539

0F7549

4

5

0F7774

0E9579

0F8998

6 0F6591

7

8

0F8078

099502

9 056482

10 0C3168

11 0D1838

12

13

14

15

0D1846

0C7038

0F9396

0D2559

16 0C7038A

0F4179

17 0C7758

18 0388050AD0

19 0C2417A

20 0F6528

21 066386

22 029451

23 049451

24

25

26

27

022237

035685

0E9549

051731

28

29

30

022145

049820

0G0676

4

1

1

SCREW SHC M8-1.25 X 20mm

STATOR

ROTOR

1 CARRIER, REAR BEARING

1 FAN, 12” CURVED BLADE

1 FAN, 12” CURVED BLADE (10KW)

1 MUFFLER

1 TAIL PIPE, MUFFLER

2 CLAMP HOSE #24 B1.06-2.00 (10KW)

1 BEARING

3 5/16 SPECIAL LOCK WASHER

1 BOLT, IHHCS 3/8”-24 X 15.50”

4 BOLT, IHHCS M8-1.25 X 345mm

1 BRACKET, ALTERNATOR MOUNTING

1 DUCT, ALTERNATOR AIR

1 GASKET, ALTERNATOR AIR DUCT

1 BRACKET, ENGINE MOUNTING

1 PLATE, MOUNTING ENG 530HSB

4 RUBBER MOUNT

1 CABLE, #6 48” BLACK BATTERY

1 EARTH STRAP 3/8 X 3/8

1 EXHAUST FLEX

1 ASSEMBLY BRUSH HOLDER

2.6 FT TAPE ELEC UL FOAM 1/8 X 1/2

1 WASHER FLAT .406ID X 1.62OD

1 WASHER LOCK 3/8

1 CLAMP HOSE #28 1.32-2.25 (10KW)

1 HOSE, INTAKE GTH530 HSB (10KW)

4 SCREW HHC M8-1.25 X 50

18 WASHER FLAT 5/16 ZINC

4 NUT LOCK HEX M8-1.25 NYL INSERT

2 SCREW THTT M6-1.0 X 10



10, 13, and 16kW, V-twin Generators – Drawing No. 0G4392-A


31

32

33

34

35

36

37

022129

022259

059637

0E9591

0F7065

048031M

0E9589


8 NUT LOCK HEX 5/16-18

2 SCREW TAPTITE 3/8-16 X ¾

1 SPRING-CHOKE RETURN (10KW)

3 FT HOSE RES ½ LP GAS

4 HOSE CLAMP ¾” I.D.

1 CHOKE HSG (10KW)

38 0G0414

39 0D5823

40 0E9369

0C4138

41

42

43

44

040173

074995

066849

0F7799

0F8115

1

3

2

PLATE, “HOT”

U-BOLT 5/16”-18 X 1.62” WITH SADDLE

GASKET, EXHAUST PORT (10KW)

2 CLAMP HOSE #5.5 0.62”-0.62” (10KW)

1.44 FT HOSE ¼ ID LPG 350PSI UL21 (10KW)


1 EXHAUST MANIFOLD

1 EXHAUST MANIFOLD (10KW)

45 0G30430GS0R 1 FLEX COVER

0G30440GS0R 1 FLEX COVER (10KW)

46 0E9595 2 SCREW PPPH HI-LO #6/1/2 W/ #5HD

(10KW)

56

57

58

59

60

61

47

48

49

50

090388

045771

039253

0F0710

51

52

0F8079

0F9273

53 0E9592

54 0E9588

55 077091

0E9581

0E9594

0E9590

0E9542

0D1683

077075

7

4

2

2

1

1

2

1

1

1

SCREW TAPTITE M6-1.0 X 12

NUT HEX M8-1.25

SCREW HHC M8-1.25 X 20

RIVET POP 0.125” X 0.337”

BRACKET MUFFLER ACCESS

SOLENOID, 6 VOLTS DC (10KW)

SCREW PPHM $4-40 X 3/8 SEMS (10KW)

LINKAGE, CHOKE (10KW)

COTTER PIN (10KW)

1 AIR CLEANER GTH530 HSB (10KW)

3 SCREW PPPH HI-LO #14-15 X ½ (10KW)

1 ASSEMBLY, CHOKE SHAFT (10KW)

1 VALVE, CHOKE (10KW)

2 SCREW PFHM M3-0.5 X 5 (10KW)

BOOT, CHOKE SOLENOID (10KW)

61

62



7 & 10kW, GN-410/GT-530 Regulator – Drawing No. 0F9425-B



7 & 10kW, GN-410/GT-530 Regulator – Drawing No. 0F9425-B

070728

0C6069

0C5762

0F9189

045764

0C6731

0C6067

0C4706

0C6068

0C4643A

072683

072683

0A4032

0D3308

024310

0D3973

042907

028414A

035483

0G0247

0F9773B

0F9773A

0D5694

0F9285

0F5022

0C4647

0D4166

0F8822

022145

022129

0F4795

0C5760P

0C6606

0C6606

097934

0C4645

0C5761

0C5968

0C6066

0C5759

0C5764A

0C5764

27

28

29

30

31

32

33

34

35

36

37

18

19

20

21

22

23

24

25

26

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

1

2

1

1

1

2

1

1

4

1

1

1

4

2

2

2

16

2

2

2

2

2

1

2

1

1

2

2

2

2

2

2

1

1

1

1

1

1

2

2

4

1

CASTING, TWIN REGULATOR HOUSING (7KW)

SOLENOID COIL, 12VDC

GASKET , SOLENOID

PLUNGER, LP REGULATOR ASSEMBLY

WASHER FLAT 5/16-M8

WASHER LOCK 5/16-M8

SCREW PPHM SEMS M4-0.7 X 10

FUEL JET GASEOUS REGULATOR (7KW)

BARBED STRAIGHT ½ NPT x ½ (7KW)

BARBED STRAIGHT ½ NPT x ½

ADJUSTER SCREW, TWIN REGULATOR (7KW)

SUPPORT, INLET SEAL

PIN, PIVOT ARM

SPRING, REGULATOR (7KW)

SCREW, PFHMS M3-0.5 x 5

COVER, TWIN REGULATOR (7KW)

SCREW, TAPTITE M4X8 BP

RIVET, POP .118 X .125

CAP, DIAPHRAGM SUPPORT

INLET, TWIN REGULATOR 11.11 DIA.

PLUG STD PIPE 1/8 SOCKET HEAD (7KW)

PLUG STD PIPE 1/8 SOCKET HEAD

PIN, LIMITED ADJUSTMENT (7KW)

WASHER, FLAT M3 X 10mm O.D.

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

PLUG, EXPANSION 16mm (7KW)


BARBED STRAIGHT 1/8”NPT X ¼” (10KW)

NIPPLE PIPE 1/8” NPT X 1-1/2” (10KW)

SOLENOID, LP/NG DC12V (10KW)

63

64



13 & 16kW, GT-990 Regulator – Drawing No. 0F9426-A

045764

0C6731

0C6067

0C4706

0C6068

0C4643A

072683

049226

0D3308

051713

0F8979

051716

0E9533

0E9534

0E9535

0F9285

0F5022

0C4647

0D4166

0F8096

022145

022129

0F4795

045771

0C6606

042907

026915A

0C5761

0C5968

0C6066

0C5759

0C5764

070728

0C6069

0F9189

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11

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13 & 16kW, GT-990 Regulator – Drawing No. 0F9426-A

2

3

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4

4

16

2

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2

1

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1

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1

SOLENOID COIL, 12VDC

GASKET , SOLENOID

PLUNGER, LP REGULATOR ASSEMBLY

BRKT REGULATOR MOUNTING 990

WASHER FLAT 5/16-M8

WASHER LOCK 5/16-M8

SCREW PPHM SEMS M4-0.7 X 10

NUT HEX M8-1.25

BARBED STRAIGHT ½ NPT x ½


NIPPLE CLOSE ¾ X 1.375 WITH VIBRA SEAL

SUPPORT, INLET SEAL

PIN, PIVOT ARM

SCREW, PFHMS M3-0.5 x 5

SCREW, TAPTITE M4X8 BP

RIVET, POP .118 X .125

CAP, DIAPHRAGM SUPPORT

INLET, TWIN REGULATOR 11.11 DIA.

PLUG STD PIPE 1/8 SOCKET HEAD

WASHER, LOCK, M5

WASHER, FLAT M3 X 10mm O.D.

WASHER, FLAT, M5

SOLENOID COVER PLATE

NUT HEX M5-0.8

ASSY, FUEL SYSTEM PLENUM

65

66

Section 9 — Mounting Dimensions


Drawing No. 0F9424-D

Section 9 — Mounting Dimensions


Drawing No. 0F9424-D

67

Section 10 – Warranty


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

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission

Control System Warranty on your new engine.

* In California, new utility, and lawn and garden equipment engines must be designed, built and equipped to meet the state’s stringent anti-smog standards. 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 system and exhaust system. 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 1995 and later model year 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 due to 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 contacting 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 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.

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

For Air-cooled Product ...

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297

WHITEWATER, WI 53190

Part 1

For Liquid-cooled Product ...

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

211 MURPHY DRIVE

EAGLE, WI 53119

68



EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines:

(a) Applicability: This warranty shall apply to 1995 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 CARB pursuant to its 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 owner. Such use shall not reduce Generac

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:

1.2) LPG/Natural Gas carburetion assembly and its internal components.

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) Prepackaged Standby Generator

2) Auxiliary Power Unit (APU) Generator

3) Standby Generator

Part 2

69



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 S ystems, 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 S ervice 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 S ervice 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 " S tandby" applications.

WARRANTY SCHEDULE

YEAR S 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 S ystem - All Components

S teel 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.

S ystems.

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

• Damage to generator system (including transfer switch) caused by improper installation or costs necessary to correct installation.

not normally exist.

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

• teel 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.

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. quake, 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. tive part(s).

• Failure due to misapplication.

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

• 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).

• S tarting batteries, fuses, light bulbs and engine fluids.

THI S WARRANTY I S IN PLACE OF ALL OTHER WARRANTIE S , EXPRE SS ED OR IMPLIED. S PECIFICALLY, GENERAC MAKE S

NO OTHER WARRANTIE S A S TO THE MERCHANTABILITY OR FITNE SS FOR A PARTICULAR PURPO S E. S ome 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 S HALL BE THE REPAIR OR REPLACEMENT OF PART( S ) A S S TATED ABOVE. IN NO EVENT

S HALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CON S EQUENTIAL DAMAGE S , EVEN IF S UCH DAMAGE S ARE A

DIRECT RE S ULT OF GENERAC' S NEGLIGENCE. S ome 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.

GENERAC ® POWER SYSTEMS, INC.

P.O. BOX 297 • WHITEWATER, WI 53190

Part No. 0F9421 Revision L (08/14/07)

Revision (09/01/06)

Printed in U.S.A.

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