GENERAC POWER SYSTEMS, INC. Installation and Owner’s Manual 7, 10, 13 and 16kW Air-cooled, Automatic Standby Generators Models: 005251 (6 kW NG, 7 kW LP) 005252 (9 kW NG, 10 kW LP) 005253 (13 kW NG, 13 kW LP) LISTED 005254, 005255 (15 kW NG, 16 kW LP) GENERA Oo OJ AQ, Not intended for use as Primary Power in place of utility or in life-support applications. DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!INTRODUCTION ‘Thank you for purchasing this model of a compact, high performance, air-cooled, engine-driven genera. tor designed to automatically supply electrical power to operate critical loads during a utility power fail- ‘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 This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG) ® READ THIS MANUAL THOROUGHLY Ifany portion of this manual is nol understood, contact the nearest Authorized Dealer for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 person” nel to special instructions about a particular opera- tion that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their defini- tions are as follows: A DENTE A- After this heading, read instructions that, if not strictly complied with, will resutt in serious person- al injury, including death, in addition to property damage —A warnine A— After this heading, read instructions that, if not strictly complied with, may result in serious person- al injury or property damage. “AL caution Ae— 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 emph ‘These safety warnings cannot eliminate the haz- ards 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 infor- mation that, if not followed, could endanger personal safety and/or property of others. Ay This symbol points out potential explosion haz- ard. ‘Ay This symbol points out potential fire hazard. AX This symbol points out potential electrical shock hazard, ‘The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recom- mends that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strong- ly 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: + 05251 - 6 kWNG, 7 kW LP single-cylinder GH-410 Engine + 05252 - 9.0 kW NG, 10 kW LP Vwin GT530 Engine + 05253 - 13 KW NG, 13 kW LP Vtwin GT-990 Engine + 05254 & 05255 - 15 kW NG, 16 kW LF V-twin GT: 990 Engine ® OPERATION AND MAINTENANCE ICis the operator's responsibility to perform all safety checks, o 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 num- ber 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 cal this number: 1-800-333-1322 DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER or visit ‘www.gencrac.com.Table of Contents TABLE Introduction Inside Front Cover Read This Manual Thoroughly. Fc Contents. Ire Operation and Maintenance Ire How to Obtain Service IFC ‘Authorized Dealer Locator Number IFC Safety Rules 2 Standards Index 3 Section 1 - General Information 4 1.1 Unpacking/luspection 4 1.2. Protection Systems 4 1.3 NEC Requirement for Arc Fault Circuit Interruption Breaker for Bedrooms 4 14 The Generator 5 15. Specifications... 6 1.6 System Set LED 7 1.7. Fuel Requirements and Recommendations ...7 1.8 Puel Consumption 7 1.9 Reconfiguring the Fuel System .. 8 1.10 Location 9 1.11 Battery Requirements. seonnnees 10 1.12 Battery Installation 10 1.13 The Battery . . . u Section 2 - Post Installation Start-up and Adjustments 2.1 Before Initial Startup 2.2 Check Transfer Switch Operation col 2.3. Electrical Checks 12 2.4 Generator Tests Under Load. so lB 2.5 Checking Automatic Operation 13, 2.6 Adjusting the Fuel Regulator - 7kW (Natural Gas Only) 13 2.7. Engine Governor Adjustment. 4 2.8 Voltage Regulator Adjustment... 15 ‘Air-cooled Generators oF Section 3 - Operation 3.1 Using the AUTO/OFF/MANUAL Switeh .....15 3.2. Automatic Transfer Operation. 16 3.3. Sequence of Automatic Operation 16 3.4 Manual Transfer Operation. 16 3.5 Setting the Exercise Timer... 17 3.6 Protection Systems. 18, Section 4 - Maintenanc 4.1 Fuses 4.2. Checking the Engine Oil Level 19 4.3. Changing the Engine Oil... 20 4.4 Changing the Engine Air Cleaner 21 4.5 Spark Plug(s) . “ 21 4.6 Battery Maintenance. 22 4.7 Adjusting GH-410/G7-530/990 Valve Clearance. . 22 4.8 Cooling System 23 4.9 Attention After Submersion, son 8 4.10 Corrosion Protection 24 4.11 Out of Service Procedure. . 24 4.12 Service Schedule 25 Section 5 - Troubleshooting. 5.1. Troubleshooting Guide. Section 6 - Notes Section 7 - Mounting Dimensions.. Section 8 - Electrical Data Section 9 - Exploded Views and Parts Lists. Section 10 - WarrantySAFETY RULES. IMPORTANT SAFETY INSTRUCTIONS AN ‘Air-cooled Generators 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 opera- tors and potential operators of this equipment. aA es + The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. cancer, birth defects or other reproductive harm. Study these SAFETY RULES carefully before install- ing, operating or servicing this equipment. Become familar 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 warn- ings 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 uti- lized does not render the generator unsafe. —A EEE A- 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. Z\ GENERAL HAZARDS /\ For safety reasons, the manufacturer recommends, that the installation, initial startup and main- tenance of this equipment is carried out by an Authorized Dealer. ‘The engine exhaust fumes contain carbon monox- ide, 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 com- pliance with applicable codes and standards. Following installation, do nothing that might ren- der 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 4s operating. Adequate, unobstructed flow of cooling and venti lating air is critical to correct generator operation, Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seri- ously 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 gen- erator, disconnect its battery cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (Q) 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 con- ditions from leaking exhaust gases, fuel leakage. oil Leakage. etc.IMPORTANT SAFETY INSTRUCTIONS SAFETY RULES. Ay 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 opera- tion. 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 oper- ating unil, 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 sys- tem, the generator may crank and start at any time without warning. When this occurs, load cir- cuits are transferred to the STANDBY (generator) power source. To prevent possible mjury 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 154, fuse from the generator control panel, In case of accident caused by electric shock, imme- diately shut down the source of electrical power. If this 18 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 equip- ment. Jewelry can conduct electricity resulting clectric shock, or may get caught in moving com: ponents causing injury. Ay FIRE HAZARDS A, For fire safety, the generator must be installed and maintained properly. Installation must always comply with applicable codes, standards, laws and regulations. Adhere stricily 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 installa- tion, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regu- lations. Air-cooled Generators AN + Keep a fire extinguisher near the generator at all umes. Extinguishers rated ‘ABC’ by the National Fire Protection Association are appropriate for use on the standby electric system. Keep the extin- guisher properly charged and be familiar with its use. Consult the local fire department with any questions pertaining to fire extinguishers. As EXPLOSION HAZARDS + Do not smoke around the generator. Wipe up any fuel or oil spills immediately, Ensure that no com- bustible materials are left in the generator com- partment, or on or near the generator, as FIRE or EXPLOSION may result, Keep the area surround- ing the generator clean and free from debris. + Gaseous fluids such as natural gas and liquid pro- pane (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 permit- ted, @ STANDARDS INDEX In the absence of pertinent standards, codes, regu- lations and laws, the published information listed below may be used as installation guide for this equipment. 1. NFPA No, 37, STATIONARY COMBUSTION NGINES 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, avail- able from the Food and Energy Council, 909 University Avenue, Columbia, MO 65201 8. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARMSTANDBYELECTRICAL 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Section 1 — General Information GENERAL nFoRMATION ‘Rir-cooled Generators Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regu- lations, 1.1 UNPACKING/INSPECTION Aller unpacking, carefully inspect the contents for damage. + This standby generator set is ready for installa. tion 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 im Joad 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 Usted, 2-pole switch ts rated at 100 AC amperes at 250 volts maximum. This transfer switch is for indoor use only (if equipped). —A warnine A— A\ Hi this generator is used to power electrical load circuits normally powered by a utility power is required by code to installa transfer 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 gen- erator 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 personis) making the delivery note all damage on the freight bill or allix their signature under tie consignor's memo of loss or damage If a loss or damage is noted after delivery, separate ‘the damaged materials and contact the carrier for claim procedures, ‘Concealed damage” is understood to mean damage to the contents of a package that is not in evidence at the time of delivery, but is discovered later. 1.2 PROTECTION SYSTEMS Unlike an automobile engine, the generator may have to run for long periods of time with no operator pres- ent to monitor engine conditions. For that reason, the engine is equipped with the following systems that protect it against potentially damaging conditions: 4, Overspeed 5, RPM Sensor 6. Low Battery 1. Low Oil Pressure Sensor 2, High Temperature Sensor 3, Overcrank 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.) 1.3. NEC REQUIREMENT FOR ARC FAULT CIRCUIT INTERRUPTION BREAKER FOR BEDROOMS In 2001, the National Electrie Code (NEC) intro- duced 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. @ 1.3.1 SECTION 210.12 ARC FAULT CIRCUIT INTERRUPTER PROTECTION 1. Definition: An arc faull cirewit 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-ener- gize the circuit when an arc fault is detected. 2. Dwelling Unil 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 circu. 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 voll circuits. There is no prohibition against provid- ing AFCT 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, il MUST be replaced with a 15A”AFCI breaker Likewise, a 20A breaker MUST be replaced with a 20A AFI. ‘These AFCI breakers are available at the nearest hardware store, Siemens Item # Description Qlisar 15A Single Pole AFCI Q120aF 20A Single Pole AFCLSection 1 ~ General Information — ‘GENERAL ‘Air-cooled Generators lr Ormcancny 1.4 THE GENERATOR Figure 1.1 - 7kW, Single Cylinder GH-410 Engine _Figure 1.2 - 10kW, V-twin GT-530 Engine ot aster Dipotek Deca. Cover Cononsnbae FW Baty Comput compete Dae curr axtryconpuere Figure 1.3 - 13kW and 16kW, V-twin GT-990 Engine a 2 a P< ier aa cont “ Pant ow oat Dptex Drea! Exhaust J Enclosure —_| = i Fl ] inet (ese) Regustor, Compose Base outerSection 1 — General Information GENERAL lnFoRMATION ‘Air-cooled Generators 1.5 SPECIFICATIONS © 15,1 GENERATOR Model 7 kw. ono Kw 13/13 KW, 15/16 RW, Rated Max, Continuous 000 NG/7,000 LP_| 8,000 NG/10,000 LP | 13,000 NG/13,000 LP |15,000 NG/16,000 LP Power Capacity (Watts") Rated Voltage 120/240 120/240 120/240 120240 Rated Max. Continuous Load Current (Amps) 120 Volts** SOONGSS3SLP | S0NGRSSLP | 1OSSNGIORSLP | 195 NG/AS3.3 UP 240 Volts 25.0NG292LP | 37 5NGAL7LP | S41 NGBAILP | 52.5 NG/66.6 LP ‘Main Line Girouil Breaker 30 Amp. 45 Amp 35 Amp 65 Amp. Curette" SOA, 240V : - 1 0A, 240V. z 1 1 30A. 240V) 1 1 1 20a. 240V - 1 - n 20a. 120V. 1 3 3 5 15A. 120V) 5 3. 5 5 Phase 1 1 1 1 Number of Rotor Poles 2 2. 2. 2 Rated AC Frequency, 60 Hz 50 Hz 60 He 60 Hz Power Factor r 1 1 1 Recommended Air Filler Part # C8127 Part # 089581 Part # 08127 Part # 0cai27 Battery Requirement Group 26 Group 26 Group 26 Group 26 12 Volts and 12.Volis and 12,Volls and 12 Volts and 350 Cold-cranking Amperes Minimaum 525 Cold-cranking Amperes Minimum 525 Cold-cranking Amperes Minimum 525 Cold-cranking Amperes Minimum Battery Warming Blanket ‘OF6145DSRV ‘Weight (Unit Only) 336 Pounds 375 Pounds 425.5 Pounds | 445 & 414 Pounds Enclosure SteeVAluminum. Normal Operating Range + Load erent ve stn for 120 va te manana TOTAL aes fo ~20F (28 0) to 100F 0G) 7 wai care ce RTO Ao a TG i ae, chp a in SN wo spate rs The msm cet nah cs sat ot ae te ve tated fo 240 + Cres o be moved mst be pote by sae se reser: For example, 15 ap ces mala panel mast be & 15 ampere nants © 15.2 ENGINE Model 6/7 Kw. 9/10 KW 13/13 KW. 15/16 KW. ‘Type of Engine GH-410 ‘GT530 ‘GT990 ‘GT990 Number of Cylinders 1 2. 2. 2. Rated Horsepower 145 @3,600rpm | 18 @ 3.600 rpm 30. @ 3.600 7pm 30. @ 3.600 pm Displacement 40ce 530ce 92c0 92ce Cylinder Block ‘Aluminum wast | Aluminum wast | Aluminum wCast | Aluminum wiCast Iron Sleeve Iron Sleeve Iron Sleeve Iron Sleeve Valve Arrangement ‘Overhead Valves: ‘Overhead Valves ‘Overhead Valves ‘Overhead Valves Ignition System Solid-state wMagnelo | Solid-state wiMagneto Solid-state wMagneto ‘Recommended Spark Plug RCIAYC, 'BPRGHS RCT2YC ‘Spark Flug Gap 10-76 mn (0,030 inch) | 0.76 mm (0.030 inch) 1,02 anm (0.040 inch) ‘Compression Ratio 8.61 95:1 251 9.51 ‘Starter 12 vae 12 vac 12 vac 12 vae (Oil Capacity Including Fiter | Approx 1.5 gis ‘Approx 1.7 ats ‘Approx 1.7 ats Approx 1.7 ats ‘Recommended Oil Filter Part # O70185E. Part # 0701855. Part # 0701855. Part # 0701855, Recommended Air Filter Part # 0c8127 Part # 0c8127 Part # 0C8127, ‘Operating RPM, 3,600 3,600 3.600Section 1 ~ General Information 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 volt- age 1s 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 pres- sure, high temperature, ete. 1.7 FUEL REQUIREMENTS AND RECOMMENDATIONS With LP gas, use only the vapor withdrawal sys- tem. 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 yystem 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 {0 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 instruc- tions on reconfiguration of the fuel system, Recommended fuels should have a Btu content of at east 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 com- ply 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 liq- uid propane. Prior to installation of the generator, the installer should consult local fuel suppliers or the fire mar- shall 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 GENERAL ‘Air-cooled Generators InrorauaTion Special considerations should be given when install- ing 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 startup in accordance with local codes, standards and regulations. 1.8 FUEL CONSUMPTION Unit Nat. Gas C) TP Vapor (=) “Wload | Fulltoad | W2tead | Full toad arm [66 a ognn0 [47s aria kw | 102 36 1.28/46 [1337 Tis kW] 156 20 [1587 [2.1878 TftekW 173 225 [1.5958 [251/82 *natarl gost meu feet pe howe i in gallons per houricube fel per hour ive evn ae sprente @ 1.8.1 BTU FLOW REQUIREMENTS - —_— NATURAL GAS BTU flow required for each unit based on 1000 BTU per cubic foot, + 6kW— 119,000 BTUAIour + 9kW— 156,000 BTU/Hour + 13kW — 220,000 BTU/Hour + 15kW — 245,000 BTU/Hour —A BE A— Ay 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.Section 1 — General Information ‘GENERAL ‘Bir-cooled Generators InForMaTion 1.9 RECONFIGURING THE FUEL SYSTEM © 19,1 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 pres- sure 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 NG FUEL SYSTEM 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 con- nection 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 pres- sure 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. Open the roof. 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 secure- yy For 13 and 16kW units: remove the air cleaner + 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, 3. Close the roof. 4. Reverse the procedure to convert back to natural gas.ion 1 — General Information = GENERAL Figure 1.5 - 10kW, GT-530 (Inlet Hose Slid Back) Fuel Selection Lever "iy Posiionfor | —~_| Natural Gas = Fuel +r x Figure 1.6 - 10kW, GT-530 (Inlet Hose Slid Back) Fuel Selection Lever-" Position for Liquid Propane (Vapor) Fuel Figure 1.7 - 13/16kW, GT-990 (Airbox Cover Removed) Fuel Selection Lever -"In® Position for Natural Gas Fue! ‘Air-cooled Generators lnForwaTION Figure 1.8 - 13/16kW, GT-990 (Airbox Cover Removed) Fuel Selection Lever - "Out" Position for Liquid Propane (Vapor) Fuel 1.10 LOCATION Install the generator set. in its protective enclosure. outdoors, where adequate cooling and ventilating air 4s always available (Figure 1.9). Consider these fac- tors: + 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 open- ings 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.Section 1 — General Information GENERAL ~ Section 2 ~ Post Installation Start-up and Adjustments INSTALLATION STARTUP. ADJUSTMENTS ‘Bir-cooled Generators 2.1 BEFORE INITIAL START-UP NOTE: ‘These units have been run and tested at the fac- tory 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 gencrator'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 Tl and 72 5. Check the engine crankcase oil level and, if neces- sary, fill to the dipstick FULL mark with the rec~ ommended 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 bbe open, —A caution A— Never operate the engine with the oil level below the “Add” mark on the dipstick. Doing this could damage the engine. 2.2. CHECK TRANSFER SWITCH OPERATION Refer to the “Manual Transfer Operation” section, of the owner's manual for procedures. —A EEE A— Do not attempt manual transfer switch opera- tion until all power voltage supplies to the transfer switch have been positively turned off. Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock. 2.3. ELECTRICAL CHECKS Complete electrical checks as follows: 1. 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, Twn OFF all breakers on the load center of the transfer box (T1 and 2) 4, Turn on the utility power supply to the transfer switch using the means provided (such as a utility main line circuit breaker) —A EEE A— 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 ter- minals N1 and N2. Nominal line-to-line voltage should be 240 volts AC. 6. Check utility power source voltage across termi nals N1 and the transfer switch neutral lug; then across terminal N2 and neutral. Nominal line-to- neutral voltage should be 120 volis AC. 7. When certain that utility supply voltage is compat. ible with transfer switch and load circuit ratings, turn OFF the wulity 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 cireuil breaker to its ON (or CLOSED) position, —A EEE] A— A\ Proceed with caution! Generator power voltage is now supplied to the transfer switch, Contact with live transfer switch parts will result in dan- gerous and possibly fatal electrical shock 10. Connect an accurate AC voltmeter and a frequen- y 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 250-252 volts at a frequency of 57.5-59.5 Hertz, 11, Connect the AC voltmeter test leads across (er- minal lugs E1 and neutral; then across E2 and neutral, In both cases, vollage reading should be 121-126 volts AC (7kW), and 125-126 volts AC (20, 13 and 16KW), 12. Set the generator’s main circuit breaker to its OFF (or OPEN) position. Let the engine run at no- load for a few minutes (o stabilize internal engine generator temperatures 13, Set the generator's AUTO/OFF/MANUAL switch to 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.ion 2 — Post Installation Start-up and Adjustments Posh oD 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 ils OFF (or OPEN) position. 2. Turn OFF all breakers on the load center of the transfer box (T1 and T2) 3, Set the generator's AUTO/OFF/MANUAL switch to OFF, 4, Turn OFF the utility power supply to the transfer switch, using the means provided (such as a util- ity main line circuit breaker) —A warninc A— AQ Do not attempt manual transfer switch opera tion until all power voltage supplies to the transfer switch have been positively turned off. Failure to turn off all power voltage supplies II result in extremely hazardous and possibly fatal electrical shock. 5, Manually set the transfer switch to the STANDBY position, 1e., 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 (1 and 72). 10. Connect an accurate AC voltmeter and a frequen- cy meter across terminal lugs E1 and E2. 7KW voltage should be greater than 230 volts and frequency should be greater than 58 Hz, 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. 15. Set the generator's main circuit breaker to its OFF (or OPEN) position. 14, Let the engine run al no-load for a few minutes. 15. Set the AUTO/OFF/MANUAL switch to OFF. The engine should shut down, INSTALLATION STARTUP ADJUSTNENTS. ‘Air-cooled Generators 2.5 CHECKING AUTOMATIC 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 uulity main line circuit breaker} 4. Manually set the transfer switch to the UTILITY position. i.c., load terminals connected to the wtil ity power source side. 5. Turn ON the utility power supply to the transfer switch, using the means provided (such as a util ity 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 1s 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 cir- cuits 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. 2.6 ADJUSTING THE FUEL REGULATOR - 7KW (NATURAL GAS ONLY) NOTE: All V-twin engine units DO NOT require a fuel reg- ulator adjustment due to the fuel system design. Although the generator has been factory set to pro- vide maximum power, i 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.vost 25> INSTALLATION Sanrue Section 2 — Post Installation Start-up and Adjustments ADJUSTMENTS. 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 posi: tion, Allow the generator to start. Before loading the generator, confirm that the No Load Frequency, with the roof open and door olf, is set to 63-63.5, Hz, Transfer load to emergency circuits. ‘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 120 Volts 240 Volts 7 kW 50.0 amps 25.0 amps When 9/4 load has been achieved. Connect a fre- quency meter to the output lugs of the generators main line circuil breaker, The fuel regulator is fitted with one adjustment screw. While watching the frequency meter, slowly turn the adjustment screw clockwise or counter- clockwise 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 2.1) Figure 2.1 — 7kW Fuel Regulator 4100c Engine Adjustment | Screw sy} (One OY Only) 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. ‘Turn utility power to the main distribution panel back on. This can be done by switching the ser- vice main breaker to the on or closed position. Allow the generator to shut down, —A warninc A— Do not make any unnecessary adjustments. Factory settings are correct for most applica- tions. However, when making adjustments, be areful to avoid overspeeding the engine. If this procedure or the test equipment is not avail able, 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: @ 2.21 7KWUNITS —A warning As— A\ The engine must be OFF to perform steps 1 and 2. 1. Loosen the governor clamp bolt (Figures 2.2) 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 Nem). 3. Start the generator; let it stabilize and warm up at no-load. Figure 2.2 — Engine Governor Adjustment Single Cylinder Engines SECONDARY ADJUST SCREW ( \ GOVERNOR a sovennon JEFF TH hunny CLAMP Lf ‘aust BolT: ~~ ‘SCREWOPERATION 4, Connect a frequency meter across the generators AC output leads. 5. Tum the primary adjust screw to obtain a fre- quency 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 voll- age regulator may require adjustment (See the Voltage Regulator Adjustment section), @ 2.72 13 KW AND 16 KW UNITS NOTE: All V-twin units DO NOT require an engine gover- nor adjustment due to their design. @ 2.73 ADDITIONAL CORROSION PROTECTION Periodically spray all engine linkage parts and brack- ets with corrosion inhibiting spray such as WD-40 or a comparable product. 2.8 VOLTAGE REGULATOR ADJUSTMENT @ 2.8.1 7KW UNITS With the frequency between 62-63 Hertz at no-load, slowly turn the slotted potentiometer (Figure 2.3) until line voltage reads 248-252 volts. © 28.2 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 232-236 volts. Figure 2.3 - Voltage Adjustment Potentiometer Tuto adjust voltage. Section 3 — Operation i-coaled Generators © 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 gen- erator'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. 3.1 USING THE AUTO/OFF/MANUAL SWITCH (FIGURE 3.1) @ 3.1.1 “AUTO” POSITION Selecting this switch position activates fully automatic system operation. It also allows the unit to automati- cally start and exercise the engine every seven days with the setting of the exercise timer (see the Setting the Exercise Timer section), 2 “OFF” This switch position shuts down the engine. This position also prevents automatic operation. Figure 3.1 - Generator Control Panel a ( = @ 3.1.3 “MANUAL” POSITION Set the switch to MANUAL to crank and start the engine. Transfer to standby power will not occur unless there is a utility failure. —A warning 4— A\ 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 pre- set 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 genera tor panel and on the transfer switch.OPERATION Section 3 ~ Operation © cpa ‘Ai-cooled Generators 3.1.4 CHOKE OPERATION 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 con- trolled by the electronic control board. 3. 410 engines do not have a choke. 3.2. AUTOMATIC TRANSFER OPERATION To select automatic operation, do the following’ 1. Make sure the transfer switch main contacts are set to their UTILITY position, ie.. loads con- nected to the utility power source (Figure 3.2), 2, Be sure that normal UTILITY power source volt- age is available to transfer switch terminal lugs NI and N2 (Refer to the Electrical Data section) 3, Set the generator's AUTO/OFF/MANUAL switch to AUTO. 4, Set the generator's main circuit breaker to its ON (or CLOSED) position, With the preceding steps complete, the generator will start automatically when utility source voltage drops below a preset level. Aller the unit starts, loads are transferred to the standby power source. Refer to the Sequence of Automatic Operation section. 3.3. SEQUENCE OF AUTOMATIC OPERATION ‘The generator's control panel houses a control logic circuit board. This board constantly monitors util- ity 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 acti- vate and connect load circuits to the standby power supply (load terminal lugs T1/T2 connect (o terminal lugs E1/E2), Refer to the Electrical Data section, ‘The generator must run at 50 Hz or greater for the tvansfer output to be activated. Once activated, it will remain active even if the frequency dips below 50 He, Upon restoration of utility source voltage above a preset level, generator circuit board action signals the twansfer switch {o 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 wility 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 wility 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 trans- ferred to the standby source CC. Standby Voltage Sensor + This sensor monitors generator AC output volt age. When the voltage has reached 50 percent of the nominal rated voltage, transfer to standby D. Utility Voltage Pickup Sensor + This sensor monitors utility power supply volt age. When that voltage is restored above 75 per- cent of the nominal source voltage, a retransfer tume delay starts timing, E, Retransfer Time Delay + This timer runs for about 15 seconds. + Atend of a 15-second delay, circuit board action de-energizes transfer relay in the transfer switch if uulity 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 tim: ing + The timer will run for about one minute, and the generator will then shut down, 3.4 MANUAL TRANSFER OPERATION @ 3.4.1 TRANSFER TO GENERATOR —_—— 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, 2. Set the generator's main circuit breaker to ils OFF (or OPEN) position. 3. Turn OFF the utility power supply to the transfer switch using the means provided (such as a utility main line circuit breaker) —A EEG] A— AX 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 extremely hazardous and possibly fatal elec- trical shock,Section 3 ~ Operation OPERATION 4, Use the manual transfer handle inside the trans- fer switch to move the main contacts to their STANDBY position, ic., loads connected to the standby power source (Figure 3.2) 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 7. Set the generator's main circuit breaker to its ON (or CLOSED) position. The standby power source now powers the loads. Figure 3.2 - Manual Transfer Switch Operation — tt LOAD CONNECTED TO UTILITY POWER SOURCE LOAD CONNECTED TO STANDBY POWER SOURCE MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER, @ 3.4.2 TRANSFER BACK TO UTILITY POWER —— Source When ulility power has been restored, transfer back to that source and shut down the generator, This can ‘be accomplished as follows: 1. Set the generator’s main circuit breaker to its OFF (or OPEN) position. 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. —A EE A— A\ 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 possi fatal electrical shock. ly ‘air-cooled Generators © Dp 5. Use the manual transfer handle inside the trans- fer switch to move the main contacts back to their UTILITY position, i., loads connected to the util ity power source (Figure 3.2). 6. Turn ON the utility power supply to the transfer switch using the means provided. 7. Sel the system (o 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 approx- imately 12 minutes and then shuts down, Transfer of loads to the generator output does not occur during the exercise cycle unless ulility power is lost. A switch on the control panel (see Figure 3.1) per mils 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. 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 approximate- ly 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 per- formed. 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 dur- ing weekly exercise periods for quieter operation. If this Dip switch is set to ON, the generator will exer- cise 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.OPERATION Section 3 — Operation © pL Fircooled Generators 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. futility fs 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. Af 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 PROTECTION SYSTEMS @ 3.6.1 LOW OIL PRESSURE SWITCH ‘This switch (Figure 3.3) has normally closed con- tacts that are held open by engine oil pressure dur- ing cranking and operating. Should oil pressure drop below the & 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 tem- perature should exceed approximately 140° C (284° 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 @ 3.6.3 OVERCRANK ‘This feature prevents the generator from damaging itself when it continually attempts to start and anoth: er problem. such as no fuel supply, prevents it from starting The unit will crank and rest for a preset time limit. Then, t 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. 3.13.1 Approximate Crank Cycle Times 7RW 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 gen- erator from supplying an output that could poten- tually damage appliances connected to the generator circuit, Contact the nearest Authorized Dealer if this failure occurs,S-— Section 4 ~ Maintenance @ 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. Ifthe RPM signal is subsequent- ly lost again, the control board will try one more re-crank attempt before latching out and flashing the overspeed LED. © 3.6.6 LOW BATTERY ‘The microprocessor will continually monitor the ballery vollage 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 moni- tored during the crank cycle. 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 [| sesewser G00 MAINTENANCE S—o ‘Air-cooled Generators 4.2. CHECKING THE ENGINE 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. —A caution A— A\ Never operate the engine with the oil level below the “Add” mark on the dipstick. Doing this could damage the engine. 4. Install the dipstick 5. Reset the AUTO/OFF/MANUAL switch to its origh- nal position. Figure 4.2 — Oil Dipstick and Fill, 7kW Ke Oil Dipstick and Fill UX 7/5 =S-— Section 4 — Maintenance MAINTENANCE S—o ‘ir-cooled Generators Figure 4.3 — Oil Dipstick and Fill, 10kW Figure 4.4 — Oil Dipstick and Fill, 13kW and 16kW lipstick 3 CHANGING THE ENGINE OIL 43.1 OIL CHANGE INTERVAL See the "Service Schedule” section, Use all season SAE 5W-30 synthetic ofl or use SAE 30 oil of American Petroleum Institute (API) Service Class SG, SH, SJ or SL. —A caution A— Any attempt to crank or start the engine before it has been properly serviced with the recom- mended oil may result in an engine failure. @ 43.3 OIL & OIL FILTER CHANGE PROCEDURE To change the ofl, 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, Figure 4.5 - Oil Drain Hose and Filter Low Oil Switeh High Temp Switch Change the engine ofl 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 gas. ket 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), 4. Refill with the proper recommended oil (sce the Engine Oil Recommendations section). See the Specifications section for oil capacities 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e— Section 4 ~ Maintenance 4.4 CHANGING THE ENGINE AIR CLEANER © 4.4.1 7.13, AND 16KW GENERATORS _ Sce Figures 1.1 and 1.2, for the location of the air Cleaner, Use the following procedures (Figure 4.6, TKW: Figure 4.8, 13/16kW) 1. Lift the roof and remove the door. 2. ‘Tum 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 Install the new air cleaner into the air box. Install the cover. Turn the two cover screws clock- wise to tighten. See the Service Schedule section for air cleaner main- tenance. See the Specifications section for air filter replacement part number. Figure 4.6 — 7 kW, Engine Air Cleaner Location Air Cleaner ae" Hole Sce 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. Tum the worm gear clamp screw counterclock- wise to loosen. Pull the old filter off the divider panel hub. Wipe away dust or debris from the panel hub, Install the new air cleaner onto the hub. ‘Turn the worm gear clamp screw clockwise to tighten, Replace door and roof, MAINTENANCE S—o ‘Air-cooled Generators Figure 4.7 — 10kW Engine Air Cleaner Control Panel Air Filter Figure 4.8 — 13 kW and 16 kW Engine Air Cleaner 4.5 SPARK PLUG(S) Reset the spark plag(s) gap or replace the spark plugis) as necessary See the Service Schedule section Tor aimtenance 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 condi- tion. 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.ea Section 4 — Maintenance MAINTENANCE =e) “Bir-cooled Generators 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 4.6 BATTERY 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, Have the state of charge and condition checked. ‘This should be done with an automotive-type bat tery hydrometer. —A EXE A— e. The Do not dispose of the battery in a battery is capable of exploding. A battery presents a risk of electrical shock and high short circuit current. The following pre- cautions 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 disconnecting battery terminals. —A warninc A— Do not open or mutilate the battery. Released electrolyte has been known to be harmful to the skin and eyes, and to be toxic. to connecting or 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 bicar- bonate 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 touch ing the battery by first touching a grounded metal surface. A\ 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. Ay 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 bat- tery posts as the cables are attached and cause an explosion. 4.7 ADJUSTING GH-410/GT-530/990 VALVE CLEARANCE After the first six (6) months of operation, check the valve clearance in the engine, adjust if neces- sary. 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.e— Section 4 ~ Maintenance + 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 direc- tion. 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. To adjust valve clearance (if necessary): + Make sure the engine is at 60° to 80° FE + 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). NOTE: Hold the rocker arm jam nut in place 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 aylbs. torque. After tightening the jam mut, recheck valve clearance to make sure it did not change the pivot Figure 4.10 - Valve Clearance Adjustment Rocker Phot Ball Arm + 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. MAINTENANCE S—o ‘Air-cooled Generators + 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. 4.8 COOLING SYSTEM Air inlet and outlet openings in the generator com- partment must be open and unobstructed for con- tinued proper operation. This includes such obstruc- tions 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 loca- tions.) Make sure the doors and roof are in place dur- ing operation as running the generator with them. removed can effect cooling air movement. Figure 4.11 - Cooling Vent Locations oils $$) —A warninc A— 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. —A caution A— The maximum ambient temperature for the gen- erator is 40° C (104° F),. 4.9 ATTENTION AFTER SUBMERSION Ifthe generator has been submerged in water, it must not be started and operated. Following any submer- sion 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 wuhiy is returned,Sr Section 4 — Maintenance MAINTENANCE So Air-cooled Generators 4.10 CORROSION PROTECTION Periodically wash and wax the enclosure using auto- motive type products. Frequent washing is recom- mended in salt water/coastal areas. Spray engine Inkages with a light ol 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, pre- pare the generator for storage as follows: 1. Start the engine and let it warm up. 2, Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down, 3. Once the unit has shut down, it will signal a low oil fault. 4, Set the generators main circuit breaker to its OFF (or OPEN) position. 5. Set the AUTO/OFF/MANUAL switch to OFF and turn off the wUlity 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, dram 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 recommend- ed ofl is used in the engine (sce the Engine Oil Recommendations section). If necessary, drain and refill with the proper ofl. 3. Check the state of the battery, Fill all cells of unsealed batteries to the proper level with dis- tilled water. DO NOT USE TAP WATER IN THE BATTERY. Recharge the battery to 100 percent state of charge. or, if defective, replace the battery. Sce “Specifications,” for type and size. Clean and wipe the entire generator, 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 shutoll 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 exer- cise timer must be reset. oeSection 4 — Maintenance Sr Air-cooled Generators MAINTENANCE. So 4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Authorized Dealer. |S¥STEM/COMPONENT PROCEDURE FREQUENCY, Ix = Acton Inspect Change Clean W = Weekly Ik = Replace as Necessary M = Monthly |» = Notify Dealer Y= Yearly sf Repair is Needed FUEL uel mes and connections” x M LUBRICATION OM tevel x M on x EVERY 100 HOURS** AND Y 0 filter x EVERY 100 HOURS** AND Y COOLING Enclosure lowers x x w BATTERY Remove corrosion, x x M ensue dryness Clean and ughten x x Datlery terminals ‘Check charge state x R EVERY 6M Blectrolyte level x R EVERY 6 M {unsealed batteries only)* ENGINE AND MOUNTING ‘Ar cleaner x R ¥ Spark plugs) x R ¥ GENERAL CONDITION Vibration, Noise, Leakage x M ‘Temperature* COMPLETE TUNE-UP* ‘TO BE COMPLETED BY AN y AUTHORIZED DEALER * Contact the nearest Authorized Dealer for assistance if necessary. ** Change oil and filter after frst eight (8) hours of operation and then every 100 hours thereafter. Change sooner when operating under a heavy load or in a dusty or dirty environment or in high ambient temperatures.‘TROUBLESHOOTING Section 5 = Troubleshooting “Fir-cooled Generators 5-1 Problem TROUBLESHOOTING GUIDE Cause Correction [The engine will not crank, T. Fuse blown, 2. Loose, corroded or defective battery cables. 3. Defective starter contactor. (7 kW) 4, Defective starter motor. 5. Dead Battery. T. Correct short circuit condition, replace 15A fuse in generator control panel. 2. Tighten, clean or replace as necessary, a a+ 5. Charge or replace battery. [The engine cranks but jsrill not start, 1. Out of fuel 2. Defective fuel solenoid (FS) 3. Open #14 wire from engine control board 4. Defective spark plug(s). 5, Valve lash out of adjustment, 6. Choke not operating. 1. Replenish fuel/Turn on fuel valve. a+ 3° 4. Clean, re-gap or replace plug(s) 5. Reset valve lash, 6. Verify choke plate moves freely. [The engine starts hard land runs rough, T. 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. 1. Check, replace air cleaner 2. Clean, re-gap or replace plug(s) 3. Set Fuel Regulator. 4, Confirm fuel pressure to regulator ts 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 kis set to OFF. but the engine lcontinues to run, Defective switch, AUTO/OFF/MANUAL switch wired incorrectly. 3. Defective control board. be LS a+ 3° [There is no AC output from the generator 1. Main line cireuit breaker is in the OFF (or OPEN) position. 1. Reset cireuit breaker to ON (or CLOSED), 2. Generator internal failure a7 [There is no transfer to 1. Defective transfer switch coil. 1 lstandby after utility 2, Defective transfer relay. 2 lsource failure 3. Transfer relay circuit open, 3. 4, Defective control logic board. 4a [Unit consumes large 1, Engine over filled with ofl 1. Adjust oil to proper level lamounts of oil, 2. Engine breather defective 2* *Contact the nearest Authorized Dealer for assistance.Section 6 — Notes ‘Air-cooled GeneratorsSection 6 — Notes “ir-cooled GeneratorsSection 6 — Notes ‘Air-cooled GeneratorsINSTALLATION — ed | i HE a \ a, “Do NOT LIFT BY ROOF”Section 8 ~ Electrical Data INSTALLATION Electrical Schematic - MA wk —OLp Ns — 1 2-2 ir-cooled Generators 10, 12 and 16 Circuit Load Center ~ Drawing No. OF9775 a ‘ sce NEUTRAL (WHITE) - - se I 2—> eRcur ! cereus 3 erour wa | 1 crcumr |__s3— oncurre |_s3— oncumrs | _s3— oncumre + $5 orcur 1 45 = oncuns 8 3 oncure } ss — orcu7 0 js oncurs AATS-AUTOMATIC TRANSFER SWITCH ‘CHUTILITY COIL & RECTIFI js >— oncunt (C2-GENERATOR COIL & RECTIFIER FUF2SA, OO FUSE 1 __s-3— oneutrte LCCIRCUIT BREAKER (LOADS) TR-TRANSFER RELAY TSTERMINAL STRIP mou 8 XAXBLIMIT SWITCHES J ‘CIRCUT LOAD CENTER 10CIRCUIT LOAD CENTER 12 CIRCUIT LOAD CENTER 16CIRCUIT LOAD CENTER ceReutT 161m 8 — Electrical Data | l soled Generators Je Same +] Wiring Diagram ~ 10, 15 & 16kW, V-win ~ Drawing No, 0F7822 ENGNE WING os Ts 1 A Ay NANA AS} PittsCONTROL ave 80K peeSection 8 — Electrical Data ‘ir-cooled Generators evecTRican Electrical Schematic ~ 10, 13 & 16K, V-Twin - Drawing No. 0F7823 | "para" | ENGINE AND ALTERNATOR: | —— a ae a = 7 . T i rTTll 6 © ! | i —t “ i “ roa 4 _ —]°~C~—“i‘i‘Ci‘C:*W “0 Lt — ml Tr |Section 8 — Electrical Data Tir-cooled Generators J Gmc" +] Wiring Diagram ~ 7kW, Single Cylinder - Drawing No. 0F7820 ENGINE WIRINGFHI tonSection 8 — Electrical Data “Fir-cooled Generators Electrical Schematic - 7KW, Single Cylinder ~ Drawing No. OF7821 | — L Ls. : ana “Section 8 — Electrical Data Air-cooled Generators Electrical Schematic ~ 7kW, Single Cylinder - Drawing No. OF7821 le oa | ENGINE AND ALTERNATOR aS LR rel i | _ . — : . ® 6 it | eT t — i i iiT1— Te [— BLK— RED— 38 qaa__) aiW2ad 11n9a19 | hv14 > ind ino SLIHM J xgLva3na9 OL TNIV >NOILNSTaUSTC 2 NIVA ) TaNve WALN3NJ NIVA OL SvAgve err 2 Linowr9 ! * LINgaTS | 9 LINSATO 8 LINdar9 or sinoatd 2t aingaia__| I LIngaId 91 sinaala st Lingard et Lingo 1 Lin9w7g 6 Linsa1a | LINaIO Wiring Diagram ~ 8, 10, 12 and 16 Circuit Load Center ~ Drawing No. 0F9070-A E 3 i e g 3 & ‘ir-cooled Generators “16 CIRCUIT LOAD CENTER 12 CIRCUIT LOAD CENTER: LINgaIg. | 10 CIRCUIT LOAD CENTER: CIRCUIT LOAD CENTER “ S Lingara € 1 AIngata T CONDUCTORS NOT SHOWN FOR ALL CIRCUIT CLARITY GROUNDED a0Section 8 — Electrical Data ‘Air-cooled Generators Wiring Diagram ~ 8, 10, 12 and 16 Circuit Load Center ~ Drawing No. 0F9070-A Je a | —BLK BLK. —RED- RED tt Nee Te NIA 126 Neal an a qf UJ Mba 126 aT 1eel|a U Er 00 Eons 33 126 126 ely (a ae 80 Nia NIA {O 7 1 te| eas ats \S NY pN2at-———nea 20 00 N=) “balls 38 BLK BLK: Hoe °° RED RED aa 205 8 |O)//O ce = ru cet Et Ee 20s BLK} RED TI Ta. Et (| ol LEGEND ATS-AUTOMATIC TRANSFER SWITCH UTILITY COIL & RECTIFIER GENERATOR COIL & RECTIFIER Fi, Fe-58, 600V FUSE LC“CIRCUIT BREAKER ¢LOADS> C16 CIRCUIT SHOWN FOR REFERENCE ONLY? N=NEUTRAL TR-TRANSFER RELAY TS-TERMINAL STRIP XA, XB-LIMIT SWITCHESGorse Section 9 — Exploded Views and Parts Lists = ‘ir-cooled Generators OG) Trieare Stonng na orsestc \ 8 PRE PACKAGED UNITS ONLY ‘SHEET METAL PAINT/MATERIAL CODE LEGEND ‘The folowing exploded views contain part numbers of various sheet metal components, Only the base pat number is Iistd, When ordering sheet metal, he corct coor and materalinormatin must be includes as a sux athe end of he part number as shown alow, Color Solar Order As" N=Tan oot F6522 NeTan OF 6522SN, G=Gray Doot oF 6555 G=Gray OF 6SB5AG B=Blace Divider OF 6558 B=Black ——_OFB558S8Section 9 — Exploded Views and Parts Lists ITEM PART NO. QTY. DESCRIPTION oF 9653 o4s771 022128 022129 022145 o«at07 90388 003700 003700" 22087" 22ers" vests" oses2 o946s2 oFes7t oF 8080 oF 8248 oFeet5 OF 6558 092120 0F 7825 oF 7824 oF 6549 oF Ta24A ootado arent oman oF710 ont 008735, 029780 oo7i76 oF7a27 06570 F657 0929788 oo297ec 022087 022087 022473 oF 828 oF o1854 0F 6550 oFot64a 013308 0212678 05968 oFoT65 oFot64 oct0as ongs75 go4o0 0F 6552 0F 9579 ootae oF 8210 oF 8709 oF 9078 oF 5458 PAD, 24 X 48° WITH MOUNTING HOLES NUT HEX M-1.25, WASHER LOCK 516 WASHER LOCK 5116 (7K) WASHER FLAT 5/16 SCREW HHO M-1.25 X 25 SCREW TAPTITE ME-1.0X 12 NUT, LOCKING FLANGE M6-1.9 NUT, LOCKING FLANGE M6-1.0 WASHER LOCK me-18 WASHER FLAT 114.M6 ZINC NUT HEX M6 X1.0 SCREW HHTR 5/1618 X SCREW HHTR 5/1618 X 3 SCROLL, FAN (7KW, 10KW) SCROLL. FAN PANEL, ALTERNATOR DIVIDER (7KW) cx, PANEL, ALTERNATOR DIVIDER NUT LOCK TRIC MX 1.0 FORM, MUFFLER BOX FRONT FOAM, MUFFLER BOX END ENCLOSURE, EXHAUST SIDE FOAM, MUFFLER BOX END BRACKET, BOTTOM SUPPORT SCREW HHC Mé-1.0X 16 G8.8 (7KW) SCREW HHC M6-1.0X 16 G8.8 RIVET PO? 0.125" x 037° WASHER NYLON Mée1i¢" SUPPORT, ROOF FOLDING (CLOTH HARDWARE 266.?mm X 387.4mm WASHER, SELF LOCKING. FOAM, EXHAUST ENCLOSURE COVER COVER, FRONT EXHAUST ENCLOSURE CLOTH, HARDWARE 266.7mm X 148mm CLOTH, HARDIVARE S¢3mm X 145mm WASHER LOCK 66-18 (7KW) WASHER LOCK Me. WASHER FLAT Mé-ti4 FORM, MUFFLER BOX BACK HINGE TYPE 8 WITH STUDS, SOCKET ENCLOSURE, SIDE & BACK HINGE TYPE A WITH STUDS, SOCKET GROMMET, 98.1 CROSS SLIT WITH HOLE PLUG PLASTIC 1.5 BLINO GROMMET GASKET, EXTRUDED TRIM. HINGE TYPE A WITH STUDS. PIN SCREW PPHM M305 X38. LWASH SPECIAL #10 \WIRE ASSEMBLY, GROUND ENCLOSURE, ROOF FOAM, ROOF ENCLOSURE BRACKET, TOP SUPPORT REGULATOR ASSEMBLY (7K\) REGULATOR ASSEMBLY (10KW\) EGUALTOR ASSEWLY SCREW PLASTITE H-LOW #10 X 38 Air-cooled Generators See Enclosure ~ biawing na apo OG) UIEM PART NO. QTY, DESCRIPTION a 48 05438 OF5434 oF 8283 OF 7886 F885 neat 903058A 08245, 903058 ‘0016054 oF 798 0F8980 op3472 ca2es, 003167 e130 onatt6 o4stt6 086729 F8039 onai27 3880404,0 oF 8847 oFB43¢ oF 8968 oczes7 49813 oAt658 oG0817 92079 55414 oF 8234 oft F8257 0¢3906 OF 6555 OF 8555 003097 903037 oF e143 oF 8261 oF S440 oF 8328 sare 051713 22152 36897 022158 oceett 026850 031879 009784 HARNESS, ENGINE (7KW) HARNESS ENG V-T HSB PANEL, ENGINE DIVIDER (7AW) PANEL, ENGINE DIVIDER (10K) PANEL. ENGINE DIVIDER BUSHING SNAP SB-1500-18 FOAM, FRONT INTAKE BAFFLE (7KW) FOAM, FRONT INTAKE BAFFLE FOAM, BACK INTAKE BAFFLE (TKW) BAFFLE, INTAKE (7KO) BAFFLE, INTAKE FOAM, TOP INTAKE BAFFLE GROMMET OVAL 31.78 X 508 BRACKET, BATTERY SUPPORT GASKET, BATTERY SUPPORT BRACKET (GROMMET, 36.1 DIA. CROSS SLIT SCREW HC, MG-1.0.X 12 G8 8(740) SCREW HHC M6-1.0 X 12 G88 CCONTACTOR, STARTER (7K) MOUNTING CUP NUT HEX 14-20 (7K) ‘CABLE, #6 RED BATTERY 98,5" GASKET, FRONT DIVIDER GASKET. FRONT DIVIDER (10KW) FUEL LINE, 12" OUTDOOR (NOT SHOWN) BRACKET, BATTERY HOLD DOWN (7KW) NUT HEX Mé-.0 68 LOCK WASHER SPECIAL 1/4 EXTERNAL CONNECTION BOX ‘SCREW TAPTITE M6-10 X25 BP LUG SLOLSS #2488 x 17/64 CU ASSEMBLY, ENCLOSURE BASE (7K) ASSEMBLY, ENCLOSURE BASE FOAM, FRONT ENCLOSURE SSELF-ALIGN SCREW Mé HH ENCLOSURE, FRONT GASKET, DOOR SEAL ERTURN LOCKING TURN NON-LOCKING LATCH, uas PAWL, DOOR OAK, BACK ENCLOSURE HARNESS GENERATOR TO EXTERNAL ‘CONNECTION BOX (7K) HARNESS GENERATOR TO CONNECTION BOX (10KW) HARNESS GENERATOR TO EXTERNAL ‘CONNECTION BOX WASHER FLAT MS WASHER LOCK #10 ‘SCREW PPHMATO-32X 1 NUT HEX at0-32 POWER BLOCK WASHER SHAKEPROOF EXT 1/4 STEEI WASHER FLAT #4 NUT HEX LOCK M3-05 NAL “ITEM 7 FOR MODELS WITH ALUMINUM ENCLOSUREPART STS Section 9 — Exploded Views and Parts Lists Road Ceara OG) —_Siralranl rong no. oses5cSection 9 — Exploded Views and Parts Lists 07886 07886) oatsot oFs7t9 oozi74 oF 1504 032300 022678 4494 E7890 o7a4s4e 075476 asta 06480 soda oct0as: oct0as: 580004 297 08040 oF 9282 075235 03928 oos7a4 CIRCUIT BREAKER 308 x 2° 240V (7KW) CIRCUIT BREAKER 45A X 2° 240 oko CIRCUIT BREAKER SSA x 2° 240 (3k CIRCUIT BREAKER 65A x 2° 240 (isk [ASSENBLY, BATTERY CHARGER ENGI ASSEMBLY, POTTED REGULATOR RELAY, 12V 258 SPST (NON 7KW) BLOCK TERMINAL * POSITION SCREW HHO MB-1.0 x 30mm ASSEMBLY, HOME STANDBY ‘CONTROLLER ASSEMBLY, HOME STANDBY ‘CONTROLLER (7KW) HOLDER, FUSE FUSE, 15 AMP X AGCIS ‘SWITCH, ROCKER DPOT ON-OFF-ON CIRCUIT BREAKER MOUNTING BRACKET SNAP BUSHING ‘SCREW PPHM M07 x 16mm MB LOCK WASHER (NON 7K\) NUT HEX LOCK W4-0.7 NYLON INSERT (CURRENT TRANSFORNER, [DLE ‘CONTROL (NON 7KVN) SSOREW PPHM M3-05 x 8mm ‘SCREW PPHM M05 x &mm (TKW) 1MB.055 TRIC NUT (NON KW) WASHER FLAT #10 ‘CONTROL, PANEL BOTTOM (CONTROL, PANEL BOTTOM (7KYy) 'SOREW HHO M5-08 x 30mm ‘SWITCH, SPST NUT HEX LOCK M3-0.5 NYLON INSERT Ai ‘ooled Generators See contol Panel ~ Crewing Nov oseoee OG) 4 25 28 a 2 3 “ one7es ‘opaso2 o3te79 ot879 0F 5433 05437 74908 49813 2025 ‘oG0827 022507 2087 46689 63617 7875 3180 oFB04 oF 9283 048770 E7866 oe 867 003700 oz0g7" 02473" 813" ‘oco400 e284 ont658 022673 NUT HEX LOCK 3-05 NYLON INSERT Ky NEUTRAL BLOCK WASHER FLAT #4 WASHER FLAT 44 (7K¥) HARNESS, CONTROL PANEL WIRE (NO? SHOWN) HARNESS, CONTROL PANEL WIRE (NOT SHOWN) (7KYY) SCREW HHTT, M5-03 x 10 BP NUT HEX M6-1.0 NUT HEX LOCK M5-0.8 NYLON INSERT XFMR 240/16V 1VAASEVA WIPTC SCREW HHC 1820 x 12" WASHER LOCK Me-14" ‘TERMINAL STRIP 4 POSITION RELAY PANEL 12VDC DDT 10A 240VAC SCREW PHN M&0.7 x 10mm WASHER FLAT Ma ‘CONTROL PANEL COMPONENT ‘CONTROL PANEL COMPONENT HHO M5.0.8 x10mm ‘CONTROL PANEL WASHER LOCK Me" WASHER FLAT 114.06 NUT HEX M6 X19 \WIRE ASSEMBLY, GROUND SCREW HHTR 1/20 X 3 WASHER LOCK SPECIAL 18" WASHER FLAT 11¢-N6 “ITEM 4 FOR MODELS WITH ALUMINUM ENCLOSURESection 9 — Exploded Views and Parts Lists 03092 oFeat2 ozs? o77220 772208 082574 eaaes or4o0e on4gr2 oAt858 069617 oF 9219 01495 atest 022473 ot t08 oF s199 opssaa 004684 BOX LOAD CENTER ‘COVER, 8 CIRCUIT LOAD CENTER: (COVER, 10 CIRCUIT LOAD CENTER ‘COVER, 12 CIRCUIT LOAD CENTER COVER, 16 CIRCUIT LOAD CENTER TRANSFER SWITCH HOME STANDBY 100A 2P 250 con UTLITY COIL STANDBY INSULATOR-SIDEWALL (NOT SHOWN) LIMIT SWITCH OPERATION (NOT SHOWN) ‘SCREW HHTTMS-08 X 1 LOCK WASHER, SPECIAL-1/" RELAY PANEL 12VDC DPDT 10a@240VAC 8 CIRCUIT LOAD CENTER ‘2GIRCUIT LOAD CENTER (ALSO USED FoR 10 CIRCUIT) 18 CIRCUIT LOAD CENTER, ‘SOREW HHTT Ni-0.7 X 10 RIVET POP .156°X 875" WASHER FLAT 1/4248 ZINC PLUG PLASTIC PLUG PLASTIC HARNESS ADAPTER PLATE ‘8 CIRCUIT HARNESS ADAPTER PLATE ‘SUBPLATE, LOAD CENTER. U-CHANNEL WASHER LOCK #10 ‘SOREW HWWHS 86:25 X [ARM EXTENDER PIN HOLDER GABLE TIE HARNESS, 8 CIRCUIT LOAD CENTER TO MAIN PANEL HARNESS, 10 CIRCUIT LOAD CENTER TO MAIN PANEL HARNESS, 12 CIRCUIT LOAD CENTER TO MAIN PANEL HARNESS, 16 CIRCUIT LOAD CENTER TO MAIN PANEL 40 a Air-cooled Generators ransfer Switch Assembly ~ Drawing No. OF9774- o7atse 026993 77083 ‘48850 028739 oaziio stat 003088 73501 735908 402193 ores 78884 078383 78880 078880 OE 7B88E 003320, 0F5439 oFssar oFs720 oFs720 75475 oATa1s 08199 AR AR AR AR AR @er LUG QUICK DISCONNECT NIS 10x45, DEG BRASS /7IN SCREW PPHM 810-92 X 218° LUG SLDLSS 110-+14xa16 AUCU BLOCK TERMINAL 208 8 X 6 X 1100 TE WRAP 38° X.. ‘SWAGE 114-20 x 12" INC RELAY & TERMINAL BLOCK WIRE HARNESS, LOAD CENTER (NOT SHOWN) FUSE HOLDER FUSE 5A SUPPORT SNAP-IN 1-8" 810 12 16CIRCUT OIRBRK 20427 1 CIR BRK 308 2° 1 CIRBRK15A1P 5. CIRBRK2041P 1 CIR BRK 4a 2° CIR BRK 508 2° COVER - HARNESS ENTRY HARNESS, 8 CIRCUIT LOAD CENTER TO EXT CONN BOX HARNESS, 10 CIRCUIT LOAD CENTER ‘TO EXT CONN BOX HARNESS, 12 CIRCUIT LOAD CENTER ‘TO EXT CONN BOX HARNESS, 16 CIRCUIT LOAD CENTER ‘TO EXT CONN BOX PPHM M407 X10 SW 1/820 5/8" WITH WASHER 5 5 115 & 16kW, GT-990 Engine ~ Drawing No. OF9430-E - Part 1 Section 9 — Exploded Views and Parts Lists ‘Air-cooled Generators Se usts 0G Be 98 BS zy ‘Se 2 91 51'S |Section 9 — Exploded Views and Parts Lists ITEM PART NO. QTY. DESCRIPTION oosr28 09643 090388 005972 063005 039728 0080678 7983 02961 07985 021583 1466 opsoat 00297 ocse43 ogot40e 08228 oo2157 06098 0081284 03027 05908 00497 oF 26646 005305 006147 ‘Air-cooled Generators See 15 A TehW, 1.990 Engine - Drawing No: oto Pat OG) ASSEMBLY, CRANKCASE HOUSING WITH SLEEVE ‘SEAL, 38 LD. CRANKSHAFT ‘SCREW, TAPTITE ME-.0 X 12¥C ASSEMBLY, BREATHER GASKET, BREATHER COVER ‘SEPARATOR, OIL BREATHER ASSEMBLY, HEAD #1 G&S RETAINER, PISTON PIN 20 ROCKER, COVER NO OIL FILL PISTON, He ‘SET, PISTON RING 904M PIN PISTON ASSEMBLY, CAMSHAFT & GEAR. GASKET, CRANK CASE SEAL, OIL PASSAGE ASSEMBLY, CRANKSHAFT HORIZONTAL DIRECT DRE ASSEMBLY, CONNECTING ROD ‘SCREW SHC W6-1.0 X50 G88 ‘SOREN, OIL PIOKU? ASSEMBLY, OL PUMP. ‘RING 48 1D X 07 THIGK (COVER, OIL RELIEF ‘SPRING, OIL RELIEF BALL, 1/20 OIL RELIEF WASHER, LOCK RIB Mé ‘SCREW, PLASTITE HLLOW #10 CORING, 38° X 12° COLAWP, OIL TUBE PLUG-ORANKCASE ASSEMBLY, DIPSTICK WITH HANDLE ‘TUBE, DIPSTICK ‘SCREW HHF Mé-1.0 x tomm 43790 9842 008731 0¢3006 80818 3064 961839 27290 902978 6515 oza7a 3867 78672 ocss7t 072694 00533 003998 ‘8024 002976 086516 0229 8897 9080678 98530 002978 obaota op4or2 086754 0086758 opaots: 786990 0786993 BARBED ELBOW 90 SPT X 318 SEAL, 42 1D, CRANKSH/ ASSEMBLY, HOUSING COVER WITH SLEEVE SCREW, HHEC M10-15 x 55 SCREW HHFC MB-1.0X 25 ASSEMBLY, OI FILL GAP LUFT HOOK Greea760, ROCKER, COVER WITH OIL FILL GASKET, VALVE COVER KEEPER, VALVE SPRING RETAINER, VALVE SPRING SPRING, VALVE SEAL VALVE STEM D7 WASHER, VALVE SPRING STUD, ROCKER ARM PIVOT ROCKER ARM NUT HEX MB-1.0.G8 YEL CHR PLATE, PUSH ROD GUIDE SCREW KHFC MB-125 X 65 VALVE, EXHAUST ‘VALVE, INTAKE TAPPET, SOLID ASSEMBLY, HEAD 42 G&S PUSHROD, 147 GASKET, HEAD KIT GASKET KIT BREATHER ASSEMBLY KIT HEAD ASSEMBLY CYLINDER 1 KIT HEAD ASSEMBLY CYLINDER 2 KIT OI REL? SLEEVE DOWEL PIN 14 DI SLEEVE DOWEL PIN 12 018.Goris Section 9 — Exploded Views and Parts Lists Firzoaed GeertSection 9 — Exploded Views and Parts Lists ITEM PART NO. QTY. DESCRIPTION 101 02 108 104 105 108 107 108 109 022145 0051364 oca0d ocs040 003025 7292 o7otas, 03083 2094 075281 035481, 06301 oozes 08506 ooa764 cao crea 70008 1070006 040976 048756 ¢303t 003725 OF T1708 oo7ess oaoata 82774 0030364 ocao1e cao Air-cooled Generators See 15 & TehW, 7.990 Engine - Drawing No: oto Patt OG) WASHER FLAT Ma - 5/16 NOB, AIR CLEANER (COVER, AIRBOX NGL a R, ELEMENT, AIR CLEANER ASSEMBLY, MIXER/AIRBOX 990 ‘SCREW SHLDR(@MN) Mé-1.0X 21 WASHER RUBBER 14" X 1/8" THICK ‘SPARKPLUG,GTe@0 HSB ‘SOREW TAPTITE NS -08 8 WRAPPER, LOWER CYLINDER 2 ‘SWITCH, OIL PRESS NIPPLE, 47-16 UNF OILFILTER AASSY, OIL DRAIN HOSE ‘SCREW M3 -05X 6 SEMS SWITCH, THERMAL 284 BARBED STRAIGHT 14NPT X 338 ‘CLAMP, HOSE OETIKER 165M HOSE, 96"1D.X6°LG COOLER, OL ‘SCREW PLASTITE 11415 x 94 GASKET, MANIFOLD / PORT MANIFOLD CYLINDER 2 WASHER FLAT MB SS. WASHER LOCK Me SSTL SSOREW SHC WB 1.25 X 206129 ‘SCREW TAPTITE MS - 1X10 YELLOW ‘CHROME ASSY,GROUND WIRE CONNECTOR WASHER, 254M 10, NUT. HEX M24 NUT. GROMMET 14 PLUG GUARD, FAN HOUSING, BLOWER NG COOLER ‘SCREW HHC MB -1.25 X 12.G9.8 WASHER SHAKEPROOF INT NB SS PLATE, FAN FAN, NYLON FLYWHEEL ASSEMBLY PLATE, BACKING WITH OIL COOLER MANIFOLD CYLINDER 1 SLEEVE, RUBBER EY, WOODRUFF 4X 190 HOSE BREATHER WRAPPER, LOWER CYLINDER 1 WRAPPER, UPPER CYLINDER 1 10 m1 1 113 1“ 15 18 7 8 19 120 121 12 123 124 125 127 128 128 130 131 132 133 134 135 138 37 138 139 140 141 142 143 148 45 148 7 148 49 150 151 152 153 154 185 158 opras 99323 ‘61806 onztze ortiz? 022097 092079 60788, oco7e83 99568 (E8565 onsoz7 ocd 0c4756 o7se7? oss oEt644 069572 9784 05108 e342 09570 0957 E5846 oe 8«i9 oca7eo oF 9253 08553 09554 E894 09599 (E9595 090887 E9409 969571 E8380 on8345 08598 99593 08684 969575 08357 onr094 09574 oF 8273 F487 09557 \WRAPPER, UPPER CYLINDER 2 STARTER MOTOR HEAR REDUCED 1KW SCREW HHC MB 1.25 X 85 G88 WASHER LOCK Ma 518 ASSEMBLY, GROUND WIRE WASHER LOCK M6 1/4 SCREW TAPTITE MB — 1.0 X 25 BP [ASSY, IGN COIL WIDIODE, CYLINDER 1 AASSY, IGN COIL WIDIODE. CYLINDER 2 ASSY, THROTTLE SHAFT PPHM MS -05 x5 DUST, MIKIAIRBOX PHM M5 ~058 X 20, FHOMS 10X12 BHSC M6-1.0 x 12.88 ‘STEPPER MOTOR NUT HEX LOCK Mi3— 0 NYLON INSERT ASSY, CONTROLLER. BALL STUD, toMmt ASSY, THROTTLE ROD BELLOWS, INTAKE EXPANSION PLUG m00RING PLUG, MANIFOLD ASSY, AIR BOX BASE PIN, FUEL SELECTOR PIN, FUEL SEL STOP SOLENOID COVER LINKAGE, CHOKE SCREW PPPH HLLO 46 X 1/2 SCREW PHIT W305 8 RETAINER, CHOKE RETURN SPRING SPRING, CHOKE RETURN (WASHER, BELLEVILLE SPRING SCREW PPHM M204 X8 CHOKE ARM SCREW SHOULDER 3-05 X6 VALVE, CHOKE SHAFT, CHOKE SEAL, GOVERNOR ARM PHI 84-40 X 18 ‘SOLENOID SOLENOID, 6vOC NUT HEX M8 126 YELLOW ZINC SPRING, CHOKE VALVE ADJUSTSection 9 — Exploded Views and Parts Lists “Bir-cooled Generators 10kW, GT-530 Engine ~ Drawing No. 0F9429-D - Part 1 |47|2,5,14,25,29,39,55,60,61 68,85 |49/6,29,0,31,22,33,34,38,39,40,42,43,44 45,46 |50|29,30,31 ,82,33,34,37,36,39,40,42,43,44,45,46Section 9 — Exploded Views and Parts Lists aseeaseses 12 cess oE99678 0053154 ocsat4a 03592 ocaraa 08390 aa56 ates goers G0274 go27s 090276 08502 goats 720 o7acoas ocs03 049790 operas ary. Air-cooled Generators VOKW, GT-530 Engine ~ Drawing No. 0F9429-D - Part 1 DESCRIPTION ‘ORANKCASE SEAL D 95 48.2 SSOREW HHFC We ~ 1,020 AASSY, BREATHER GASKET BREATHER ASSY (CYLINDER HEAD 1 ‘COVER, ROCKER PLAIN PISTON PIN RETAINER RING PISTON PIN PISTON PISTON RING SET ASSY CONNECTING ROD AASSY, CAM & GEAR GASKET CRANKCASE ASSY CRANKSHAFT WIPLUG SCREW HHO MB —1.0X 12 WASHER LOCK M6 RIBBED ASSY GEROTOR ‘SPRING OIL PRESSURE RELIEF BALL 11/32 DIA PRESSURE RE (GEROTOR OUTER OM THICK GEROTOR INNER SMM THICK GEAR COVER SSOREW HHFC WB - 1.25 X 45 O-RING 38 X12 SSOREEN Ol. PICK-UP AASSY, OIL FILL GAP ‘COVER, ROCKER, W/ FIL GASKET, VALVE COVER, KEEPER, VALVE SPRING VALVE RETAINER ‘SPRING VALVE SEAL, VALVE STEM WASHER, VALVE SPRING ‘SPARKPLUG SCREW HHC MB 1.25 X56 CYLINDER HEAD 2 VALVE EXHAUST GASKET CYLINDER HEAD VALVE INTAKE TAPPET, SOUD 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, 67530, SSOREW HHFC M6 1.0 25 ‘SEPARATOR, OIL BREATHER GT530 SLEEVE DOWEL PIN 12.018 SEAL, OIL PASSAGE BARBED E1 20:3 NPTX<8 PLUG STD PIPE 318 STEEL SQ HO @erSection 9 — Exploded Views and Parts Lists ‘Oka, GT-550 Engine - Drawing No. 0F9429-D - Part 2 " Filed Geert OG) PARTS BeSection 9 — Exploded Views and Parts Lists SSISaeagsess 099997 022128 Air-cooled Generators See tol, 61530 Engine - Drawing No Beoeas.8 Patt OG) WASHER LOCK Mé-118 INTAKE ADAPTER. GASKET, AIRBOX TO CARBMIXER, GASKET, MANIFOLD TO CARBIMDX BOLT, CARB MOUNT M6 - 1.0 X 85, NUT HEX LOCK M308 ASSY, CONTROLLE BALL STUD, 10 M04 AASGY, THROTTLE ROD ‘GUARD, FAN GASKET INTAKE BREATHER HOSE. SCREW SHC MB 1.25X 206129 WASHER LOCK M8516 ‘SCREW HHC MB -1.25 X85 ‘STARTER MOTOR ‘SOREW HHFC MB 1.25 X 14 LIFTING HOOK WRAPPER OUTER CYLINDER 1 WRAPPER INNER CYLINDER 1 TUBE, DIPSTICK AASSY, DIPSTIOK TEXT BLOWER HOUSING ‘SCREW HHFC M6-1.0X 10 68.8 ‘SCREW HHFC M6-.0 8 G88 WRAPPER INNER CYLINDER 2 WRAPPER OUTER CYLINDER 2 GASKET, OL FILTER ADAPTER |ASSY, DIRECT OIL COOLER ADAPTER ‘SCREW PLASTITE HLLOW #10X318 104 108 1 048757 71358 ‘084090 0F 2094 003083 ABs o#zr74 97208 0695148 995140 (026850 oebeas oF 6301 60288 60479 08340 996250 9486 045992 e571 067880 067198 oc30s2 08997 08408 061705 08450 08976 99550 o2een6 SCREW HHO M6 -1.0X 25 OL FILTER THERMAL SWITCH SCREW PPHM M805 X 6 ASSEMBLY, OIL DRAIN HOSE lL PRESSURE SWITCH KEY, WOODRUFF 4X 18D 'ASSY, GROUNDING Wi [ASSY IGNITION COIL CYLINDER 1 [ASSY IGNITION COIL GYLINDER 2 WASHER SHAKEPROOF EXT 116 ASSY, MIXER DUAL FUEL CLAMP, HOSE OETKER 16.54M HOSE SI81D X 6° SAE Ja0R® HOSE 3/81D X 7.25 SAE J30R@ BACKING PLATE ASSY, FLYWHEEL & RING GEAR. FAN, FLYWHEEL, 20 FIN, 218.8 0D WASHER LOCK INT MB SCREW KHC M8 ~ 1.25 X 10 NUT HEX M20 ~15 WASHER BELY ~20 x 22 PLATE, FAN [ASSY, GROUND WIRE CONNECTOR, oll. COOLER, SCREW KHFO M6 -1.0X 14 CENTER BAFFLE INTAKE MANIFOLD FRONT COVER ELBOW - 1/8 NPT‘i i parts Section 9 — Exploded Views and Parts Lists Goats ‘Air-cooled Generators wa Og ‘TKW, GN-410 Engine ~ Drawing No. OF 94 ary. DESCRIPTION ASSENBLY, CONNECTING ROD PIN, PISTON D20, ET, PISTON ING 80MM PISTON, HC 1 1 1 1 2 RETAINER, PISTON PIN 20 1 ASSEMBLY, CRANKSHAFT GH410 SMALL TAPER 1 |ARW, GOVERNOR ROSS 1 PIN, “R’ GOVERNOR ARM 2 WASHER, GOVERNOR ARM THRUST 1 (CRANKCASE, SUBASSEMGLY WITH PLUGS GHs10 2 ‘SEAL, 35 LD. CRANKSHAFT 1 ASSEMBLY, GOVERNOR GEAR, 1 ‘CARING, GOVERNOR GEAR RETAINER 1 ‘SPOOL, GOVERNOR. MACHINE 1 ASSENBLY, CAMSHAFT & GEAR, 6 076701, 1 GASKET, CRANKCASE 7 0217138 1 GASKET, HEAD 410 18 o7gést 1 ‘COVER, OL PRESSURE RELIEF 19 oas77t 1 SPRING, OIL RELIEF 360 2% 085776 1 BALL, DIA 11/32 PRESSURE REUEF a 076361 1 WASHER, THRUST GOVERNOR GEAR 2 (088980 1 ASSENBLY, COVER, GEAR TOP CHECK / FILL 2 onz274 2 AETAINER, VALVE SPRING 2 ocagot 2 VALVE SPRING LF % 036025 1 SET(GEROTOR 12TH 28 oF 8341 1 BALANCER 2 02174 1 ASSENBLY.CYLINDER HEAD SEATS & GUIDES 28 085516 1 VALVE, EXHAUST 2 086517 1 VALVE, INTAKE 30 0098538 2 PUSH ROD 1749 3 aae97 2 TapPET 3 o77158 1 ASSEMBLY, SOREN OIL PICK-UP 3 oosts0 1 (GASKET, ROCKER COVER 410, oa 072684 2 ‘STUD, D20 PIVOT BALL 6 89007 2 ROCKER ARM 8 072606 2 NUT, JAM (ROCKER ARM) a o7aes 1 38 021742 4 SSOREW, HEFL M10-1.5X 105 38 08034 1 |ASSENLY, ROCKER COVER BREATHER, 40 076328 1 PLUG, OIL FILL PLASTIC a 57 1 O-RING 178 10.x24 2 008738 1 PLUG, STANDARD PIPE 318 STEEL SQUARE HEAD 4% orde08 1 SCREW, TAPTITE M5-0.8 X 10 8 44 036515 4 KEEPER, VALVE SPRING 45 078608 4 ‘SCREW & LOCKWASHER M6-1 X 12 46 oatase 8 SCREW, HHFC MB-125 X 42 a7 o7as72 1 ‘SEAL, VALVE STEM D7 8 089673 2 WASHER, VALVE SPRING 48 oBzt04 1 WASHER, LARGE SPRING 50 o7eee9c 2 DOWEL, SEAMED SLEEVE 3t oA7627 1 ‘SHAFT, GOVERNOR ROSS 82 0497808 1 BARBED ELBOW 90 VENPT X 9/8 LOCKTITE 33 088580 1 DOWEL DIA 12 X 18L. 4 o7aee08 1 DOWEL, SLEEVE SEAMED 12 DIA,PARTS & ists Section 9 — Exploded Views and Parts Lists 6) ‘Aircooled GeneratorsSection 9 — Exploded Views and Parts Lists Air-cooled Generators ‘TKW, GN-410 Engine - Drawing No. OF9428 - Part 2 @er (TEM __ PART NO. ary. DESCRIPTION 1 oct0s9 5 ‘SCREW, TAPTITE Mé-1.0X8 YELLOW CHROME 2 002922 1 HOUSING, BLOWER 3 0F 8428 1 TUBE, DIPSTICK 4 009997 1 GUARD, FAN. 5 osssé 1 WRAPPER, 3OTTOM 6 048756 " ‘SCREW, TAPTITE Mé-1X10 VELLOW CHROME 7 0#176a 1 WRAPPER, TOP 8 90048 1 AASSY, STARTER 8 059085 2 SCREW, SHC MA-1.25 X 45 612.8 10 022129 a WASHER, LOCK MaS'16 1 07458 1 BACKPLATE, LF DIF 2 oaasr2 1 ‘SCREW, TAPTITE Mé-1.25 X 16 3P 13 opr401A 1 BREATHER TUBE 4 09039 1 GASKET, INTAKE ADAPTER 15 009619 1 ASSENBLY, PLASTIC CARB 6 o4eett 2 WASHER, FLAT M6 7 022087 4 WASHER, LOCK M614 18 o4oa4s 2 SCREW, SHC M6-.0 X20 6128 19 036999 1 GASKET(OL FILTR ADAPTER. 2% 0058674 1 ADAPTER, OIL FILTER a 049821 2 SCREW, SHC M8-1.25 X 0 6129 2 099238 1 SWITCH, OIL 80 PSI 2 o7otess, 1 OILFITER, 2 82774 1 KEY, WOODRFF 4 x 180 % 92226 1 FLYWHEEL WITH RING GEAR 32066, 28 o57198N, 1 WASHER BELV-20 X 2.2 2 67890 1 NUT, HEX.» FLYWHEEL 28 E7585 1 ‘SPARKPLUG 2 o7arss 1 ASSENBLY.GOVERNOR LEVER 12 HP 0 072795 1 ROD.GOVERNOR CONTROL, 3 003978 1 SPRING, ANTLLASH 3 ocs040 1 ASSEMBLY, WIRE. 3 D870 1 ASSEMBLY, IGNITION COIL 4 2 ‘SCREW, TAPTITE ME-.0 X25 8? 6 1 ‘SPRING GOVERNOR 8 1 BOLT, GOVERNOR ADJUST MS a 1 NUT HEX LOCK W5.0.8 NYINS ZINC 38 003083, 1 ASSEMBLY, OIL. DRAIN HOS: 38 1 ASSENBLY, CAP & DIPSTICK 40 1 O-RING af16 x 34x 9192 a 075281 1 SWITCH, THERMAL 2 022145 1 WASHER FLAT 5/16 - M8 48 oF 2094 2 ‘SCREW, M3-05 X 6 SEMS 44 008973 1 ‘SPACER, ENDFRAME 45 0227178 1 GONMET 46 1 SPRING SECONDARY a 1 BRACKET SECONDARY GOVERNOR SPRING 8 1 ‘SCREW HHO MB-1.25 x20 48 003751 1 SPRING, IDLE RETURNING 50 21 1 BARREL GOVERNOR ADJUSTMENT 3 8493 1 SSOREW SHC N5-08 x 30 82 008758 1 ENGINE LIFT HOOKGoris Section 9 — Exploded Views and Parts Lists O) ‘Air-cooled Generators 0 7kW, GN-410 Engine ~ Drawing No. 0F9422-8‘i is pans Section 9 ~ Exploded Views and Parts Lists Goats ‘Air-cooled Generators 1hW, CN-10 Engine - Brg no apoens 8 OG) (TEM __ PART NO. ary. DESCRIPTION 1 oFe185 1 ADAPTOR, ENGINE 2 540H 1 STATOR 3 93934H 1 ROTOR 4 OFTTP4A 1 ‘CARRIER, REAR BEARING 5 098096 1 FAN, 8° CURVED BLADE. 6 oFes91 1 MUFFLER 7 078 1 TAIL PIPE, MUFFLER 9 56482 1 BEARING 10 ocsi68 3 5/16 SPECIAL LWASH " 056147 1 BOLT ROTOR HHCS 5/6724 X 19-127 G5 2 opted? 4 BOLT STATOR IHHCS MB-1.25 x 305mm 13 oc70aec 1 ‘BRACKET, ALTERNATOR MOUNTING 4 oF 485 1 DUCT, ALTERNATOR AIR 15 oF 497 1 GASKET, ALTERNATOR AIR DUCT 16 070388 1 ‘BRACKET, ENGINE MOUNTING 7 ocr7s8 4 RUBBER MOUNT 18 0388050AE0 1 ‘CABLE, 46 40" BLACK BATTERY 19 oozat7a 1 (RTH STRAP 818X 318 2 OF 6528 1 HAUST FLEX a 086385 1 ASSENBLY BRUSH HOLDER 2 029451 18FT TAPE ELEC UL FOAM 18 X 12 2 o4aast 1 WASHER FLAT 40810 X 1.6200 24 022287 4 WASHER LOCK 8 % 072511 4 BOLT HH ai-16 X 1-1 Gs % 022131 4 WASHER FLAT a8 2 039287 4 ‘SOREW HHO MB-125 X 45 68.8 2 022145 18 WASHER FLAT 5/16 2 049820 4 NUT LOCK HEX M6-1.25 NYL INSRT 0 090388 8 ‘SCREW TAP Mé-1.0x12 31 022128 7 WASHER LOCK We-5/16 2 022258 8 NUT HEX st6-18, 3 059657 2 ‘SCREW TAPTITE 318-16x ai 4 agai 3 BAND, HOSE CLAMP 25.05 DIA. 3% 009592 1 BELLOWS % agate 2 HOSE CLAMP ait 37 040978 2 SCREW SHC MB-1.25 X 206129 8 goats 1 PLATE HOT 39 028287 3 L-BOLT 5/1618 X 1.38" SADDL 40 090238 1 GASKET, EXHAUST 41 8989 1 STINGER, ENGINE AIR I 2 oorata 1 BASE, AIR CLEAN: 8 oc8127 1 ELEMENT, AIR CLEANE “4 oca024 1 ‘COVER, AIR CLEANER NLP 4% 002273 1 TUBE, 125°0D. x 20Ge, x 12.125" LONG. 4% o55ea4N 1 (CLAMP VINYL 1.31 X.281 2 a7 07065 1257 HOSE LP 12°10. 48 0051364 2 KNOB, AIR CLEANER @ 039253 2 SSOREW HHC MB-1.25 X 20 68.8 50 22473 4 WASHER FLAT 1/4 82 osse49 2 SSOREW HHTT N5-08 X 16 33 oF 6551 1 FLEX COVER, 54 oF e079 1 BRACKET MUFFLER ACCESS: 35 oFo710 2 AIVET POP 0.125°X 0.337" 56 0F 8256 1 EXHAUST MANIFOLD 37 045771 4 NUT HEX 8-125 NY INS. 88 00676 2 SSOREW THT Méet.0 x 10 38 074908 4 SCREW HHTT N6-1.0 X 2010, 13, and 16KW, V-twin Generators ~ Drawing No. 0F9423-C Section 9 — Exploded Views and Parts Lists “Bir-cooled Generators 2 Lists pars ©) BeITEM PART NO. QTY, DESCRIPTION oFata6 oF see OF 538 OF 548 oF 785, oF 538 oF 549 oFr774 069578 oF 3998 oF 581 oFa078 oF7787 oFstat oss4e2 ocates optass optads oc7o3e oF 9386 002559 oc7oaea oFai79 067758 (388050000 oczat7Aa oF 6528, 058386 o794st 049451 o2zes7 ozestt on2i3t 051731 o2atas, o49e20 0G0676 022128 022259 059697 ‘i i parts Section 9 — Exploded Views and Parts Lists Goats 10, 13, and 16KW, V-twin Generators ~ ADATOR, ENGINE STATOR (1640) STATOR (18K) STATOR (10K) ROTOR (16KW) AOTOR (13KW\) ROTOR (T0KW) ‘CARRIER, REAR BEARING FAN, 12 CURVED BLADE FAN, 12 CURVED BLADE (10K) MUFFLER TAILPIPE, MUFFLER, LEK BASE, FLEX BASE (10K) BEARING 16 SPECIAL LOCK WASHER, BOLT, IMHCS 88-24 x 15.50" BOLT, IHHCS MB-1.25 X 845mm RACKET, ALTERNATOR MOUNTING DUCT, ALTERNATOR AR ‘GASKET, ALTERNATOR AIR OUCT RACKET, ENGINE MOUNTING PLATE, MOUNTING ENG 530HSB AUBBER MOUNT ‘CABLE, #8 48° BLACK BATTERY ARTH STRAP 318 X38 EXHAUST FLEX ASSEMBLY BRUSH HOLDER TAPE ELEC UL FOAM 1/8X 12 WASHER FLAT 406ID X 1.6200 WASHER LOCK 318 SCREW HHO 38 X 16 X 114 WASHER FLAT 4/8 ZINC SCREW HC MB-1.25 X50 WASHER FLAT 5/16 ZINC NUT LOCK HEX M@-1.25 NYL INSERT ‘SCREW THTT M6-1.0X 10 WASHER LOCK M8-5/16 NUT LOCK HEX St6-18 ‘SCREW TAPTITE 38-16 X tes oF 7065 a oegost, ogoste 005823 08369 068138 oao17s orgs ossee oF 7799 ores OF 7796 oF 8208 oF 9385 9038 04571 039253, oFo7t0 oFort0 F079 F273 9502 09588 or7ost 08581 09594 09500 9542 oDt683 o77075 9505 Ge Dae e eee oN eg Eww eee 09589 09591 09549 03565 099502, 08585 Aircooled Generator ing oS C O~ SOREW 5/16-18 X 34" HOSE RES 1: LP GAS HOSE CLAMP "1D, PLATE, HOT” UBOLT 6/618 x 1.62" WITH SADDLE GASKET, EXHAUST PORT (10KW) GASKET, EXHAUST PORT CLANP HOSE #5.5 0527-0.2"(10KW) HOSE i 1D LPG asoPSI UL21{T0KI) SOREW HHTT 5-08 X 16 EXHAUST MANIFOLD EXHAUST MANIFOLD (10K) FLEX COVER FLEX COVER (10K) FLEX COVER EXTENSION (10KW} SOREWTAPTITE M6-1.0X 12 NUT HEX W8-1.25 SCREW HHO Ni-1.25 X 20 IVET POP 0.125" 0.397 (10K) RIVET POP 0.125°X 0.337" BRACKET MUFFLER ACCESS SOLENOID, 6 VOLTS DC (10K) SCREW PPHM $40 X 3/8 SEMS (1040) LINKAGE, CHOKE (Tok) COTTER PIN (10K) AIR CLEANER GTH530 HSB (10K¥) SCREW PPPH HILO £14-15X ¥(10K¥) ASSEMBLY, CHOKE SHAFT (10KW) ‘VALVE, CHOKE (10K) SCREW PFHM M305 X'5 (10K¥Y) BOOT, CHOKE SOLENOID (10KW) SCREW PPPH HILO #6tt2 WW 54D (10K) CHOKE H8G (10K) SSPRING-CHOKE RETURN (10K) HOSE, INTAKE GTHS30 HSB (T0KW™) CLAN HOSE #28 1322.25, CLAMP HOSE #24 B1.06-2.00 SCREW SHC ME-.25X 18 GSection 9 — Exploded Views and Parts Lists Gris ‘Air-cooled Generators Or, 17 & 1OKW, GN-410/GT-530 Regulator ~ Drawing No. OF9425 O%) tEM____PART No, or. DESCRIPTION 1 cosess 1 CASTING. TWN REGULATOR HOUSING KM) _ 1 CASTING. THN REGULATOR HOUSING 2 oesoze 1 SOLENOID COL. T2vDe 3 oct 1 GASKET. 0. 5N00 ‘ votes 1 PLUNGE, LP REGULATOR ASSEMBLY 5 orstzz 1 REGULATOR BACHE? é oats 2 WaSHeR FLAT S68 ; ais > WASHER Loc sa 2 8 ‘ SCREW PPvON SENS M97 X10 : oes 1 FUELIET GASEOUS REGULATOR (7K) ” oceeos 1 BARGED STRAIGHT 6 NPT (KW) ce) > BARBED STRAIGHT NPT 1 osrese i O-ING 7K) 2 cae 1 ADIUSTER SCREW, THIN REGULATOR [KK % ocsret 2 LEVER REGULATOR ¥ ocssse 2 SUPPORT MET SEAL 5 oceoss 2 SEAL NET 8 ocsr58 2 PN, PROT ARM " ocean 2 SPRING, REGULATOR (A) ocsiea 2 SPRING, REGULATOR 8 ororee t SCREW, >rHMS NO-05 x5 8 ose 2 GASKET, OP HRAGI » ocsrez 2 COVER THN REGULATOR (A) 8 2 OVER UMN REGULATOR a oasret 8 SOREUTAPTITE Mex 3P 2 ocerat 2 AVET POR 318125 2B octos? 2 5SUP20RT PHA % oes 2 DIAPHRAG TWIN REGULATOR 3 oceoss 2 CAP DIPHRAGM SUPPORT 8 ocieaan 2 INLET TWIN REGULATOR #111 DA 2 ovestba 2 Pula STD PE 1 SOCKET HEAD (x oraseoa i LUG STD PIE 8 SOCKET HEAD 2s nose 1 PIN, LANITED ADLUSTMENT (0) 3 ooss t WASHER FLAT MBX tom 0 2 oaasta 1 LUG. STANDARD PPE TI STEEL SQUARE HEAD (7H) a oosers 1 PLUG, EXPANSION t6nen (KY) 2 oacec? > Sonew ric 125316 3 ooastta i BARBED STRAIGHT VENPTX (10K) % oass7ea 1 PPLE CLOSE 1aNPT (KM) s oazer 1 SOLENOID, LPG DCT (10K 8 1 SOLENOID WIRE, 0 (10K) 1 SOLENOID WIRE, #14 (10K0)‘i i parts Section 9 — Exploded Views and Parts Lists Goats ‘Air-cooled Generators cveieg ne sre Of) 15 & 16KW, GT-990 Regulator (TEM __ PART NO. ary. DESCRIPTION 1 09785 1 ‘CASTING, TWIN REGULATOR HOUSING 2 22 1 SOLENOID COIL, 12v0¢ 3 octsa7 2 GASKET , SOLENOID 4 opsis6 1 PLUNGER, LP REGULATOR ASSEMBLY 5 98 1 ‘BRKT REGULATOR MOUNTING 880 6 022145 4 WASHER FLAT S/16-Me 7 022128 4 WASHER LOCK 5116-68 8 0F 4795 a ‘SCREW PPHM SEMS Mé.0:7X 10 8 045771 2 NUT HEX M-1.25 0 08806 2 BARBED STRAIGHT Js NPT x " 042907 2 SSOREW HHC MB-1.25 X 16 2 026915 1 NPPPLE CLOSE % x 1.375 WITH VIBRA SEAL B 005761 2 LEVER, REGULATOR “4 05968 2 ‘SUPPORT, INLET SEAL 6 8066 2 SEAL, INLET 16 005759 2 PIN, PIVOT ARM v ocs7e4 2 ‘SPRING, REGULATOR 8 o7o728 4 ‘SCREW, PFHMS 3-05 x5 8 8069 2 GASKET, DIAPHRAGM 20 89 2 ‘COVER, TWIN REGULATOR a 045768 6 ‘SCREW, TAPTITE MaXs BP 2 008731 2 AIVET, POP 118 X.125 2 08067 2 ‘SUPPORT, DIAPHRAGW 24 cero 2 DIAPHRAGM, TWIN REGULATOR 25 05068 2 ‘CAP, DIAPHRAGM SUPPORT 26 casas 2 INLET, TWIN REGULATOR 11,11 DIA, 2 0726838 3 LUG STD PIPE 1/8 SOCKET HEAD 28 049226 4 WASHER, LOCK, MS 29 003308 4 WASHER. FLAT M3 X torn O.. 30 051713 4 WASHER, FLAT, Ms 31 oFe979 1 ‘SOLENOID COVER PLATE 32 051716 4 NUT HEXN5-08 3 09538 1 SOLENOID ADAPTER 34 1 |ASSY, FUEL SYSTEM PLENUM, ra 1 PLENUM GASKESection 10 ~ Warranty ‘Air-cooled Generators 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 mect 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 modifica: lion 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. Uf, dur- {ng 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 fon 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 andor all warranty coverage or responsibilty if your engine, or a parYcomponent thereof, has failed due to abuse, neglect , mproper maintenance or unap- proved 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 warranty repairs should be completed in a reasonable amount of time, nol to exceed 30 days, 1a problem occurs. The ‘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. Sec also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to yo by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conllict 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 ser~ vice, 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 address: For Air-cooled Product .. For Liquid-cooled Product ATTENTION WARRANTY DEPARTMENT ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS, INC. GENERAC POWER SYSTEMS, INC. P.O. BOX 297 211 MURPHY DRIVE WHITEWATER, WI 53190 EAGLE, WI 53119Section 10 ~ Warranty ‘Air-cooled Generators 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 1s (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 im 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 fatls 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 ispection 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 stich 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 4 scheduled for replacement as required matatenance in the Owner's Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. I the part fils 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 (o the first écheduled 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 sullicient 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 Warranly obligations. (9) Unapproved, add-on, modified, counterfett 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 sullicient grounds for disallowing an ECS Warranty claim. Generac shall not be held lable 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) Buel Metering Systems 3) Igution System including: 1.2) LPGWWatural Gas carburetion assembly and sts internal com- 8) Spark plug ponents ») Ignition module a) Fuel controller tf so equipped) 4) Catalytte Mailer Assembly 1 80 equipped) including 1) Mixer and its gaskets (i so equipped) a) Matfer gasket 6) Carburetor andl its guskels (if s0 eqspped) ') Exist mantfold 4) Primary gas regulator (if so equipped) 5) Crankease Breather Assembly sneluding: ©} LP lguid vaporizer (if so equipped) 8) Breather connection tube 2) Air Induction System including: a) Intake pipeimanifold >) Air cleaner ‘Generac engine types covered by this warranty statement inckude the fllowing: 1) Prepackaged Standby Generator 2) Alisty Power Unit (APU) Generator 3) Standby GeneratorSection 10 ~ Warranty ‘ir-cooled Generators GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR HOME STANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELOW For period of two (2) years trom the date of sale, or start-up by Authorized Cerlied Generac Power Systems Dealer, or branch thereat, Generac Power Systems, Inc. wil atts option, repair or replace any pars) which, upon examination, inspection, and testing by Generac Power Systems or lan AuthorizediCerfied Generac Power Systems Deale, of branch there, is found o be detective under normal use and service in accordance with the warranty sonedule set forth below, Any equipment that the purchaserfowner claims to be detective must be examined by the nearest Authorized \Ceritied Generac Power Systems Dealer, or branch thereot. Ths warranty applies only to Generac Power Systems Generators used in "Standby" lappicatons, as Generac Power Systems, Inc. has defned Standby, provided Said generator nas been propery installed and inspected on-site by lapbroprate personnel. Scheduled maintenance, as oulined by the generator owner's manual, is highly recommended. This shouldbe performed by lan Autnorzed/Certied Generac Power Systems Dealer, or branch thereo. This wil verily service has been performed on the uni throughout tne warranty period WARRANTY SCHEDULE |YEARS ONE and TWO — Limited comprehensive coverage on mileage, labor, and parts liste. | - ALL COMPONENTS Start-up andior Owing Registration. or Registration Card. along wih Proof of Purchase, must be performed andlor sent in ‘Guidelines: + Any and all warranty repairs andor concerns, must be perormed andor addressed by an AuthorizedICerities Generac Power Systems Dealer, of branch thereat |- & Generac Power Systems, Ine. Transl Switch is high} recommended tobe used in conjunction withthe genset, I a Non - Generac Power Systems, In, Transfer Switch 'ssubsttuted for use and dvecty causes damage tothe genset, no warranty coverage shall apply, + Allwarrany expense allowances are subject othe conitons defined in Generac Power Systems Warrany, Polis, and Procedure Flat Rate Manual + Units that have boen resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable. + Unit enclosure i only covered against rust or corrosion the fist year ofthe warranty provsion, + Use of Non-Ganerac replacement parts) wil void the warranty in its entirety. 1 (loek-heater}, heater controls and circulating pumps are only covered during the fist year ofthe warranty provision (i + Engine coolant he applicable. ‘THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING: = Any unit bull/manufactued prior to vanuary 1, 2005, CCosts of normal maintenance (ie. tune-ups, associated part(s), adjustments, loaseileaking clamps, instalation and start-up), Any failure caused ay contaminated tues, ol, coolantsantiresze o* lack of proper fuel, ole 0° eoolanslaniecze. Units sold ated or used for "Prime Power’ Taller Mounted” or "Rental Unt applications as Generac Power Systems have defined Prime Pow Taller Mounted or Rental Unt. Contact a Generac Power Systems Distibutor or Prime Power, Taller Mounted or Rental Unit defniton and warranty 5. Units used fr prime power in place of existing lily power where uly is present or in place of uty power where utlly power service does nat normally exist. 6, Failures caused by any external cause or act of God euch as, but nt limited to, calison, fire, thet, freeing, vandal, rot or wars lighting, farthquako, windstorm, hal, volcanic eruption, water 0 flood, tomado, hurricane, terorist acts or nuclear holocaust 7. Product that are modified or altered ina manner nat authorized by Generac Power Systems i wring. Failures due, out not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing 9. Any incidental, consequential or nditect damages caused by detects in mateils or workmanship, or any delay in repair or replacement ofthe detective pats). 10. Falure due to misapplicaton, misrepresentation, or bfuel conversion, 11, Telephone, facsimile, cell phone, satelite, interme, or any other communication expenses, 12, Rental equipment usea while warranty repairs are belng performed (0. renal generators, cranes, et) 18, Overtime, holiday, or emergency tor. 14, Planes, forties, raltoad, busses, halcopters, snowmobiles, snow.cals,of-toad vehicle or anyother mode of transportation d 415. Any and all expenses incur rac materials andlor workmanship were the direct cause ofthe proslem. 16, Startng batteries, fuses. ight bulbs, engine fui, and overnight freight cost for replacement parts). ITHIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAG POWER SYSTEMS IMAKES No OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do rot allow limitations on haw long an implied warranty lass, so the above irtation may not apply to purchasev/owner |GENERAG POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT |SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A JDIRECT RESULT OF GENERAG POWER SYSTEMS, INC, NEGLIGENCE, [some states do not allow the exclusion or limitation of incidental or consequential damages, s0 the above Italions may nol apply to purchaser! Jowner. Purchaseslowner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gves purchaser/owner [spect legal nghts. Purchaseriowner also may have other rights that vary trom site to state, Generac Power Systems, Inc. - P.O. Box 8 - Waukesha, WI53187 Ph: (262) 544-4811 - Fax: (262) 544-4851 investigating performance complaints unloss detective Ge re No, OG0492 Revi jon A (06/76/06) Printed in USA.